Replacing the output shaft seal on a Mitsubishi Evolution IV or V can be a bit technical, but I’ll break it down into simple steps. click here for more details on the download manual…..

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Before you begin, make sure you have the necessary tools and materials on hand. Here’s a basic guide:

### Tools and Materials Needed:
– New output shaft seal
– Socket set
– Wrenches
– Screwdrivers
– Pliers
– Jack and jack stands
– Drain pan
– Gear oil
– Clean rags
– Seal puller (optional but helpful)

### Step-by-Step Guide:

1. **Safety First**:
– Park the car on a flat surface and engage the parking brake.
– Put on safety glasses and gloves to protect yourself.

2. **Raise the Vehicle**:
– Use a jack to lift the front of the car and secure it with jack stands. Make sure it’s stable before you crawl underneath.

3. **Drain the Gear Oil**:
– Place a drain pan under the transmission. Remove the drain plug (usually located at the bottom of the transmission) to let the old gear oil drain out completely. This might take some time.

4. **Access the Output Shaft**:
– Once the oil is drained, locate the output shaft. This is usually where the driveshaft connects to the transmission. you may need to remove the driveshaft or other components to gain clear access to the output shaft seal.

5. **Remove the Old Seal**:
– Use a seal puller or a flat-head screwdriver to carefully pry out the old output shaft seal. Be careful not to damage the surrounding area. If you’re using a screwdriver, gently work your way around the seal to pop it out.

6. **Clean the Area**:
– Before installing the new seal, clean the area around the output shaft thoroughly with a rag to remove any debris or old oil.

7. **Install the New Seal**:
– Take the new output shaft seal and apply a little bit of gear oil to the inner lip of the seal. This helps it seat better and reduces the chance of damage during installation.
– Carefully press the new seal into place. you can use a socket that matches the outer diameter of the seal to gently tap it in evenly. Make sure it’s seated flush against the transmission.

8. **Reassemble Everything**:
– Reinstall any components you had to remove (like the driveshaft). Make sure all bolts are tightened to manufacturer specifications.

9. **Replace the Gear Oil**:
– Once everything is back together, replace the drain plug if you removed it.
– Refill the transmission with new gear oil through the fill plug (located on the side of the transmission). Use a funnel to avoid spills, and fill it until it starts to dribble out of the fill hole.

10. **Check for Leaks**:
– Before you lower the car, check around the new seal for any leaks. If everything looks good, you can lower the vehicle.

11. **Test Drive**:
– Take the car for a short drive to ensure everything is working properly and check again for leaks.

### Final Tips:
– Make sure to dispose of the old gear oil properly, as it can be harmful to the environment.
– If you’re unsure about any step, consult your vehicle’s repair manual or seek help from a professional mechanic.

By following these steps, you should be able to successfully replace the output shaft seal on your Mitsubishi Evolution IV or V. Good luck!
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