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Dozends of questions... http://4g61t.org/forum/viewtopic.php?f=22&t=40551 |
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Author: | big&bad [ Wed Feb 17, 2016 9:57 pm ] |
Post subject: | Dozends of questions... |
I tried to find the answers to my questions, but all I got was too many results without the right answers... My 1989 Mirage Turbo will be restored to original shape - no modifications, just stock or going for more reliable parts... Of course I know companies like Summit or Rockauto, I bought a lot of stuff there for my old Dodge, because I'm too far away to walk into the next store. Every part must be available as an internet-order, best with an internet catalogue.. So... 1st: I want to buy a complete engine rebuild kit - any suggestions about a reliable brand, that will fit to 100%? Where to buy? 2nd: The headgasket is equal to the 1.6 non-turbo? 3rd: Is there a company that offers forged pistons and rods for the 4g61t? 4th: A good brand for a turbo repair-kit? Where to buy? 5th: A good brand for brake discs? If I drive with 130 mph at our Autobahn, I want to stop safely... 6th: Someone wrote about new manufactured driveshafts from carquest. Any other shop that offers them? 7th: Better, stronger Replacement for the stock clutch in the combination 4g61t/KM210? Without big modifications? Thx! |
Author: | Flying Eagle [ Tue Feb 23, 2016 2:42 pm ] |
Post subject: | Re: Dozends of questions... |
1st: Factory OEM Mitsubishi gaskets, or OEM Hyundai 1.6L gaskets USDM 92-94.5 (electronics changed after 94.5 maybe block too?). www.JNZtuning.net (US side, OEM Mitsubishi parts), www.RTMRacing.com, (Canadian side, can order anything OEM or in stock items for 4g63 type parts - large parts selection on the shelves with pictures, transitioning to a new owner but Ziggy is still around!). 2nd: Head gasket is identical in composition to the 4g63, BUT uses a larger fire ring for each cylinder/piston hole. Purchase OEM Mitsu or OEM Hyundai composite style gaskets and you will be good up to power levels well beyond what you will use the motor at. You can install ARP studs (4g63 listings) if you want possible peace of mind at higher output levels, but it is not necessary with a new gasket and proper surfaces. MLS or multi layer steel should only be used on confirmed/nearly perfectly flat metal surfaces. Some guys use copper spray or some such for minor surface imperfections but composite gaskets are best no matter what you are doing. 3rd: There is a member here that is using custom pistons so there is a company that made them for him. Much higher compression from 8.0:1 though. There is always room to reduce compression via the manufacturer but that would be a question direct to them, to ask. This guy here, " Shawn J ". Otherwise it is stock pistons from which ever company is still wanting to make them for you. Some companies out there make custom pistons, but you would have to search around. Stock pistons had issues with weak ring lands, but a proper tune may be to blame for so many suffering ring/land failure. There weren't enough properly documented cases to make a proper diagnosis in this regard, just a bunch of anecdotal evidence when rings/lands were broken. 4th: Tradegreg has many good rebuild kits or could custom make one for you once he knows what turbo frame you are working with. Maybe others out there with links too ... 5th: Do not buy cross drilled rotors!! They will microfracture and eventually fail in spectacular fashion if you like "racing". Also, they corrode in the dimples/hole areas and rust outwards from there. - Brembo lists rotors in the 266mm variety, or machine the hubs down smaller, install DSM/Eclipse/GVR4 front rotors 276mm outboard like most cars, with a small ~6mm (if I remember correctly) spacer to accomadate the rotor moving over. t04garret has a brake thread on the site, should still have some pictures up. Also, install longer studs on the hubs to make up for the thickness of the rotor moving the rim away from the hub. If you are really keen, you can drill and countersink the hub face to match a pair of screws with tapered head/base just like factory cars now. Keeps the rotor centered and makes sure the only torque needed is the rim to rotor, with fewer changes of things being off center. 