Transaxle rebuild complexity???

[gsxtacy]

How Hard is it to rebuil your own AWD transaxle???? I have done some research here on DSMTUNERS.com as well as on Dsmtalk, and can't find anyone saying how hard this is to do.

I have thought about buying a TRE rebuilt AWD transaxle for $1800 but they haven't had any cores to rebuild so they don't have any ready to go, and want me to ship mine in for a rebuild. That would be a lot of downtime for me seeing I am in Germany. I think it would be better for me to putt around here for a few weeks while my parts are on their way and then just tear it down and rebuild the tranny and install a new ACT 2100 at the same time.

Is this hard for the novice-experienced mechanic? I know I could do it if I had the rebuild procedure in front of me AND all the tools.

Anything I need to look out for?

Appreciate any insight to this. Decisions are pending on your responses.

Thanks

GSXTACY

 

[90GSX]

I rebuilt mine myself this summer. It hasn't broken yet.

If you're good at looking at something and understanding how it works, then it's not too bad. There are some good picture sites on the VFAQ's that detail the procedures. Also, a Mitsu tech manual will be very helpful. Good luck.

 

[NJGSX96]

I just did mine this past weekend. It is not difficult. The DSM Manual CD helps a lot. You will need a bearing press or a place that can press off the old bearings and press on the new bearings. Other than that, it is pretty straight forward. if you use the same gears, you shouldn't need any different shims. if you go with any new gears (like going with the dual 2nd - my 96 didn't have it althouh all 2Gs are supposed to) you may need new shims.

Like mentioned before, sme good sites under the VFAQ. ANother good one I just found today actually is:
http://www.geocities.com/htamotorsports/rebuild.html

Look over the sites on the vfaq along with this one and se if you think you can do it. If so, go for it.

 

[gsxtacy]

Do I need the bearing splitter and press to install new shift forks? What about syncros? I do not have access to a splitter or press, but the rest of the necessary tools I have available. There isn't a transmission place in Germany that could do this for me...so I am forced to drive the car till I get it fixed. Which needs to be soon, so I do not shell the gears. Thanks for the great link.

GSXTACY

 

[NJGSX96]

You need the press to remove the bearings which allows you pull apart the gear stacks. Gears and sycnros are removed and reinstalled by hand. You then need the press one more time to press on the new bearings.
Other than that, the rest is done by hand or with simple tools available at any tool store (like snap ring pliers, a puller - for bearing races, 12mm socket - or is it 14mm?, screw driver and I think that is it.).

Shift forks slide in place when you put the stacks back in the tranny. Done by hand, just be patient.

Any auto shop should have a press. Doesn't need to be a trans shop. Call around. If you find a shop that has one, perhaps you can pull apart the trans and bring them the gear stacks to have the bearings pressed off. Go home, assemble the stacks with new parts and return to get the new bearings pressed on. It takes 5 minutes to do. offer them $50 - $25 each visit.

Are there any types of shops on base (I see you're in the Air Force)? How do they fix their vehicles there? Perhaps a shop on base has one?

 

[gsxtacy]

You are right there is a flight called vehicle maintenence that "probably" has a press and a bearing puller. Sweet. Now if I can just get the parts cheaper than I can get a used tranny.....I have replied to a couple of used tranny ads on the 'trader...awaiting responses. Thanks for waking me up to the possibility of getting a 'Transportation buddy to hook me up. Thanks

GSXTACY

 

[NJGSX96]

Cool. Keep us posted what happens. If you go the route of rebuilding yourself, email me. I have some sound advice for you that will give you something to think about and can save you a lot of money. [email protected]

 

[gsxtacy]

I just recieved a email from TRE about a parts price quote. I asked for a price quote on:

1-2 steel shift fork
3-4 steel shift fork
Pair of shift rails
1-5 syncros


Anyways.....Ming replied saying that if I wanted the steel shift forks I would need the HD gear set. Is this completely true? My gears are in great shape, but I bent the 3-4 shift fork. I am going to do a clutch sap at the same time, and I am trying to upgrade what is broken and save some money in the progress.

Give me your insight, so i can make effiecient decisions.
[email protected]

thanks

GSXTACY

 

[90GSX]

Humm... Ming didn't tell me that. I bought a set of EVO forks from him a couple months ago. I'm very happy with them, in that I haven't managed to break one yet.

 

[mrmadmax]

Yeah, I bought a set as well... Maybe you have to upgrade the gears on the 2G?