1G Equal Length Half Shafts Mod (AWD axle in a FWD)

Overview:

Using Equal Lenth Half Shafts on a FWD is supposed to reduce torque steer and wheel hop while improving handling and traction, especially during cornering.

Swapping to Equal Length Half Shafts involves installing an AWD driver's side axle and intermediate shaft on a FWD DSM. This will only work on 1990 - late 1992 FWD DSMs. Starting in late 1992 the FWD's used a bigger spline shaft that goes into the transmission. The AWD splines are the same size from 1990-1999 and match the 1990-1992 FWD splines.


Tools Recommended:

• Jack and jack stands
• Lug wrench (13/16")
• Flat head screwdriver
• Ratchet with 14, 17, 24, and 32 mm (or 1 1/4") sockets
• 17 and 19 mm wrenches
• Hammer
• Ball joint separator (recommended)
• 4' Cheater bar (recommended)
• Small pry bar (recommended)
• Torque wrench (recommended)

Parts needed:

• AWD intermediate shaft
• AWD Drivers side axle
• 1 MD707184 1g FWD output shaft seal
• 2 MB297860 Bolts which attach the intermediate shaft to the block
• 2 MF450406 Lock washers for the above bolts
• 1 MB297732 Spacer which is only needed if A/C compressor bracket is removed
• 2.3 quarts of transmission fluid (SAE 75W-85W gear oil was recommended from the factory)(Redline MT-90 is recommended by most DSM transmission specialists).

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Steps:

1. Engage the parking brake, block the rear tires, break loose the driver's side front lug nuts, lift the front of the vehicle, support it securely on jack stands, and remove the driver's side front tire.
   
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2. Drain the transmission. The drain plug is 24 mm. Collect all of the fluid and dispose of it properly.
   
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3. Remove the cotter pin from the driver's side axle nut. Break the axle nut loose. The axle nut is 32 mm (1 1/4") and can be a pain. I recommend to stick a screwdriver in the middle of the brake rotor to keep the axle from spinning and use a 1/2" drive breaker bar and a 4' cheater bar as shown here:
   
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4. Disconnect the lower ball joint by removing the top bolt, which is 19 mm, and separate the ball joint from the lower control arm using a ball joint separator.
   
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5. Disconnect the strut mount from the knuckle. For this you will need a ratchet with a 17 mm socket and a 17 mm wrench.
6. Now that everything is disconnected, pull the FWD axle out of the wheel hub. By now the transmission should be drained so use a small pry bar to pop the FWD axle out of the transmission and remove it from the vehicle.
   
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7. Pop your old output shaft seal out with a flat head screwdriver or your small pry bar. Press the new seal into place and tap it in. I used my 4' cheater bar as an extension and hammered the seal into place. Take your time and make sure it goes in evenly and goes all the way in.
   
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8. Now you are ready to install the AWD intermediate shaft. Insert the shaft into the transmission. Push it in while twisting and wiggling it a little, do not hammer it in. You will know when it is all the way in when you can no longer see the splines.
9. Once the shaft is in the transmission you need to bolt it to the block. Use the two bolts, lock washers, and spacer (if you don't have the A/C bracket). The spacer goes on the bolt closest to the wheel between the shaft bracket and the block. Use a 14 mm socket to tighten them to 26-33 ft. lbs.
   
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10. Now we get to install the driver's side AWD axle. Insert it over the end of the intermediate shaft and push it all the way in. Feed the other end back through the wheel hub and reattach the lower ball joint (43-52 ft. lbs.), shock mount (80-100 ft. lbs.), axle nut (144-188 ft. lbs.), and reinsert the cotter pin.
    
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11. Reinstall the driver's side wheel and lower the vehicle to the ground. Torque the lug nuts to 87-101 ft. lbs.
12. Lastly we need to refill the transmission. Reinstall the drain plug and tighten it to 22-25 ft. lbs. Loosen the fill plug, which is 17 mm. Fill the transmission until the fluid starts to flow out of the fill hole. The FWD turbo transmission (FM533) takes 2.3 quarts of fluid. Once the transmission is full, reinstall the fill plug and torque it to 22-25 ft. lbs.
    
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