Gearbox Manual Mitsubishi EVO IX 5-Speed Sequential · 2020. 11. 19. · Pole Position Mitsubishi EVO IX 5-Speed–Revision: 000 Gearbox Manual 2 In Gearboxes Warning Please be aware

Gearbox Manual Mitsubishi EVO IX 5-Speed Sequential

2 Gearbox Manual Mitsubishi EVO IX 5-Speed– Revision: 000 Pole Position

In Gearboxes

Warning Please be aware that information in this manual may be inaccurate, incomplete or contain typographical errors. The content of this manual is subject to

change without notice and should, therefore, be used for informational purposes only. Consequently, replacement parts must always by ordered according

to the part number engraved on the part.

If you find information in this manual that is incorrect or incomplete, we would appreciate your comments and suggestions.


In Gearboxes

Contents Warning ............................................................................................................................................................................................................................................. 2

Contents ............................................................................................................................................................................................................................................ 3

1. Technical Specifications................................................................................................................................................................................................................. 5

1.1. General Specifications ............................................................................................................................................................................................................ 6

1.2. Oil ............................................................................................................................................................................................................................................ 7

2. Gearbox Assembly ......................................................................................................................................................................................................................... 8

2.1. General Instruction Notes....................................................................................................................................................................................................... 9

2.2. Bearing Assembly .................................................................................................................................................................................................................. 10

2.3. Gearbox Assembly ................................................................................................................................................................................................................ 12

2.4. Assembly Push/Pull cable & Tunnelmount ........................................................................................................................................................................... 42

2.5. Assembly Push Rod & Tunnelmount .................................................................................................................................................................................... 46

2.6. OEM Parts ............................................................................................................................................................................................................................. 52

2.7. Rotary Sensor ........................................................................................................................................................................................................................ 53

3. Accessories .................................................................................................................................................................................................................................. 57

3.1. Gear Lever ............................................................................................................................................................................................................................. 58

3.2. Gear lever Bracket Paddle shift ............................................................................................................................................................................................ 59

3.3. Gear Indicator ....................................................................................................................................................................................................................... 60

3.4. Display Unit ........................................................................................................................................................................................................................... 61

3.5. Switchbox .............................................................................................................................................................................................................................. 62

3.6. Oil Breather Catchtank ......................................................................................................................................................................................................... 63

3.7. Paddleshift System ............................................................................................................................................................................................................... 63

3.8. Differential Bearing/Cover .................................................................................................................................................................................................... 66

4. Contact Information .................................................................................................................................................................................................................... 67


In Gearboxes

4.1. Contact Details ...................................................................................................................................................................................................................... 68

Appendix A: Technical Bulletins ...................................................................................................................................................................................................... 69

Appendix B: Amendments ............................................................................................................................................................................................................... 71


In Gearboxes

1. Technical Specifications


In Gearboxes

1.1. General Specifications

Mitsubishi EVO IX

Application Circuit, Hill Climb & Rally

Type 5-Speed Sequential

Torque rating 900Nm

Weight (dry weight) 57kg


In Gearboxes

1.2. Oil

Oil Type Motul 75W140 Gear Competition

Oil Quantity Gearbox 3.1 litres (excluding external oil lines & oil cooler)

Oil Quantity Transferbox 0.6 litres


In Gearboxes

2. Gearbox Assembly


In Gearboxes

2.1. General Instruction Notes The following information is intended for mechanics to (dis)assemble the gearbox. This is illustrated using exploded views including the corresponding Bill Of

Materials (BOM). Specific notes related to the (dis)assembly of a part are shown in the notes column of the BOM. For more details on the bearing

installation see §2.2 Bearing Assembly.

Please read the manual and make sure all parts are present before starting to assemble. Also ensure that all parts are clean and undamaged. It is

recommended to replace nuts, seals and circlips after removal. Only genuine Drenth Gearboxes parts should be used when overhauling the gearbox.


