Changing Fluids - Manual Transmission, Transfer Case and Rear

[EvolvedDSM]

These are pictures from my EVO, but are very similar in location to a DSM and you follow the same procedure. Diagrams are from DSM manual.

You first want to raise the vehicle off the ground and secure it on jackstands. I find it easiest to drive the front onto ramps (if you can fit them underneath), jack the rear in the air (using the diff housing as the jack point) and place a jack stand on either side (i.e. the scissor jack points). This will give you room to work underneath while still maintaining a somewhat level angle.

The green circles indicate the fill plug/hole and the red indicate the drain plug/hole. Break loose both bolts and take out the fill bolt first. Keep track of the crush washers (they sometimes stick to the casings and/or fall into your drain pan). You may notice some fluid already coming out at a slow pace--this is normal. Place your finger over the fill hole and remove drain plug (this will keep things a little cleaner). Once you are out of the way, remove your finger and release the fluids (a fair amount will already be coming out). Allow to drain until you see drops rather than a stream. Clean, replace the drain bolt (flip the crush washer around if you don't have a new one) and torque to spec. Fill with proper fluid (I find using a suction gun works best). Once fluid starts to seep out of the fill hole, you are done. Clean, replace fill bolt (flip crush washer around if you don't have a new one) and torque to spec. Spray with brake cleaner to remove any excess fluids.

Transmission--FWD and AWD
17mm fill bolt (23 ft-lbs)
24mm drain bolt (23 ft-lbs)
2-3 qts gear oil (Mitsubishi Diamond Lube 75W-85 GL-4 for EVO 5-speed, Mitsubishi Super DiaQueen 75W-85 GL-4 for EVO 6-Speed, Texaco MTX Fluid FM for 2GNT, 75W-90 for all others)

http://www.columbusdsm.com/forum/files/tranny_186.jpg

Upper is 4G##, lower is 420A. Note two possible locations of drain plug due to AWD/FWD differences on 4G63:
http://www.columbusdsm.com/forum/files/tranny_136.jpg

My first change at 3500mi showed a good bit of shavings on the plug:
http://www.columbusdsm.com/forum/files/3.5ktranny_209.jpg

My next change (7300mi) showed a more normal amount of shavings:
http://www.columbusdsm.com/forum/files/7.3ktranny.jpg

Transfer Case--AWD only
17mm fill bolt (23 ft-lbs)
24mm drain bolt (23 ft-lbs)
~0.5 qt gear oil: Hypoid gear oil API classification GL-5
? '03/'04: SAE90
? '05+: MITSUBISHI limited slip differential oil (LSD) or equivalent

http://www.columbusdsm.com/forum/files/xfer.jpg

http://www.columbusdsm.com/forum/files/xfer_148.jpg

Drain plug with a typical amount of particles:
http://www.columbusdsm.com/forum/files/7.3kxfer.jpg

Rear Differential--AWD only
24mm fill bolt (37 ft-lbs)
24mm drain bolt (47 ft-lbs)
0.5-0.8 qt gear oil: Hypoid gear oil API classification GL-5 or higher
? Above -23?C(-10?F): SAE90,85W-90, 80W-90
? -34 to -23?C(-30 to -10?F): SAE80W, 80W-90
? Below -34?C(-30?F): SAE75W(75W-90 or 80W-90)

http://www.columbusdsm.com/forum/files/rear.jpg

http://www.columbusdsm.com/forum/files/rear_581.jpg

Drain plug with typical amount of particles:
http://www.columbusdsm.com/forum/files/7.3krear.jpg

I'd recommend the Mitsu DiaQueen LSD for both transfer and rear diff(especially if you're dealing with an '05+ model). As an alternative, I use Amsoil 80W-90 Gear Lube. I would not suggest using any level of Shockproof.