GalantVR4.org The Mitsubishi Galant VR-4 Forum
NOTICE: This forum is for archiving information and discussions. Please do not reply to threads unless you have valuable information to add. Do not post questions or problems here.

Galant VR-4 Forums » Galant VR-4 » How To and Info Archive » GVR4 Tranny rebuild. Difficult?
Previous thread Next thread

GVR4 Tranny rebuild. Difficult?


thejeebus2002
Unregistered


Galant VR-4 org Post #: 19471 posted 08/24/03 09:22 AM     Remind Me!  Send Private Message   Edit Post      
I'd like to tackle the job for rebuilding my gvr4 tranny myself but i had a few questions if anyone out there can help me. I had the transmission rebuilt by a friend, and it's starting to grind again. However the parts he put in were a mix of tre and evo parts. The questions im posing are these:

1. Are there part numbers on all the synchros and shift forks.

2. What specialty tools will i need.

Thanks
scott
GVR4#581

| | | IP: (152.163.252.33) | Report this post to a Moderator

spoulson
0 people like this


Galant VR-4 org Post #: 19472 posted 08/24/03 10:03 AM     Remind Me!  Send Private Message   Edit Post      
I'm about to do the same thing myself. I bought my parts from TRE. Jon recommended all the parts I bought, plus I got the double synchro 2nd.

I do know you will need a shop press, snap ring pliers, and god knows what else. I'll know when I start digging into it. You will definitely need the FSM to guide your rebuild as it will have all the endplay specs and assembly diagrams.

Posts: 2907 | From: Middletown, DE | Member Since: 02/05/03 | IP: (204.154.71.104) | Report this post to a Moderator

Romanova
the coolest person to ever post in the past 2 hours


Galant VR-4 org Post #: 19473 posted 08/24/03 10:19 AM     Remind Me!  Send Private Message   Edit Post      
quote:
Originally posted by spoulson:
I'm about to do the same thing myself. I bought my parts from TRE. Jon recommended all the parts I bought, plus I got the double synchro 2nd.

How much did all the parts set you back?

Posts: 3855 | From: Cypress, TX | Member Since: 08/07/02 | IP: (12.230.40.214) | Report this post to a Moderator

atsiauto
Senior Member


Galant VR-4 org Post #: 19474 posted 08/24/03 10:56 AM     Remind Me!  Send Private Message   Edit Post      
yeah lets get a list going Id like to rebuild mine as well . and Im not scurred.

Posts: 1575 | From: Richmond Va, | Member Since: 10/21/02 | IP: (68.57.96.24) | Report this post to a Moderator

turboflanagan
I would give myself something respectable.
478/1000


Galant VR-4 org Post #: 19475 posted 08/24/03 11:19 PM     Remind Me!  Send Private Message   Edit Post      
quote:
Originally posted by spoulson:
You will definitely need the FSM to guide your rebuild as it will have all the endplay specs and assembly diagrams.

You need the overhaul manual. Rebuild info isn't in either body or mechanical FSM. I just printed the info from my backup cd manual.

The biggest pain for me was the fact that my local Mitsu place doesn't stock ANYTHING!!! And all the spacers and shims had to be ordered. Don't use soldier like the manual says! Use plastigage.

Posts: 2551 | From: Peachtree Corners, Georgia, US... | Member Since: 03/05/01 | IP: (65.114.37.193) | Report this post to a Moderator

spoulson
0 people like this


Galant VR-4 org Post #: 19476 posted 08/24/03 01:07 PM     Remind Me!  Send Private Message   Edit Post      
quote:
Originally posted by Romanova:
How much did all the parts set you back?

About $600 with the double synchro 2nd, and probably about $350 without the upgrade. This includes synchro rings, 1/2 and 3/4 shift forks, hub springs, bearings, oil filter, magnet, pins, and some other parts I'm not fully educated on. I did not get spacers or shims. The upgraded 2nd includes a new hub, slider, double synchro and 2nd gear assembly, which is why it costs so much.

My 2nd gear is probably toast anyway, so I didn't see the waste in replacing it.

Posts: 2907 | From: Middletown, DE | Member Since: 02/05/03 | IP: (204.154.71.104) | Report this post to a Moderator

GVR-4
Creative Name Huh?
77/1000


Galant VR-4 org Post #: 19477 posted 08/24/03 01:31 PM     Remind Me!  Send Private Message   Edit Post      
What perfect timing! I'm gonna rebuild mine soon too. I've started doing the research to decide on upgrades. I plan on taking mine out and putting a friends spare tranny in for now. Then I can take my time rebuilding mine. So far I want to do a new input shaft, double synchros for 1st thru 4th, 1/2 & 3/4 shift forks, HD shift rails (or possibly just the ends), 10% taller 5th gear and the HD trash magnet. I'm undecided on what to do about the center diff and the 4 spider gear upgrade. I'd like a Quaife, but they're pricey. Eventually I plan on building up a stroker and I want the tranny to be able to handle the torque.