6th: The drive shafts/cv axles listed are the only ones members have found, AND posted about, recently. Technically any shop that can get outer and inner ends can use your center portions and either you or they install them with grease/boots. IF you have some place local, it will save you on shipping large heavy items (VAT!). 7th: http://www.teamrip.com/choosing_the_pro ... _info.html + http://www.teamrip.com/clutch_info.html Some interesting information from Tim Zimmer himself posted to Galantvr4.org: I can't find a link to the other stuff at the moment, but there is more from Tim concerning clutch types and what might work at higher levels, but for street use. I think you mainly could get away with a stock DSM/Eclipse 90-94 FWD 4g63t turbo flywheel and the next stage up matching, full face, sprung pressure plate clutch. This will net you a 225mm versus 215mm setup, same ring gear tooth count and spacing. Trans rebuild information: Quote: Tranny Shim Specs:
The following is for W5M33 AWD 5-speed DSM transmissions: Ok, stock specs are: The Preload Setting is listed in SAE (inches): Input Shaft --> 0.000" - 0.002" ENDPLAY Intermediate Shaft --> 0.003" - 0.005" PRELOAD Center Differential --> 0.003" - 0.005" PRELOAD Output Shaft --> 0.003" - 0.005" PRELOAD Front Differential --> 0.002" - .0067" ENDPLAY These are what I normally use: Stock/Street Transmissions with less than 400TQ at the crank: Input Shaft --> 0.004" - 0.007" PRELOAD Intermediate Shaft --> 0.005" - 0.007" PRELOAD Center Differential --> 0.005" - 0.007" PRELOAD Output Shaft --> 0.003" - 0.005" PRELOAD Front Differential --> 0.002" - .0067" ENDPLAY Street/Strip Transmissions with less than 600TQ at the crank: Input Shaft --> 0.005" - 0.007" PRELOAD Intermediate Shaft --> 0.007" - 0.009" PRELOAD Center Differential --> 0.005" - 0.007" PRELOAD Output Shaft --> 0.003" - 0.005" PRELOAD Front Differential --> 0.002" - .0067" ENDPLAY All out RACE Transmissions that are Rebuilt/Inspected regularly with more than 600TQ at the crank: Input Shaft --> 0.007" PRELOAD Intermediate Shaft --> 0.008" - 0.010" PRELOAD Center Differential --> 0.005" - 0.007" PRELOAD Output Shaft --> 0.004" - 0.006" PRELOAD Front Differential --> 0.002" - .0067" ENDPLAY For Extremely HIGH HP/TQ transmissions (As in ~900-1000+TQ at the crank): Input Shaft --> 0.007" PRELOAD Intermediate Shaft --> 0.010" - 0.012" PRELOAD Center Differential --> 0.005" - 0.007" PRELOAD Output Shaft --> 0.004" - 0.006" PRELOAD Front Differential --> 0.002" - .0067" ENDPLAY From Tim Zimmer: For the higher HP numbers, I would run a higher preload. Personally on mine, (AWD), I am running FWD style tapered roller bearings with 0.010" preload on my front diff. If someone is looking at this thread for preload/endplay information for an AWD front differential utilizing standard roller bearings NOT tapered roller bearings, you must use ENDPLAY on the bearings to prevent thrust loading the bearings. Use a range of 0.000"-0.005" ENDPLAY on AWD front differentials. OEM spec is 0.003"-0.005". For reference, FWD transmissions get bearing preload on ALL shafts, no matter what the OEM manual tells you. All shafts use tapered roller bearings, so preload ANY tapered roller bearing. For reference, AWD transmissions get bearing preload on the input shaft, intermediate shaft, output shaft and center differential while having endplay on the front differential, no matter what the OEM manual tells you about putting endplay on the input shaft. We preload the input shaft as high as 0.007-0.012", and the intermediate shaft in the 0.009-0.015" range. The more preload on the input shaft, the better ability it will give you in slowing the transmission down to shift better at higher rpm and putting less stress on the synchro and the clutch assembly. The more preload on the intermediate shaft, the better ability it will have in reducing thrust-loading and pushing away the shaft from the input shaft resulting in improper gear mesh and risk of gear tooth/shaft failure. The