Clutch Kit

Remove the transmission assembly to access and replace the clutch disc, pressure plate, and release bearing. Includes flywheel inspection and resurfacing preparation.

Warnings

Tools required

Parts

• Clutch disc × 1 — Use OEM or performance kit specification
• Pressure plate × 1 — Use OEM or performance kit specification
• Release bearing (throw-out bearing) × 1 — Use OEM or performance kit specification
• Pilot bearing × 1 — Use OEM specification
• Transmission input shaft seal × 1 — Use OEM specification
• Flywheel bolts (if reusing flywheel) × 8 — Use OEM specification - single-use stretch bolts

Fluids

• 75W-90 GL-5 gear oil (transmission) — 2 qt

Preparation

1. Park vehicle on level ground and engage parking brake
2. Disconnect negative battery terminal and secure cable away from battery post
3. Raise front of vehicle and support securely on jack stands at front subframe or manufacturer jacking points
4. Remove front wheels
5. Remove engine undertray and front splash shields
6. Drain transmission fluid into catch pan by removing drain plug on transmission case
7. Allow engine to cool completely if recently operated

Procedure

1. 1

   Remove front axle halfshafts
   Remove the front axle halfshafts from both sides. Remove the 32mm axle nut from each side (center punch and chisel the staked portion first). Separate the lower ball joint from the knuckle on each side (verify attachment method and fastener size against OEM spec). Pull the knuckle outward and use a soft mallet to tap the axle shaft out of the hub. Support the outer CV joint to prevent damaging the boot. Carefully pry each inner CV joint from the transmission case using a pry bar between the inner CV housing and transmission. Fluid will drain, so position catch pan accordingly. Support halfshafts with wire or set aside safely.
2. 2

   Disconnect shift linkage and electrical connections
   Locate the shift linkage at the transmission. Disconnect the shift control linkage from the transmission. Remove the retaining clips/bolts and disconnect the shift and select rods/levers from the transmission shift linkage arms. Disconnect the reverse light switch connector, vehicle speed sensor connector, and any other electrical connectors on the transmission case. Label connections if needed for reference during reassembly. Note: Locate the shift linkage at the transmission. Remove the shift control rod retaining clips/pins and disconnect the shift and select control rods from the transmission linkage arms.
3. 3

   Remove starter motor
   Disconnect the main power cable and trigger wire from the starter solenoid. Remove the 2 starter mounting bolts (14mm) and remove the starter motor from the bell housing. Set aside in a safe location.
4. 4

   Disconnect transfer case and propeller shaft
   Mark the orientation of the front propeller shaft to the transfer case flange for reassembly. Remove the 4 bolts securing the front propeller shaft to the transfer case output flange (12mm). Support the propeller shaft and remove the center bearing support bracket bolts (12mm). Lower the propeller shaft and set aside. Drain the transfer case fluid if not already drained with transmission fluid.
5. 5

   Support engine and remove transmission mounts
   Position a floor jack with a block of wood under the engine oil pan to support engine weight. Remove the transmission rear mount bracket bolts (17mm). Remove the transmission crossmember mounting bolts (17mm) from the chassis and remove the crossmember assembly. The transmission is now supported only by the bell housing connection to the engine.
6. 6

   Disconnect hydraulic clutch line
   Locate the clutch slave cylinder on the side of the transmission bell housing. Disconnect the hydraulic line from the slave cylinder (verify fitting type for this vehicle — may be a threaded/banjo fitting rather than a quick-disconnect). Alternatively, unbolt the slave cylinder from the bell housing and set it aside with the line still attached to avoid introducing air. Some fluid will leak, so have a rag ready. Do not depress the clutch pedal with the line disconnected or air will enter the system. Note: Disconnect the hydraulic line from the slave cylinder (the line uses a threaded fitting — verify the connection type on this vehicle before disconnecting).
7. 7

   Remove bell housing and transmission mounting bolts
   Position the transmission jack under the transmission and secure with the jack saddle and safety chain. Remove all bell housing bolts connecting the transmission to the engine block. There are typically 4-6 bolts of varying lengths around the perimeter of the bell housing (14mm and 17mm). Note the location of each bolt length for proper reassembly. Ensure all bolts are removed before attempting to separate the transmission.
   Torque spec

   Transmission Bell Housing Bolt55 Nm (40.6 lb-ft)
8. 8

   Remove transmission assembly
   With all bolts removed and transmission supported on jack, carefully pull the transmission straight back away from the engine. The input shaft will slide out of the clutch disc and pilot bearing. Do not allow the weight of the transmission to hang on the input shaft as this can damage the clutch disc. Once the input shaft is clear, lower the transmission jack and roll the transmission out from under the vehicle. Have an assistant guide and stabilize during removal.
9. 9

