EDIT 7/22/13 Replaced clutch bell housing assy. Pics added to help others with this issue.
Here is the transmission out and a picture of what I'm talking about.....




This is what you'll need to fix the problem if anyone ever runs into it. Pretty straight forward. No special tools required. Although having a lift and air tools is def. a bonus. Up until today, my buddy and I have never worked on Mitsubishi's or Evo's in general. To be honest, it's not much different than working on honda's.


Here's the tranny on the table, accessories for the tranny, and case removed.




The input/output shaft's removed and differential removed....



The new clutch housing.....


Re-assembled with new housing and case....



And the clutch that's going in while we're fixing this problem....



We know about the throw out bearing and pressure plate deal. It's not as bad as some of the threads that I've read. Still awaiting on shift fork and shaft kit from mitsubishi which will arrive tomorrow. Will update again tomorrow with how she runs.




So today my buddy and I dropped his 2003 evolution 8 gsr transmission and found the mounting point for the clutch fork broke clean off. What I mean is, if you remove the transmission, there will be a 10mm holding the shaft that goes through the shift fork. Well, the part that holds the shaft in place broken clean off.

So the question is, can we use a evolution 6spd outter transmission case on his 5 speed? I checked online and its roughly $821 for the outter transmission case for a 6speed. Can't find any 5 speeds. Will have my dealership contact mitsubishi tommorrow and see if we can get it or not.

Not sure how this happened, he just bought the car a week ago and when he got home the clutch pedal would not fully engage, come to find out a the damn shaft holding the shift fork isn't even in place anymore.

 

This happened to a friend of mine. He actually had good luck welding the broken piece back in place. From what I have noticed there are external differences between the 2 cases, and I will go out on a limb and say that internals will not swap between cases. Have you tried contacting any of the big name transmission shops to see if they have a good case lying around?

 

It's cast aluminium, just get it welded. Or buy a clutch with a hydraulic release bearing. Then you don't need the clutch fork.

 

Correct, I believe the the 6speed case is slightly larger than the 5speed. Welding it back in place is a good option assuming you have the part which broke off. If not I'm sure a good fabricator could whip something up. FYI the case is aluminum IIRC so keep that in mind if you try to source a good welder. If you dont believe it can be repaired I'd hit up a couple drivetrain shops such as Jon@TRE and see if he can be of assistance.

 

Yeah welding would work out the best.... Is this khoi's car?

 

Thanks for all the replies guys. We ending up over nighting one from Mitsubishi, it was $338 and also ordered a new fork and shaft kit while we were at it.

 

I'll take the old one.

 

Blackonblack2 - yes it is Khoi's car, and may I ask who are you?

Got psi? - you can have the old clutch bell housing if you wanna pick it up, doubt he'll ship.

Anyway, got the flywheel back from the machine shop. Just put in a competition clutch stage 2. Just awaiting the shift fork kit. If anyone is interested I can post pics for those that may run into this problem.

 

Make sure you have the machine shop balance the clutch and flywheel together, most people don't think about this but not doing it is like balanceing a wheel and then putting the tire on.

 

Upgrade to a hydraulic TOB
Slave cylinders go out pretty often on a high stage clutch from my experience..

 

updated with pics of damage and fix.

 

Well mine did the same thing last week. As a matter of fact for the last 4 0r 5 months it was having a hard time going into 1st gear from a stop. I had to buy a used one from an import salvage yard. Now I wonder if I should try to get the replaced one modified so it doesn't happen again. Sucks! I can't believe that is so weak that it would brake.