more heat in the transmission, the more the case will thermally expand, reducing preload on the shafts. If the transmission is in a high-temperature environment, adding a transmission cooler will help, and higher preloads are recommended to help the transmission shift good at 200+ degrees. The solder trick is an easy way of finding out the gap between the bearing race and the case. Remove the bearing race and old shim, then place the bearing race on top of the differential bearing, then use some lube or grease to hold the solder in place. Use 0.062" diameter electrical rosin core solder and cut two pieces approximately 1/2" to 3/4" long and gently bend them into a curve matching the bearing race curvature and place these two pieces evenly spaced across from each other on top of the bearing race. Then, reinstall the case section and torque the bolts down to 29 ft/lbs. Remove case bolts, remove case section, and you should have two evenly flat pieces that you can take measurement from to get the bearing preload for your FWD transmission. Using either an accurate digital caliper or a micrometer, measure the thickness of the two pieces of solder. They should be close in thickness. If they are unevenly squished or way off in thickness, redo until you get evenly squished/close thickness measurements. Once you have two decent thicknesses, add the two thicknesses together and divide by two to get an average thickness. This number will be your "zero" preload/endplay value. To add preload, you will add around .007" to your calculated number to get a preload of .007" on your FWD front differential tapered roller bearings. SHIMS Part Description Part Number ID Number Thickness (in) Shim - Input Shaft MD727661 80 0.0315 Shim - Input Shaft MD720937 83 0.0327 Shim - Input Shaft MD720938 86 0.0338 Shim - Input Shaft MD720939 89 0.0350 Shim - Input Shaft MD720940 92 0.0362 Shim - Input Shaft MD720941 95 0.0374 Shim - Input Shaft MD720942 98 0.0386 Shim - Input Shaft MD720943 1 0.0398 Shim - Input Shaft MD720944 4 0.0409 Shim - Input Shaft MD720945 7 0.0421 Shim - Input Shaft MD710454 J 0.0433 Shim - Input Shaft MD700270 D 0.0445 Shim - Input Shaft MD710455 K 0.0457 Shim - Input Shaft MD710456 L 0.0468 Shim - Input Shaft MD700271 G 0.0480 Shim - Input Shaft MD710457 M 0.0492 Shim - Input Shaft MD710458 N 0.0504 Shim - Input Shaft MD706574 E 0.0561 Shim - Input Shaft MD710459 O 0.0527 Shim - Input Shaft MD710460 P 0.0539 Shim - Input Shaft MD706573 - 0.0551 Shim - Input Shaft MD710461 Q 0.0563 Shim - Input Shaft MD710462 R 0.0575 Part Description Part Number ID Number Thickness (in) Shim - Intermediate Shaft MD720948 80 0.0315 Shim - Intermediate Shaft MD720949 83 0.0327 Shim - Intermediate Shaft MD720950 86 0.0338 Shim - Intermediate Shaft MD720951 89 0.0350 Shim - Intermediate Shaft MD720952 92 0.0362 Shim - Intermediate Shaft MD720953 95 0.0374 Shim - Intermediate Shaft MD720954 98 0.0386 Shim - Intermediate Shaft MD720955 1 0.0398 Shim - Intermediate Shaft MD720956 4 0.0409 Shim - Intermediate Shaft MD720957 7 0.0421 Shim - Intermediate Shaft MD720958 10 0.0433 Shim - Intermediate Shaft MD720595 13 0.0445 Shim - Intermediate Shaft MD720960 16 0.0457 Shim - Intermediate Shaft MD720961 19 0.0468 Shim - Intermediate Shaft MD720962 22 0.0480 Shim - Intermediate Shaft MD712346 25 0.0492 Shim - Intermediate Shaft MD712347 28 0.0504 Shim - Intermediate Shaft MD712348 31 0.0516 Shim - Intermediate Shaft MD712349 34 0.0527 Shim - Intermediate Shaft MD712329 37 0.0539 Shim - Intermediate Shaft MD712330 40 0.0551 Shim - Intermediate Shaft MD712331 43 0.0563 Part Description Part Number ID Number Thickness (in) Shim - Center Differential MD736928 13 0.0445 Shim - Center Differential MD736929 16 0.0457 Shim - Center Differential MD736751 19 0.0468 Shim - Center Differential MD736931 22 0.0480 Shim - Center Differential MD726166 25 0.0492 Shim - Center Differential MD718517 28 0.0504 Shim - Center Differential MD718518 31 0.0516 Shim - Center Differential MD718519 34 0.0527 Shim - Center Differential MD718520 37 0.0539 Shim - Center Differential MD718521 40 0.0551 Shim - Center Differential MD718522 43 0.0563 Shim - Center Differential