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Project Clean 420a

38K views 225 replies 25 participants last post by  FormulaDz92  
#1 ·
Finally, 50 posts and I can start a build thread of my own :)

First off don't expect anything huge on this thread. No engine tear-downs, after-market turbo kits, huge rust-outs etc. This is a thread about my goal to turn my 97 RS (bone stock) from the bronx into some thing clean and enjoyable to look at and hopefully drive. Nothing more and nothing less.

I bought the car early this past spring (2010) from the Bronx in NYC. The car seemed in decent condition with little rust, 77,000 miles, and a $2,500 craigslist price. In case your wondering I bought a 420a because I couldn't afford the insurance on a turbo model and because I want something to look forward to after collage. (2G GSX fingers crossed).

I'm a high-school senior with NO experience with cars to speak of. I didn't know how to change oil or what a spark plug is or... well you get the idea. Since this point I have learned tons of useful stuff mainly from this site and youtube.

Here's a list of what I've done so far(as best as I can remember)
1. refurb. headlights
2. repaint wipers
3. Color-code mirrors(white)
4. Factory low-rise wing removal
5. quarter window tints
6. 6 CD changer removal(it was crap)
7. New non-rattling/leaking sunroof
8. 17x7 Kosei K1 TS Rims in light grey
9. Megan Racing Exhaust+ New CAT
10. New oil+filter
11. New Spark plugs
12. New factory floor matts
13. New Flex Pipe
14. Antenna delete
15. Patch holes left by spoiler + prime

Thats all I can remember right now. I'll probably have to update multiple times. Also, understand that I love my car to death I'm doing all these mods purely for the hell of it and to gain some basic experience with tuning/maintenance. Below is a list of what I plan to do which is subject to change.

1. Paint + clear-coat holes in trunk
2. install new radio with AUX
3. patch all chips in paint
4. general winter-proofing
5. foam for interior side mirror inserts
6. order factory spec. 2Gb sideskirts
7. Order factory spec 2Gb front bumper
8. fix skuffs in clear-coat
9. paint scratch on rear bumper
10. remove all paneling+ check for rust
11. order+ install Sparco pedals
12. order+ paint ext. door handles(white)
13. Injen CAI
14. DC Sports Headers
15. ?DC Sports Strut tower brace?
16. Sand + paint old wheels black for winter
17. ?Black/CF Hood?
18. finish all tints
19. New wiper blades
20. Eibach ProKit Springs
21. Tokiko HP Shocks
22. ?Racing Seats?
23. New Speakers(no subs, amps, etc.)
This is supposed as much DIY as possible so bear with me. It takes a lot longer with a lot more trial and error if you do it yourself(esp. with no experience). Obviously I'll get the real important stuff done by professionalls since this is my DD and all.

Pics tomorrow
 
#176 ·
Alright Its winter break and from the 22nd til the 28th I'll have a back up car. I'm all set to drop the tranny and change the throw out bearing and I even have a mechanically-inclined friend to help. Is there anywhere I could find a good step by step write-up of how to do this. A video would work too. I have the factory repair manual but I can't find anything called a throw-out-bearing only a "clutch release cylinder"

I'm LOW ON TIME so any help would be appreciated especially since I'll have to order the part very soon. Thanks
 
#178 ·
Removing the tranny isn't as hard as it sounds... jack the car up so you can comfortably work underneath it, rest it on safety stands. Take off wheels. Drain transmission. Remove however many of the 54587329507293487 million balljoints 2G's have to be able to pop out the axles a few inches out of the trans. Remove any crossmembers if needed. Remove intake, shifter linkages, battery, etc. Anything that gets in the way from the top. Unbolt from trans, remove engine mount(s), and usually one person over top and over under is all that's needed to pull it off and lower to the ground.
 
#181 ·
Alright I've got the bell housing off the car but I'm having a little difficulty getting the clutch out of it. I understood that it was supposed to slide right out. What am I doing wrong?

sidenote: I'm very pressed for time and I need this whole thing back together by tomorrow so a quick answer would be appreciated
 
#186 ·
Yeah the car is running great now. No issues at all. I've pretty much broken the clutch in with about 350 miles of city/suburban driving. Only thing is i need ti replace an axle now because i popped an axle boot (covers the CV joint). only about $77 tho.

Also I just bought a 1989 rust free 240sx :)
 
#188 · (Edited)
I talked to Paramus Mitsubishi and they said that replacing the boot would take a lot longer and unfortunately I don't have much time to get this thing fixed so i just went ahead and bought the axle. I plan on doing that sometime this week. btw around here i can't find a boot unless its from a dealer and they're more expensive than that.

