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Well, you can do it even easier....
You can use an AWD transmission by doing it the way you want to (by removing the viscous coupler, and installing a viscous coupler eliminator), OR you can do it this way:
*Have transmission drained and sitting with bellhousing side down/5th gear cover side up.
*Remove 5th gear cover bolts and cover.
*Remove the viscous coupler snap ring, viscous coupler, and detent ball.
*Shift the transmission into reverse (lever up, and pull other shift lever away from transmssion -- the reverse synchro will be engaged by the 5th/reverse slider).
*Remove the 36mm end shaft nuts with 1/2" air impact and proper socket. *Replace end shaft nuts with new ones when reassembling, and use factory torque specifications, then peen the indents using a hammer and peening punch tool.
*Use a 1/8" roll pin removal punch tool and hammer to remove the 5th/reverse shift fork roll pin.
*Remove the 5th/reverse hub and slider assembly using two small pry bars GENTLY between synchro and 5th gear, or UNDER 5th gear and case if you have space.
*Remove the 5th intermediate gear using two small pry bars GENTLY so you don't chip the gear face, OR use a push-puller tool (OTC small gear splitter with push-puller attachment), by attaching the splitter to the upper flange of the 5th intermediate gear, and pulling the gear off the shaft with the push-puller tool attachment.
*Remove the three shift rail poppet plugs, springs and balls with a magnetic pickup tool.
*Remove the reverse switch (22mm wrench or deep socket).
*Gently using two pry bars, remove the intermediate case section to expose the gearset and center differential.
*Remove the center differential completely.
*Remove the output shaft (and needle bearing from the inside of the output shaft pinion gear IF you are doing a rebuild.
*Reassemble the transmission (leaving the center diff, output shaft, and viscous coupler, viscous coupler detent ball and snapring out of the transmission). Follow factory specs for torque values.
*Remove the output shaft seal from the transmission bellhousing side.
*Install freeze plug that fits the output shaft hole in bellhousing.
*I would also recommend installing a Phantom grip into the transmission at a minimum, as the front differential will just be a one-wheel monster with real power.
There you go!
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Tim Zimmer
1999 Mitsubishi Eclipse GSX
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