In Gearboxes

2.2. Bearing Assembly

To reduce the risk of bearing or casing damage, heat mounting is used to install or remove bearings. Drenth Gearboxes highly recommend to use an oven to

ensure an even heat distribution. Casings should not be heated above 130°C. Fit the bearings promptly after removing the casing from the oven to avoid

extra heating cycles being required.

Note

Bearing size of the mainshaft needs

to be checked before assembling.

Check if the Ø72mm is still within

spec. (Ø72mm -0.01/-0.02)

When hole is out of spec Drenth

advises to change Insert Sleeve

Mainshaft (Pos 1) for Ø72,5mm

oversize sleeve. (38.03.0096)

Therefore hole needs to be

machined to Ø72,5mm 0/+0.01


In Gearboxes

Distance of the bearing (Pos 9) needs to be 61.2 +/- 0.05

Height can be adjusted with shims. (Pos 2 & 3)

Final check if the distance between mounting surface and the

outer track of the bearing is 38.2 +/- 0.05

POS Part Number Description QTY NOTE

1 38-03-0089 Insert Sleeve Mainshaft 1 Depends on bearing hole casing (Oversize Sleeve 38-03-0096)

4 38-03-0090 Oil Seal 1

5 38-03-0800 Bellhouse Mitsubishi EVO IX 1

7 38-03-0094 Diff. Bearing 1

9 38-08-0090 Roller Bearing 1

11 38-03-0037 Ball Bearing 1


In Gearboxes

2.3. Gearbox Assembly

Make sure Selector rod is aligned correct.

Unscrew after alignment


In Gearboxes


2 37-02-0314 Bolt M4 2

3 38-10-0016 Selector Plate 1

4 38-10-0092 Ratch 2

5 37-08-0027 Spring 2

6 38-10-0091 Ratchet Carrier 1

8 35-01-0334 Dowel 2

9 38-10-0012 Housing Ratchet Unit 1

13 42-08-0309 Ball Bearing 1

14 37-08-0020 Ball Bearing 1

15 38-10-0032 Selector Rod 1


In Gearboxes


In Gearboxes


1 38-03-0092 Gear Speedometer 1

2 38-03-0850 OEM Center Differential 1

3 38-03-0042 Crown Wheel (13) - 56 1 Depending on gear ratio

4 38-03-0047 Crown Wheel Bolt M12 10


In Gearboxes

Note:

- Pre-load OEM Differential bearings: 0.4 – 0.5mm.

- Drenth Differential bearings: No Pre-load. (Free play 0.00 – 0.05mm)


