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EVO00X - Evolved AWD Coupe

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#481
bazeng

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Good to hear you are back in action!

Thanks for taking the time to share these photos also .

I know how much of an effort it can be.

Edited by bazeng, 02 December 2012 - 07:45 PM.


#482
Evo-00x

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No probs Baz. Its good to show the guys that have been following the coupe's build some progress again :)
Keeps me busy too :thumbsup:
AWD. 2 Litre. GTX3076R 0.82.
330kw atw @ 28psi 98 pump fuel.

372kw atw @ 28psi E85 Flexfuel.
EVOLVED AWD COUPE
WWW.EVOCOUPE.NET

#483
EVL20T

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Awesome job Rob :)
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#484
GSRWRC

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*Insert post here because Rob is a crybaby* :lol:

That 3076R on yet? :P

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#485
Evo-00x

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lol... not yet. Will finish the gearbox over the weekend and bolt it back to the engine ready to chuck back into the car.
But before doing so, I wanna change the oem fuel line from the tank to the firewall to the 3/8" hard alloy fuel lines and fittings Ive had sitting here waiting for months :)
Aiming to have it all back together and running again in January sometime beause the rego is due in Feb.
AWD. 2 Litre. GTX3076R 0.82.
330kw atw @ 28psi 98 pump fuel.

372kw atw @ 28psi E85 Flexfuel.
EVOLVED AWD COUPE
WWW.EVOCOUPE.NET

#486
jack be nimble

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There is some talk of the centers failing because of oil starvation to the cross shafts. This maybe remedied by small scoops on the outer of the centre housing to direct oil into the spinning centre rather than the spinning action throwing the oil out of the centre.
There was some pics on a us site depicting this mod.

Any thoughts, or is it worth doing while your box is apart?
4g93t jumbuck conversion. PRANGED 18/3/12, CHECK MY MEMBER RIDES Page 11. no serious human injuries.
ON THE ENGINE STAND. g4cs 2.4l + Gt35r. PLUS: auto conversion + Awd coming.
thanks for parts and help: BMGTZ, EVOCPE, cwolf, Benozi, Jamo-GSR, 1JUM2NV, RXVII..much appreciated, cheers guys.
Aerodynamics are for people who can't build engines. —Enzo Ferrari
REMEMBER: you cant polish a turd, but you can roll it in glitter.

#487
Evo-00x

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Yeah Jack. The oem cross-shaft is shithouse and made of weak metal. When you hold one in your hand you realise just how small and fragile they feel. When you modify the oem cross-shaft by machining it down to accept an additional 2 spiders for a 4 spider conversion, you actually make it weaker!! (see pic of a spare modified oem cross-shaft I have on the green bubble wrap below). This is probably the reason why those whom have tried a 4-spider conversion previously with a modified OEM cross-shaft still ended up breaking theirs!! You really start to wonder how such a small part can survive 400hp atw let alone a few good hard launches lol. No wonder they break easy! When it comes to oiling the shaft surfaces and side washers where the spider gears spin against, the oem design leaves a lot to be desired. The shafts eventually heat and gall til they seize and faill. Ive pulled apart heaps of centre diffs where the shafts, side washers, spider gear spinning surfaces etc showed bad scoring, galling and wear.

If a gearbox has been run with very little oil in it, or the oil has degraded and been way overdue for replacement, you can guarantee that the centre diff internals will not be happy. The spider gears, side washers, cross-shaft and upper pinion shim will suffer badly as a result. Ive got parts of a centre diff here where an owner ran the box with minimal oil in it and the oil was black and smelt putrid. When I opened it up his centre diff internals were ratshit and throw-aways. All the pinions were scored and worn, the upper pinion shim was so badly galled that it actually disintegrated and seized the upper pinon into the centre diff cover, the spider gears worn grooves into the cross-shafts and the side washers were as thin as a piece of paper and all galled up. Luckily for him the housing was still OK to be used for a welded centre diff conversion! lol

Im actually using an aftermarket chromoly cross-shaft available through TMZ performance in the US (Tim had them made by Beyond Redline Performance). Its a hardened and much stronger component and he has never broken one himself nor heard of anyone breaking one ever lol. It has oil grooves included in its design which will assist with oil flow into where the spider gears spin on the shafts. Here's the spec description from his website:

This custom cross-shaft is designed by Beyond Redline Performance and is used in our Heavy Duty 4-spider center differential upgrade for the DSM AWD 5-speed transmission.

