Are all 2g transfer cases interchangeable?

Posted by ileagleracing, Nov 14, 2017

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  1. ileagleracing

    ileagleracing Supporting Member

    197
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    Joined Sep 27, 2007
    Montreal, QC, Canada
    If I buy a used Manual 2g transfer case for my 98, does it matter what year the replacement is from?
     

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    My DSM:
    1995 Eagle Talon TSi AWD

    Autocross Build

    160 whp   190 lb/ft
    1998 Eagle Talon TSi AWD

    Autocross Build

    313 whp   305 lb/ft
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  2. Black95TSIawd

    Black95TSIawd Proven Member

    1,620
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    Joined Jan 28, 2003
    Dirty, New Jersey
    Yes. Get one from a 97+.
     
    My DSM:
    1998 Eagle Talon TSi AWD

    184.4 whp   251.0 lb/ft
    1997 Mitsubishi Eclipse GSX (sold)

    Drag Race Build

    20g   manual
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  3. ileagleracing

    ileagleracing Supporting Member

    197
    81
    Joined Sep 27, 2007
    Montreal, QC, Canada
    What is the difference? Is it internal, or would it not even mate up to the trans or drive shaft?
     
    My DSM:
    1995 Eagle Talon TSi AWD

    Autocross Build

    160 whp   190 lb/ft
    1998 Eagle Talon TSi AWD

    Autocross Build

    313 whp   305 lb/ft
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  4. 91talonts1

    91talonts1 Proven Member

    495
    164
    Joined Dec 29, 2008
    Spencer, North Carolina
    Internal. Ring gear in the trans must match the t case. 95-96 has 58 teeth, I believe the 97+ has 59.
     
    My DSM:
    1997 Eagle Talon TSi AWD

    Drag Race Build

      manual
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  5. GRNDSM

    GRNDSM Moderator

    1,940
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    Joined May 16, 2002
    Chelmsford, Massachusetts
    Externally, they look the same. But ratios are off, ever so much. Just mark it with the sharpie and count ;)
     
    My DSM:
    1996 Eagle Talon TSi AWD

    Autocross Build

    12.9 @ 103 MPH

    Street Build

    11.74 @ 118 MPH
    1994 Eagle Talon TSi AWD

    10.123 @ 138.060 MPH
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  6. pauleyman

    pauleyman DSM Wiseman

    4,614
    755
    Joined Nov 19, 2011
    oklahoma city, Oklahoma
    If you happen to have the trans out it is possible to swap a ring and pinion on the front diff and use a 91-96 tcase.
     
    My DSM:
    1997 Eagle Talon TSi AWD

    Street Build

    T25   manual
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  7. 1990TSIAWDTALON

    1990TSIAWDTALON Moderator

    2,961
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    Joined Nov 14, 2013
    Independence, Kansas
    What is the 1g auto count? I have a spare auto 1g (I hope) case that I want to make sure of.
     
    My DSM:
    1992 Eagle Talon TSi AWD

    Street Build

    14b   automatic
    1990 Eagle Talon TSi AWD

    13.620 @ 108.460 MPH
    1990 Eagle Talon TSi AWD

    13.612 @ 107.760 MPH
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  8. twicks69

    twicks69 DSM Wiseman

    3,135
    523
    Joined Mar 12, 2004
    Milwaukee, Wisconsin
    Regarding transmission front diff ring gear tooth count vs. transfer case ring and pinion tooth counts:

    1990-1996 5-speed transmissions had 58-tooth front diff ring gear; 1997-1999 had 57-tooth front diff ring gear.

    OEM 2Gb 1997-1999 DSM transmissions that have not been fooled around with will have the transmission code of W5M33-2-MUZT. This one will have the 57-tooth front diff ring gear. There are others, but they are found in things like the Evo 3 (63 tooth) or RVR (57-tooth) that would use a 1997-1999 transfer case as well.

    The 1997-1999 transfer case is a 1.074 final drive ratio and consists of a 29-tooth driven gear (pinion shaft to driveshaft) and 27-tooth drive gear (side cover gear).

    Now, if you are dealing with a transmission that is from 1990-1996 OR using a front diff ring gear swapped from a 1991.5-1996 transmission with 58-teeth and the tooth profile matches the pinion shaft profile, you can simply swap the ring gear by itself, BUT there were two early variations before 1991.5 that had different tooth profiles or pitch angles and had matching output pinion shafts that need to be swapped together to be used.

    The 1990-1996 transfer case is a 1.090 final drive ratio and consists of a 24-tooth driven gear (pinion shaft to driveshaft) and 22-tooth drive gear (side cover gear).


    Now, the easiest way to check is to simply unbolt the 5x 14mm head bolts holding on the side cover. Then, hit the input sleeve with a dead blow hammer and the cover pops off. Count the teeth on the drive gear; it will be 22 teeth for an auto or 5-speed 1990-1996 transfer case; and it will be 27 teeth for an auto or 5-speed 1997-1999 transfer case.

    If you are too lazy to take off the cover and you have a spare transmission output shaft sitting around, then use a sharpie marker and mark a starting point on the input sleeve and the tail shaft, then count your revolutions until the markings match back up. 12 revolutions = 1990-1996, 14 revolutions = 1997-1999.

    If you need to do the same with the transmission, that can be done as well by counting revolutions of the front diff ring gear; 4 revolutions = 58 teeth, 5 revolutions = 57 teeth.

    Now, if you put on a transfer case with the wrong final drive, your car will act very squirrelly. Your front wheels will be spinning at a different speed than your rear wheels by about 4 mph at speeds. Handling will feel awkward, the car will feel like it is loading up alot and you can overheat or kill a head gasket or other components. You will also nuke your transmission viscous coupler for the center differential and can damage other components.
     
    My DSM:
    1999 Mitsubishi Eclipse GSX

    Drag Race Build

    9.499 @ 155.00 MPH
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  9. 1990TSIAWDTALON

    1990TSIAWDTALON Moderator

    2,961
    888
    Joined Nov 14, 2013
    Independence, Kansas
    Thanks, very informative Tim!!!!
     
    My DSM:
    1992 Eagle Talon TSi AWD

    Street Build

    14b   automatic
    1990 Eagle Talon TSi AWD

    13.620 @ 108.460 MPH
    1990 Eagle Talon TSi AWD

    13.612 @ 107.760 MPH
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