In Gearboxes


In Gearboxes


In Gearboxes


1 38-03-0015 Dog Gear 2nd (13)-26 1 Depending on gear ratio

2 37-02-0505 Needle Bearing 1

3 38-03-0012 Dog Ring 1

4 38-03-0011 Hub 1st/2nd Gear 1

5 38-03-0010 Split Ring 2

6 38-03-0043 Dog Gear 1st (12)-36 1 Depending on gear ratio


8 38-03-0001 Inputshaft 12-(36) / 13-(26) 1 Depending on gear ratio

9 38-03-0088 Mainshaft 13-(56) 1 Depending on gear ratio


In Gearboxes


In Gearboxes


1 38-03-0022 Dog Ring 5th/Reverse Gear 1

2 38-03-0021 Hub 5th/Reverse Gear 1

4 38-03-0020 Dog Gear 5th (28)-24 1 Depending on gear ratio

5 38-03-0019 Dog Gear 4th (18)-20 1 Depending on gear ratio


7 38-03-0018 Dog Ring 3rd/4th Gear 1

8 38-03-0016 Hub 3rd/4th Gear 1

9 38-03-0017 Dog Gear 3rd (17)-25 1 Depending on gear ratio

10 38-03-0006 Circlip 1

11 38-03-0005 Washer 1

12 38-03-0004 Splined Gear 5th 28-(24) 1 Depending on gear ratio

13 38-03-0003 Splined Gear 4th 18-(20) 1 Depending on gear ratio

14 38-03-0002 Splined Gear 3rd 17-(25) 1 Depending on gear ratio


In Gearboxes


In Gearboxes


1 37-02-0102 Circlip 1

2 38-03-0036 Inner Track 1

3 38-10-0071 Dog Gear Reverse 41-(26)-(13) 1


5 38-03-0023 Inner Track 1


In Gearboxes


In Gearboxes


1 37-02-0508 Ball Bearing 1

2 37-02-0310 Conveyer Rotary Sensor 1 Make sure marks are aligned

3 38-10-0018 Selector Drum 1

4 38-10-0019 Shaft Selector Fork 1

5 38-10-0022 Selector Fork 5th/Reverse Gear 1

6 38-10-0021 Selector Fork 3rd/4th Gear 1

7 38-10-0020 Selector Fork 1st/2nd Gear 1


In Gearboxes

Note:

Main shaft bearing (Pos 1): No Pre-load. (Free play 0.00 – 0.05mm)

Lay shaft bearing (Pos 3): No Pre-load. (Free play 0.00 – 0.05mm)