Here's a pic of the new car.
 
#189 ·
LoL what a lazy ass ... Replacing the boot take something like 10 minutes once the axle is out. They are every-where in part store like auto-zone or Napa. You just been rip off by your mechanic like every-one who deal with a mechanic :rofl:

See, that's one reason why you're not ready for a turbo car.
 
#190 ·
Not sure if you're trying to be a dick or not but you are probably right about the turbo car part. I'm too preoccupied and lacking in common sense to have a turbo car at this point. As for the other thing the dealer I went to wasn't my mechanic and neither was the parts store that I tried(the store was a pro-stock store). I probably should have just tried NAPA or autozone before giving up and next time research it further. Oh well what's done is done.

Just sort of a mental/literal note to myself:
Got to do in the next week or so:
Install Axle
Get a new suspension bolt(old one seems stripped)
Figure out while a stupid check engine light came on(O2?)
Make sure everything is tight.
Install some new exhaust gaskets
Put all of interior back together.
Fix that squeaky acessory belt that is driving me fucking nuts.
Bleed clutch + fill with more clutch fluid(see if it get back to its old strength)

*I'm sure this will take more than a week but hopefully the important stuff will be done my then.
 
#191 ·
Sorry bro, didn't wanted to sound like a dick ... Just wanted to point your mechanic for not saving you money since he didn't wanted to replace the boot and I know you can work. Once you'll have it in your hand take a look to see what the job would have been just for fun.
 
#192 ·
...yeah so i couldn't for the life of me get the axle nut off. I've only had sundays to do it and so far I've failed twice. The first time because I didn't have a socket that was a 32 mm. The second time because dispite using a 2 ft. breaker bar, and an aditional 2 ft extension for leverage...and standing on it...AND pushing down from the ceiling the bolt did not give way. It should also be mentioned that I used an absolute $#it ton of pB Blaster.

So I just went out to Home Depot to buy a 6 ft pipe that I can use as more leverage. Oh and after geting angry and jumping on said bar the rectangular part that goes into the socket part broke right off the breaker bar. Luckily it had a lifetime warranty on it. So can't wait until next fricken sunday to fix that. I did change the oil today though so thats a plus. I was about 1000 miles overdue but no real stress was put on it in any of those 4000 miles and it was mobil one synthetic. Still wish I hadn't done it. It was the first time I've ever changed it with more than 3000

And DSM4LIFE-AWD don't worry about it
 
#193 ·
Yea, if you've never had that axle out, the nut and axle stub is probably seized together in the hub. When this happens guys will go buy a knuckle and hub assembly. I would return the axle. Order a boot kit from Rock Auto and try to do the boot in the car (guessing its an outter one?) You maybe able to seperate the upper ball joint, undo your brake line from the knuckle. Cut the boot off, using a block of wood and hammer, hammer the inner joint thats on the axle off. Clean out the greese as best as you can. Put new greese in, slide the new boot and clamps on the axle. Push the joint back on. Put your clamps on and save for a knuckle/hub-bearing incase that axle or wheel bearing go bad.
 
#194 ·
Yeah but I literally only have one day each week to try to get this done. Maybe like 5 hrs total. And take into account that it took me several WEEKS just to change a clutch. At this point I don't want the CV joint seizing on me. Especially since I have no back up car at the moment and I have to drive into Newark every day. I pretty much assumed that time has run out to save the joint and a new axle is needed either way now. As for the hub I'm going to try again with the new bar and another ton of PB Blaster. I'd like to drive the cheaper way but it'll prob take more than a day(for me) and that is all I have and I need the car first thing in the morning.

btw its the boot closest to the trans on the drivers side. not the one by the hub.
 
#195 ·
Car is working. I've got another bad idle pulley though. That makes three so far: the first one which lived a good life, the second which was defective and a third which was just put in with a new acessory belt has again started to squeak. My car has quite an apetite for them i guess.
 
#197 ·
Summer Plans:
-Fix Rust
-Fix AC compressor
-Fix tear in front bumper
-Have all Patches/scratches fixed
-Replace Old Springs, Shocks etc.
-New Headliner :(
-Rob bank to replace money spent on stupid expensive headliner(haha jk)
-?New Sunroof?

Also need to sell/give away a 2G Door, Hatch, and low rise wing. Oh and stock flexpipe.
 
#200 · (Edited)
Here's a pic of the wheels on the car. Its kinda crappy if I get a better one Ill change it. They're definitely an improvement but they still look too small for the car.

Also I have since replaced my eclipse with a 2005 civic then changed my mind and decided to keep the eclipse. One bit of rust should be fixed by tomorrow.