Mitsubishi Outlander (2003+). Manual — part 164

SEALANTS AND ADHESIVES

MANUAL TRANSMISSION OVERHAUL

22B-9

SEALANTS AND ADHESIVES

M1222000500106

FORM-IN-PLACE GASKET (FIPG)
This transmission 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
applying it. Bead size, continuity and location are of
paramount 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
without 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.

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 surface 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 (in less
than 10 minutes after application). Do not allow FIPG
to spread beyond the sealing areas during
installation. Avoid operating the transmission or
letting 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.

Item

Specified sealant

Clutch housing-transaxle case mating surface

MITSUBISHI Genuine sealant part No. MD997740 or
equivalent

Under cover-transaxle case mating surface
Control housing-transaxle case mating surface
Air breather

3M SUPER WEATHERSTRIP No.8001 or equivalent

Differential drive gear bolt

3M STUD Locking No.4170 or equivalent

LUBRICANTS

MANUAL TRANSMISSION OVERHAUL

22B-10

LUBRICANTS

M1222000400132

TRANSMISSION

TRANSFER

SPECIAL TOOLS

M1222000600181

Item

Specified lubricant

Each O-ring

Hypoid gear oil SAE 75W-90 or 75W-85W conforming to
API classification GL-4

Each oil seal
Select lever shoe

MITSUBISHI genuine grease part No.0101011 or
equivalent

Input shaft front oil seal

Item

Specified lubricant

Each O-ring

Hypoid gear oil API classification GL-5 SAE 90

Each oil seal

Tool

Number

Name

Application

MB990935

Installer adapter

Installation of differential case
taper roller bearing outer race
<F5M42> and center differential
case rear taper roller bearing
outer race <W5M42>

MB990938

Handle

Use with Installer adapter

MB990927

Installer adapter

Installation of sealing cap

MD998801

Bearing remover

Installation and removal of
gears, bearings and sleeves

MD998812

Installer cap

Use with Installer and Installer
adapter

B990938

SPECIAL TOOLS

MANUAL TRANSMISSION OVERHAUL

22B-11

MD998813

Installer-100

Use with Installer cap and
Installer adapter

MD998816

Installer adapter (30) Installation of input shaft front

bearing

MD998825

Installer adapter (52) Installation of 1st-2nd speed

synchronizer hub, 3rd-4th
speed synchronizer hub and 1st
speed gear sleeve

MD998824

Installer adapter (50) Installation of 4th speed gear

sleeve, 5th speed gear and
thrust plate stopper

MD998818

Installer adapter (38) Installation of input shaft rear

bearing, roller bearing inner
race, reverse gear sleeve and
output shaft rear ball bearing

MD998917

Bearing remover

Installation and removal of
gears, bearing and sleeves

MD998814

Installer-200

Use with Installer cap and
Installer adapter

MD998822

Installer adapter (46) Installation of 2nd speed gear

sleeve and 3rd speed gear

Tool

Number

Name

Application

SPECIAL TOOLS

MANUAL TRANSMISSION OVERHAUL

22B-12

MD998819

Installer adapter (40) Installation of 5th-reverse

speed synchronizer hub, 4th
speed gear and 5th speed gear
sleeve

MD999566

Claw

Removal of taper roller bearing
outer race

MD998772

Valve spring
compressor

Removal of output shaft front
roller bearing outer race

MD998346

Bearing outer race
remover

Removal of output shaft front
roller bearing outer race

MB990934

Installer adapter

Installation of output shaft front
roller bearing outer race

MB991550

Bearing outer race
installer

Installation of center differential
case front taper roller bearing
outer race <W5M42>

MD998325

Differential oil seal
installer

Installation of differential oil seal

MB990926

Installer adapter

Installation of clutch housing
input shaft oil seal

Tool

Number

Name

Application