It is forged 4340 chromoly tool steel that is machined from an ingot by a 5-Axis CNC Mill, then oil-grooved, shot-peened, heat-treated and carbonized. Rockwell hardness is around 60-62. That results in an approximate tensile strength around 115,000-120,000psi. It is essentially classified as a hardened tool steel part.

It is by far the strongest cross-shaft on the market for these vehicle applications and provides owners with complete streetability on high-horsepower AWD applications. Instead of machining down the stock cross-shaft to accept 4 spider gears, this part started from scratch with better material, a beefier structure, surface hardening, and oil passage grooves on its posts to provide proper oiling to the spider gears to prevent surface galling.

The Beyond Redline Performance cross-shaft has been proven to hold over 1000HP and 950TQ at the crank on my race car for the last 5 years without signs of galling or damage. It has been proven on the race track, the street, and the dyno to survive the harshest conditions without failure.



You mentioned above about the 'scoop' mod. Yeah Jacks Transmissions had welded 2 little scoops to the outside of his centre diff housing as a trial a couple years back to help pull oil into the housing whilst its spinning. You can read up on it here: http://forums.jackst...12&p=1296#p1296 . When you think about it, the nature of any liquid is to centrifugally spin away from the centre of a rotating assembly so no matter what you do, oil is going to want to spin away to the inner walls of the centre diff. But how does that theory come into effect when the centre diff is located at the bottom of the gearbox with much of it submersed under oil anyway? If you look at the attached pic of the inside of the W5M33 gearbox, you can see the centre diff is located at the bottom. I drew a yellow line from the oil fill bolt across to the opposite side of the box to get an indication of where the oil fill level may be when its full. Hmmm.... the centre diff looks as though it would be swimming in oil.

Now, if you look at an OEM centre diff housing (pic attached) it already has 2 scoop-like pickups in the casting to help guide oil into the centre diff. What Jacks Transmissons has done is expand on this idea and created a larger scoop to [help?] guide more oil in. Im all for anything you can do to try to improve lubrication where it counts, but Im not going to do this mod because I think the problem has more to do with the design of how the oil lubricates the spider gears on the cross-shaft, not the amount of oil inside the centre diff around the cross-shaft. I'll have a good look at it over the weekend when I get a chance to physically play with some in front of me and get back to you.

Attached Thumbnails

  • Oil Fill Level.jpg
  • DSC03946.jpg
  • DSC03944.jpg
  • DSC03942.jpg
  • DSC03941.jpg
  • lube.jpg
  • OEM cross-shaft modified for a 4-spider conversion.jpg
  • Cross-shaft comparisons - Beyond Redline Performance in Middle.jpg
  • OEM Housing Scoop.jpg

Edited by EVO-00X, 10 December 2012 - 03:49 PM.

AWD. 2 Litre. GTX3076R 0.82.
330kw atw @ 28psi 98 pump fuel.

