OK I've got one for ya.

I'm rebuilding my transmission, 1st timer, lots of Qs - 2G AWD - I have both the Mitsubishi Repair Manual & Downloaded the W5M33 PDF Manual.

I've notice some parts are missing & were never in the transmission to begin with! I know because I saved every single part, spring, steel ball etc. .. bagged everything in Ziploc bags and put it in a box that hasn't moved since the tear down.

Missing parts - attached pages of the manual so you can see what I'm referring to.
40 - Oil Guide - Don't have P/N, not in ASA from what I can see.
44 - Spacer - Where can you get these? It looks like I have to crush solder & measure to determine size.
52 - Needle bearing - MD749902? - I could not find it, or see where it would fit in. There was an outer race in the notch where the intermediat shaft went. Was it possibly pressed onto the shaft somewhere?
63 - Oil Guide - MD726480
68 - Magnet Holder - MD727258
69 - Magnet - MD955485 - *Are there better / stronger ones available
* No transmission filter either, & the manual doesn't specify one. I ordered part MD738053 for it but there's no way to connect it unless I used RTV. Or JB weld or something along those lines.

So i'm looking to see what would be needed. Could all of these parts be optional? Is it common practice to leave some of these things out thinking they aren't necessary for our intended use, kind of like people do balance shaft deletes? Think I'd feel more comfortable having everything that was intended to be in a working transmission. Beyond all the missing parts, here's another one. I saw that there was a sharp lip on the front differential. I noticed it when it cut my gloves up. Should I get a replacement for that part of the diff, cut off the sharp lip, or just leave it? See attached image for this one.

Thanks![DOUBLEPOST=1407886525][/DOUBLEPOST]Anybody?? I could really use some help.

Guys, I could really use some help if anyone's up for the challenge!

Anybody

Hello..? Is everyone still at the shootout?

Bump

- You need all of those parts except maybe number 40 which it looks like they dropped for 2g's (it was in 1g turbo AWD models D27A as part MD725085). Don't know why they dropped it.
- 44: Must be gotten at Mitsu (JNZ Tuning, Mitsubishiparts, SW Mitsubishi parts, etc). Yes you have to crush solder to measure.
- 52: Doesn't it go inside the bearing on 51?
- The oil filter (screen) is MD749902. If yours isn't damaged just wash it with gasoline. Mine was riveted in.
- Don't know about your front diff sharp lip.
- Here is a great article on tranny rebuild (link doesn't always work but I have copy): http://www.twingles.com/ideck/rebuild3/dretranny.htm.
- Contact DSM tranny rebuilder twicks69 for more questions.

Not every tranny had both oil guides. They also all didn't have the filter by the front diff.[DOUBLEPOST=1408830560][/DOUBLEPOST]Specifically that 40 guide isnt always there.
44 Spacer is an dealer part and there is one for every set of bearing pairs.
52 needle bearing is for the output shaft. Sometimes it gets left on that shaft or inside the shaft that drives the front diff
63 is a plastic disc underneath the intermediate shaft bearing race. If you didnt remove that race it should still be there.
The magnet holder and magnet go inside a pocket on one of the cases. Look around the edges.

Thanks to you both for the responses. I put together a list of parts to order. What would be the best way to install the filter? (already bought a new one) it fits right over the posts that come out of the housing, but how to secure it? I really cannot find the magnet anywhere, so I guess i'll start Google-ing.

So I really have the one big important thing to figure out, which is what to do about the front differential. And yes, I have contacted Tim (twicks69), but I don't exactly expect him to drop everything just to help solve my issue.

Actually Tim did drop everything to answer my questions when I rebuilt mine! I just asked him about guide 40 for ya and he said: "The small oil guide? That was on 1989-1992 transmissions only; the later model cases had the pin tab at the bottom but not the retainer hole in the main gear cluster case to hold it in place.".

PM Tim about how to secure the filter and the front diff issue. He's a professional dsm tranny builder and also has parts (only he had certain spacers that Mitsu ran out of).

Below is the magnet location on my FWD.

Most of the trannies I've ever seen including my own had no filter. As far as the magnet if its not in the hole then somebody didnt put it back.

luv2rallye said:

Actually Tim did drop everything to answer my questions when I rebuilt mine! I just asked him about guide 40 for ya and he said: "The small oil guide? That was on 1989-1992 transmissions only; the later model cases had the pin tab at the bottom but not the retainer hole in the main gear cluster case to hold it in place.".

PM Tim about how to secure the filter and the front diff issue. He's a professional dsm tranny builder and also has parts (only he had certain spacers that Mitsu ran out of).

Below is the magnet location on my FWD.

Click to expand...

Excellent . Do you know of where I would be able to find out the year of the transmission?