I hope we can help each other on our respective rebuilds. It's always good to have a pool of information. A dedicated thread would be awesome (hint hint).

Dave Peter

Posts: 2599 | From: Asheville, NC USA | Member Since: 04/22/02 | IP: (68.115.168.17) | Report this post to a Moderator

slvrblt
Unregistered


Galant VR-4 org Post #: 19478 posted 08/24/03 01:47 PM     Remind Me!  Send Private Message   Edit Post      
I dont think you can double synchro 1,2,3, and 4. There is only room for double synchros on 2 and 3 since they are on different hubs. TRE does 1,2, and 3 with a little machine work. I also have some part numbers that apply for this rebuild:

MD739795 1992 3-4 Rail
MD742728 1992 3rd Gear
MD742729 1992 4th Gear
MD742777 3-4 Synchro Keys
MD747646 1992 3-4 Hub/Sleeve/Synchro Kit
MD741558 1992 3-4 Fork
MD723439 1998 1-2 Fork
MD726235 Taper Bearing, Input Shaft Endcap Side
MD737652 Needle Bearing, Interm Shaft
MD745477 1998 1st Synchro
MD746435 1998 2nd Dual Synchros -- $66
MD748577 1998 2nd Gear
MD749414 1998 1-2 Hub/Sleeve
MD736638 1992 Taper Bearing, Interm Shaft Endcap Side
MD726326 1992 Taper Bearing, Interm Shaft Clutch side
MD738053 2G Trans Filter
MD742051 1992 Reverse Brake Synchro
MD732314 1992 Taper Bearing, Input Shaft Clutch Side
MD742775 1998 1-2 Synchro Keys
MD742445 1998 1-2 Synchro Springs
MD742441 1992 3-4 Synchro Springs
MD701722 Roll Pins

That list was posted a while bak on here (sorry I forgot who posted it). notice the various years of the parts. I have NOT checked the accuracy of the list or part numbers.

| | | IP: (68.35.27.99) | Report this post to a Moderator

CKA
Captain Kick Ass


Galant VR-4 org Post #: 19479 posted 08/24/03 03:13 PM     Remind Me!  Send Private Message   Edit Post      
Andre Cardadeiro (dre99gsx) has a rather informative tranny rebuild web sight with good outlined steps and pictures, check it out if you haven't already found it.

http://www.twingles.com/ideck/rebuild3/dretranny.htm

Posts: 168 | From: Wisconsin, United States | Member Since: 03/22/02 | IP: (66.84.245.211) | Report this post to a Moderator

GVR-4
Creative Name Huh?
77/1000


Galant VR-4 org Post #: 19480 posted 08/24/03 05:03 PM     Remind Me!  Send Private Message   Edit Post      
Yeah, all I've done so far is reading, so I don't know if 1-4 double synchros are possible. TRE lists them as options on their website, but maybe not all in combination with one another. I could live with 1-3 double synchros.

Thanks for the parts list slvrblt. Are those all available through the dealer?

dp

Posts: 2599 | From: Asheville, NC USA | Member Since: 04/22/02 | IP: (68.115.168.17) | Report this post to a Moderator

slvrblt
Unregistered


Galant VR-4 org Post #: 19481 posted 08/24/03 05:19 PM     Remind Me!  Send Private Message   Edit Post      
They should be readily available, but that depends on the dealer.

| | | IP: (68.35.27.99) | Report this post to a Moderator

spoulson
0 people like this


Galant VR-4 org Post #: 19482 posted 08/24/03 07:28 PM     Remind Me!  Send Private Message   Edit Post      
TRE is the only dealer I know of that will sell you just the parts for double synchro modifications. BM and Shepard will only these parts as part of a rebuild job.

I've talked with Jon about the synchros and he really believes there's no reason to overdo the double synchros by trying to put it on every gear. Are you shifting at 8500rpm in every gear? 2nd gear takes the most abuse in our trannies, so I got it for that one. It's also extremely cost prohibitive to get the additional double-synchro gears.

4-spider center diff is an excellent upgrade for durability. If you're going to make decent power, it'll be a tranny saver one day. If I can spare the cash, I'll be doing it, too. Send it out to TRE, Shepard, or BM for the upgrade, they all charge the same rate. I don't see a reason to go with an LSD center.

