4g63 AWD Manual Transmission Rebuild 1 - Disassembly
ฝัง
- เผยแพร่เมื่อ 4 ธ.ค. 2018
- Our 4g63 swap is just not shifting right so we're tearing it down and diagnosing what is wrong. Not only will we fix what's wrong, but we also upgrade several parts in the transmission since we're already in here. This Mini Cooper is going to rip down every track it's put on haha
Check us out on Patreon at patreon.com/InitialDIYmods
Please subscribe for more videos like this and be sure to hit the bell button to turn on notifications
Also on:
Facebook.com/InitialDIYmods
InitialDIYmods
/ initialdiymods
Wheelwell.com/ryan-gilroy
Be sure to check us out at
InitialDIYmods.com
and visit the store at InitialDIYmods.com/shop to help support the channel with some merchandise. - ยานยนต์และพาหนะ
Great video!
Thanks mates! I'm glad to hear y'all enjoyed it
Awesome video man, please keep showing us and help keep dsm alive !
Thanks mate. I'll do my best to help the platform 😉👍
Nice work. It's good to see that you are still at it...
Thanks Alex. Glad to see you're still checking out the progress. How's everything up there? Weren't you going to rebuild or modify a barn for a shop up there? How are your projects going
Hope you're staying plenty warm too ;-)
Subscribed. Been hoping for aomeone to do this for a while. Thank you for the awesome vid!!!!!
great stuff! great help for rebuilding my 95 gsx.
Please don't stop making the 4g63 mini cooper its the build i want to do and i love how you've been doing the videos maybe at the end add total cost on parts
Thanks for the encouragement mate. I've got a lot filmed but no time to edit since we've just moved garages/houses again and I'm hoping to make it to a bunch of summer events. I'm going to spend today editing as much as I can though and get some videos ready for release for ya 😉👍
Definitely going to do a final video to wrap up all the costs and parts needed. You can surely do it for cheaper and faster than me if you buy the right parts the first time instead of buying, fabricating, and trying different parts to see what works best.
Thank you so much for teaching me i have 2 gsx to get done
Sounds like you have a lot of work in your future then haha. I hope the next transmission videos help you prepare for your builds ;-)
Just was browsing through diy ecu videos and I found your build looks cool as hell! Looking to do a ecu on my Chevy s10
Thanks a bunch Nick. What are you planning for your S10? Custom ECU on an LS or a modded GM ECU with hptuners? So many options with Chevy ;-)
Initial DIY mods I’m actually either going with a megasquirt or aem I haven’t decided yet and I’m going to keep my 2.2l 4cylinder and turbo it. The factory ecu can only be tuned by hptuners or id have to send it out. Which I kind of a bummer since gm didn’t make the ecu unlocked/flushable from factory
Oh nice, that'll be unique. Not sure what's your experience is but if you're only running a four cylinder, Speeduino could be an option. It really depends how DIY you want to get. MS is a very capable ECU with more pinouts for more cylinders if you ever decide to reuse, sell, or throw a V8 into the truck. It also has a lot more community support for an open software than Speeduino. AEM will have the most support and will be the easiest to configure, but they all will do what you want. I thought hptuners could do turbo swaps too but maybe I'm wrong. It may depends on if you're going to use a MAF or speed density for your tuning.
I'm not a wizard with GM stuff but if you ever need help on general car stuff like turbos, ECUs, and swaps, feel free to ask
Sweet video!! ive been wanting to rebuild my trans just wasnt very confident but now i may try it.
Did you get a chance to try it?
I thought u were joking when u said mini Cooper swap, then the Pic flashed... that thing is awesome!
Thanks a bunch mate. It sure is loads of fun 😊
thanks for the video man
Anytime 😉👍
Awesome
Nice video! I really dig the shirt by the way haha
Haha thanks, my brother used to go there and I got this free shirt during his visit when we were in high school. It was pretty cool.
@@InitialDIYmods I should have specified haha the shirt at like 3:35 on.
