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Specializing in the 3g CSM
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 Post subject: Re: 91 sedan swap.
PostPosted: Tue Mar 27, 2012 5:00 pm 
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Some call me a god

Joined: Mon Sep 24, 2007 5:50 pm
Posts: 1219
Location: Htown, TX
Stock driveshaft will work in a sedan without any modifying. The hardest part is the mounting points and getting the angles decent.


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 Post subject: Re: 91 sedan swap.
PostPosted: Mon Apr 02, 2012 11:50 pm 
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Some call me a god

Joined: Wed Oct 04, 2006 3:03 pm
Posts: 1134
Location: Calgary, AB, Canada
made a little progress, removed km210 and fwd turbo flywheel. An aluminum AWD flywheel will be going in with the same clutch.

Image

_________________
05 wrx wagon
99 Benz ML 320
91 eagle summit swapped - 6/4 bolt combo
94 Audi s4 - sold
88 Eagle Vista Turbo LX sedan, RIP


Last edited by j2dapo on Sun Apr 08, 2012 9:38 pm, edited 1 time in total.

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 Post subject: Re: 91 sedan swap.
PostPosted: Sun Apr 08, 2012 9:37 pm 
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Some call me a god

Joined: Wed Oct 04, 2006 3:03 pm
Posts: 1134
Location: Calgary, AB, Canada
Use AWD fidanza with new hardware and friction surface.
Image

Installed, twice. Yup forgot to swap the starter plate.
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Cleaning up the w5m33, all drive-train parts where pulled out of a 92 laser.
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It's got a red "R" painted on it...
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I'm going to see about drilling out the pin on the shift lever and installing the colt km201 lever on it for a nice shift.

_________________
05 wrx wagon
99 Benz ML 320
91 eagle summit swapped - 6/4 bolt combo
94 Audi s4 - sold
88 Eagle Vista Turbo LX sedan, RIP


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 Post subject: Re: 91 sedan swap.
PostPosted: Tue Apr 17, 2012 11:22 pm 
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Some call me a god

Joined: Wed Oct 04, 2006 3:03 pm
Posts: 1134
Location: Calgary, AB, Canada
I invested a few hours getting the transmission clean. Here you can see the difference between a DSM and a CSM shift lever the shorter bent one is from a 3G CSM.

Image

To swap them I chose to drill out the pin that holds the level onto the selector shaft. I used a 1/8 bit and went slow; slow drill speed and a good bit. I didn't get a picture of this part sorry.

Once the pin is out you can't reuse it. My plan was to use a bolt. What I did was tap the lever with a M6x1 threads, (the same ones thread most of the small bolts use that are found in these cars).

Starting from the top of the pin hole on the lever, I threaded it through until the tap was in the center but I did not continue all the way through. This is it because my cheap taps aren't long enough. Then I put the lever selector on to the shaft and ran the tap through it. This must be done with the lever on the shaft so that the threads line up.
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Once the threads where started on the shaft I took off the lever and tapped the shaft itself.
Image
If you have a long M6x1 tap then its not a problem.

As I said I did not run the tap on the bottom end of the shift lever pin hole. What I did was to grind down the threads on the end of the bolt just enough so that the bolt would fit tight into this bottom end of the pin hole. Sorry, its hard to explain....

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Ready for installation.
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I don't like to press these up and into position myself . This is easier for, but it takes longer. I use a jack when I need to adjust the length of one of the two straps.

Image

_________________
05 wrx wagon
99 Benz ML 320
91 eagle summit swapped - 6/4 bolt combo
94 Audi s4 - sold
88 Eagle Vista Turbo LX sedan, RIP


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 Post subject: Re: 91 sedan swap.
PostPosted: Wed Apr 18, 2012 4:50 am 
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Spends Too Much Time Under The Hood
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Joined: Mon Jul 18, 2011 9:20 pm
Posts: 269
Location: Louisville, KY
I literally never thought of that with my trans. You're a genius. I had all the supplies and instead chose to wear myself out trying to benchpress the damn thing in place. Three times in a week...

_________________
1991 Dodge Colt - 1.5L 4G15 - Swap Project
1989 Dodge Colt GT - 2.0 4G63T - Racecar
1995 Honda Prelude - H23A2 - DD


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 Post subject: Re: 91 sedan swap.
PostPosted: Wed Apr 18, 2012 8:18 pm 
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Some call me a god

Joined: Wed Oct 04, 2006 3:03 pm
Posts: 1134
Location: Calgary, AB, Canada
I can't take credit for the strap idea. I'm just a messenger for the tip.

_________________
05 wrx wagon
99 Benz ML 320
91 eagle summit swapped - 6/4 bolt combo
94 Audi s4 - sold
88 Eagle Vista Turbo LX sedan, RIP


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 Post subject: Re: 91 sedan swap.
PostPosted: Tue May 29, 2012 12:32 pm 
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Spends Too Much Time Under The Hood
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Joined: Wed Jun 22, 2005 11:03 am
Posts: 253
Location: Auburn, AL
Quote:
Any comments on the rear axle placement? Too far forward? These are16"x7" rims with a 38 offset. The tire is 195/50. I measured from the tire to the lower lip of the fender. It was 2" at the front and more than 3" at the back.

I remember this question came up in another thread long ago. IIRC, the wheel should not sit in the center of the wheel well. Instead, it should actually sit a little forward. I think your wheel placement is close to ideal. If I ever do the swap myself, I will try to get the wheel base specs from the "Cyborg" model, or whichever model Mirage/Lancer that came AWD (overseas, of course) and then place my rear end based on that information.