Missing parts - attached pages of the manual so you can see what I'm referring to.
40 - Oil Guide - Your transmission does not have this guide; it is a 1990-style guide only
44 - Spacer - Front differential shim; I have attached a list of applicable shims below. Measure out one for 0.003"-0.007" endplay, choose proper shim then.
52 - Needle bearing - This is the output shaft needle bearing. It slides between the output shaft and the output pinion shaft. The part number is MD718578.
63 - Oil Guide - MD726480 - This is a black plastic disk oil guide that is installed in the bellhousing before you install the inner intermediate shaft tapered roller bearing race.
68 - Magnet Holder - MD727258 - The magnet tray should be installed with either a OEM magnet or a neodymium magnet.
69 - Magnet - MD955485 - The factory magnet sucks ass, go to http://appliedmagnets.com/neodymium-magnets-n50-3-4-in-x-1-8-in-disc-p-538.html
* No transmission filter either, & the manual doesn't specify one. I ordered part MD738053 for it but there's no way to connect it unless I used RTV. Or JB weld or something along those lines. Your case "should" have 5 posts for the metal filter to be installed and the posts peened over the filter by the front differential on the main gear cluster case section. If for some reason you have broken posts, or missing posts, simply do not use it, and install a good neodymium magnet on the fill plug and drain plug as well. Use http://appliedmagnets.com/n52-neodymium-magnets-1-2-in-x-1-8-in-rare-earth-discs-p-803.html for the drain plug, and http://appliedmagnets.com/n52-neodymium-magnets-3-8-in-x-1-8-in-rare-earth-disk-p-886.html for the fill plug magnets.

I saw that there was a sharp lip on the front differential. I noticed it when it cut my gloves up. Should I get a replacement for that part of the diff, cut off the sharp lip, or just leave it? See attached image for this one. That damage to the front differential looks like it came from a crappy passenger side axle as well as likely being run without the proper shim installed in the transmission causing the diff to flop around and get damaged. Grind the damage down until smooth.

Here is a list of all applicable AWD DSM shims. The input shaft and front differential share the same shims for reference:

