1G Output shaft splines damaged

[Bumbax]

hi all, i'm restoring my talon tsi, yesterday i disassembled the transfer case and i noticed that the output shaft is very damaged, what should i do? is it available as a spare? Is it necessary to open the gearbox to replace it?
ps: obviously the part on the transfer case side is also very worn.

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[bastarddsm]

Need both parts. No spares really. Boostin has a 23spline 300m version, but idk if I'd put that in a street car.

 

[Bumbax]

Need both parts. No spares really. Boostin has a 23spline 300m version, but idk if I'd put that in a street car.

Thanks for the reply, so what do you suggest I do? have them handcrafted by some workshop?
Can the output shaft be removed from its seat like the axle shafts or is it necessary to disassemble and open the gearbox to remove it?

 

[dwb]

Thanks for the reply, so what do you suggest I do? have them handcrafted by some workshop?
Can the output shaft be removed from its seat like the axle shafts or is it necessary to disassemble and open the gearbox to remove it?

I bought a new OEM 23 spline output shaft from Jacks Transmissions about 2 years ago, not sure if they still have them or not but worth checking around.
You will also need the driven gear in the transfer case that meshes with the output shaft. Those are NLA from Mitsu. I had to source a good used one.

The output shaft can be swapped with the trans still in car. You have to pull the transfer case and the top cover to the transmission. Then the viscous coupling and check ball. Once the ball is out, the shaft will slide out towards the engine.

This was mine at about 265k miles:

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[Bumbax]

I bought a new OEM 23 spline output shaft from Jacks Transmissions about 2 years ago, not sure if they still have them or not but worth checking around.
You will also need the driven gear in the transfer case that meshes with the output shaft. Those are NLA from Mitsu. I had to source a good used one.

The output shaft can be swapped with the trans still in car. You have to pull the transfer case and the top cover to the transmission. Then the viscous coupling and check ball. Once the ball is out, the shaft will slide out towards the engine.

This was mine at about 265k miles:

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mine was completely rusted, i think it got ruined by that. Unfortunately jacks transmissions has practically nothing left for the dsm.
I will find out if any company can make it for me by hand, because here in Italy it is very difficult to find spare parts for these cars and buying in the USA is very expensive due to customs duties.
Thanks anyway for the info, in the meantime I'll start disassembling the piece, then I'll look for a solution.

 

[diambo4life]

I don't think that output shaft can be removed with the trans in the car, at least on my Galant it can't because there just isn't enough room to pull it out. The tcase part is easy to swap out though.

 

[dwb]

I don't think that output shaft can be removed with the trans in the car, at least on my Galant it can't because there just isn't enough room to pull it out. The tcase part is easy to swap out though.

It absolutely can on a 1g. I personally did it.

 

[1990TSIAWDTALON]

I think it would be worth giving these guys a call and ask if tney have a good used output shaft for a W5M33.
Their ad says if you don't see it to call.

KM FM3 Catalog: TRANSMISSION, Assembly - Transmission Supply

Partial TRANSMISSION, Assembly parts listings for Mitsubishi F5M31, F5M33, KM210, W5M31, W5M33 manual transaxles.

mmerlinn.com

 

[Bumbax]

It absolutely can on a 1g. I personally did it.

I removed it easly, thanks!
Now, with a little luck, I'll look for someone who can build me a new one here in Italy.

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[Bumbax]

I think it would be worth giving these guys a call and ask if tney have a good used output shaft for a W5M33.
Their ad says if you don't see it to call.

KM FM3 Catalog: TRANSMISSION, Assembly - Transmission Supply

Partial TRANSMISSION, Assembly parts listings for Mitsubishi F5M31, F5M33, KM210, W5M31, W5M33 manual transaxles.

mmerlinn.com

thanks, I contacted them on the mail, let's see what they say

 

[Bumbax]

sorry guys, last question:
the driven gear is all this piece in the picture? or can it be disassembled further? (apart from the bearings of course)

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[bastarddsm]

Yes, the spool "coupler" presses out of the gear pretty easily. The bearings are pretty standard stuff and easy to get at any bearing house in the states. Be advised that you will likely need to adjust the preload shims if you have a new "coupler" made.

you can see on the output shaft the first section of splines don't really wear and can be used for reference.

 

[Bumbax]

Yes, the spool "coupler" presses out of the gear pretty easily. The bearings are pretty standard stuff and easy to get at any bearing house in the states. Be advised that you will likely need to adjust the preload shims if you have a new "coupler" made.

you can see on the output shaft the first section of splines don't really wear and can be used for reference.

Greetings! i was able to retrieve both pieces from japan. They are original mitsubishi spare parts, will I still have to adjust the preload shims? If so, how is it done?
thanks

 

[twicks69]

Pretty much all the shims are obsolete. Assemble and see what your backlash and side cover preload is like. Realistically it shouldn't be a huge issue. I am assuming you are replacing the bearings.

As well, typically the center differential has an upper pinion gear oiling washer failure between the gear and the cover that causes this issue, so I am hoping you are tearing down your differential to find out.