LOLOLOL oh yeah that's a dope shirt. I think my wife got that one for me and it's cooler than the U of Miami shirt
@@InitialDIYmods for sure! Haha
The cheapest tool I have seen used on this channel a penny lol good video for sure.
We love to throw in our 2 cents where we can ;-)
man im in need of a rebuild but im terrified to try to attempt this job myself. more learning and research and it could happen in the future but for the first one im considering white shed speed to do mine. Great vid though! 100% subscribed!
Thanks for the sub. The first time is the scariest but if it's not your daily driver, you can always have time to fix it. Once you have the tools, all it takes is your time to fix (and sometimes money lol). Nothing wrong with having the pros giving it a go the first time. Cost me about the same money overall but much longer to do myself. Waiting for the shims and parts was the biggest delay. Would've been done in a few weeks at a shop but there isn't a better way to learn than to get in there and do the work. Just make sure you don't have any crazy deadlines that'll stress you out like a big race, or a big move haha
@@InitialDIYmods she's my daily unfortunately. If I can find another 2g awd trans to pick up I may give it a go. I've been looking for some good write ups or even a service manual/trans overhaul manual somewhere. Haven't found enough to make myself confident. Eventually I would love to get into the transmission repair world though. Nothing better than being able to fix it yourself 👌
Fwd trans video for eclipse would be awersome
8:00
Damn, now i know what happens to my car i guess haha
Thx 4 the video bro
Haha no problem at all. The shift fork is easy enough to replace once the transmission is out of the car. Depending how long you've been having issues, you may need to replace one or more of your gears as the teeth wear down a lot with this issue. I had to replace first and second and also decided the upgrade to double sychros on 1 and 2 while I was at it. Need to order new shims and the transmission will be done and I can finish editing the next two transmission rebuild videos 😉👍
@@InitialDIYmods got the issue right after i bought the car, 600 km ago. there was no problem while test driving. i think the pre owner had a "last ride" with the car haha...
anyway, i will give my GST a X so i will solve this problem on a total different way ^^
But maybe i will restore the old tran later for sale... your Vids will help alot.
looking forward to the new videos! :)
Oh wow that's pretty lousy of them if that's what happened. Glad the videos will help give you an idea of what to expect and what you'll need. I'm waiting on some snap rings to finish the 2nd video and some shims before I wrap up filming the final part of the 3rd video.
The AWD conversion will be pretty cool too. I'm a huge fan of converting "normal" cars into something more unique ;-)
so helpful. about to do 2nd gear on my Eclipse gsx.
Thanks mate, I'm glad it helped. Best of luck with the install 👍
@@InitialDIYmods just finished the rebuild. absolute top notch video. was great reference for when things seemed seem to fight me a bit. pretty sure i cooked it due to incorrect fluid not allowong the synchro to grab. thanks again for help. she shifts like a dream. was a pain getting fork rods out.... you def werent exaggerating.
Fantastic mate. I'm happy the videos helped you out. That was a quick turnaround on your build so you must work fast haha. Yeah slipping the synchros too much with a too slippery fluid is one way to cook them, but another way is not rev matching or getting close so the synchros don't have to work as hard to align the spinning gear assemblies. Sometimes it makes for slower shifts around town, but then you can save all the life and hard shifts for the race track 👍
I hope you get a nice long life out of this transmission rebuild and really enjoy the car.
Nice video. Currently, I'm studying about manual transmissions and this is very informative . This will really help me a lot, however I have a suggestion. Can you do a step by step tear down of a 4G63 engine? That would be great.
Hey thanks for writing in. I'll see what I can dig up from the tear down. I think I have some footage but it was an unexpected teardown so I can remember if I got as much detail.
I highly recommend you check out Jafromobile on TH-cam because he has phenomenal videos about the 4g63 engine as well as improvements to make with things like the oil system, valvetrain, and countless other things. I probably won't be able to match his level of detail but I'll get a video together once I get back from my winter holiday. I still need to put the engine and transmission back together after all haha
Thanks for watching and I hope the next videos help with your studies
@@InitialDIYmods I actually subscribed. You're videos are great :)
What a coincidence, I picked up an 92 Lancer GSR someone had gotten into but never finished. The transmission came disassembled in a box and not nicely packed and dirt free like your pieces are. I'm currently arranging for parts so it will be good to get a full video to watch along with the service manuals.