SHIMSDSM Input Shaft and Front Differential, Evo Output Shaft,
Part Description-Part Number-ID Number-Thickness (in)
Shim - Input Shaft-MN168147-0.44-0.0173
Shim - Input Shaft-MN168148-0.48-0.0189
Shim - Input Shaft-MN168149-0.52-0.0205
Shim - Input Shaft-MN168150-0.56-0.0220
Shim - Input Shaft-MN168151-0.60-0.0236
Shim - Input Shaft-MN168152-0.64-0.0252
Shim - Input Shaft-MD727659-0.65-0.0256
Shim - Input Shaft-MN168153-0.68-0.0268
Shim - Input Shaft-MN168154-0.72-0.0283
Shim - Input Shaft-MD727660-0.74-0.0291
Shim - Input Shaft-MN168155-0.76-0.0299
Shim - Input Shaft-MN168156-0.80-0.0315
Shim - Input Shaft-MD727661-80-0.0315
Shim - Input Shaft-MD720937-83-0.0327
Shim - Input Shaft-MN168157-0.84-0.0331
Shim - Input Shaft-MD720938-86-0.0338
Shim - Input Shaft-MN168158-0.88-0.0346
Shim - Input Shaft-MD720939-89-0.0350
Shim - Input Shaft-MD720940-92-0.0362
Shim - Input Shaft-MN168159-0.92-0.0362
Shim - Input Shaft-MD720941-95-0.0374
Shim - Input Shaft-MN168160-0.96-0.0378
Shim - Input Shaft-MD720942-98-0.0386
Shim - Input Shaft-MN168161-1.00-0.0394
Shim - Input Shaft-MD720943-1-0.0398
Shim - Input Shaft-MD720944-4-0.0409
Shim - Input Shaft-MN168162-1.04-0.0409
Shim - Input Shaft-MD720945-7-0.0421
Shim - Input Shaft-MN168163-1.08-0.0425
Shim - Input Shaft-MD710454-J-0.0433
Shim - Input Shaft-MN168164-1.12-0.0441
Shim - Input Shaft-MD700270-D-0.0445
Shim - Input Shaft-MN168165-1.16-0.0457
Shim - Input Shaft-MD710455-K-0.0457
Shim - Input Shaft-MD710456-L-0.0468
Shim - Input Shaft-MN168166-1.20-0.0472
Shim - Input Shaft-MD700271-G-0.0480
Shim - Input Shaft-MN168167-1.24-0.0488
Shim - Input Shaft-MD710457-M-0.0492
Shim - Input Shaft-MN168168-1.28-0.0504
Shim - Input Shaft-MD710458-N-0.0504
Shim - Input Shaft-MD706574-E-0.0516
Shim - Input Shaft-MN168169-1.32-0.0520
Shim - Input Shaft-MD710459-O-0.0527
Shim - Input Shaft-MD710460-P-0.0539
Shim - Input Shaft-MD706573-1.4-0.0551
Shim - Input Shaft-MD710461-Q-0.0563
Shim - Input Shaft-MD710462-R-0.0575
---
---
Part Description-Part Number-ID Number-Thickness (in)
Shim - Intermediate Shaft-MD720948-80-0.0315
Shim - Intermediate Shaft-MD720949-83-0.0327
Shim - Intermediate Shaft-MD720950-86-0.0338
Shim - Intermediate Shaft-MD720951-89-0.0350
Shim - Intermediate Shaft-MD720952-92-0.0362
Shim - Intermediate Shaft-MD720953-95-0.0374
Shim - Intermediate Shaft-MD720954-98-0.0386
Shim - Intermediate Shaft-MD720955-1-0.0398
Shim - Intermediate Shaft-MD720956-4-0.0409
Shim - Intermediate Shaft-MD720957-7-0.0421
Shim - Intermediate Shaft-MD720958-10-0.0433
Shim - Intermediate Shaft-MD720959-13-0.0445
Shim - Intermediate Shaft-MD720960-16-0.0457
Shim - Intermediate Shaft-MD720961-19-0.0468
Shim - Intermediate Shaft-MD720962-22-0.0480
Shim - Intermediate Shaft-MD724156-22-0.0480
Shim - Intermediate Shaft-MD712346-25-0.0492
Shim - Intermediate Shaft-MD724157-25-0.0492
Shim - Intermediate Shaft-MD712347-28-0.0504
Shim - Intermediate Shaft-MD724158-28-0.0504
Shim - Intermediate Shaft-MD712348-31-0.0516
Shim - Intermediate Shaft-MD724159-31-0.0516
Shim - Intermediate Shaft-MD712349-34-0.0527
Shim - Intermediate Shaft-MD712329-37-0.0539
Shim - Intermediate Shaft-MD712330-40-0.0551
Shim - Intermediate Shaft-MD712331-43-0.0563
---
Part Description-Part Number-ID Number-Thickness (in)
Shim - Center Differential-MD736928-13-0.0445
Shim - Center Differential-MD736929-16-0.0457
Shim - Center Differential-MD736751-19-0.0468
Shim - Center Differential-MD736931-22-0.0480
Shim - Center Differential-MD726166-25-0.0492
Shim - Center Differential-MD718517-28-0.0504
Shim - Center Differential-MD718518-31-0.0516
Shim - Center Differential-MD718519-34-0.0527
Shim - Center Differential-MD718520-37-0.0539
Shim - Center Differential-MD718521-40-0.0551
Shim - Center Differential-MD718522-43-0.0563
Shim - Center Differential-MD718523-46-0.0575
Shim - Center Differential-MD718524-49-0.0587
Shim - Center Differential-JDM-MD718525-52-0.0598
Shim - Center Differential-MD718526-55-0.0610
Shim - Center Differential-MD718527-58-0.0622
Shim - Center Differential-MD718528-61-0.0634
Shim - Center Differential-MD718529-64-0.0646
Shim - Center Differential-MD718530-67-0.0657
Shim - Center Differential-MD718531-70-0.0669
Shim - Center Differential-MD721959-73-0.0681
Shim - Center Differential-MD721960-76-0.0692
Shim - Center Differential-MD721961-79-0.0705
---
Part Description-Part Number-ID Number-Thickness (in)
Shim - Output Shaft-MD746510-1.07-0.0421
Shim - Output Shaft-MD746511-1.10-0.0433
Shim - Output Shaft-MD756755-1.13-0.0445
Shim - Output Shaft-MD756756-1.16-0.0457
Shim - Output Shaft-MD756757-1.19-0.0469
Shim - Output Shaft-MD756758-1.22-0.0480
Shim - Output Shaft-MD756759-1.25-0.0492
Shim - Output Shaft-MD726167-28-0.0504
Shim - Output Shaft-MD726168-31-0.0516
Shim - Output Shaft-MD726169-34-0.0527
Shim - Output Shaft-MD724326-37-0.0539
Shim - Output Shaft-MD724327-40-0.0551
Shim - Output Shaft-MD724328-43-0.0563
Shim - Output Shaft-MD724329-46-0.0575
Shim - Output Shaft-MD724330-49-0.0587
Shim - Output Shaft-MD724331-52-0.0598
Shim - Output Shaft-MD724332-55-0.0610
Shim - Output Shaft-MD724333-58-0.0622
Shim - Output Shaft-MD724334-61-0.0634
Shim - Output Shaft-MD724335-64-0.0646
Shim - Output Shaft-MD724336-67-0.0657
Shim - Output Shaft-MD724337-70-0.0669
Shim - Output Shaft-MD724338-73-0.0681
Shim - Output Shaft-MD724339-76-0.0692
Shim - Output Shaft-MD724340-79-0.0705
Shim - Output Shaft-MD724341-82-0.0716
Shim - Output Shaft-MD724342-85-0.0728
Shim - Output Shaft-MD724343-88-0.0740
Shim - Output Shaft-MD724344-91-0.0751

Wow thank you!

I will comb through this info later when I get home.

I also enjoyed your comment about the stock magnet