Hey everybody,

I am the owner of a mitsubishi outlander turbo with a 2.0L petrol turbo engine , type 4G63T and 148kW (201 HP ) . couple of month ago i decided to change the fluids in my car so i went to the local mitsubishi dealer , and he provided me mobil1 oils for gearbox, Tcase and rear diff. after a time I started to hear some whining ...then it becamed louder and louder .....so luod like a bad bearing ! was louder then the stereo i had !
one day , inevitable happened .... i hear clunk-buf-clank-bum-clank , i stopped the car .... i looked arround , couldn't saw anything suspicious .
I continued to drive the car home on slow speed , but i could feel some resistance from time to time ...like something braking the transmission and the noise was clunk-clunk-clunk-clunk-clunk like iron on iron / steel on steel sound.

Here is the tests i have made:

1. I lift the car , only the front wheels on stands , front wheels being in air , and rear wheels on the ground....I accelerate a little and slowly release the clutch ...... the car did not wanted to move .

2. I lift the car , only the rear wheels on stands , rear wheels being in air , and front wheels on the ground....I accelerate a little and slowly release the clutch ...... the car wanted to move

I said to myself , that's it ! i need a rear differential and problem is solved.
I have replaced the rear differential and then drove the car. At begining there was no clunk-clunk-clunk sound , so i said to myself.... cool, my car is fix ! ....then i accelerate ......and i saw smtg wierd .... i did not had the speed i supposed to have on that RPM ! WTF !??? i drove the car and i saw revs was going as fast as it should be , but speed not ! ...more wierd even in 3rd gear when i push hard the acc pedal .... i could hear the wheels spinning fast ....it seems i still have NO rear traction

I am waiting for opinions and ideas ..... my guess is my Tcase is broke ...is there any rebuild option for it ? maybe a stage 1 upgrade ? stock Tcase sucks !

what oils are recomanded to be used in gearbox , Tcase and rear diff ?

Thank you all for future answers !



here is the transfer case when i toke it out from gearbox , only numbers on it are showed here:





different angle of Tcase:













Unscrew the drain fluid :



oil smell bad , don't know the words to explain the smell, but for sure is not factory smell , as you can see , i found there grease + metal "span" ( small or thin parts of metal )







After seeing this i said to myself ... " i better open visitor window to see what's inside " ..... here is me doing that :



Again that wierd not-normal smell comming from inside the Tcase , but the worst part is just showing up :



using a contact cleaner spray , i tried to reveal what is that "thing" mixed with grease , and i did saw it , thin metal pieces







I lost my mood and curiosity to look inside the Tcase , but here are some photos :





looking deeper :







looking deeper and deeper

 

i found the answer : NO
they look the same , but internals are not the same, different ratios
parts can not interchange

 

Sorry for posting in this old thread but need to ask. Possible to use the Evo case if you change the rear axle/diff as well?

I think the 600hp Evo-Lander used Evo stuff.

Great forum BTW!

 

not sure it will fit on gearbox ..... i have no ideea .
PM me if you want to share the few information i have found .
cheers

 

They probably used both gearbox and trasfer case to make it work.

On the other hand some say it´s the same gearbox as Evo 8 with transfer case as only difference.

Will PM right away!

 

Just found this, pretty good info. From the Israel built Evo-Lander.

"Transmission -
Stock 5 speed gear box (same as Evo-8) with a short shifter.
CARBONETIC - ATS triple carbon Clutch, for coping with the power and torque but with spring lowed that will be not harder than a stock clutch.
Jacks Transmissions (USA) upgraded 4AWD EVO-8 transfer-case with viscous, capelin central differential 50/50%.
WaveTrac front LSD, a torque biasing differential with a difference! Design automatically improves grip in low traction conditions. Construction: 9310 steel gears run in case-hardened billet steel bodies. ARP® fasteners used throughout. Limited lifetime warranty. Evo-9 RS rear LSD."

