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Need help rebuilding 2g AWD trans

Posted by dwdsm, Aug 12, 2019

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  1. dwdsm

    dwdsm Proven Member

    393
    16
    Joined Apr 28, 2005
    Scenery Hill, Pennsylvania
    Hi all. With the help of Tim @ TMZ I took on the task of rebuilding my own 2G trans. I wiped out 4th gear in my 10 year old shep trans and had a spare lying around so the goal was to combine the two. I have it all broken down and had a few questions on where to proceed and I hate bothering Tim too much as he has given up a ton of time for me already. I purchased Jacks rebuild kit at the shootout last year and were ready to rock with these exceptions.

    1. The Jacks kit only comes with bearing 303/28 r-w and TFR 28-9G and I have no idea where the hell these go. I want to replace all the taper bearings on the input and intermediate shaft but I can't find a breakdown with part numbers anywhere. The part numbers on the bearings coming out don't match anything in the FSM or anything off of STM's website. So I need a breakdown with part numbers for ordering and reassembly. This would also be helpful so I can make a "grocery list" to order through TMZ.

    2. Some of the needle bearing are split and some are solid. Are these interchangeable?

    3. My Shep 2nd gear is odd as the teeth for the hub slider are cut at a 45 degree angle instead of the usual "peak". Was this his "spec" 2nd gear he used to sell as an upgrade?

    4. The Jacks 3-4 hub slider is a larger diameter then the old Shep trans. It does match the donor trans along with a different shift fork design in the donor trans vs the shift fork design that come from the Shep. What is the deal with these and are there any interchangeability problems?
     

    Attached Files:

    Last edited: Aug 12, 2019

    930  0

    1997 Eagle Talon TSi AWD
    11.797 @ 118.450 · 2G DSM
    Loading...
  2. dwdsm

    dwdsm Proven Member

    393
    16
    Joined Apr 28, 2005
    Scenery Hill, Pennsylvania
    Found an old post of Tim's answering my own question 1... It took no kids and lots of coffee but I found it!
    Input Shaft and Gearset Info:
    Input Shaft (1990.10-1999) MD747884
    Input Shaft Inner Tapered Roller Bearing MD732314
    Input Shaft Outer Tapered Roller Bearing MD726235
    3rd Gear Subgear MD741925
    3rd Gear Subgear Wave Washer MD723535
    3rd Gear Subgear Snap Ring MD724392
    3rd Gear Needle Bearing MD718033
    3rd Gear MD748582
    3rd/4th Gear Hub Springs MD742445 x 2
    3rd/4th Gear Hub Keys MD748663 x 3
    3rd/4th Hub/Slider MD749416
    4th Gear Needle Bearing MD749902
    4th Gear MD741838
    Input Shaft Snapring (1.4mm) MD723276
    Input Shaft Snapring (1.45mm) MD730889
    Input Shaft Snapring (1.5mm) MD723277
    Input Shaft Snapring (1.55mm) MD730890
    Input Shaft Snapring (1.6mm) MD723278
    Input Shaft Snapring (1.65mm) MD730891
    Input Shaft Snapring (1.7mm) MD723279
    Input Shaft Snapring (1.75mm) MD730892
    5th Gear Needle Bearing MD719137
    5th Gear MD743162
    5th/Rev Hub Springs MD742441 x 2
    5th/Rev Hub Keys MD742777 x 3
    5th/Rev Hub/Slider MD747654
    Input Shaft End Shaft Oil Seal MD739390

    Intermediate Shaft and Gearset Info:
    Intermediate Shaft (1991.5-1999) MD748830
    Intermediate Shaft Inner Bearing (ALL YEARS) MD726236
    Intermediate Shaft Outer Bearing (ALL YEARS) MD736638
    Intermediate Shaft Snapring (1.4mm) MD703779
    Intermediate Shaft Snapring (1.5mm) MD703780
    1st Gear Needle Bearing (1990-1999) MD737652
    1st Gear (DSM 3.083 Gear Ratio) MD743179
    1st/2nd Hub Springs MD742445 x 4 (use 4 springs with shallow synchro -- 2x springs per side, 3 springs with OEM synchro -- 2x springs on 2nd gear side/1x spring on 1st gear side)
    1st/2nd Hub Keys MD742775 x 3
    1st/2nd Hub/Slider MD749414
    2nd Gear Needle Bearing (1991-1999) MD737652
    2nd Gear MD748577
    5th Intermediate Gear (ALL YEARS) MD742581