   Remove pressure plate and clutch disc
   With the transmission removed, the clutch assembly is now visible on the flywheel. If reusing the pressure plate, mark its orientation to the flywheel with a paint pen for balanced reassembly. Insert a flywheel holding tool or large flathead screwdriver between the flywheel teeth and block to prevent rotation. Loosen the 6 pressure plate bolts in a gradual crisscross pattern, turning each bolt 1-2 turns at a time to release spring pressure evenly. Once all bolts are loose, remove them completely and remove the pressure plate. Carefully remove the clutch disc from the flywheel, noting which side faces the flywheel (the side with the dampening springs typically faces the transmission).
   Torque spec

   Pressure Plate Bolt25 Nm (18.4 lb-ft)
10. 10

    Inspect flywheel and remove if necessary
    Inspect the flywheel surface for heat checking, cracks, deep grooves, or hot spots. If resurfacing is needed, mark the flywheel orientation to the crankshaft with a paint pen. Use the flywheel holding tool to prevent rotation. Remove the flywheel mounting bolts (verify exact count against OEM spec for the 4G63 — commonly 7). Remove the flywheel and take it to a machine shop for resurfacing if needed. The flywheel bolts are single-use stretch bolts and must be replaced with new bolts during reinstallation.
    ⚠Flywheel bolts are single-use and must be replaced if flywheel is removed.
    Torque spec

    Flywheel Bolts80 Nm (59 lb-ft)
11. 11

    Replace pilot bearing
    Remove the pilot bearing from the center of the crankshaft. This can be done using a slide hammer with an internal puller attachment or by packing the bearing cavity with heavy grease and using a close-fitting drift to hydraulically pop the bearing out. Clean the pilot bearing bore in the crankshaft thoroughly. Install the new pilot bearing using a correctly sized driver or socket that contacts only the outer race. Drive the bearing in until it is flush with or slightly recessed from the crankshaft face.
12. 12

    Clean and inspect all components
    Clean the flywheel surface with brake cleaner and a wire brush (if not removed for resurfacing). Clean the pressure plate mounting surface and inspect for cracks. Inspect the transmission input shaft splines for wear, burrs, or damage. Clean the splines with a wire brush. Inspect the release bearing sleeve on the transmission input shaft bearing retainer for wear. Replace the input shaft seal in the transmission bell housing if any seepage is evident.
13. 13

    Install flywheel (if removed)
    If the flywheel was removed, align it to the crankshaft using the previously made orientation marks or align the dowel pin holes. Install new flywheel bolts and tighten in a crisscross pattern to the OEM-specified torque (verify against factory spec for the 4G63 — typically approximately 135 Nm / 100 lb-ft). Use the flywheel holding tool to prevent rotation during tightening. Note: Install new flywheel bolts and tighten in a crisscross pattern to the OEM-specified torque (verify against 4G63 Evo VIII service data — typically approximately 135 Nm / 100 lb-ft; confirm exact value and any angle spec).
    Torque spec

    Flywheel Bolts80 Nm (59 lb-ft)
14. 14

    Install new clutch disc and pressure plate
    Lightly lubricate the transmission input shaft splines with a small amount of high-temperature clutch grease (do not over-apply). Insert the clutch alignment tool through the new clutch disc and into the pilot bearing to hold the disc centered. Ensure the clutch disc is oriented correctly per the markings stamped on the disc (typically marked 'flywheel side' or 'getriebe seite/transmission side'); install the disc with the longer hub boss facing the transmission unless the disc markings indicate otherwise. Position the disc against the flywheel. Place the new pressure plate over the clutch disc, aligning the dowel pins if equipped or matching previous orientation marks if reusing. Hand-thread all pressure plate bolts (verify exact count against OEM spec). Tighten the bolts gradually in a crisscross pattern to prevent warping, bringing each bolt to the OEM-specified torque (verify against factory spec for the 4G63). Remove the clutch alignment tool after all bolts are fully torqued.
    ⚠Do not touch the friction surface of the clutch disc with greasy hands. Contamination will cause clutch chatter and slippage.
    Torque spec

    Pressure Plate Bolt25 Nm (18.4 lb-ft)
15. 15

    Install release bearing
    Inspect the release bearing fork inside the bell housing for wear or cracks. Lightly lubricate the release bearing contact points on the fork and the input shaft bearing retainer sleeve with high-temperature grease. Install the new release bearing onto the input shaft bearing retainer sleeve. Engage the release bearing with the release fork arms, ensuring it clips or seats properly onto the fork.
16. 16

    Reinstall transmission assembly
    Apply a light coat of high-temperature grease to the input shaft splines (do not over-apply). Position the transmission on the transmission jack and carefully align the input shaft with the clutch disc splines. Use the alignment marks or guide the input shaft through the clutch disc into the pilot bearing. Push the transmission forward while rotating the output shaft slightly to help the splines engage. Once the input shaft is fully inserted, push the transmission flush against the engine block. Install all bell housing bolts in their correct locations and tighten in a crisscross pattern to the OEM-specified torque for each bolt position (verify against factory spec; larger bolts will have higher torque values than smaller ones). Do not force the transmission into place by tightening bolts; it should slide in smoothly once aligned. Note: Install all bell housing bolts in their correct locations and tighten each to the OEM-specified torque for its size (verify exact values against 4G63 Evo VIII service data; larger M12 bolts are typically ~60 lb-ft and smaller M10 bolts ~35 lb-ft).
    ⚠If the transmission does not slide flush with the engine block easily, do not force it with bolts. The input shaft may be misaligned with the clutch disc splines. Withdraw and realign.
    Torque spec

