4g61t.org

A few weeks ago I was driving and heard a pop, and magically no power to the wheels. I thought the diff blew apart. Needless to say I wasn't happy. Well I went out to where I have the car stored and got to looking at it. Has anyone ever had an issue with the intermediate shaft shearing the bolts where it mounts to the block??? I don't why or how it happened but where it bolts to the block both bolts are completely sheared off and the whole half shaft/intermediate shaft assembly is hanging down. Could this be why I'm not getting any power to the wheels or should I pick up another transmission? Any help is appreciated.
Thanks
Josh

i have had that happen 2 times.. if u get a chance get under the car and look to see if the shaft going into the trans came out some?...even if it only came out 1/2 inch that will make u lose power to the DS wheel..and with that not working..the PS wont get power either..

also when my first one broke..the only reason I noticed it was cause I had a puddle of gear oil under my car...it tore the trany seal so I had to order 1 from the dealership and replaced it.


Steve

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Steve 89 colt 2.3 stroker stock top end. evo3@20 psi 13.489@99.30mph 3/10 2012
On drag radials.auto trans.launching @ 5 psi and no traction thru 2nd.

I was wondering that's why I was getting power to the wheel. I'll get on it tomorrow and see if that solves the problem.
Thanks Again
Josh

on mine I had to scrap the first block.. I couldnt get the broken parts out of the block... it is possible to do it while in the car.. but its easier...and u have a better chance of getting the broken parts out with the motor either out..or drop the subframe and motor/trans to get the clearance u need.


Steve

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Steve 89 colt 2.3 stroker stock top end. evo3@20 psi 13.489@99.30mph 3/10 2012
On drag radials.auto trans.launching @ 5 psi and no traction thru 2nd.

I had mine pop out once. It can and does happen. If you use bolts that aren't hardened, they'll snap like butter. Don't forget the hardened washers as well, you cannot have movement and regular bolts will snap and regular washers will squish.

_________________
Had a:
1991 Eagle Summit ES Hatchback - 4g15 12v 5spd
1991 Dodge Colt -4g15 12v 4spd
Have a:
1978 Oldsmobile Cutlass - 468BBO TH350
Round 3:
1990 Dodge Colt-4G63T 5spd

Factory bolts and washers, red Loc-tite, and torqued to spec. Are the axles factory 4g61 style? Is the half shaft original 4g61t or the DSM version that also fits properly?

I wouldn't do red loctite but plenty of blue. If it ever strips it'll have to be removable.

_________________
Had a:
1991 Eagle Summit ES Hatchback - 4g15 12v 5spd
1991 Dodge Colt -4g15 12v 4spd
Have a:
1978 Oldsmobile Cutlass - 468BBO TH350
Round 3:
1990 Dodge Colt-4G63T 5spd

This thread worries me a little as I just swapped over my 61t inner shaft with 61t axels to the 63t block, haven't installed the motor yet so I think I'll be re-installing these with some loc-tite to be safe, also reusing the oem hardware. Didn't even think shearing those bolts off would be possible, that area seemed very sturdy to me

Also, are you using the half shaft bracket (i think its also an a/c bracket) or did you delete it?

_________________
89 Mirage Billet 20g 63t 12.4@120 417whp 400wtq @ English Racing.
89 Colt GT E316g
06 Silverado SS
07 ZX6R

I think I used the bracket and a 2 washers. It's what it took to space the shaft out to be spinnable by hand while bolted down. Either oem bolts or hardened bolts/washers, both will take the abuse. The problem comes when people don't want to spend $4 on hardware when they can spend $1 and then they end up with broken bolts. Plenty of blue loctite and torque them fairly well.

_________________
Had a:
1991 Eagle Summit ES Hatchback - 4g15 12v 5spd
1991 Dodge Colt -4g15 12v 4spd
Have a:
1978 Oldsmobile Cutlass - 468BBO TH350
Round 3:
1990 Dodge Colt-4G63T 5spd

If you dont have the proper spacers in there... (1g dsm intermediate shafts need two spacers......) i think the DOHC CSM ones also need a spacer. If your not using them it will cock the intermediate shaft and cause the bolts to snap off and it could possibly wreck the diff and axle seal.

_________________
-1989 Colt GT (stock for now)
-1993 Dodge colt 4g63 swap
-1992 Mitsubishi Lancer Evo GSR (genuine)
-1992 Eagle Summit AWD 4g63t swap (SOLD)

Well it's a good thing this thread came up right when I'm about to install the motor. Why have I not heard of this spacer thing before? I have never seen it brought up in my last few years of researching this swap and it seems to me to be a fairly serious step.

_________________
89 Mirage Billet 20g 63t 12.4@120 417whp 400wtq @ English Racing.
89 Colt GT E316g
06 Silverado SS
07 ZX6R

i know on this board and others the topic has come up numerous times.....


Not sure if its part of any write ups but most DSM guys (AWD guys) know you need those spacers in there if you use the intermediate shaft that bolts to the block.


DSM's use the A/C compresser bracket as the spacer... so if you take the a/c bracket off and are using a DSM intermediate shaft you need put washers or the proper spacer in there in place of the A/C bracket.

On a DOHC CSM then they have two spacers...the same size and they go on both bolts and space the intermediate shaft out a bit from the block.

The CSM and DSM intermediate shafts bolt up to different spots on the block as well...

_________________
-1989 Colt GT (stock for now)
-1993 Dodge colt 4g63 swap
-1992 Mitsubishi Lancer Evo GSR (genuine)
-1992 Eagle Summit AWD 4g63t swap (SOLD)

Ok, I'm using a CSM intermediate shaft on a DSM block and it bolts up fine.. So I'm good to go, correct?

_________________
89 Mirage Billet 20g 63t 12.4@120 417whp 400wtq @ English Racing.
89 Colt GT E316g
06 Silverado SS
07 ZX6R

No they don't. Both use the same holes.

_________________
Had a:
1991 Eagle Summit ES Hatchback - 4g15 12v 5spd
1991 Dodge Colt -4g15 12v 4spd
Have a:
1978 Oldsmobile Cutlass - 468BBO TH350
Round 3:
1990 Dodge Colt-4G63T 5spd

^ confirmed



89turbomitsu, I'm curious to hear the verdict.

_________________
89 Mirage Billet 20g 63t 12.4@120 417whp 400wtq @ English Racing.
89 Colt GT E316g
06 Silverado SS
07 ZX6R