Oh nice find. Hopefully the parts are not broken or chipped at all. Check to see if there is any rust or pitting as well. If something is too just messed, better just replace it. Worst case, rebuild kits are somewhat cheap and you can replace whatever may be broken and reuse the rest. You can get a full replacement set of internals with some upgrades depending on what your needs are
@@InitialDIYmods Only rust was on the transfer case output shaft and not to bad at that. A few missing ball bearings for the detents/viscous coupler and the speedo gear housing. But the PO did a decent job storing it. Bearings have definitely seen better days, same with the 5th gear slider.
@@david929190 oh yeah that output shaft always rusts at the splines. A little clean up and dab of grease should stop that from spreading. As long as it's only on the exposed area that sticks out past the seal. You don't want rust on the sealing area or it will most likely leak.
Wait mid typing I realize, are you talking about the output shaft of the transfer case where the driveshaft goes or do you mean the output shaft to the transfer case from the transmission?
Glad the PO at least stored it well, usually we are never that lucky and only get to buy parts when it's someone elses headache haha. You should be able to get some new ball bearings for the shift detents, viscous coupler, etc. I don't know what the part number would be but I am sure you could find a replacement online. If you decide to shop aftermarket and can't find the size, let me know so I can throw a caliper or mic on them for you before I put everything back together again ;-)
@@david929190 and definitely replace the bearings. They're pretty cheap relatively speaking. No sense putting old bearings back in anything like this with shaky history
@@InitialDIYmods I'll be getting a full rebuild kit from Jack's Transmissions. I've rebuilt an Auto for an Escape and been into one of these a decade ago at 17 so it should go smoothly. Only real concern will be getting the right shims for setting the pre-load, that may add some time to the build unless I get a variety to start.
Good job . When are you heading back to Texas ? SHORTTRACK OUT !!!!!
Thanks mate! I'm hoping to move back around March to April of 2020. Nothing official yet but that's what I'm aiming for
Question for you!
I’ve cracked open two different all-wheel-drive transmissions. 1990 and a 1992.
Inside both of them was what looks like a needle bearing except it’s half the length of any needle bearings in these transmissions And its diameter is thinner. What the heck Could they be from??? I wonder if maybe they were wedged inside of the roll pins for the shift fork, but why only one and why was there one loose in each transmission????? Lol
Thank you so much for the upload! I cracked my case a while back whilehorse playing after I got my 20G. Luckily I've got a spare that has some chewed-up gears, I plan on swapping the section of case that is cracked. Did you actually use old school vintage copper pennies or current steel ones that are copper plated??
That's a good question. The pre 1982 pennies are a little softer if you have one on hand, but if not, then any one will do. The modern ones are not steel though, they're mostly zinc. Basically they used to be mostly copper with 3-5% zinc where they are now 97.5% zinc with 2.5% copper. Both metals are pretty soft though and shouldn't harm the hardened steel gear teeth of a transmission.
@@InitialDIYmods awesome, thanks for the info!
Great video. Have you ever rebuilt a DSM trans before? Looking forward to the other videos!!!
Thanks mate, no I'm relatively new to the DSM world but it's a relatively simple system and there's an abundance of information scattered about the internet. It works like any other transmission though 😉👍
Keep up the great work!!!
Where did you find front differential taper bearing’s. Thanks for the info 👌
I had searched a bunch of orders and searched all my emails before rewatching the video. I didn't use taper bearings for the front diff. The awd doesn't come with them however, the fwd transmissions do if that's what you're looking for. All those parts can be found on Jack's transmissions website. I also cover this info in video 4 of this series
@@InitialDIYmods nice I appreciate the info 👌
This one get in my be golf 4 2.0 vtec AWD and galant 3.5l v6 vtec awd
is it possible to replace the "output shaft oil seal" with out having to remove the shaft? like pop the seal out and tap the new on in?