 

I was hoping that it was the same

 

sorry to revive an older thread, but I have some info to add on this topic that someone may find useful (like I would have a few months ago)

firstly the gear ratios are different, BUT close enough to work

the outlander has 53/16 (crown/pinion) making 3.3125
the evo has 43/13 making 3.307

the actual difference in speed front/rear would then be about .15% which is of no real significance (to put this into context, this is the same difference you would get if the tyres at one end of the car were worn .5mm more/less than the other end of the car)..

infact I know of people who have put evo rear diffs into Legnums (legnums have 3.3125 tcase ratio and evo have 3.307 rear diff ratio) and nothing terrible has happened. so these ratios are close enough to work together.

so it isn't the ratio that is the problem


however the big issue is that the internals are completely off..

the outlander one has MUCH smaller splines (and diameter) in the gearbox/tcase interfaces..

also the outlander diff (inside the tcase) has much smaller shafts running to it.

ontop of that the VCU on the outlander is about 1cm (12mm to be exact i recall) shorter than the evo one, AND has different diameter connectors to the housing.

so to put it short,internally they are very different.

and you cant swap an evo diff into an outlander case/vice versa as the diff/housing units are different sizes (outlander one is 12mm smaller due to the shorter VCU).

also you cant simply swap over the VCU units to make it fit as the VCU/diff housing interface is off aswell!



and finally, the shoulder that the ring gear slips onto is a different size on the outlander so even if you did manage to overcome all the other things and get an evo housing into a outlander case/other way round then the ring gear either wouldn't fit without being ground down, or would float about (depending what your swapping!)


This picture summarizes the differences internally :




HOWEVER:

im not entirely sure about evo 7/8/9 measurements (my diff unit came from a 6 i think)!

if anyone on here has access to an evo 7/8/9 non acd tcase you can crack open and take some measurements off please PM me, would love to find outif theres a difference that could make this work. (over here in aus every evo 7/8/9 has ACD as far as i can tell, so i havent been able to source one locally for me to measure myself)

 

I am kinda I terested In this also will a 03 USDM outlander tcase fit a 03 Evo

 

No It wont.

all the internals and mating parts are completely different.

the diff housing is way smaller on the outlander the transfer shafts are thinner, the VCU is smaller and the actual case itself is smaller (to accommodate the smaller VCU).

the only parts that appear to be the same physical size are the ring and pinion gears. But even then they are different ratios (evo 3.307:1, outlander 3.3125:1). theoretically they are close enough to work, but I have no idea if the outlander gears are comparable in strength to evo ones. I would guess not.

If you happen to have a trashed transfer case from an evo 3 though please send me a PM, I may be interested in a few of the internal parts for my project car build!

 

Again, revive an older thread... My Evo 4 rear diff dies.. And I would like to know if the Outlander rear diff could fit in my Evo.

I read some older threads that said VR$ or 8G Galant 2.4 AWD rear diff non AYC fit in Evo 4 (ratio is 3.312), but in my country is harder to find this car, and I dont have more that $600-$700 to buy an Evo rear diff + axles to swap in my evo 4.

 

I got 3 as spare, but i am sure shipping would be a killer .........

 

but It will fit or no???
Supostly today I will buy an OEM Evo 4 rear diff, but I dont know what to do,

 

at this question I think only person I know and can give a honest answer is Steffan Thorman from Germany !

 

5 year truole diamond tech. Unless you have sawc. Which likely dont when lifting fron tires and not rear only front will spin. T case is open diff and rear end is open diff. T case will act just like a one wheel peel rear end and only send power to the least resistance. Ievwheels in the air. If clunking in 4wd when corninging drive coupler. 100 percent throttle in lock sends approx 60 % rear 40 front. To truley test you need to getvon a somewheat slippery surface ie snow sand dirt. 100 percent throttle tl determine if drive coupler is engaging. Rarely of ever t case. Or rear diff. Theyvwill explode if run dry and have nothing but slude. Filings are normal for. T case and diff. But not large metal chunks. Never seen a tcase or rear diff fail. Have seen a few d couplers. But commonly the wiring going tobd coupler has failed or been rubbed through. I would dif into drive coupler