Posts: 2907 | From: Middletown, DE | Member Since: 02/05/03 | IP: (204.154.71.105) | Report this post to a Moderator

GVR-4
Creative Name Huh?
77/1000


Galant VR-4 org Post #: 19483 posted 08/24/03 09:56 PM     Remind Me!  Send Private Message   Edit Post      
Thanks for the input, Shawn.

Please keep it coming everyone.

dp

Posts: 2599 | From: Asheville, NC USA | Member Since: 04/22/02 | IP: (68.115.168.17) | Report this post to a Moderator

Arty
Junior Member


Galant VR-4 org Post #: 19484 posted 08/25/03 12:09 AM     Remind Me!  Send Private Message   Edit Post      
You'll need a 3/16 pin punch to remove the roll pins. Best to have a puller with 2mm thick hooks in case 5th gear is jammed on tight. If you want to remove all the taper bearing races you'll need a puller with thin hooks facing outwards that can fit between the bottom of the bearing race and the gearbox casing.  -
Long socket to use as a drift, can't remember the size 36mm I think, to remove the drive shaft seal.

John.

Posts: 384 | From: Victoria. Australia | Member Since: 09/09/02 | IP: (202.12.233.21) | Report this post to a Moderator

spoulson
0 people like this


Galant VR-4 org Post #: 19485 posted 08/25/03 09:10 AM     Remind Me!  Send Private Message   Edit Post      
Could you use a press for gear and bearing removal, too? I don't think Andre's VFAQ showed any gear pullers for his job.

Posts: 2907 | From: Middletown, DE | Member Since: 02/05/03 | IP: (204.154.71.104) | Report this post to a Moderator

Arty
Junior Member


Galant VR-4 org Post #: 19486 posted 08/25/03 06:30 PM     Remind Me!  Send Private Message   Edit Post      
You do need a press and the appropriate sized bearing separators to disassemble the gears and bearings from the shafts.
Dre's VFAQ is the most useful resource I've found.
You need the puller if the 5th gear is stuck on the shaft, as mine was.
The 5th gear pictured in the VFAQ is installed upside down though.When I used screwdrivers to try and lever off the 5th gear, I chipped the corners of its teeth. Then I realised that the 2.5mm groove around the top of the gear is there to attach a puller.

John.

Posts: 384 | From: Victoria. Australia | Member Since: 09/09/02 | IP: (202.12.233.21) | Report this post to a Moderator

turboflanagan
I would give myself something respectable.
478/1000


Galant VR-4 org Post #: 19487 posted 08/25/03 11:31 PM     Remind Me!  Send Private Message   Edit Post      
quote:
Originally posted by Arty:
You do need a press and the appropriate sized bearing separators to disassemble the gears and bearings from the shafts.
Dre's VFAQ is the most useful resource I've found.
You need the puller if the 5th gear is stuck on the shaft, as mine was.
The 5th gear pictured in the VFAQ is installed upside down though.When I used screwdrivers to try and lever off the 5th gear, I chipped the corners of its teeth. Then I realised that the 2.5mm groove around the top of the gear is there to attach a puller.

John.

Yep, yep, and yep. Chipped my teeth too. Don't want to think about how long I cussed that oops. Didn't have a puller that would fit in that groove.

Posts: 2551 | From: Peachtree Corners, Georgia, US... | Member Since: 03/05/01 | IP: (64.63.212.144) | Report this post to a Moderator

iceman69510 Galant VR4.org Moderator
Turn Right Racing
855/2000


Galant VR-4 org Post #: 19488 posted 08/27/03 11:56 PM     Remind Me!  Send Private Message   Edit Post      
I did mine with some help from TRE and some usage of the dealers tools, and it was one of the most complicated jobs I have ever done. I hope not to have to do it again. I replaced every synchro and bearing plus two gears doing mine. Also two shift forks.

If you have someone with experience to help you, or have done another tranny before, that helps.

Posts: 10730 | From: Michigan | Member Since: 03/05/01 | IP: (12.1.210.130) | Report this post to a Moderator

ken inn
BJ Titsengolf lifer


Galant VR-4 org Post #: 19489 posted 08/27/03 02:05 PM     Remind Me!  Send Private Message   Edit Post      
quote:
Originally posted by turboflanagan:
quote:
Originally posted by Arty:
You do need a press and the appropriate sized bearing separators to disassemble the gears and bearings from the shafts.
Dre's VFAQ is the most useful resource I've found.
You need the puller if the 5th gear is stuck on the shaft, as mine was.
The 5th gear pictured in the VFAQ is installed upside down though.When I used screwdrivers to try and lever off the 5th gear, I chipped the corners of its teeth. Then I realised that the 2.5mm groove around the top of the gear is there to attach a puller.

John.

