~Slideways~

Back to the oil leak. It's shockingly bad. The mechanics report said something about the transfer case/diff. But I'm pretty certain its the rear main seal. So either way the automatic transmission has to come out. That's when I found someone advertising a gearbox from a CL2A, which is the mirage of similar age but equally rare awd option. Also with the 4g15. So I thought, I should buy this. Did a bunch of research to find that Mitsubishi's gearboxes are all very similar. The only major when it comes to Evo's is after the Evo 1-3 they move the gearbox to the passenger side. This seems to also mean that, unlike the 1-3, the 4 onwards Evo 4g63 had a bigger bellhousing that only fits the 4G63. Previously models the gearbox could fit a 1.8 4G93 as well as the 2L 4G63. I had a think and check pricing on the Evo 4-9 gearbox decided to buy the gearbox and transfer case that fits only the 4G9* anyway. Worst case is I'd have to build a 1.8L turbo. The interesting thing is that it seems based on the model numbers, this gearbox should be as strong, if not stronger than the 1-3 Evo's had. Don't take these as gospel but this is what I think I understand of the gearbox history through the evolutions/gsr-utions. Evo/GSR 1-3 = w5m33 with a 225mm clutch Mirage 1.5L CL2A = w5m42 (also used in a manual 2.4 Outlander, so should be strong right?) GSR (CM5A) = ?? finding it hard to find info. But should be the same bellhousing bolt pattern as the CL2A one above. Evo 4-8 or 9 = w5m51 with a 240mm clutch So in theory, the w5m42 can fit a 225mm clutch and likely has quite close gear ratios. So could work quite well with a 4g93 turbo?

The specs. Engine: 4g15 A 1.5L which is also Twin Cam (JUST LIKE AN EVO), weird because every single other lancer (non GSR or Evo) of this era seems to have a SOHC 4g93 1.8L. Why did they make a twin cam for the 1.5? Wheels: 13" factory steelies. EDIT: 4x100 too which I didn't expect. I think they might be 175's? Basically like the Evo 5 on those thin ice gripping tyres! Auto: 4 speed I think. Evo 7's had an auto option. Same thing. Wind up windows: JUST LIKE AN Evo RS! Rear Diff: IRS, 3.3 I think....just. like. an. RS. No AYC there. Interior: grey. Didn't the Evo RS have Glxi seats? 4G15 twin cam. Probably 100hp maybe?

Always wanted an Evo 5. Prices are nuts now though. Every time I walk my dog I'd walk past this rough '98 Lancer and I noticed the AWD sticker on the back a few years ago. Had a chat to the owner recently and said if he ever wants to sell it let me know. That day came about a week ago when he left me a note saying it has a massive oil leak and do I still want it? *voice over* He did still want it. My main interest was what sort of Mitsubishi 'parts bin' is going on here? How similar is it to the Evo, which is obviously just based on the small 4 door family car that is the Lancer. But SURELY they wouldn't have made a different floor pan for this one model right? I did some part catalogue searches to compare this, which is a CM2A and an Evo 5 CP9A it does look like the rear diff is the same as an RS Evo and the drive shafts are the same too. I think the outer will be different though. The rear subframe itself does look different, there are apparently 2 extra mounting points for the Evo subframe. But it will still bolt in from what I've found...still to be proven, if I want to go that way. Too much words without pictures, so here it is. Stunning. It sure doesn't look like an Evo 5. I've replace that front guard with one from Pick a Part, its just cosmetic damage which is good. I thought the headlight wasn't lining up and thought maybe the radiator support was bent but its just the guard being bent, which is all bolt on. One tab is broken too.

Scope creep! Scope creep! Scope creep! yaaaaay!

I haven't tried it yet but I bought an eSun dry box thing to try fix that. Even my PLA is showing signs of absorbing moisture so prints have come out messy so I think it's the best way to do it. Have you looked at Making for Motorsport on youtube? He did quite a bit of heat testing on Carbon Nylon and even printed it using a basic Ender 3 with a knock off metal hot end. EDIT: and I think he also did tests with fuel but not sure if Ethanol based etc.

I might have missed it, but have you looked at Carbon Nylon instead of HIPS? I've recently got the bits to upgrade my 3d printer to be able to print my ITB manifold with it. Might be a better option? It was about $100 for the filement so not too bad.

That's really good info about the torque rating, I haven't seen that before. In the quote did you mean for the one in bold to be a 51? That makes a lot of sense. If the earlier Evo's on had gboxes to handle 330Nm how on earth did they survive the drag racing hey day?! I have found a W5M42 so will likely be doing that, I was a bit reluctant with not being able to go with a 4g63 but they are all going to be a bit tired anyway. So going straight to a 4g93t plus spool rods or something would be good. If it could handle 200kw at the wheels that would be plenty, maybe that's too much, not sure.

Bit more research and it looks like the 1-3 GSR and Evo's had a gearbox that could be swapped between 93 and 63 blocks. But when they went to the 4-9 with the switched orientation, you can't use a gearbox from a 4g93 on a 63. So that means using a W5M42 on my Lancer, being Evo 4 shape it has the gearbox in the passenger side. I THINK that means the W5M42 used on these 1996 onwards cars is probably very similar to the W5M33 used on the Evo3 etc. They also use a 225mm clutch, unlike the big later evo box using 240mm (W5M51). One thing that goes against this theory of only being able to use a 1.8L 4g9* block is that Google tells me that Outlanders also use this w5m42 gbox in 2.4L... which I thought would be a 4g69?? So I'd probably need to stick to the 4g93 block at most. BUT I could fit a 4G92 1.6 Mivec head which'll flow plenty. Just needs better conrods which looks like the main weakness of the 1.8 4g93's. In the mean time I could fix the 1.5L beast that's in it and at the same time manual swap it with the same w5m42. I should start a project thread but I feel like I've got too many already.

