Mitsubishi Lancer Evolution X. Manual - part 623

 

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Mitsubishi Lancer Evolution X. Manual - part 623

 

 

LUBRICANTS

TSB Revision

MANUAL TRANSAXLE OVERHAUL

22B-5

FORM-IN-PLACE GASKET (FIPG)

This transaxle has several areas where the 
form-in-place gasket (FIPG) is used for sealing. To 
ensure that the FIPG fully serves its purpose, it is 
necessary to observe some precautions when apply-
ing it. Bead size, continuity and location are of para-
mount importance. 
Too thin a bead could cause leaks. Too thick a bead, 
on the other hand, could be squeezed out of location, 
causing blocking or narrowing of fluid passages. To 
prevent leaks or blocking of passages, therefore, it is 
absolutely necessary to apply the FIPG evenly with-
out a break, while observing the correct bead size.
FIPG hardens as it reacts with the moisture in the 
atmospheric air, and it is usually used for sealing 
metallic flange areas.

CAUTION

When re-applying liquid gasket (FIPG), be sure 
that:

1. Residues of FIPG are cleared from all the ins 

and outs of parts;

2. Use Mitsubishi genuine parts cleaner 

(MZ100387) or equivalent to well degrease the 
FIPG-applied surface.

3. FIPG is correctly applied in accordance with 

FIPG Application.

.

Disassembly

Parts sealed with a FIPG can be easily removed 
without need for the use of a special method. In 
some cases, however, the FIPG in joints may have to 
be broken by tapping parts with a mallet or similar 
tool. 

.

Surface Preparation 

Thoroughly remove all substances deposited on the 
FIPG application surface, using a gasket scraper. 
Make sure that the FIPG application surfaces is flat 
and smooth. Also make sure that the surface is free 
from oils, greases and foreign substances. Do not fail 
to remove old FIPG that may remain in the fastener 
fitting holes.

.

FIPG Application

Applied FIPG bead should be of the specified size 
and free of any break. FIPG can be wiped away 
unless it has completely hardened. Install the mating 
parts in position while the FIPG is still wet. Do not 
allow FIPG to spread beyond the sealing areas dur-
ing installation. Avoid operating the transaxle or let-
ting oils or water come in contact with the sealed 
area before a time sufficient for FIPG to harden 
(approximately one hour) has passed. 
FIPG application method may vary from location to 
location. Follow the instruction for each particular 
case described later in this manual.

LUBRICANTS

M1222000400819

TRANSAXLE

TRANSFER

Item

Specified sealant

Transaxle oil

Mitsubishi Genuine DiaQueen NEW MULTI GEAR 
OIL API classification GL-3, SAE 75W-80

Control shaft oil seal lip gear oil
Oil seal (transaxle case)
Select lever shoe

Mitsubishi Part No. 0101011 or equivalent

Input shaft oil seal lip gear oil

Retinax A

Item

Specified lubricant

Transfer oil

Hypoid gear oil API classification GL-5, SAE90

O-ring

Mitsubishi Genuine DiaQueen ATF SPIII

Oil seal

Retinax A

ADJUSTMENT SNAP RING AND SPACERS

TSB Revision

MANUAL TRANSAXLE OVERHAUL

22B-6

ADJUSTMENT SNAP RING AND SPACERS

M1222012000799

Snap ring (For adjustment of input shaft rear bearing end play)

Spacer (For adjustment of input shaft end play)

Snap ring (For adjustment of output shaft 3rd speed gear end play)

Snap ring (For adjustment of output shaft rear bearing end play)

Thickness mm (in)

Thickness mm (in)

1.23 (0.0484)

1.55 (0.0610)

1.27 (0.0500)

1.59 (0.0626)

1.31 (0.0516)

1.63 (0.0642)

1.35 (0.0531)

1.67 (0.0657)

1.39 (0.0547)

1.71 (0.0673)

1.43 (0.0563)

1.75 (0.0689)

1.47 (0.0579)

1.79 (0.0705)

1.51 (0.0594)

Thickness mm (in)

Thickness mm (in)

0.80 (0.0315)

1.16 (0.0457)

0.83 (0.0327)

1.19 (0.0469)

0.86 (0.0339)

1.22 (0.0480)

0.89 (0.0350)

1.25 (0.0492)

0.92 (0.0362)

1.28 (0.0504)

0.95 (0.0374)

1.31 (0.0516)

