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2G Will an Expo T-Case work in a DSM

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cficare68

10+ Year Contributor
88
0
Aug 29, 2010
Boise, Idaho
I have been collecting parts to perform an auto swap on my 95 Talon. I originally purchased an Auto T-case used from a 1995 Talon. Upon inspecting the case the transfer case was locked up. I contacted the seller and was told that they had another in stock that they would send me. When I received the second transfer case in was tagged that I had came out of a 92 Mitsubishi Expo. Is there any differences between the two cases or am I ok if I run this case on my car?
 
I don't know much about Expo T-cases, but let's start simple ... Do they look the same in a side by side? Bolt holes for mounting to the transmission the same? If so, good. But you still need to figure out whether the front diff ring gear matches. I assume your using a 95 transmission, which means you need a 57 tooth ring gear in the T-case. You can check it by rotating the assembly and counting. There's a great how-to video here:
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The other thing you'll need to look into is the splines on the axles and make sure they match up. Hopefully it's OK and works out for you.
 
I don't know much about Expo T-cases, but let's start simple ... Do they look the same in a side by side? Bolt holes for mounting to the transmission the same? If so, good. But you still need to figure out whether the front diff ring gear matches. I assume your using a 95 transmission, which means you need a 57 tooth ring gear in the T-case. You can check it by rotating the assembly and counting. There's a great how-to video here:
You must be logged in to view this image or video.
The other thing you'll need to look into is the splines on the axles and make sure they match up. Hopefully it's OK and works out for you.

Don't have grounds to perform a side by side comparison since I had to return the bad t-case back to the seller before they would ship out the new one. I purchased my car as a rolling shell. No interior, engine, t-case, trans, or wiring harness. It also was originally a manual transmission car so I am doing an auto swap on it.

The transmission that I have purchased though is out of a 95 though, as well as the lsd rear diff. I have gotten found very limited information but from what I have read the 92 expo has the same trans that the 1g 6 bolt dsms have and the 93-96 models using the same as the 2gs. However I was not able to verify that outside of the one post that I have read this one.
 
Definitely verify that the trans you have is a 95 b/c that may change the t-case you need.. I recently bought a 97, only to discover after I pulled the trans it was out of a 95. I don't know much about auto trans and their markings between years, but I'm sure the information is on the forum here. There's a flat plate on the bell housing that has a number inscribed, should start out KW5M33 ...

You might find some more info here ??? http://www.dsmtuners.com/threads/1g-2g-transmission-driveline-compatibility.402630/#post152586425
 
Definitely verify that the trans you have is a 95 b/c that may change the t-case you need.. I recently bought a 97, only to discover after I pulled the trans it was out of a 95. I don't know much about auto trans and their markings between years, but I'm sure the information is on the forum here. There's a flat plate on the bell housing that has a number inscribed, should start out KW5M33 ...

You might find some more info here ??? http://www.dsmtuners.com/threads/1g-2g-transmission-driveline-compatibility.402630/#post152586425

I'm well aware of what the transmission came off of I verified it by VIN number. That has nothing to do with the question that I asked. As I have previously stated I have done research and have not come up with anything hence why I'm asking.
 
I beg to differ. It has everything to do with the question you asked. You want to know whether that Expo t-case has any differences w/ a dsm t-case. You can't find and answer and no one else is chiming in. I'm saying I think the first thing you need to determine is whether or not the diff ring gear is correct on that Expo case for your trans. We need to know what trans you have so you can match the t-case to it. Since you're sure you have a 95 trans, you need a 57 tooth gear. Go out and spin the thing and count. If it does have 57 and the bolt holes line up to the trans, and the axles slide in - you're probably good to go, they're of the same vintage, so chances are good.

Since you've already done research and came up empty, then I think you have to go on the things listed above and see what happens. If that makes you uncomfortable, hopefully you can find a more definitive answer.
 
I beg to differ. It has everything to do with the question you asked. You want to know whether that Expo t-case has any differences w/ a dsm t-case. You can't find and answer and no one else is chiming in. I'm saying I think the first thing you need to determine is whether or not the diff ring gear is correct on that Expo case for your trans. We need to know what trans you have so you can match the t-case to it. Since you're sure you have a 95 trans, you need a 57 tooth gear. Go out and spin the thing and count. If it does have 57 and the bolt holes line up to the trans, and the axles slide in - you're probably good to go, they're of the same vintage, so chances are good.

Since you've already done research and came up empty, then I think you have to go on the things listed above and see what happens. If that makes you uncomfortable, hopefully you can find a more definitive answer.


I had already stated that I bought a 95 trans. Prior to my last comment. I don't need to be told I need to verify something when I already know what I purchased.

And I figured out the answer to my question. Already so thanks for trying to help.
 
Seriously this is pretty easy to figure out. Visually inspect the tcase. Pull the side cover bolts and give the input sleeve a whack with a dead blow hammer. Count the teeth on the drive gear.

An early (1991.5-1994.08) expo should be 24/22 1.090 ratio, which is the same as the 91-96 DSM transfer cases. But they are also listed as having the 29/27 1.074 ratio tcase in the 1994.08 - 1996.08 vehicles which is the same as 97-99 DSM tcases.

There's only two things it can be, and it's as easy as using a 14mm socket and impact, and a dead blow, and your math skills of counting teeth.

If it is for certain out of a 92 expo, then it's a 1.090 ratio tcase. If your automatic transmission is a 95-96, it will have a 72 tooth front diff ring gear , and is model number W4A33-1-UPQ2. If your transmission is a 97-99, it will have a 71 tooth front diff ring gear, and is model number W4A33-1-FNQ. The 1.090 ratio tcase matches to the 95-96, and the 1.074 ratio matches to the 97-99.
5 speed front diff ring gear differences are 58 tooth for 1990-1996 (output shaft spline count changed at mid 1991 to 23 spline from 22 spline for earlier ones), and 57 tooth for 1997-1999 transmissions. Model numbers for 95-96 vs. 97-99 are W5M33-2-NPZT vs W5M33-2-MUZT respectively.
 
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5 speed front diff ring gear differences are 58 tooth for 1990-1996 (output shaft spline count changed at mid 1991 to 23 spline from 22 spline for earlier ones), and 57 tooth for 1997-1999 transmissions. Model numbers for 95-96 vs. 97-99 are W5M33-2-NPZT vs W5M33-2-MUZT respectively.

Your right, I said 57 teeth above, I should have said 58 for a 95. I had them flipped in my mind. I guess it's irrelevant though since he's dealing with an auto trans and I see from your post above they have yet another ring gear count.
 
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