In Gearboxes


1 37-02-0501 Roller Bearing 1

2 38-03-0062 Shim 2

3 38-03-0038 Ball Bearing 1

4 38-03-0068 Shim 1

5 38-03-0067 Shim 1

6 38-03-0065 Shim 1

7 38-03-0066 Shim 1

8 38-03-0093 Tapered Bearing 1

9 38-03-0061 Shim 1

10 38-03-0060 Shim 1

11 38-10-0044 Plate Oil Sump 1


In Gearboxes


In Gearboxes


1 38-03-0847 Bolt M10 1

2 37-02-0027 Washer M10 1

3 38-03-0822 Bolt M10 13

5 38-03-0802 Dowel 2

6 38-10-0026 Dowel 1

8 38-10-0010 Endcover 1


In Gearboxes


In Gearboxes


1 38-03-0809 Circlip 1

2 38-03-0808 Belleville Washer 1

3 38-03-0807 Washer M22 1

4 38-03-0033 Idler Gear Reverse (41)-26-(13) 1


6 38-03-0804 Shaft Idler Gear Reverse 1

7 38-03-0806 Ball 1

8 38-03-0811 Seal M10 1

9 38-03-0810 Bolt M10 1

10 38-03-0827 Seal M16 1

11 38-08-0924 Oil Plug M16 1


In Gearboxes


In Gearboxes


1 38-03-0826 Oil Plug M18 - Magnetic 1

2 38-03-0857 Bolt M6 6

3 38-03-0812 Cover Reverse Gear 1


In Gearboxes


In Gearboxes


1 38-08-0961 Bolt M8 2

2 37-08-0032 Spring 1

3 37-08-0031 Cup 1

4 38-10-0032 Selector Rod 1

5 37-08-0156 Washer M24 1

6 37-08-0034 Nut M24 1

7 37-08-0035 Oil Seal 1


In Gearboxes


In Gearboxes


1 38-10-0063 End Cap 1

2 38-10-0062 Circlip 1

3 38-03-0814 Switch Reverse Light 1

4 38-10-0031 Stud Selector Lever 1

5 37-02-0510 Outer Ring 2

6 37-02-0351 Spacer 1

7 38-10-0030 Selector Lever 1

8 37-02-0352 Washer M10 1

10 38-10-0033 K-Nut M10 1


In Gearboxes


In Gearboxes


1 25-03-0011 Rotary Sensor 1 See chapter: Rotary Sensor

2 25-03-0068 Cover Cap 1

3 37-02-0315 Washer M4 2

4 37-02-0312 Bolt M4 2

5 37-02-0721 O-Ring 1

6 38-03-0091 Oil Seal 1

7 38-10-0051 Multiseal M10 1

8 37-02-0478 Adaptor D-06xM10 1

9 37-02-0473 End Cap D-06 1


In Gearboxes


In Gearboxes


1 37-08-0045 Positioning Pin 1

2 37-02-0331 Spring 1

3 35-01-0082 Seal M14 1

4 37-08-0188 Nut M14x1.5 1

5 37-08-0189 Guide Cable 1

6 38-08-0919 Stud M12 4


In Gearboxes

2.4. Assembly Push/Pull cable & Tunnelmount


In Gearboxes


1 37-02-0018 Washer M8 4

2 38-10-0027 Bolt M8 3

3 38-10-0023 Bracket Push/Pull Cable 1

4 37-02-0323 Locking Nut M6 1

5 37-02-0021 Washer M6 1

6 37-02-0409 Rod End Housing M8 1

7 37-02-0479 Fitbolt M6 1

8 38-10-0034 Release Nipple 1

9 38-10-0045 Set Screw M4 1

10 38-10-0046 Hose 1

11 37-02-0481 Adjustment Bolt M6 2

12 37-02-0344 Cover Outer Cable 3

13 37-02-0343 Outer Cable 2

14 37-02-0342 Inner Cable 2

15 37-02-0346 Lock Screw 1

16 38-10-0024 Push/Pull Cable 1


In Gearboxes


In Gearboxes


1 37-02-0405 Fitbolt M8 1

2 37-02-0027 Washer M10 1

3 37-02-0089 Bolt M8 4

4 37-02-0403 Spacer 2

5 37-02-0406 Locking Nut M8 1

6 37-02-0018 Washer M8 1

7 38-07-0058 Bracket Gearlever 1

8 37-02-0409 Rod End Housing M8 1


In Gearboxes

2.5. Assembly Push Rod & Tunnelmount


In Gearboxes


1 37-02-0344 Cover Outer Cable 4

2 37-02-0343 Outer Cable 2

3 37-02-0481 Adjustment Bolt M6 2

4 37-02-0342 Inner Cable 2

5 38-10-0043 Bracket Release Cable 1

6 37-02-0018 Washer M8 2

7 38-10-0027 Bolt M8 2

8 38-10-0046 Hose 1

9 38-10-0034 Release Nipple 1

10 38-10-0045 Set Screw M4 1

11 37-02-0346 Lock Screw 1


In Gearboxes


In Gearboxes


1 37-02-0479 Fitbolt M6 3

2 37-02-0018 Washer M8 3

3 37-02-0449 Rod End M8 2 Threaded Left

4 37-02-0021 Washer M6 3

5 37-02-0323 Locking Nut M6 3

6 37-02-0357 Nut M8 Left 2

7 37-08-0516 Stud M8 Left 1

8 38-10-0037 Shift Rod Gearbox 1

9 37-08-0517 Stud M8 1

10 37-02-0358 Nut M8 2

11 38-10-0030 Selector Lever 1

12 37-02-0510 Ball Bearing 2

13 38-10-0038 Rod 1

14 38-10-0035 Bracket Selector Lever 1

15 35-01-0085 Washer M12 1

16 38-10-0048 Bolt M12 1

17 37-02-0351 Spacer 1

18 37-02-0352 Washer M10 1

19 35-01-0083 Bolt M10 1

20 37-02-0409 Rod End M8 1 Threaded Right


In Gearboxes


In Gearboxes


1 38-10-0039 Bush 1

2 38-10-0038 Rod 1

3 37-08-0517 Stud M8 1

4 37-02-0358 Nut M8 1

5 37-02-0409 Rod End M8 1 Threaded Right

6 37-02-0089 Bolt M8 4

7 37-02-0406 Locking Nut M8 1