372kw atw @ 28psi E85 Flexfuel.
EVOLVED AWD COUPE
WWW.EVOCOUPE.NET

#488
Evo-00x

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OK Jack, after physically examining several dead centre diffs and internals and cross-referencing my beliefs with some of the names in the aftermarket Mitsu tranny rebuild industry, I thoroughly believe the problem with centre diff failures originally stems from where the spider gears spin on the cross-shaft posts. Lack of lubrication induces excessive friction, heat, wear and freeplay til eventually the spider gears and/or the cross-shaft siezes and breaks. Also after physically examining the different cross-shafts, I strongly believe that modifying an OEM cross-shaft to accept an additional couple of spiders for a 4-spider conversion is a BIG NO-NO!!. DONT DO IT!! I found that by doing so will create an even bigger problem with severe lack of lubrication to the newly created posts on the cross-shaft because there are no provisions for oil slots to feed them. Some people have made make-shift oil slots for the 2 new spiders gears, however their efforts are futile because the other big problem is a severe reduction in strength! This ties in with what the boys at Team Rip have to say: When they cut through the hard nickel chrome plating it ruins the tribology so it'll gall up and seize the spider gears. Why do you think Mitsubishi went through the trouble of plating this part in the first place!!

If anyone is interested, I've put together some pics I've borrowed from around the traps and collated them into this image to show you that the oem cross-shaft sucks big time, especially these days in your tired old transmisson. Any of the big names like Team Rip (TRE), TMZ Performance and Jacks Transmissions can fix you up with a 4-spider conversion and aftermarket cross-shaft. They're not cheap, but for guys whom want the streetability of a normal daily driver (and dont want to go down the path of a welded centre diff - they're not exactly suited to everybody's patience lol) its well worth the investment to beef up to a 4-spider centre the next time you do a tranny rebuild.

http://i1175.photobu...rconversion.jpg

Posted Image

Edited by EVO-00X, 10 December 2012 - 03:50 PM.

AWD. 2 Litre. GTX3076R 0.82.
330kw atw @ 28psi 98 pump fuel.

372kw atw @ 28psi E85 Flexfuel.
EVOLVED AWD COUPE
WWW.EVOCOUPE.NET

#489
Rockabilly

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Very good upgrades in your centre diff Rob. I'll throw 2 bob in.
Back filling grooves at least 2mm deep where the cross wares the housing with tungsten stick rods
will never see the cross wobbling out of square which causes the shims to get fucked.
I do like Jack's idea of adding scoops, but I personaly think one scoop should scoop in & face the
other one for out. Cheers !

Edited by Rockabilly, 11 December 2012 - 02:22 PM.


#490
Evo-00x

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I dont think that'll be a good idea though Aldo. The centre diff has its own 2 scoops inbuilt in the housing. If you have one facing correctly in the direction of the spin its OK, and angles oil into the housing. But if you have the other scoop facing the opposite way it'll mean that it wont work. Therefore for every revolution you only have one scoop angling oil into the housing instead of two. Ive spoken to TMZ in the meantime and I wont say publicly what his thoughts were about the scoop mod lol.
AWD. 2 Litre. GTX3076R 0.82.
330kw atw @ 28psi 98 pump fuel.

372kw atw @ 28psi E85 Flexfuel.
EVOLVED AWD COUPE
WWW.EVOCOUPE.NET

#491
Rockabilly

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Rob I mean 4 scoops. 2 scoops for oil in & 2 deflectors for shielded oil out while spinning.
My way of thinking is the 2 scoops for in can't get much in if the out has the outside oil
presure slowing it down from getting out. No scoops at all would be pretty damn hot inside
a centre diff with the oil NOT changing at all while spinning. So I partly like Jack's idea !!
I don't give 2 f's if the sheep overseas don't think of bettering anything.
Cheers !
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#492
Evo-00x

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The hybrid gearbox is done :thumbsup:

