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2G Talon AWD 5-speed gear issue -- Any Huntsville local SME's?

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vanroth

Probationary Member
4
0
Apr 7, 2019
Harvest, Alabama
Just picked up my first DSM, a 2nd Gen Talon TSI. Car has quite a few mods, but hasn't had the best life in recent years.

3rd and 4th gear appear to be gone, so I'm assuming the 3-4 shift fork is broken. Any quick methods to validate before I pull the transmission?

I don't know much about these cars, but willing to learn. Best place to pick up a service manual?

Thanks,
J
 
I have all the resources already posted on this website.

Covers several platform transmissions; you are interested in the W5M33 transmission sections.
FSM1 - https://www.dsmtuners.com/threads/1...-transfer-case-rebuild-service-manual.517379/
FSM2 - https://www.dsmtuners.com/threads/1...ory-mechanics-training-service-manual.517370/
FSM3- https://www.dsmtuners.com/threads/1...-transfer-case-rebuild-service-manual.517367/

Then I have forum posts with how-to's.

For 3rd/4th shift forks you will use:
3rd/4th Gear Shift Fork (90-Early 92) 2-hole MD741558
3rd/4th 1992.5-1999 Gear Shift Fork 3-hole MD746854

If you have a broken 2g style 3rd/4th shift rail end, then you will use:
2G AWD 3rd/4th Shift Rail (95-99) MD749454 -- works with all 3-hole shift fork years (1992.6-1999); will only work with late model shift selectors and matching 1/2 and 5/R shift rails (1991.6-1999).

End shaft nuts (preferably not reusable) - MD731948 x 2
Roll pins, you can use the OEM MD701722 or you can use a M5x26mm heavy duty slotted or spiral roll pin.

For teardowns, here are a few detailed links with tool information, part information, and directions. If you need further than this, there are alternate how-to's.

This one will tear down the trans enough to deal with gearset removal and shift rail / fork removal -
https://www.dsmtuners.com/threads/needing-advice-on-front-diff-replacement.387171/#post-152396943

The FWD is a bit different than the AWD, but easy to tear down as well.

This is for a FWD DSM trans, so there are a few details that are different, but most are similar enough for you to get through and open it up -

https://www.dsmtuners.com/threads/broken-3-4-shift-fork.390941/#post-152454232
 
Last edited:
Wow, thanks for all that information. FSM's downloaded -- now time to get to work.
 
Updated with a typo; I forgot to add the FSM #1, there are 3 I have on here to work with. I also have the dealership mechanics training module manual.
 
Just an update, the shift bushings were shot. Replaced them with solid brass units. Fourth works great now, but third still doesn't engage (acts like neutral). Could that still be a symptom of a broken shift fork with just one gear out? I'm working on another Mitsu at the moment, so I don't have time/space to pull the transmission out at the moment.

Also am getting a random rotating rattling noise. Sounds a bit like I'm dragging a chain. The center carrier doughnut had some play, but the shafts universals themselves looked good. At first I thought it was a bad carrier bearing. Definitely loud but it isn't a consistent noise.

All fluids were changed as well. Transmission and center diff all looked decent. No metal to speak of.
 
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