8 37-02-0018 Washer M8 1

9 37-02-0403 Spacer 2

10 37-02-0027 Washer M10 1

11 37-02-0405 Fitbolt M8 1

12 38-07-0058 Bracket Gearlever 1


In Gearboxes

2.6. OEM Parts

Part Number Description QTY NOTE

38-03-0818 Guide Release Bearing 1 OEM Nr: MR980735

38-03-0819 Release Bearing 1 OEM Nr: MR145619

38-03-0820 Fork Release Bearing 1 OEM Nr: MD770376

38-03-0821 Plain Bearing 2 OEM Nr: MR953913

38-03-0823 Bolt M6 2 OEM Nr: MF140208

38-03-0824 Cover Fork Release Bearing 1 OEM Nr: MD747413

38-03-0829 Speedometer Sensor 1 OEM Nr: MD756706

38-03-0830 Gearwheel Speedometer 1 OEM Nr: MD747055

38-03-0831 Breather Back 1 OEM Nr: MD746523

38-03-0832 Endcap 1 OEM Nr: MF665535

38-03-0833 Breather Front 1 OEM Nr: MD711443

38-03-0834 Cover Clutch Housing Inspection Hole 1 OEM Nr: MD747412

38-03-0848 Assembly Cylinder Release Bearing 1 OEM Nr: MD748617

38-03-0851 Bolt 4 OEM Nr: MF140203

38-03-0852 Spring Dowel 1 OEM Nr: MD749672

38-03-0853 Oil Seal 1 OEM Nr: MD749474

38-03-0854 Shaft Fork Release Bearing 1 OEM Nr: MR980758

38-03-0855 Spring 1 OEM Nr: MD749673

38-03-0859 Bracket Oil Hose 1 OEM Nr: MD770815

38-08-0981 Gasket 1 OEM Nr: MF660035


In Gearboxes

2.7. Rotary Sensor

The gearboxes come with a Penny & Giles SRH280DP rotary sensor. The rotary sensor signal is used to show the engaged gear on the Drenth Display Unit /

Drenth Gear Indicator or any other display. For correct gear indication, it is necessary that rotary sensor is properly connected and calibrated. Information

related to the wiring of the sensor is shown in the table below.

Cable Colour Description

Red + 5 V Supply

Yellow Output 1

White Output 2

Black 0 V Supply (GND)

Depending on the type of gearbox, Output 1 or Output 2 is used. The table below shows which output is used for the different types of gearboxes:

Gearbox Type Output Cable Colour

DG350 Output 2 White

DG350 Direct Replacement Output 1 Yellow




DGT250 Output 2 White

DGT350 Output 2 White

Mitsubishi Lancer Evolution VI-IX Output 1 Yellow

Mitsubishi Lancer Evolution X Output 1 Yellow

MPG Output 1 White


In Gearboxes

The connection diagrams when using output 1 or output 2 are shown below:

Please note that the above information does not apply to other sensors!


In Gearboxes

Make sure small dent is pointing in the direction of the cable


In Gearboxes


In Gearboxes

3. Accessories


In Gearboxes

3.1. Gear Lever

Drenth Gearboxes offers a one-piece DMS aluminium gear lever with integrated electronics which, in combination with shift rods or a push/pull cable, can

be used on any Drenth sequential gearbox to change gear. The analogue output signal of the gear lever electronics can be used to configure the ignition cut

enabling flat-shifting. An optional Switchbox is used to convert the analogue signal when a digital output signal for programming the ignition cut is required.

The DMS gear lever can also be used to program down shift throttle blip if the car is equipped with drive-by-wire.

The gear lever has a length of:

• 360 mm


1 25-03-0059 Assembly Gearlever Long/Inter stud 1 Color: Alu

2 25-03-0082 Assembly Gearlever Long/Inter stud 1 Color: Black


In Gearboxes

3.2. Gear lever Bracket Paddle shift

Drenth Gearboxes offers 2 types of gear lever brackets for mounting the (DMS) gear lever in the car. One bracket for gearlever only, second bracket can be

used with gearlever in combination with paddle shift:


1 38-10-0103 Assembly Bracket Geartronics Gearlever 1 Suitable for ACT3232 Cylinder


In Gearboxes

3.3. Gear Indicator

Designed to work seamlessly with every Drenth sequential gearbox, the gear indicator uses the rotary sensor signal to show the selected gear. Using the

supplied software, it is possible to show up to 8 forward gears as well as neutral and reverse on the display with integrated light sensor. In addition, the gear

indicator features an option to control the reversing light.

