P/N: MD747707 is correct and was installed into my transmission with no issues. I ordered most of my parts from amayama.com although some can be found at stmtuned.com etc. I order about 80% of that list and installed all parts with no issues.

OIL SEAL,M/T INPUT SHAFT ($19.07 Japan)
Genuine Mitsubishi (MD741818)

OIL SEAL,T/F CASE COVER,FR;OIL SEAL,T/M FR/FL DIFF CASE ($2.87 Japan)
Genuine Mitsubishi (MD755526)

CAP,M/T CASE SEAL ($5.30 Japan)
Genuine Mitsubishi (MD746157)

Meh ... LanceNot

 

Hi LanceNot

Quite detailed your post, with a lot of photos and references, great thanks.
Did you manage to solve the rubbing issue?
The manual is quite poor in this area, especially checking assembly and checking clearances etc.

I am about to rebuild my F5M42-2-B7B4 transmission from a CS9W Lancer, that's a European Lancer Sport Wagon 2.0 DOHC with a 4G63 non boosted engine.
The transmission is disassembled and now comes to quest of finding parts. I am using partsouq to find part numbers and are comparing them to your OEM numbers but I have no matches so far.
The B7B4 suffix of the transmission is all about the ration of the internals:
speedometer gear ratio 30/36
First gear 3.583
Second gear 1.947
Third gear 1.379
Fourth gear 1.030
Fifth gear 0.82
Reverse 3.363
Gear ratio of the main gear 4.058

If I try to search for 'RING ASSEMBLY , M/T 1 Gear Synchro' with your link amayama, I get the OEM md749031 but partsouq tells me MR581896 or 2551A011?
Do you know by chance if the sleeves and synchro rings (per gear of course) are all the same in the F5M42 family and the difference in OEM numbers is just part number history or something?
Do you thing it is ratio dependent?
My idea was also to change the 5th gear (input / output shaft) to a lower ratio (Galant or possibly an EVO gear ) to get better MPG on the highway. I life in Europe so we drive around 120 - 140 km/h and with my current gear setup I am around 4000 RPM. Do you know if I change the 5th gear, do I need another synchro ring, I think this would make sense as the new gear is smaller in diameter.

Sorry for the bunch of questions, I just very eager to learn some facts from you as there is simply nobody else that tackled this job it seems.
Thanks
xordonkey

 

As far as I know all F5M42 transmissions essentially have the same parts, even the early models. I don't believe that any parts cross over from W5M42 to the F5M42 perhaps some one has done more research in this department and might know more. Changing the 5th gear ratio should be fine just use the syncro\sycro key P/N needed for your 5th gear. I wouldn't surprised if you could use the same P/N's I have provided for your build. Please verify all P/N's by using MMC ASA parts looks up software you should be able to download it here https://mitsubishi-asa.com/ or do some google searching and you will find it.

LanceNot ....

 

Thanks for your reply, I really appreciate it that you revived this thread even after such a long time, thanks man.
The ASA software was a great tip thanks a lot! Painful to use but very helpful, it creates a part list from the parts I select and then it shows all the updated part numbers by displaying the manufacturer bulletins - this is very useful as partsouq doesn't have all up-to-date part numbers and amayama doesn't know my model.
So my F5M42-2-R7B4 shares all syncro keys with your model but syncro rings only for 3rd, 4th and 5th gear. The input / output shaft and differential bearings are the same, although my part number is MD710663.

CS9W (2000/DOHC(WAGON)) LNHML6 (SPORT(MPI),5FM/T LHD) H02 Exterior: A31B Interior: 92J
Part Spec Ref-Price Order Qty
001 MR581896 22545A RING ASSY,M/T 1ST SPEED GEAR SYNCH 1
002 MD747707 22409 BEARING,M/T OUTPUT SHAFT ROLLER,70 1
003 MR581389 22595 SPRING,M/T SYNCH KEY 1
004 MR581389 22595 SPRING,M/T SYNCH KEY 1
005 MR581896 22546A RING ASSY,M/T 2ND SPEED GEAR SYNCH 1
006 MN168937 22596 RING,M/T SYNCH 1
007 MR581383 22595 SPRING,M/T SYNCH KEY 1
008 MN168857 22558 SLEEVE,M/T 5TH & REV SYNCH 1
009 MN168936 22592 RING,M/T OUTPUT SHAFT REV SYNCH 1
010 MD747740 22409W BEARING,M/T OUTPUT SHAFT BALL,72 1
011 2526A001 22008 BEARING,M/T INPUT SHAFT BALL,68 1
012 MR581382 22596 RING,M/T SYNCH 1
013 MR581383 22595 SPRING,M/T SYNCH KEY 1
014 MR581381 22562 SLEEVE,M/T 3RD & 4TH SYNCH 1
015 MN168937 22596 RING,M/T SYNCH 1
016 MD717670 22008W BALL,62
22602 BEARING,M/T INPUT SHAFT BEARING,M/T DIFF CASE 1
017 MD710663 TAPER ROLLER,72 1

The parts sum up to a crazy amount. When I check EVO gearbox rebuild kits a syncro ring is 40$. It would be interesting to find out if F5M and W5M transmissions share the same input (they share the same 4G63 spline) and output shafts, gears and seals. This would mean I could build a F5M42 box with cheaper and available evo parts. The gear ring of the differential is bolted to the differential shaft so this could be replaced with mine if the fixed gear on the output shaft is different (I assume this is the case due to the difference in ratio). The part number for the differential bearing is the same as mine, the other bearing have different part number. If I had the dimensions of the shaft and inner/outer race of the bearings I could verify this, but it impossible to find anything in the net.

I found your solution to the rubbing problem. The only explanation I have is that the press in special tool MB990935 has a large enough outer diameter that it makes contact first with the casing during pressing in, this would mean that the bearing is flush with the casing instead of being pressed all the way to the bottom, but the workshop manual doesn't mention it and usually they do if it is necessary (as with the busing installation one page before). But again I cannot find any dimension on the tool.Still curious why a deeper location of the bearing would impact geometry of the shaft. The press fit is the same (as the whole outer race is pressed in in both cases) unless there is a tolerance in the boring of the bearing seat there or in the shaft itself (I doubt the latter), mechanically it doesn't matter if the shaft runs inside a bearing that is 1mm deeper pressed in or not.
Do you still have your car?

Thanks again for your help!

 

I stand corrected, I found some dimensions on input shaft bearings.
The F5M42 has a 22mm OD spline then comes the bearing (partsno. 18) 68 OD x 25mm ID at the end the bearing (partsno. 2) is 62 OD x 30mm ID.
The W5M42 has a 22mm OD spline then comes the bearing (partsno. 18) 72 OD x 30mm ID at the end the bearing (partsno. 2) is 80 OD x 35mm ID.
So it seems the shaft has a 5mm larger outer diameter and therefore the gears are different.

 

Hi xordonkey, Did you have any luck with the 5th gear swap to get a different ratio?