Internals
* EVO III UPYE case with oil screen (non LSD by the gearbox code, but it now has an LSD)
* EVO I, input shaft (you need this to run EVO 1 1st and 2nd gears)
* EVO I, 2.571 1st gear
* EVO I, 1.600 2nd gear - double synchro and dual springs on 2nd gear
* EVO III, Intermediate shaft
* EVO III, 1.160 3rd gear - double synchro
* EVO III, 0.862 4th gear (new) - double synchro
* EVO III, 0.617 5th gear (I was going to use a GSR 5th gearset to bring the ratios from 4th to 5th closer together for better acceleration, but I don’t think the rare occasions I'll be WOT in 5th is going to outweigh the benefits of the EVO 5th gear which will help drop the rpm a little bit better for everyday cruising, especially on the highway)
* GSR RS viscous front LSD (I decided against using the mech Cusco MZ LSD I had due to the car mainly being street driven)
* GSR RS 58-tooth front viscous crownwheel (deburred and detailed)
* GSR output pinion (new)
* New cone and ball bearings all round
* New needle bearings all round
* New synchros all round
* New keys all round
* New springs all round
* New oil seals all round
* New end retaining nuts
* New heavy duty roll pins
* New input shaft oil guide
* New case shims (gearbox shimmed to TMZ 600TQ specs)
* New 1st/2nd hub and slider
* EVO III 3rd/4th and 5th/Rev hubs and sliders (deburred and polished)
* EVO III full solid cast steel selector forks (took me a while to find but these are as new!!)
* EVO III shift forks and rails (deburred and polished)
* Neodymium rare earth magnet N42 20mm x 2mm (replaces weak oem trash magnet)
* 50 hours+ of deburring, detailing and polishing internals

Centre Diff
* Machined centre diff housing to allow for a 4-spider centre conversion
* Machined centre diff cover to allow Torrington bearing upgrade
* New Torrington bearing and upper shim
* Shotpeened centre diff pinions and spider gears
* New centre diff spider gear washers
* New lower pinion oiling shim (thicker than oem)
* Beyond Redline Performance h/duty Chromoly cross-shaft (from TMZ Performance)
* New bearings

Other
* Glass beaded gearbox case
* Custom internal mesh screen filters (was an ex EVO 3 rally gearbox case and they help trap broken debris when shit breaks! lol)
* Deburred and detailed gears and shafts
* Magnetic oil drain plug
* Evo 1 reverse lever arm
* New GSR 31 tooth speedo drive
* New Competition Clutch forged clutch fork
* New Competition Clutch pivot ball

Transfer Case
* GSR/EVO I/II 1.09 transfer case
* New bearings
* New seals
* New o-rings
* Preloaded with oem shim ~2Nm (no shaft play in/out or side/side. Tested with output shaft and needs a bit of a squeeze with one hand to get the transfer to turn = good)

Just some pics of some of the goodies lol

Attached Thumbnails

  • 2012-11-22 18.40.21 (Medium).jpg
  • 2012-11-22 18.46.16 (Medium).jpg
  • 2012-11-22 18.43.36 (Medium).jpg
  • 2012-11-22 18.40.57 (Medium).jpg
  • Robs transfer case rebuild parts.jpg
  • 2012-10-14 14.24.18 (Medium).jpg

Edited by EVO-00X, 16 December 2012 - 01:31 AM.

AWD. 2 Litre. GTX3076R 0.82.
330kw atw @ 28psi 98 pump fuel.

372kw atw @ 28psi E85 Flexfuel.
EVOLVED AWD COUPE
WWW.EVOCOUPE.NET

#493
3zercrowd

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SO MUCH WIN here!!!!!!!! :thumbsup:
:lol: QUOTE OF THE YEAR>>>

BTW... does anyone else have a sore ass??


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[email protected]!!!

STILL Needs more Kilowatts!

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#494
jack be nimble

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Thanks for sharing your thoughts about the cross shafts and scoops. Very inciteful
4g93t jumbuck conversion. PRANGED 18/3/12, CHECK MY MEMBER RIDES Page 11. no serious human injuries.
ON THE ENGINE STAND. g4cs 2.4l + Gt35r. PLUS: auto conversion + Awd coming.
thanks for parts and help: BMGTZ, EVOCPE, cwolf, Benozi, Jamo-GSR, 1JUM2NV, RXVII..much appreciated, cheers guys.
Aerodynamics are for people who can't build engines. —Enzo Ferrari
REMEMBER: you cant polish a turd, but you can roll it in glitter.