_________________
2003 Evo, 89 Mirage Turbo, 88 Conquest 4G64


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 Post subject: Re: 91 sedan swap.
PostPosted: Wed May 30, 2012 12:54 am 
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Some call me a god

Joined: Wed Oct 04, 2006 3:03 pm
Posts: 1134
Location: Calgary, AB, Canada
Yeah I recall reading somewhere that is should be forward more within the wheel arch but I had to move it back, the drive shaft did not want to line up straight with the rear axle being further forward like that.

Here are the extended top hats I made. The struts I got from Pick n Pull off a Galant GSX.
Image

_________________
05 wrx wagon
99 Benz ML 320
91 eagle summit swapped - 6/4 bolt combo
94 Audi s4 - sold
88 Eagle Vista Turbo LX sedan, RIP


Last edited by j2dapo on Wed May 30, 2012 1:01 am, edited 1 time in total.

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 Post subject: Re: 91 sedan swap.
PostPosted: Wed May 30, 2012 12:59 am 
Offline
Some call me a god

Joined: Wed Oct 04, 2006 3:03 pm
Posts: 1134
Location: Calgary, AB, Canada
Here is the rear sitting back about 1/2' more. It's might be slightly too far back but the driveshaft fits well now. Also this is with the extended struts - I need to roll the car forward - i just lowered it onto the ramps.

Image

and before

Image

Where you place the front of the boomerang is important too I wanted it to not hang too low. Placing higher or lower does affect your angles and final axle/wheel position.


I've spent hour's rolling under this car trying to get it right. I hope I've succeeded once I'm done the AWD.

_________________
05 wrx wagon
99 Benz ML 320
91 eagle summit swapped - 6/4 bolt combo
94 Audi s4 - sold
88 Eagle Vista Turbo LX sedan, RIP


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 Post subject: Re: 91 sedan swap.
PostPosted: Wed May 30, 2012 1:08 am 
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Some call me a god

Joined: Wed Oct 04, 2006 3:03 pm
Posts: 1134
Location: Calgary, AB, Canada
lining up the driveshaft.

Image

I can see why some rework the rear part of the tunnel. My drive shaft will not be straight. unless I make it deeper right where the tunnel ends.
Image

_________________
05 wrx wagon
99 Benz ML 320
91 eagle summit swapped - 6/4 bolt combo
94 Audi s4 - sold
88 Eagle Vista Turbo LX sedan, RIP


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 Post subject: Re: 91 sedan swap.
PostPosted: Wed May 30, 2012 1:15 am 
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Some call me a god

Joined: Wed Oct 04, 2006 3:03 pm
Posts: 1134
Location: Calgary, AB, Canada
Im using a laser level for this.
Image

Any one know if the drive shaft has to be perfectly straight? Unless I modify the back most part of the tunnel, the back most carrier bearing will be a slight angle.

_________________
05 wrx wagon
99 Benz ML 320
91 eagle summit swapped - 6/4 bolt combo
94 Audi s4 - sold
88 Eagle Vista Turbo LX sedan, RIP


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 Post subject: Re: 91 sedan swap.
PostPosted: Wed May 30, 2012 10:07 am 
Offline
Some call me a god

Joined: Wed Oct 04, 2006 3:03 pm
Posts: 1134
Location: Calgary, AB, Canada
Quote:
Stock driveshaft will work in a sedan without any modifying. The hardest part is the mounting points and getting the angles decent.
What's a decent angle?

_________________
05 wrx wagon
99 Benz ML 320
91 eagle summit swapped - 6/4 bolt combo
94 Audi s4 - sold
88 Eagle Vista Turbo LX sedan, RIP


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 Post subject: Re: 91 sedan swap.
PostPosted: Sun Jun 03, 2012 3:37 pm 
Offline
Some call me a god

Joined: Wed Oct 04, 2006 3:03 pm
Posts: 1134
Location: Calgary, AB, Canada
Fix, Image

_________________
05 wrx wagon
99 Benz ML 320
91 eagle summit swapped - 6/4 bolt combo
94 Audi s4 - sold
88 Eagle Vista Turbo LX sedan, RIP


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 Post subject: Re: 91 sedan swap.
PostPosted: Sun Jun 03, 2012 3:40 pm 
Offline
Some call me a god

Joined: Wed Oct 04, 2006 3:03 pm
Posts: 1134
Location: Calgary, AB, Canada
Straight down the line.
Image
Image

_________________
05 wrx wagon
99 Benz ML 320
91 eagle summit swapped - 6/4 bolt combo
94 Audi s4 - sold
88 Eagle Vista Turbo LX sedan, RIP


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 Post subject: Re: 91 sedan swap.
PostPosted: Sat Jun 16, 2012 11:52 am 
Offline
Some call me a god

Joined: Wed Oct 04, 2006 3:03 pm
Posts: 1134
Location: Calgary, AB, Canada
So,..... If you've seen the LILEVO awd swap DVD, remember where Jason shows and warns about a carpet fire while welding the drive-shaft mounts?

I DO! I was lazy, and thought, "just tacking this up will not be a problem, I'll remove the carpet when I fully weld it"

Luckly, my fire did not get out of hand. I have to replace some interior wiring, the rear HVAC vent and the carpet. Carpet is optional I think the damage occured under the passenger seat.

_________________
05 wrx wagon
99 Benz ML 320
91 eagle summit swapped - 6/4 bolt combo
94 Audi s4 - sold
88 Eagle Vista Turbo LX sedan, RIP


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