How to disassemble a 1g awd 5 speed transmission - DSM Forums: Mitsubishi Eclipse, Plymouth Laser, and Eagle Talon Forum: DSMtalk.com
 
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Old 11-13-2008, 05:53 AM   #1
1gawd4g63
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How to disassemble a 1g awd 5 speed transmission

I was taking some pictures of a transmission that i am in the process of rebuilding and i though that i'd make a documentary on steps to disassemble and assemble the transmission:

Step 1: Remove all bolts from the end cover and remove the end cover (this might require a rubber hammer and a little prying to get off.

before

After


Step 2: Remove the 2 nuts on the ends of the shafts, and the snap ring on the viscous coupler, next remove the roll pin in the 5th gear shift fork, now you can remove the 5th gear assembly and the viscous coupler (be careful there is a little ball bearing in the center diff shaft that the viscous coupler slides over, make sure to remove that and set it aside. At this point you can remove the transfer case output shaft also.

5th gear and viscous coupler removed

Removing output shaft


Step 3: Remove the 3 shift selector nuts, springs and balls



Step 4: Remove the bearing plate from the end of the tranny case and remove center diff
This is the bearing plate

REmove center diff


Step 5: Remove the reverse idler retaining bolt from the back side of the trans case, remove all case bolts that hold the top to the bottom.



Step 6: Carefully pry the top casing from the bottom and remove the reverse idler gear




Step 7: At this point you can remove the front differential, and the diff drive gear assembly



Step 8: Remove the roll pins on the 1-2 and 3-4 shift forks and remove the input and intermediate shaft's




Now you can remove the shift rails and go onto cleaning and measuring everything for reassembly. I will have pics of me doing the gear sets and reassembling everything in the next week. Hope this is helpful so someone out there.
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Old 11-13-2008, 12:36 PM   #2
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Re: How to disassemble a 1g awd 5 speed transmission

Oh, this will DEFINATELY be helpful! I would think about requesting this being a sticky, or an addition to the VFAQ, even!!
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Old 11-15-2008, 11:06 PM   #3
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Re: How to disassemble a 1g awd 5 speed transmission

Def sticky, I wish someone would do this to a 2G also because I've been wanting to take my apart.
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Old 11-16-2008, 08:06 AM   #4
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Re: How to disassemble a 1g awd 5 speed transmission

The 2g transmission has the same exact internals if it is awd. The fwd's are very simular they just don't have the center diff, viscous coupler, and output shaft.
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Old 11-16-2008, 10:41 AM   #5
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Re: How to disassemble a 1g awd 5 speed transmission

This is really great. Thanks for sharing the know how with us. Any idea how to modify these transmittions like shepard.
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Old 11-16-2008, 10:43 AM   #6
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Re: How to disassemble a 1g awd 5 speed transmission

IT all depends on what you are trying to accomplish. Shep just add's alot of different parts. They are very easy to make shift like butter if you know how to setup the syncro's and clearances correctly.
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Old 11-16-2008, 12:33 PM   #7
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Re: How to disassemble a 1g awd 5 speed transmission

Quote:
Originally Posted by 1gawd4g63
The 2g transmission has the same exact internals if it is awd. The fwd's are very simular they just don't have the center diff, viscous coupler, and output shaft.
Really? That's awesome, I got the FWD.
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Old 11-16-2008, 01:21 PM   #8
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Re: How to disassemble a 1g awd 5 speed transmission

Nice! Now i just wish i didnt pay some shop to rebuild it wrong....Thanks ill use this in the near future.
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Old 02-10-2009, 12:58 PM   #9
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Re: How to disassemble a 1g awd 5 speed transmission

just saved myself $1000.00 took it apart and all it was was 1-2 shift fork. awesome thanks dude!
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Old 02-11-2009, 10:56 PM   #10
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Re: How to disassemble a 1g awd 5 speed transmission

yeah I had a similar situation, I broke a shift rail (1-2) and saved myself some dough as well
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Old 02-11-2009, 11:03 PM   #11
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Re: How to disassemble a 1g awd 5 speed transmission

This needs to be a sticky. Nice job man!
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Old 02-11-2009, 11:04 PM   #12
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Re: How to disassemble a 1g awd 5 speed transmission

Haha nice write up! I took apart my trans about a year ago cause of no 2nd gear...

I never touched a motor/trans before and now I can take it apart! This would of been helpful back in the day!

I have better pics I took.. If a mod wants to add them in or something
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Old 02-11-2009, 11:11 PM   #13
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Re: How to disassemble a 1g awd 5 speed transmission

I'm sure I will have a few questions, but I just want to know if there is any special tool involved in doing this?
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Old 02-12-2009, 01:10 PM   #14
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Re: How to disassemble a 1g awd 5 speed transmission

Yeah, I think I'm about to do a full rebuild on my 2g tranny, now to find another tranny to stick in while I rebuild!
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Old 02-12-2009, 09:13 PM   #15
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Re: How to disassemble a 1g awd 5 speed transmission

Any help on replacing synchros? Mine are cooked.
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