Features:

- Gear indication

- Reverse light

- Automatic calibration


1 25-03-0065 Gear Indicator 1


In Gearboxes

3.4. Display Unit

Designed to work seamlessly with every Drenth sequential gearbox, the display unit uses the rotary sensor signal to show the selected gear. Using the

supplied software, it is possible to show up to 8 forward gears as well as neutral and reverse on the display with integrated light sensor. In addition, the

display unit features an adjustable shift light and an option to control throttle blip or the reversing light. In combination with the DMS gear lever, the display

unit can be used for flat-shifting which allows the user to set the cut time for each gear separately. This is also possible when using any other load cell,

Switchbox or switch.

Features:

• Gear indication • Shift light • Flat-shifting

• Down shift throttle blip / Reverse light • Automatic calibration • DMS Gear Lever calibration


1 25-03-0066 Display Unit 1


In Gearboxes

3.5. Switchbox

The Drenth Gearboxes Switchbox is an analog-to-digital converter which is used in combination with the Drenth Display Unit or a programmable ECU to

enable flat-shifting. When a digital output signal is required for setting the ignition cut the Switchbox is used to convert the analogue signal. Because the

Switchbox is equipped with two potentiometers, the upshift and downshift threshold levels can be adjusted as desired.

Features:

• Adjustable downshift threshold voltage

• Adjustable upshift threshold voltage


1 25-03-0080 Switchbox 1


In Gearboxes

3.6. Oil Breather Catchtank

Drenth Gearboxes recommends the use of an Oil Breather Catch Tank for breathing the gearbox. Therefore Drenth Gearboxes offers a universal catch tank

which can be used with any gearbox. The set includes the breather catch tank, oil hose and the necessary adaptors.


1 25-03-0020 Oil Breather Catchtank 1


In Gearboxes

3.7. Paddleshift System

The Mitsubishi EVO IX can be equipped with a paddleshift system allowing the driver to change gears by using steering wheel mounted shift paddles. For

mounting the actuators of the different paddleshift systems, Drenth Gearboxes has developed various brackets for the Mitsubishi EVO IX. If the preferred

paddleshift system has a safety feature which prevent the driver from selecting neutral and reverse accidentally during downshifts, then the mechanical

blocking system can be replaced and / or removed. In this case the following parts* are required:

*Cylinder Geartronics excluded


In Gearboxes


1 37-02-0416 Bolt M8 2

2 44-09-0344 Washer M8 2

3 37-02-0021 Washer M6 2

4 37-02-0323 Locking Nut M6 2

5 38-10-0052 Bracket Geartronics Paddleshift 1

6 35-01-0097 Fitbolt M6 1

7 38-10-0047 Selector Drum 1

8 37-08-0157 Nut M14x1.5 1

9 37-02-0483 Fitbolt M6 1


In Gearboxes

3.8. Differential Bearing/Cover

For high powered EVO engines Drenth offers special differential bearings including a reinforced differential cover:


1 38-03-0154 Roller Bearing 1 Shims Included

2 38-03-0055 Differential Cover 1 Ø117mm (Also available in Ø116mm and suitable for OEM bearings)

3 38-03-0151 Roller Bearing 1 Shims Included


In Gearboxes

4. Contact Information


In Gearboxes

4.1. Contact Details Drenth Motorsport Gearboxes

Fleuweweg 10

7468 AG Enter

The Netherlands

www.drenth-gearboxes.com

Spare Parts: +31 (0)547 38 26 96 [email protected]

mailto:[email protected]


In Gearboxes

Appendix A: Technical Bulletins


In Gearboxes


In Gearboxes

Appendix B: Amendments


In Gearboxes

Date Page Modification

T +31 (0)547 38 26 96 E [email protected] W www.drenth-gearboxes.com

Documents

Gearbox Manual Mitsubishi EVO IX 5-Speed Sequential · 2020. 11. 19. · Pole Position Mitsubishi EVO IX 5-Speed–Revision: 000 Gearbox Manual 2 In Gearboxes Warning Please be aware