    Output Shaft and Pinion Shaft:
    Output Shaft (23-spline 91.06-99) MD741190
    Output Pinion Shaft (91.06-99) MD742530
    Output Shaft needle Bearing MD718578
    Output Shaft Inner Tapered Roller Bearing MD718322
    Output Shaft Outer Tapered Roller Bearing MD727861

    Center Differential:
    90-99 Center Differential Inner Tapered Roller Bearing MD727860
    90-99 Center Differential Outer Tapered Roller Bearing MD720623
    Center Differential Case 1991.5-1999 MD741919
    Center Diff Pinion Gear Kit + Spider Gears MD733338
    Center Differential Spider Gear Side Shims (x2) MD737658
    Center Differential Cover MD727551
    Center Differential Case Bolts MD727552
    1991-1999 Center Diff Oiling Washer 2.75-2.82 MD741405
    1991-1999 Center Diff Oiling Washer 2.67-2.74 MD741406
    1991-1999 Center Diff Oiling Washer 2.59-2.66 MD741407
    1991-1999 Center Diff Oiling Washer 2.51-2.58 MD741408
    1991-1999 Center Diff Oiling Washer 2.43-2.50 MD741409
    1991-1999 Center Diff Oiling Washer 2.33-2.42 MD741410
    1991-1999 Center Diff Oiling Washer 2.25-2.32 MD741411
    1991-1999 Center Diff Oiling Washer 2.17-2.24 MD741412
    1991-1999 Center Diff Oiling Washer 2.09-2.16 MD741413
    Pinion Gear Oiling Washer 1.17-1.24 MD724949
    Pinion Gear Oiling Washer 1.09-1.16 MD720677
    Pinion Gear Oiling Washer 1.01-1.08 MD720676
    Pinion Gear Oiling Washer 0.93-1.00 MD720678
    Pinion Gear Oiling Washer 0.83-0.92 MD720679
    Pinion Gear Oiling Washer 0.75-0.82 MD720680
    Pinion Gear Oiling Washer 0.67-0.74 MD724950
    Pinion Gear Oiling Washer 0.59-0.66 MD724974

    Front Differential:
    Front Differential Roller Bearings (x2) MD706566
    Front Differential Case MD763447
    Front Differential Gear Kit MD722127
    Front Differential Spider Gear Oiling Washers (x2) MN178197
    Front Differential Cross Shaft MB001106
    Front Differential Cross Shaft Roll Pin MN178199
    Front Differential Ring Gear 1991-1996 58-tooth MD748872
    Front Differential Ring Gear 1997-1999 57-tooth MD770499
    Front Differential Ring Gear Bolts (x8) MD040557
    Front Differential Shim Kit MB185340

    Shift Forks:
    1st/2nd Gear Shift Fork MD723439
    3rd/4th 1992.5-1999 Gear Shift Fork MD746854
    5th/Reverse Shift Fork w/ plastic shift pads MD748630

    Shift Shaft Assembly Parts:
    Gearshift Interlock Retainer Bolt MD717876
    Gearshift Interlock Retainer Bolt Gasket MD720602
    Shift Shaft Assembly (9405.2-1999) MD747904
    Shift Shaft Limiter Plate MD740179
    Shift Shaft Stopper Kit (w/ retainer spring) MD720248

    Shift Linkage Lever Assembly Parts:
    Inner and Outer Linkage Bushings MD719165
    Shift Linkage Lever (9405.2-1999) MD721253
    Inner Flat Washer MD713416
    Outer Flat Washer (95-99) MF450194
    Lock Washer MF450405
    End Nut MF430005
    Dust Cap MD713757
    Shift Selector Roll Pin (M5x22mm) MD705490