I assume you mean the output shaft going to the transfer case and not the axle shaft seals. You not only have to take the shaft off, I'm pretty sure you have to take the transmission apart because the seal is installed from the inside of the transmission assembly.
How do you know that's what is leaking? Have you removed the trans and confirmed? That seal is a pain to get to
@@InitialDIYmods yes the output shaft going to the tcase, i have the transmission off the car now the seal is leaking , i was following your guide to try and replace it but i just realized they sent me the input shaft seal🤦♂️
I have a question did you have to do an entire engine swap just for it to be awd? Could it be possible to keep the original motor and just prepare your transmission for an awd trans or just completely get a awd transmission and just find a awd drive train to cram into the car like you did but keeping the mini coopers motor ?
Great question. I think I could have. Most likely you'd have to swap the Mini S ALL4 transmission from the Paceman or the Countryman. I have confirmed that the rear trailing arms bolt in. The only other thing you'd need to swap over would be the brakes, maybe brake lines, maybe e brake cables and wheel speed sensor (rear wheel speed sensor on the ALL4 is the same as the front on the Mini so your old rear ones wouldn't work. Then you'd need the axles (you'll probably have to shorten them as well), the differential, subframe might swap over but I don't know for sure, and drive shaft. The front subframe may need to be swapped or modified as well. Most things should bolt up but the ones that don't are somewhat expensive which was one reason that I didn't go that route.
The biggest reason is that if I swapped everything and kept the Mini S prince engine, then I'd be stuck with the challenges of the Mini engine. Things like timing chain issues, oil leaks, burning oil, caking the intake valves, vacuum pumps, etc and that's on the stock side. The other challenge was the performance/power side. If I wanted to modify anything like swap turbos, cams, displacement, etc, I'd be left with expensive part options and challenges tuning the GDI system plus the limit of the stock 1.6L engine.
So it's not that it can't be done, if would just be hesitant to spend that much money and stay with a stock ish Mini or have to spend another 10 or 15k to get to 350 or 400 awhp.
Feel free to ask any other follow up questions on the build ;-)
Initial DIY mods thank you I was asking because I’m buying a jcw r53 06 GP and I’m thinking about making it awd and I was as well thinking about the paceman all4 and just wondering if it would be possible just to take the drive train and trans from the paceman and put it in the r53 I just want to know what would be the biggest task like would there mostly like be me cutting the frame of the r53 which I would love to steer away from but if I had to I would and you’re the only TH-camr and person I (know) that understands Mini Cooper and making it awd
Add on: I’m trying to get to 500hp+ and everything I need I already have it in a kart and it’s just about 6k which in my opinion is pretty cheap compared to other builds and if I need to add more I certainly will just my biggest project I want to do is make the car awd tuning it is no problem but like you said I wouldn’t want any issue with my performance can you elaborate more on that for me by what you meant about the performance.
6k doesn't sound bad at all. Does that include an engine build as well? I wouldn't think they'd be able to handle that much power with a stock block. Usually on an engine build the machine shop is the most expensive part. Now I know people swap R56 and R53 rear suspension so that would make me think the AWD trailing arms would fit an R53 as well but I'm not 100% since I haven't tried. Is the JCW R53 exhaust straight like the R56? Then you won't have to cut a driveshaft tunnel either.
The biggest question with the Paceman AWD transmission fitting would be the bell housing. I don't know if there changed that pattern. The easiest way to find out is to see if anyone has swapped transmissions between the different engine generations. That will be a good indicator of fit up. You may have to add mounts or something but that's easy with a welder to Fab up on the spot.