#495
Evo-00x

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Went to Officeworks today and picked up this great soft leather Bathurst Racer Chair for $123.38 + $14.20 for an extra 2 years warranty (3 years total warranty).
Aaaahhh..... looks very nice next to the computer desk now lol (they also come in red) :thumbsup:

Attached Thumbnails

  • 4FF4A2CF76A74FB0E10080010AF11387.jpg
  • 4FF40F5BD9AF50D0E10080000AF11387.jpg
  • 4FF40F60D9AF50D0E10080000AF11387.jpg
  • 4FF40F65D9AF50D0E10080000AF11387.jpg
  • hummingbird brand_bathurst_racer_chairs_0060b3c4.jpg

Edited by EVO-00X, 18 February 2013 - 08:04 AM.

AWD. 2 Litre. GTX3076R 0.82.
330kw atw @ 28psi 98 pump fuel.

372kw atw @ 28psi E85 Flexfuel.
EVOLVED AWD COUPE
WWW.EVOCOUPE.NET

#496
DOUGMO

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very flash, but whats happening with the coupe?

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all fabrication BJP AUTOMOTIVE
winton 1:27.4 /// sandown 1:21.5 /// phillip island 1:49.2 /// haunted hills 59.1
/// eastern creek 1:35.4 /// winton short 1:01.4


#497
Evo-00x

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lol yeah its been a while since last April when I took it off the road to do the gearbox (then got sick and had a couple of surgeries grrr...) .
But right now Im just waiting on a flare fitting to come in this week for the return fuel line, then the engine and gearbox will be ready to back in next weekend :thumbsup:
I wanna tidy up some engine bay wiring and revisit the oil drain line from the bottom of the turbo too, but thats not going to take long. It'll be on like donkey kong in March :)
AWD. 2 Litre. GTX3076R 0.82.
330kw atw @ 28psi 98 pump fuel.

372kw atw @ 28psi E85 Flexfuel.
EVOLVED AWD COUPE
WWW.EVOCOUPE.NET

#498
jack be nimble

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He's taken the steering wheel from the coupe, and taken up computerchair racing. he is using a officeworks ruler as a air shifter and makes broroom broom noises between shifts.
On corners sometimes there is a meow meow noise coming from back but it maybe a bush though he has checked the oil in the height adjuster.

Edited by jack of all, 17 February 2013 - 07:03 AM.

4g93t jumbuck conversion. PRANGED 18/3/12, CHECK MY MEMBER RIDES Page 11. no serious human injuries.
ON THE ENGINE STAND. g4cs 2.4l + Gt35r. PLUS: auto conversion + Awd coming.
thanks for parts and help: BMGTZ, EVOCPE, cwolf, Benozi, Jamo-GSR, 1JUM2NV, RXVII..much appreciated, cheers guys.
Aerodynamics are for people who can't build engines. —Enzo Ferrari
REMEMBER: you cant polish a turd, but you can roll it in glitter.

#499
ONPSI

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LOL Jack
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#500
Evo-00x

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Well the fittings came in today which means I can finish the fuel return line now and put the engine back in over the weekend :) woohoo!!
Im using the OEM 5/16" fuel supply hardline (aka -5AN) as my new fuel return line now. Just had to get this tube sleeve and flare fitting to I can connect my 6AN FPR return line to it.

Attached Thumbnails

  • Fuel Return Fitting - Using oem fuel supply hardline as the fuel return line.jpg

AWD. 2 Litre. GTX3076R 0.82.
330kw atw @ 28psi 98 pump fuel.

372kw atw @ 28psi E85 Flexfuel.
EVOLVED AWD COUPE
WWW.EVOCOUPE.NET


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