    Misc.:
    End Shaft Nut (x2) MD731948
    Plastic Shift Pad MD712919
    Roll Pins 5.2mm x 26mm (x3) MD701722
    Transmission Filter MD738053
    Input Shaft Seal MD741818
    Front Left Axle Seal MD719710
    Front Diff (Right Axle) Oil Seal MD707184
    Output Shaft Seal MD723202
    Throwout Bearing MD749998
    Throwout Bearing Retainer Spring MD706185
    Throwout Bearing Bellhousing Sleeve MD716349
    Clutch Fork MD770506
    Clutch Fork Pivot Ball MD719602
    Clutch Fork Boot MD718077
    Bell Housing Case MD739932
    Gear Cluster Case (8903.1-9208.1) MD726632
    Gear Cluster Case (9208.2-1999) MD744770
    Intermediate Case Section MD746412
    5th Gear Outer Cover (9105.3-1999) MD741184
    Short Outer Bolts (x9) MF241294
    Long Outer Bolts (x2) MD720558
    Transmission Case Bolts (x12) MF241288
    Black Plastic Intermediate Shaft Oil Guide MD726480
    Transmission Breather #1 (x2) MD711443
    Transmission Breather #2 MD721764
    Transmission Breather Bulb MD733296
    Bellhousing Dowels (x2) MD020260
    Transmission Case Dowels (x4) MF472405
    5th Gear Outer Cover Dowels (x2) MF472402
    Reverse Wave Spring MD744342
    Reverse Cone MD725928
    Reverse Cone Machine Screws (x3) MD736513
    Reverse Switch MD730979
    Reverse Switch Washer MF660035
    Reverse Lockout Bolt MD734488
    Reverse Lockout Bolt Washer MF660035
    Shift Rail Interlock Plunger MD720908
    Bellhousing bolts (2G): MF140471
    cont. MD740892
    cont. MF140266
    cont. MD706012
    cont. MF140021
    Viscous Coupler Detent Ball MF540008
    Viscous Coupler Snapring (1.5mm) MD720687
    Fill Plug MD701850
    Fill Plug Gasket Washer MF660036
    Drain Plug MD728088
    Drain Plug Gasket Washer MN130495
    Drain Plug Magnet MD955485
    Reverse Bracket Allen-Head Screw MD734702
     

    930  0

    1997 Eagle Talon TSi AWD
    11.797 @ 118.450 · 2G DSM
    Loading...
  3. dwdsm

    dwdsm Proven Member

    393
    16
    Joined Apr 28, 2005
    Scenery Hill, Pennsylvania
    Kinda answered my own question 2 as well... Question 3 and 4 if you please.
     

    930  0

    1997 Eagle Talon TSi AWD
    11.797 @ 118.450 · 2G DSM
    Loading...
  4. dwdsm

    dwdsm Proven Member

    393
    16
    Joined Apr 28, 2005
    Scenery Hill, Pennsylvania
    Input Shaft Inner Bearing Part Number: NSK TF R25-19g
    Input Shaft Inner Bearing Race Part Number: NSK TF R25-19g
    Entire Assembly Mitsu Part Number: MD732314

    Input Shaft Outer Bearing Part Number: KOYO HI-CAP 26118YR1-N
    Input Shaft Outer Bearing Race Part Number: KOYO HI-CAP 26283-N
    Entire Assembly Mitsu Part Number: MD 726235

    Intermediate Shaft Inner Bearing Part Number: KOYO HI-CAP 303/28R-N
    Intermediate Shaft Inner Bearing Race Part Number: KOYO HI-CAP 303/28-N
    Entire Assembly Mitsu Part Number: MD726236

    Intermediate Shaft Outer Bearing Part Number: NSK TF R28-9g
    Intermediate Shaft Outer Bearing Race Part Number: NSK TF R28-9Ag
    Entire Assembly Mitsu Part Number: MD736638

    Center Diff Inner Bearing Part Number: NSK R41-1g
    Center Diff Inner Bearing Race Part Number: NSK R41-1g
    Entire Assembly Mitsu Part Number: MD727860

    Center Diff Outer Bearing Part Number: KOYO HI-CAP LM300849
    Center Diff Outer Bearing Race Part Number: KOYO HI-CAP LM300811
    Entire Assembly Mitsu Part Number: MD720623

    Output Pinion Shaft Inner Bearing Part Number: KOYO HI-CAP 32009JR
    Output Pinion Shaft Inner Bearing Race Part Number: KOYO HI-CAP 32009J
    Entire Assembly Mitsu Part Number: MD718322

    Output Pinion Shaft Outer Bearing Part Number: NSK R31z-31g
    Output Pinion Shaft Outer Bearing Race Part Number: NSK R31z-31g
    Entire Assembly Mitsu Part Number: MD727861

    Front Differential Roller Bearing Part Number: Koyo 6207C3
    Mitsubishi Part Number: MD706566
     

    930  0

    1997 Eagle Talon TSi AWD
    11.797 @ 118.450 · 2G DSM
    Loading...

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