I didn't have to cut the frame on my build to fit the engine, but it would've made the driveshaft need a new tunnel and it would need all custom axles so I figured chopping just the rail would be easier, faster, and cheaper lol
To elaborate on the performance part, my goal is around 400 awhp which has been done so many times on the 4g63 that everyone knows what you need to make it work. Parts are relatively cheap and easy to get. With the Mini, it's a little bit more of a niche market, so there's not as many parts or the parts are just more expensive in general. Just to get my car running with AWD swap was under 3k, then upgrading stuff cost about 4k more but I went all out too. I rebuilt the engine with upgraded parts, rebuilt the head, rebuilt the transmission with upgrades, I'm swapping the rear end to get the speedometer to work, and I got a bigger turbo too. Then I spent money on stuff like powder coating and a powder coating oven, a 20T press for the transmission. Now the R53 may be easier to modify than the R56 as well. I recall seeing kits for 4 or 5k with canned tunes an then the pistons would be the limit. Plus the R56 has a pretty high compression ratio due to the GDI set up
Hope that helps and let me know if you have more questions. And update me on your project. A 500 hp AWD R53 sounds awesome :-D
Initial DIY mods the r53 is only a single cam so with new valves, valve springs, pistons, cams, etc it can probably handle that much I’m trying to keep the stock head and maybe block because I want the heart of the mini still in the car but if I have to swap the block for something different maybe with a higher compression I will find out along the way of the build and as far as the exhaust they are fairly similar the r53 exhaust pipes are pointing the opposite way from each other then go a little more towards the rear then closing in to joint together to finish off on the center of the rear of the car so like for example
---[ ]- and the box forms a littler after the rear axle so no loops or anything just goes around which I believe is the battery since on the r53 the battery is in the back of the car I’m as well added something to the head which is going to be different from common builds you would typically see that will surely help get to 500awhp+ but that I’m keeping a secret until I can get it done and post some vids on it lol
And thank you for helping me out with these questions I will have tons more and an awd r53 500hp does sound very awesome so as your build which really inspired me to go awd
Add on I ask some mini “ professionals” that tune and wor with minis like Mini Cooper wizards and they told me the bell housing is different but I don’t know if that is for certain until I try but if it is I don’t want that to be what stops me from making it awd maybe I can work something out with that
Btw yes there are kits for the supercharger especially the ALTA brand that can get your mini to 285-300hp
Just wondering if you could start disassembling from the bell housing and not from the end casing? I only want to access the final drive. Thanks.
I'm not 100% sure on that, you'd have to look at internal photos or this video very closely, but I don't think you could get the final drive out from the bell housing because of the gear stack and bearings on there being a bit hard to separate. You can access the bell housing bolts but 5th gear is held onto the shaft inside the end case so you can't get the gear stacks out, and the reverse gear mount is bolted to the inside of the bell housing and in between the gear shaft so I don't think you can actually separate anything to get it apart. It's a pretty good puzzle disassembling everything from the outside.
What exactly are you trying to do with just the final drive? Upgrade or swap it out?
Initial DIY mods had some modifications on my gearbox’s bell housing and somehow the shop forgot to cover the hole where the intermediate axle slides into, some metal shavings got inside the differential. Was planning to access the diff to remove it and prevent further problems. If i could only access that part, it would be much easier.
Ah gotcha. It's not too bad to disassemble and reassemble right away. If you're dealing with shavings in your transmission, that can wreak some havock on the bearings and synchros as the fluid circulates it. You can get it broken down in an hour or two with the right tools and reassembled in about the same time plus the sealant cure time
Initial DIY mods thanks alot. Your vid helps alot. Very informative.
Excuse me Brother I have a question about the 6g72 engine awd manual transmission, I just change my engine and transmission with a jdm engine but my transmission every gear its working except the reverse, I just want to know if I had to fix the whole transmission or do you know some tricks or normal problems with this transmission, thank you in advance, have a good day
I'm not super familiar with the 3000 motors or transmissions specifically, but there are a few areas to check depending on how it won't shift.
Is it like you can't get in like your hitting a wall, or like the shifter moved but it doesn't connect with anything?
The possible issues I see could be with a broken shift fork or idler gear that is used to select the gear. Broken or work teeth, broken fork could both cause grinding or no engagement at all. Could also be the reverse lockout being stuck engaged as well. Typically this is for 5 speeds to prevent going from 5th to reverse by accident.
It's hard to speculate without feeling it and taking it apart and searching for the issue.
Also, reverse usually in older cars/sometimes in newer cars doesn't have synchros so that's topically not an issue for not being able to engage reverse as long as you're not moving forward. If it's seized, that could block you out of gear.