MD718523 46 0.0575 Shim - Center Differential MD718524 49 0.0587 Shim - Center Differential MD718525 52 0.0598 Shim - Center Differential MD718526 55 0.0610 Shim - Center Differential MD718527 58 0.0622 Shim - Center Differential MD718528 61 0.0634 Shim - Center Differential MD718529 64 0.0646 Shim - Center Differential MD718530 67 0.0657 Shim - Center Differential MD718531 70 0.0669 Shim - Center Differential MD721959 73 0.0681 Shim - Center Differential MD721960 76 0.0692 Shim - Center Differential MD721961 79 0.0705 Part Description Part Number ID Number Thickness (in) Shim - Output Shaft MD726167 28 0.0504 Shim - Output Shaft MD726168 31 0.0516 Shim - Output Shaft MD726169 34 0.0527 Shim - Output Shaft MD724326 37 0.0539 Shim - Output Shaft MD724327 40 0.0551 Shim - Output Shaft MD724328 43 0.0563 Shim - Output Shaft MD724329 46 0.0575 Shim - Output Shaft MD724330 49 0.0587 Shim - Output Shaft MD724331 52 0.0598 Shim - Output Shaft MD724332 55 0.0610 Shim - Output Shaft MD724333 58 0.0622 Shim - Output Shaft MD724334 61 0.0634 Shim - Output Shaft MD724335 64 0.0646 Shim - Output Shaft MD724336 67 0.0657 Shim - Output Shaft MD724337 70 0.0669 Shim - Output Shaft MD724338 73 0.0681 Shim - Output Shaft MD724339 76 0.0692 Shim - Output Shaft MD724340 79 0.0705 Shim - Output Shaft MD724341 82 0.0716 Shim - Output Shaft MD724342 85 0.0728 Shim - Output Shaft MD724343 88 0.0740 Shim - Output Shaft MD724344 91 0.0751 Part Description Part Number ID Number Thickness (in) Shim - Front Differential MD727658 56 0.0220 Shim - Front Differential MD727659 65 0.0256 Shim - Front Differential MD727660 74 0.0291 Shim - Front Differential MD720937 83 0.0327 Shim - Front Differential MD720940 92 0.0362 Shim - Front Differential MD720943 01 0.0398 Shim - Front Differential MD710454 J 0.0433 Shim - Front Differential MD710456 L 0.0468 Shim - Front Differential MD710458 N 0.0504 Shim - Front Differential MD710460 P 0.0539 Quote: 1G Manual Transmission Parts
----------------------------------------------------------------- MD741558 3-4 shift fork MB599879 clutch lever - cabin MD173425 6 bolt AWD Flywheel MD302074 Manual Transmission flywheel bolt MD731948 Big Trans Staked Locking Nuts MF241251 Pressure Plate bolts MB484624 1990 AWD shifter cables 93-94 Transmission Parts ----------------------------------------------------------------- Input Shaft Parts 5th Gear Roller Bearing: MD719137 3rd / 4th Gear Synchro Key: MD742445 3rd Gear Synchro: MD745479 4th Gear Synchro: MD745479 5th Gear Synchro Key: MD742441 5th Gear Synchro: MD744782 Input Shaft Rev Brake: MD746439 Outer Tapered Bearing: MD726235 Intermediate Shaft Parts Intermediate Shaft: MD738952 5th Gear: MD742581 Lower Tapered Bearing: MD726236 Upper Tapered Bearing: MD736638 1st / 2nd Gear Synchro Key: MD742445 1st Gear Sychro: MD745477 2nd Gear Synchro (double): MD746435 Misc 32 mm nuts: MD731948 91-92 Transmission Parts ------------------------------------------------------------------------- Input Shaft Parts 3rd Gear Synchro: MD741198 4th Gear Synchro: MD741198 4th & 5th Syncho Key: MD742441 5th Gear Synchro: MD742541 Input Shaft Rev Brake: MD742051 5th and Rev Brake Key: MD742441 Outer Taper Bearing: MD726235 Intermediate Shaft Parts ------------------------------------------------------------------ Intermediate Shaft: MD738952 1st Gear Synchro: MD741644 2nd Gear Synchro: MD741645 1st & 2nd Synchro Key: MD742445 Inner Tapered Bearing: MD726236 Outer Tapered Bearing: MD736638 5th Gear: MD742581 Misc Filter: MD738053 Wave Spring: MD744342 Center Differential Parts (AWD M/T) ------------------------------------------------------------------------ MD738735 center diff housing MD725878 center diff spider/side cross MD737658 center diff washers (2 reqd) MD733338 center diff spider and side gear kit MD727551 center diff gear MD727552 center diff gear bolt (8 reqd) MD728248 center diff viscous coupler |
Author: | Flying Eagle [ Tue Feb 23, 2016 3:27 pm ] |
Post subject: | Re: Dozends of questions... |
Interesting read on clutch choice and flywheel bedding processes. http://www.dsmtuners.com/threads/those- ... se.422731/ |
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