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Need help rebuilding 2g AWD trans

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dwdsm

15+ Year Contributor
564
27
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?
 

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Last edited:
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
 
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
 
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