    Transmission Bell Housing Bolt55 Nm (40.6 lb-ft)
17. 17

    Reinstall transmission mounts and crossmember
    Install the transmission crossmember and hand-thread the chassis mounting bolts. Install the transmission rear mount bracket and hand-thread all bolts. Align all components and tighten the crossmember chassis bolts to specification (typically 40-50 Nm). Tighten the transmission mount bracket bolts to specification. Remove the floor jack supporting the engine.
18. 18

    Reconnect hydraulic clutch line and starter
    Reconnect the hydraulic clutch line to the slave cylinder, ensuring the quick-disconnect fitting clicks into place and the retaining clip is secured. Reinstall the starter motor into the bell housing and tighten the 2 mounting bolts to specification (typically 35-45 Nm). Reconnect the main power cable and trigger wire to the starter solenoid.
19. 19

    Reconnect transfer case and propeller shaft
    Raise the front propeller shaft into position and install the center bearing support bracket bolts. Align the propeller shaft to the transfer case flange using the orientation marks made during disassembly. Install the 4 flange bolts and tighten to specification (typically 40-50 Nm).
20. 20

    Reconnect shift linkage, electrical connections, and halfshafts
    Reconnect all electrical connectors to the transmission (reverse light switch, vehicle speed sensor, etc.). Reconnect the shift cables to the transmission linkage arms and secure with retaining clips. Install new circlips on the inner CV joints if required. Insert each halfshaft inner CV joint into the transmission case, pushing firmly until the circlip engages with an audible click. Insert the outer ends of the halfshafts into the wheel hubs. Reconnect the lower ball joints to the knuckles and tighten bolts to specification. Install new 32mm axle nuts and tighten to the OEM-specified torque (verify exact value against 4G63 Evo VIII service data), then stake the nut collar into the axle shaft groove.
21. 21

    Refill transmission and transfer case fluids
    Refill the transmission with the OEM-specified gear oil (verify spec — many 4G63 manual transaxles require GL-4 rather than GL-5 to protect synchronizers) until fluid begins to seep from the fill hole (verify capacity against factory spec). Install the fill plug and tighten to specification. Refill the transfer case with the OEM-specified transfer case gear oil (verify type and capacity against factory spec). Do not confuse this with the ACD (Active Center Differential) hydraulic fluid, which is a separate system. Install the fill plug and tighten to specification. Note: Refill the transmission with the Mitsubishi-specified manual gearbox oil (verify GL-4 vs GL-5 requirement for this transmission — many 4G63 synchromesh gearboxes require GL-4) through the fill plug until fluid begins to seep from the fill hole (approximately 2.0–2.3 quarts; confirm exact capacity). Note: Refill the transfer case/center differential with the Mitsubishi-specified gear oil (verify spec and capacity against service data; approximately 0.5–0.6 quarts). Note: the ACD hydraulic system uses separate dedicated ACD fluid and should not be confused with the transfer case gear oil.
22. 22

    Final inspection and test
    Reinstall the engine undertray and front splash shields. Reinstall the front wheels and tighten lug nuts to specification (typically 90-100 Nm). Lower the vehicle to the ground. Reconnect the negative battery terminal. Start the engine with the clutch pedal depressed and verify the engine starts normally. With the engine running and clutch pedal depressed, shift through all gears to verify proper engagement. Release the clutch slowly in neutral to verify no abnormal noise from the release bearing. Test drive the vehicle to verify smooth clutch engagement, no slippage under load, and proper shift operation.

Reassembly

1. Torque all fasteners to the specified values in the correct sequence
2. Ensure the clutch disc is installed with the correct orientation (damper springs toward transmission)
3. Verify all electrical connectors and hydraulic lines are properly secured
4. Check that halfshaft circlips are fully engaged in the transmission
5. Bleed the clutch hydraulic system if air entered during disconnection

Verification

• Start engine with clutch pedal depressed - engine should start normally without gear clash
• With engine running, shift through all gears with clutch depressed - shifts should be smooth without grinding
• Release clutch pedal in neutral - no abnormal bearing noise should be present
• Test drive and verify smooth clutch engagement without chatter or slippage
• Verify no fluid leaks from transmission, transfer case, or clutch hydraulic line
• Check clutch pedal feel and travel - pedal should have normal resistance and return fully

Related trouble codes on this vehicle

Codes that commonly send this job to the bay — tap one for symptoms, causes, and diagnostic steps.

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