Yep, yep, and yep. Chipped my teeth too. Don't want to think about how long I cussed that oops. Didn't have a puller that would fit in that groove.
blondes HATE vibrators. it chips their teeth.

Posts: 7529 | From: krum texas | Member Since: 02/23/01 | IP: (209.220.6.232) | Report this post to a Moderator

turboflanagan
I would give myself something respectable.
478/1000


Galant VR-4 org Post #: 19490 posted 08/27/03 04:51 PM     Remind Me!  Send Private Message   Edit Post      
[Mad] [Razz]

Posts: 2551 | From: Peachtree Corners, Georgia, US... | Member Since: 03/05/01 | IP: (64.63.212.64) | Report this post to a Moderator

spoulson
0 people like this


Galant VR-4 org Post #: 19491 posted 09/03/03 02:51 PM     Remind Me!  Send Private Message   Edit Post      
I have access to a 92 Talon FSM. Will the tranny overhaul section apply to a 91 GVR4?

Posts: 2907 | From: Middletown, DE | Member Since: 02/05/03 | IP: (204.154.71.103) | Report this post to a Moderator

iceman69510 Galant VR4.org Moderator
Turn Right Racing
855/2000


Galant VR-4 org Post #: 19492 posted 09/03/03 04:22 PM     Remind Me!  Send Private Message   Edit Post      
If it has a tranny section covering the W5M33, but I think the '92 manuals don't have engine and trans info in them. They were in separate books for 92-94 I believe.

Maybe that's Mitsu only, and the Chrysler books had it. Just check for it. (Still not very detailed in my opinion.)

Posts: 10730 | From: Michigan | Member Since: 03/05/01 | IP: (12.1.210.130) | Report this post to a Moderator

turboflanagan
I would give myself something respectable.
478/1000


Galant VR-4 org Post #: 19493 posted 09/04/03 09:48 AM     Remind Me!  Send Private Message   Edit Post      
I found a '93 Talon manual at work and it has the overhaul stuff in it, but I couldn't find the '92 book. Check section 21-63, that's where W5M33 starts in the '93 book.

Posts: 2551 | From: Peachtree Corners, Georgia, US... | Member Since: 03/05/01 | IP: (65.114.37.193) | Report this post to a Moderator

spoulson
0 people like this


Galant VR-4 org Post #: 19494 posted 09/04/03 01:13 PM     Remind Me!  Send Private Message   Edit Post      
I'll be checking out that FSM this week. He says he has all the books.

Here's another couple of links I picked up:
Limited set of pages from Mitsu training manual, rebuild W5M33
Someone's GS-T rebuild, FWD, but hey it gives a lot of close-up views of parts

I have a lead on the complete scanned PDF of the Mitsu training manual on the W5M33. I'll post it when I have it.

As far as tools required, I've been recommended to use:
- a 12t press, such as this one. (Harbor Freight = free shipping)
- snap ring pliers. The ones on Harbor Freight won't work, so someone recommended the tool from Sears or Snap-On.
- Large bearing separator
- FSM. As far as I can tell, as long as it has a section for W5M33 overhaul, that's what you need. 92+ had separate books for overhaul, fyi.

I'll post more when I get further into this. I'll be sure to take a bunch of pictures during the rebuild.

Posts: 2907 | From: Middletown, DE | Member Since: 02/05/03 | IP: (204.154.71.105) | Report this post to a Moderator

spoulson
0 people like this


Galant VR-4 org Post #: 19495 posted 09/04/03 08:27 PM     Remind Me!  Send Private Message   Edit Post   
Mitsu W5M33 Rebuild PDF

Posts: 2907 | From: Middletown, DE | Member Since: 02/05/03 | IP: (68.34.163.252) | Report this post to a Moderator


Pages: 1 | 2 | 3
Previous thread Next thread

Extra information
0 registered and 18 anonymous users are browsing this forum.

Galant VR4.org Moderator:  curtis, steve, atc250r, jcgalntvr4-244, cheekychimp, jepherz, Rausch, toybreaker, iceman69510, pot, FlyingEagle 

Print Thread

Forum Permissions
      You cannot start new topics
      You cannot reply to topics
      HTML is disabled
      UBBCode is enabled

Rating: *****
Thread views: 17961

Rate this thread


News & Events: News | Events
Galant VR-4: Newbies | General VR4 Discussions | Technical Discussions | How To and Info Archive
Marketplace: Parts For Sale | Cars For Sale | Good Guys | Bad Guys
Community: Members' Showcase

Contact Us | Privacy statement GalantVR-4.org

Generated in 0.321 seconds in which 0.109 seconds were spent on a total of 15 queries. Turbo powered.



Hertz's Galant VR-4 Page