0.98 (0.0386)

1.34 (0.0528)

1.01 (0.0398)

1.37 (0.0539)

1.04 (0.0409)

1.40 (0.0551)

1.07 (0.0421)

1.43 (0.0563)

1.10 (0.0433)

1.46 (0.0575)

1.13 (0.0445)

1.49 (0.0587)

Thickness mm (in)

Thickness mm (in)

2.23 (0.0878)

2.47 (0.0972)

2.27 (0.0894)

2.51 (0.0988)

2.31 (0.0909)

2.55 (0.1004)

2.35 (0.0925)

2.59 (0.1020)

2.39 (0.0941)

2.63 (0.1035)

2.43 (0.0957)

2.67 (0.1051)

Thickness mm (in)

Thickness mm (in)

1.31 (0.0561)

1.55 (0.0610)

1.35 (0.0531)

1.59 (0.0626)

1.39 (0.0547)

1.63 (0.0642)

ADJUSTMENT SNAP RING AND SPACERS

TSB Revision

MANUAL TRANSAXLE OVERHAUL

22B-7

Spacer (For adjustment of  output shaft end play)

Snap ring (For adjustment of reverse idler gear thrust washer end play)

Spacer (For adjustment of center differential case end play)

1.43 (0.0563)

1.67 (0.0657)

1.47 (0.0579)

1.71 (0.0673)

1.51 (0.0594)

Thickness mm (in)

Thickness mm (in)

0.86 (0.0339)

1.19 (0.0469)

0.89 (0.0350)

1.22 (0.0480)

0.92 (0.0362)

1.25 (0.0492)

0.95 (0.0374)

1.28 (0.0504)

0.98 (0.0386)

1.31 (0.0516)

1.01 (0.0398)

1.34 (0.0528)

1.04 (0.0409)

1.37 (0.0539)

1.07 (0.0421)

1.40 (0.0551)

1.10 (0.0433)

1.43 (0.0563)

1.13 (0.0445)

1.46 (0.0575)

1.16 (0.0457)

1.49 (0.0587)

Thickness mm (in)

Thickness mm (in)

1.77 (0.0697)

2.12 (0.0835)

1.82 (0.0717)

2.17 (0.0854)

1.87 (0.0736)

2.22 (0.0874)

1.92 (0.0756)

2.27 (0.0894)

1.97 (0.0776)

2.32 (0.0913)

2.02 (0.0795)

2.37 (0.0933)

2.07 (0.0815)

2.42 (0.0953)

Thickness mm (in)

Thickness mm (in)

1.07 (0.0421)

1.34 (0.0528)

1.10 (0.0433)

1.37 (0.0539)

1.13 (0.0445)

1.40 (0.0551)

1.16 (0.0457)

1.43 (0.0563)

1.19 (0.0469)

1.46 (0.0575)

1.22 (0.0480)

1.49 (0.0587)

1.25 (0.0492)

1.52 (0.0598)

1.28 (0.0504)

1.55 (0.0610)

1.31 (0.0516)

Thickness mm (in)

Thickness mm (in)

SPECIAL TOOLS

TSB Revision

MANUAL TRANSAXLE OVERHAUL

22B-8

SPECIAL TOOLS

M1222000600921

TRANSAXLE

Tool

Tool number 
and name

Supersession

Application

MD998917
Bearing 
remover

General service tool

Removal of gears and bearings

MB990842
Drag link 
bushing 
remover and 
installer B

• Removal of input shaft 5th 

speed gear

• Removal of output shaft taper 

roller bearing

• Removal of output shaft 5th 

and 4th speed gears

MD998812
Installer cap

General service tool

Use with installer and installer 
adapter

MD998813
Installer-100

General service tool

Use with installer cap and 
installer adapter

MD998819
Installer adapter 
(40)

General service tool

• Installation of taper roller 

bearing

• Installation of output shaft 5th 

speed gear

MD998822
Installer adapter 
(46)

• Installation of input shaft 

3rd-4th speed synchronizer 
sleeve and 3rd-4th speed 
synchronizer hub

• Installation of input shaft 5th 

speed synchronizer sleeve 
and 5th speed synchronizer 
hub

• Installation of input shaft 4th 

speed gear sleeve

• Installation of input shaft 5th 

speed gear sleeve

• Installation of input shaft taper 

roller bearing

• Installation of output shaft 3rd 

speed gear

 

 

 

 

 

 

 

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