It could also be the linkage, so make sure they're not bonding it caught up anywhere. I had my shift link on this transmission hit an intake pipe that was misaligned and locked me out of reverse. I resigned the pipe and added extra clearance with a hammer. Definitely worth checking before tearing everything apart again
Now you have the old transmission still? Could you bolt the non JDM trans up or are you wanting the JDM trans specifically? Or is it a swap so you don't have the old one?
Hope this helps and best of luck with the project. It sounds like a cool one for sure.
@@InitialDIYmods Thank you for you time and answer and I will go through every step you said it and hopefully I can be find something, thank you and have a good day
Long time no see. how's the mini running?
Haha yeah it's been a bit. Sadly with the transmission like this, it's not running much these days LOL. I pulled the trans to fix the shifting issues and decided I might as well inspect the engine too. That's when I noticed the engine was damaged as well (journals bearings, rod bearings, excessive bore wear,. So I got new higher compression pistons and a bigger bore with all new bearings throughout the block, and decking a tad. The head needed to get rebuilt with new valves and valve guides plus deck the head.
It sucks that fixing these things the right way with better parts is costing me as much as the entire build up to this point :-/
At least after this I won't have to worry about the engine, head, or transmission and I can max out the upgraded turbo and be happy until I need more power
Great video but my gearbox had broken can you help me ti find part to rebuild it
How is it broken? Do you know what broke and need help sourcing a part or do you just know it's broken and not how to fix it?
whats the point of that manifold? sweet car though
Thanks mate, which manifold are you referring to?
Hello I have 98 eclipse gst 4g63.. my transmission went bad, should install a use one ? Or rebuild it ? I need something with better quality.... if I rebuild what’s the best transmission kit for it ?
There isn't really a transmission parts kit that I've found to have everything you need. I had to pay shipping 4 or 5 times to get the parts I needed. It was missing a lot of bearings. You can get the all parts pretty cheap ($1500-2500 depending what you want) and you can buy the tools of you don't have them, but nothing will be cheaper than swapping in another used one which is around $300-500. If you have a shop like Jacks, TMZ, or TRE rebuild it, it will be like a new transmission again, but it will cost a little more because of the labor on top of the price of parts, but the turnaround time is waayyy faster because it all gets done at once and within a few weeks, you're back up and running.
Initial DIY mods thank you so much for your info.. how can I get in touch with them ? Just TMZ.com ?
Haha wrong TMZ, it's www.tmzperformance.com
You can also check www.jackstransmissions.com and teamrip.com
You can also check out SHEPtrans.com too
They all offer several different build types too to hold up to different power levels
Initial DIY mods
Thank you so much
No problem mate. Hope you get it all figured out and fixed soon so you can get it back on the road
I see ohio plates, will you be attending the dsm shootout? Id like to check this thing out
I didn't last year because we moved to Cali a bit before the shoot out but I'm hoping to drive up for the event. What day is it supposed to be this year? It always looks like a blast
Anyway your near virginia?
Sorry no, we are now based out of Houston, Texas
Is the transmission from a 1g or 2g?
This one is a 1g but process is very similar for a 2g. The shift rails and forks are a bit different and the shaft sizes are a bit different but overall it's the same process 😉👍
Initial DIY mods awesome. I have a noise in my trans so I’ll have to pull it apart. Your videos will help immensely! Thanks man!!
Sad to heart about the noise, that's never exciting, but I'm glad you have the videos to give you an idea of what's involved.
hai bro,,,what code your Gearbox?
W5M33 😉 let me know if you have any other questions
@@InitialDIYmods full code,,,,mine use W5M33 2UPGE
😑 I could not see the gear damage very well ...
The gear damage will be in the next video where we separate the gear sets. This video was focusing on the disassembly. The main damage here was the broken shift fork that moved the 1-2 hub slider from first to second gear. I have some close ups of that on instagram if you'd like to see that. Once I finish filming and editing the gear set video, it will be up on youtube and patreon ;-)
Hope that helps