4g61t.org

i believe you can transfer internals over from a 1g trans to a 2g trans. not sure if ALL of them will transfer over but i think the gear sets and such will. You will have to set the sideplay clearances of course when swapping them over.

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

Another option is to convert your van into 92-style/1g mounting scheme. Should be easy if you find donor 92 van.

I ended up using my spare 95 van tranny with DSM 4 spider center diff and DSM viscous coupling. Once I blow this tranny, I will swap in a 2g tranny. But I have no reason to believe that the rest of the van tranny is weaker than a DSM tranny.

As for ECU, I am on the fence... I have 1g and 2g ECUs, both with DSM link V3. But... I also have a 3 spare 1g harnesses! So I have more parts to go with simpler 1g set-up. But 2g ECU has many advantages, one of them being the fact that van already has 3 out of 4 2g ECU plugs...

_________________
Leon R.
99 Eclipse Spyder GST (AWD swap project)
93 Eagle Summit AWD (4G63 swap) 11.69@120
01 Isuzu VehiCHROSS (winter beater) 17.0@80
80 Triumph TR7 (4G63 swap project)

sweet build man! im picking a summit wagon awd tomorrow... this will be my first csm build. Man i can't wait!

If you have the 2g parts, definately use em. The van tranny is no weaker than the dsm trannies as they are the exact same thing. The number is right on there. Thats interesting to know the 92 vans had a 1g style awd trans. I wonder if it was even a dsm trans though... That coulda been something different.

I finally started tonight. No turning back now. i just have the timing mount and tranny mount holding it in now. Tomorrow i can drop the motor/trans in 20 minutes, then i can tear into the trans and then ill know what im up against.

I know of 3 differences between van and DSM AWD trannies:

1. Model number is different...
2. Bell housing has an extra mouting point, but it does bolt up to the DSM block.
3. Viscous coupling is about 60% thickness of DSM VC and to match it, center diff and most outer tranny cover is different.

I find it very odd that mitsu went through all that trouble to make a thinner VC and all the matching parts, but they did... It is possible that the rest of the inner parts are also different (weaker???), but I doubt it.

_________________
Leon R.
99 Eclipse Spyder GST (AWD swap project)
93 Eagle Summit AWD (4G63 swap) 11.69@120
01 Isuzu VehiCHROSS (winter beater) 17.0@80
80 Triumph TR7 (4G63 swap project)

I never should have doubted you.

it turns out the transfer case was the root of all the problems here. I suspect it was run out of oil at some point. It is SHOT. The blown t case seems to have caused a ripple effect, the center diff has a lot of chipped teeth and some of the gears are chipped as well. All in all though the trans is not bad. It would probably have lasted a long time with the chipped teeth, bearings all look fine.

Too bad you are too far away, I actually need a bad transfer case .

The van gears are dsm gears for sure. The 1st and 2nd gen gears can be mixed and matched as well. I should have known this already, my race colt is a 92 trans with jdm evo gears in it. I took a look at the evo case and it is a 2g case(has the 2g mount holes). So there you go. I have a spare van trans and i didnt even know it.

I have no idea why the van vc is smaller. Maybe its a weaker awd effect, for milder street manners? It does seem silly that they wouldnt just use 100 percent dsm parts, cant see the reasoning.

You didn't pay as much for the van new? lol

I dont understand.

now the build is on hiatus for a little while as i order up some parts.
I decided to use 92 gears as i opened up one of my mystery trannies and it was pristine condition 92 awd box. These are supposedly the strongest gears, also compatible with evo 3 stuff. These also have the shittiest 3/4 shift fork so i have to order evo shift forks, other than that i could have the box back together.

What i did was use the vans bellhousing section and thats it. I installed the 3 lower bearing races from the 92 box to match the 92 stuff, used everything else from the 92 box. checked all the preloads and they are good.

I also need a clutch, i have a new stock clutch, but no sense putting that in it would never last long even with a 14b.

And might as well do the t belt and all seals etc etc. Im going to leave the balance shafts in cause i dont want to piss around with high oil pressure. I want good street manners too so balance shafts in and stock flywheel too.

Keeping the air conditioning p.s, etc remote start, all that.

I had a genious idea yesterday. I have an extra 2g tranny here, its just the case, but so what. I bolted on the empty case to the back of my 4g63t and dropped it in the van. Now i can do all the rest of the work while i wait on parts which i havent even ordered yet.
So far on my list-
make custom t belt mount
relocate battery tray (im only moving it a few inches)
Intercooler install
Exhaust
walbro fuel pump install
skinny rad fans, the stock ones dont fit anymore
longer throttle cable
As i go ill find out more things that need changing im sure and i can add it to this list in case anyone else finds it helpful

Im ordering a centerforce dual friction for sure as well as evo shift forks (i wont build a trans without them) and a timing belt tensioner. Maybe a fidanza flywheel too but im undecided. It costs 70 bucks to get my old flywheel resurfaced, and 250 for a brand new 9 pound aluminum. Im still undecided on the flywheel cause it hurts the drivability a bit, makes it a little more of a pain in stop and go traffic...

I had a 9lb aluminum in my 2600lb AWD Colt and I do not feel it affected driveability at all. Opinions are like anuses though...

Flywheel preferences do vary. Personally, I think that even the ACT 11-12lbs FW is a bit on a light side. So 9lbs aluminum FW too light. But there is other reason to stay away from them:

1. They get damaged by FW bolts. After a few installs, they look really ugly.
2. They are more expensive than ACT FW’s
3. Almost no-one actually replaces the friction surface, they just junk them…

I suggest getting ACT steel FW.

To prevent damage from occuring to the piece I had, I used the bolt shim from an automatic set-up to protect the aluminum mounting surface. The thickness of the shim and the flywheel necessitates the use of longer bolts though...