2G AWD internal diagram

[zachdavidc]

Hello guys. Does anyone have a diagram for the 2g awd transmission. The diagram in alldata seemed very off. I searched on here and could not find much. I need a breakdown of parts. I believe what I need is called the cluster gear.

 

[pauleyman]

Factory manual has all you need. That isnt a single part. Its the entire intermediate shaft cluster. Looks like 2nd gear is broken which is part of the shaft itself meaning you need a new intermediate shaft. Likely the 2nd gear on the input shaft is messed up also. You must inspect everything.

 

[zachdavidc]

Wow, I never even thought of looking in the manual. Thank you very much!

 

[pauleyman]

Scratch that. Third gear

 

[spyderdrifter]

I have PDFs of the factory manuals I could share later tonight if needed (currently at work for the next 12hrs).

 

[zachdavidc]

That would be great if you could share the pdf later. I have 2 gst transmissions in the back of my shop, but unfortunately the intermediate shaft is different. I just hope I can find one somewhere.

 

[spyderdrifter]

I'll share it once I get home in a couple hrs then. If I forget tonight, tomorrow for sure, I'll be off work.

 

[twicks69]

2G AWD Intermediate Shaft cluster components -
Intermediate Shaft (1991.5-1999) MD748830 - ~10-12 days lead time
Intermediate Shaft Inner Bearing MD726236
Intermediate Shaft Outer Bearing MD736638
Intermediate Shaft Snapring (1.4mm) MD703779
Intermediate Shaft Snapring (1.5mm) MD703780 -- typically the snapring I use
Intermediate Shaft Snapring (1.6mm) MD703781
1st Gear Needle Bearing Sleeve (1991-1999) MD737651 - discontinued
1st Gear Needle Bearing (1991-1999) MD737652
1st Gear (DSM 3.083 Gear Ratio) MD743179 -- backordered weeks Japan
1st/2nd Hub Springs MD742445 (x2 normally used OEM; 3 or 4 used depending on which 1st synchro is being used)
1st/2nd Hub Keys MD742775 (x3)
1st/2nd Hub/Slider MD749414 - ~5-7 days lead time
2nd Gear Needle Bearing (1991-1999) MD737652
Double Synchro 2nd Gear MD748577- ~5-7 days lead time

2G AWD Input Shaft cluster components -
Input Shaft (1990.10-1999) MD747884
Input Shaft Inner Tapered Roller Bearing MD732314
Input Shaft Outer Tapered Roller Bearing MD726235
1991.6-1999 3rd Gear Subgear MD741925
3rd Gear Subgear Wave Washer MD723535 - discontinued
3rd Gear Subgear Snap Ring MD724392
3rd Gear Needle Bearing MD718033
3rd Gear MD748582- discontinued
3rd/4th Gear Hub Springs MD742445 (x2)
3rd/4th Gear Hub Keys MD748663 (x3)
Loaded 3rd/4th Hub/Slider (95-99) MD747647 - I have 2 remaining, extended lead time
2G 3rd/4th Hub/Slider MD749416- discontinued
4th Gear Needle Bearing MD749902
4th Gear Needle Bearing Sleeve MD728102- discontinued
4th Gear MD741838- discontinued
Input Shaft Snapring (1.4mm) MD723276
Input Shaft Snapring (1.45mm) MD730889- discontinued
Input Shaft Snapring (1.5mm) MD723277 - normally used
Input Shaft Snapring (1.55mm) MD730890- discontinued
Input Shaft Snapring (1.6mm) MD723278- discontinued
Input Shaft Snapring (1.65mm) MD730891- discontinued
Input Shaft Snapring (1.7mm) MD723279
Input Shaft Snapring (1.75mm) MD730892- discontinued
5th Gear Needle Bearing MD719137
5th Gear Needle Bearing Sleeve MD730744- discontinued
5th Gear MD743162- discontinued
5th/Rev Hub Springs MD742441 (x2)
5th/Rev Hub Keys MD742777 (x3)
5th/Rev Hub/Slider MD747654- discontinued
Input Shaft End Shaft Oil Seal MD739390- discontinued

 

[twicks69]

As for FSM's, I have a few downloaded on this forum.

https://www.dsmtuners.com/threads/1...-transfer-case-rebuild-service-manual.517367/

https://www.dsmtuners.com/threads/1...ory-mechanics-training-service-manual.517370/

https://www.dsmtuners.com/threads/1...-transfer-case-rebuild-service-manual.517379/

 

[zachdavidc]

Thank you very much!!

 

[spyderdrifter]

Well, I dropped the ball on sharing my PDFs, I apologize. Glad another member linked some.

 

[zachdavidc]

We all have a life brother, no problem. Thank you all for your help. A new intermediate shaft from mitsubishi is on its way!

 

[pauleyman]

You did inspect everything else? You probably need 3rd gear and possibly a center diff too.

 

[zachdavidc]

3rd gear is damage free. Center diff I have not even looked at. I will be taking a look at that on Saturday. Thank you for your input!

 

[zachdavidc]

Now you have me paranoid about my center differential being destroyed . I know all about our center differentials being absolutely trash even with a 4 spider. My question now is, would a front quaife lsd alleviate any stress on the center? This car will not be launched and my horsepower will probably be around 400. Btw, this transmission is from a donor car and has never been driven on by me

 

[twicks69]

The front diff being a quaife vs an open will not change much for a stock center diff. Keeping hard launches and dumb stuff like donuts to a minimum will make it survive.

 

[zachdavidc]

So I want to thank you guys for your advice! I found some carnage in the center differential. So my question now is, what is my next step? Can this be machined for a 4 spider differential? Do I need a whole new center differential? Thank you guys! I have it put back together for now in case I can send it out.

 

[twicks69]

How do the spider gears look? Backside fave and bore that goes onto cross shaft?
You need a new pinion gearset and diff cover minimum, then machine housing and hopefully reuse your two spider gears to make a 4 spider setup.

 

[zachdavidc]

Spider gears are good and backside looks good. Picture attached.

 

[zachdavidc]

Is this something you could get me parts for twicks? I'll send you my differential.

 

[pauleyman]

So I want to thank you guys for your advice! I found some carnage in the center differential. So my question now is, what is my next step? Can this be machined for a 4 spider differential? Do I need a whole new center differential? Thank you guys! I have it put back together for now in case I can send it out.

I was thinking you would find damage to the outer gear as that is driven by third gear. Look closely.

 

[zachdavidc]

I just checked again, looks good believe it or not. I'm gonna have my master tech verify it for me, but to me it looks good.

 

[zachdavidc]

Or at this point should I order a quaife center through tmz and just not launch the car?

 

[twicks69]

The quaife center is not an available option and it had quality control issues with teeth meshing causing teeth failures.

As for the center diff, ill have to see what I have remaining for 4 spider stuff.

 

[zachdavidc]

Thank you!