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
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