Yes, good point that might be a thing. I thought maybe the bigger clutch was just to get bigger surface area to hold the higher factory power.

You have failed me! haha

Just found that: W5M42 = bellhousing fits 225mm clutch W5M51 = 240mm clutch

Oh right I meant that it is a 4g15 awd manual gearbox, I think that might have read as using a fwd gearbox? Who knows, maybe fwd gboxes could have useful parts. I have seen a 4g15 awd manual gbox/xfer/diff set up for sale. Thinking whether I should go for that. Its a W5M42 which from what I can find might have also been use in 2003ish outlanders, so can't be super weak as an assumption. Evo's are w5m51 so can't be that different (wishful thinking maybe). In theory I could get a fwd manual pedal box from pick a part and clutch master...unless some are cable maybe.

That's really interesting that they used the same internals, do you think that might mean the 4g15 manual gearbox maybe be the same casing as a gsr/evo? Just different ratios possibly? If that was the case I could temporarily get away with using a 4g15 gbox and upgrade it later.

Yeah I've seen the MCM one, pretty cool using a basic 4g69.

That's interesting I thought Legnums were all v6's? Do they share the same bellhousing pattern then?

The Mitsi 4g pick a part options could be pretty good. Maybe a 2.4 turbo 4g64 block and a mivec head if I can find one? Maybe a 4g63 turbo from a dead Airtrek, they always seems to get scrapped due to auto failures. Maybe a 1.8 with mivec head? I'd love to make it looks like an evo 5 but it's tempting to keep it looking like a boring Lancer too... I wonder what kind of brakes could fit under 15's and 4x100 wheels?

Hello, I have a new project that I am doing research on. I've always wanted an Evo 5 or 6 but they are now stupid money. But I have just bought a very tired 1998 Lancer MX. Which is the weird parts bin model that has 4wd, a 4g15 and an auto. Plus it's wofd and regd. There is a hefty leak from somewhere around the transfer case though. I mainly wanted it because it's got the 4wd floor pan. Some parts number searches tell me the rear diff and axles share the same model number of the evo5. The hub end will be different because drum brakes a 4 stud. But it's a good start. I know the subframes are different, being all steel and possible suspension mounting points but I wouldn't think Mitsi would change the chassis mount points...maybe. I want to build a FrankenEvo of sorts. I've found a 5 speed from an 4wd mirage but this will be for the same 1.5L so not much use for a 4g63 if I were to swap it. I'm notnsure if any 4g will fit, surely there will be mount differences, but hopefully this won't be hard to get around. Does anyone have knowledge of what gearbox options there are, do they all fit any 4G engine (gsr/evo 4 onwards)? I'm sure I will have to match up ratios with gbox, transfer and rear diff. Can any of the current auto parts be used with another gearbox? Am I right in thinking the manual gbox for the 1.5L is not going to be very strong even though it seems like it'll fit a 4g93 etc? Kind of strange that its 4x100, but good since I have some wheels from other cars. Could maybe swap to 4x114.3 too (EDIT: meant to say 5x114.3). Any info or feedback would be great, cheers.

My bike ITB's actually did have a DBW set up but it was on the 2nd set of throttles which simple don't seal like the 'real' set do. Yep there is, he's got a build thread too. Really cool swap, I reckon it'd need a cert simply because it looks like a different engine though. Probably the same with ITB's too unless you have a real lenient wof place.

I've been wondering about this recently, the cost of ecu + tune versus fuel saving based on the 30 year old tech/tune (no oxygen sensor and basic AFM, non-variable TPS etc). I'll hopefully be back to dailying my 1.6 MX5 within the next few months after I paint it. But the funny thing is its worse on fuel than my 2L 3sge Celica (St202 with acis, which seems to work pretty well) for the same drive. I thought maybe it was just because of the way I drove the MX5, but a work mate here has had a few and he reckons they are all surprisingly thirsty. I have a Speeduino to go in, whether I do that with the stock intake or with ITB's I'm not sure. It would be interesting to see what sort of fuel economy increase I could get. They have a lowish 9.4:1 compression ratio so it would be worth shaving the head too.

Thanks man, although I've ordered a Mellow one from Aliexpress already, should hopefully be good. This one: https://www.aliexpress.com/item/33035870412.html?spm=a2g0o.order_detail.0.0.622cf19cELrdsv I reckon the NA8 would definitely need some bigger ITB's, maybe from a 1000cc bike but the idea is the same. I was tempted to put a 1.8 in mine but I like the way the 1.6 revs (its probably just the smaller flywheel to be honest but....).

Finished modelling the other side of the intake adapter thing and printed with a finer quality, took over 24hrs to print! Also added an adhesion layer to help with lifting around the edges which worked great. Easily removed afterwards too. Got some strange stringing/hairy bits but only on the middle two faces, not sure why. Internally its perfectly smooth. Both together to make the complete manifold, you can see the print quality difference: Lines up nicely with the ITB's Looking at getting an all metal hot end for the printer and a hardened steel tip so I can try print it with Carbon Fibre Nylon filamnet. Trying to decide which filament to use, there are quite a few variations to look, I guess what ever handles the heat best.

Put some high build primer on it:

Don't jinx me man!

Man how does masking take SO long? It's like a black hole, there's hours in this!