Shimming Intermediate Shaft end case. Ridiculously huge!

[randedge]

Hello all!

I drive a Lancer Evolution 1 and I too have a W5M33 AWD transmission. It is in fact a WQWE, with the JDM front viscous LSD.

Anyway, I just bought a cusco tarmac gear (35:65 F-R torque bias) and have put it in, I'm about to seal my transmission and I have done the shim process in this thread:

http://www.dsmtuners.com/forums/drivetrain-tech/432456-gearbox-shimming-expert-needed.html

While I seem to have no issues with the center diff and input shaft numbers (Center diff = 0.05785, Input Shaft 0.05205 before any preload factored in), my intermediate shaft seems to be completely bonkers.

By bonkers, I mean it is at 0.109 !!! Again, this is prior to preload being factored in! It seems as though I would have to double up on shim size!

I followed everything the Manual Transaxle repair ...uhh... manual said to do and indeed, my centre diff and input shaft shims do not seem all that out of place.

Also, prior to my dismantling the 2nd case section to get to the centre diff (which was why I had the tranny apart), as in I haven't knocked off the tranny sealant, my intermediate shaft shook ridiculously. As in, baaaad! I'll post vid up later. As well, I have always had ridiculous transmission whine.

What could be wrong? And what should I do about it?

R.

 

[donniekak]

Are the intermediate shaft bearings, and races worn badly?

 

[randedge]

Well, crap. I hadn't taken a close look the first time I took it apart - was too excited to put the Cusco Tarmac in - but my stupid Intermediate shaft bearing and bearing race is super worn.

Someone had been there before me and didn't do a good job. There's evidence that my Centre diff was purchased as a used item. Probably blew one, put another one in, then sealed it all back up without checking preloads and shims!!!! As I said, the intermediate shaft, was rattling! Hence the gear whine that was a bit excessive.

So, anyone have tips on replacing that bearing? I have to rebuild further down towards clutch bellhousing now, don't I? At minimum I foresee both intermediate tapered roller bearings to be screwed - if it had been rattling all along with excess endplay (when it should have had preload), then it must be!