Project EVO-500: Part Deux
May 14, 2006, 07:05 PM
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Project EVO-500: Part Deux
I spent a some time in the garage this weekend and basically finished the tear down. Engine, tranny and transfer case are out and there weren't too many hiccups. Lets get to the pics, that's what everyone's really waiting for
Not too many things on the white board yet! sweeeeet.
Today's presentation brought to you by: the only 2 connecting rods remaining in tact, and one of my only remaining bud lights.
First off, take these out. No prob here. unbolt the hub assembly from the strut, take out the axle bolt, give a tap (or pry) on the inside most part of the axle that you can get leverage on and they slide right out.
I'd like to pause here to give a quick shout-out to the boys at EvoMotorsports who provided everyone a lovely 'How-To' for a clutch install which I referenced throughout the process here. An engine removal is basically the clutch removal process, with 1 extra step in the middle: Taking out the last engine mount and pulling the motor. Everything else will be off already (except the AC and power steering brackets). Check it out at: EvoMoto
Back to business. Now, the output shaft from the transfer case runs through the transmission, and you have to pull this shaft out before you can remove the transfer case. Might as well get this done early. I went the EvoMoto route here and picked up a dent puller from the car parts shop, and picked up a M8x1.25 bolt from the hardware store. Weld the bolt to one of the nuts provided with the dent puller and you'll be able to thread it into the output shaft and give it a few good whacks. Boom, off in two hits. Custom tool:
Said nut and bolt, ready to be welded:
Tool inserted:
Output shaft out:
Also, your old block may now be used as a temporary workbench with the head removed.
As for the only hard part of the process... When removing the transmission from the engine, you need to pop the throwout bearing off of the wedge collar (connected to the pressure plate) or you won't be able to pull it off. This is done through the inspection hole on the tranny and was a PITA. I decided to drop the engine/tranny down (after 30 minutes of laying underneath the car) and do it in a position where I could sit on a stool. I win.
You can see a pic of the wedge collar on EvoMoto's site. I'd insert it here, but they're tricky and won't let you right-click on the image to find out the link, and I'm too lazy to find a work-around. (just kidding EvoMoto, I would never do such a thing).
Engine/Tranny removed:
Wedge color (all F'd up after I had to use a giant pry bar to get the damn TOB off. I bet Mitsu has a one-off tool for that.
With the block off, you get a nice view at all of the lovely cooling passages the rods added after they strayed from their respective pistons.
Bearing seats = copper ground mess.
Timing belt = lunch. Oil pump belt = lunch.
Crank took a BEATING.
Haha. ah.
Tranny = cracked
Transfer case = cracked
Transfer case = dented too
Now its starting to look like a garage.
Thats about all I have for now, more to come...........
Not too many things on the white board yet! sweeeeet.
Today's presentation brought to you by: the only 2 connecting rods remaining in tact, and one of my only remaining bud lights.
First off, take these out. No prob here. unbolt the hub assembly from the strut, take out the axle bolt, give a tap (or pry) on the inside most part of the axle that you can get leverage on and they slide right out.
I'd like to pause here to give a quick shout-out to the boys at EvoMotorsports who provided everyone a lovely 'How-To' for a clutch install which I referenced throughout the process here. An engine removal is basically the clutch removal process, with 1 extra step in the middle: Taking out the last engine mount and pulling the motor. Everything else will be off already (except the AC and power steering brackets). Check it out at: EvoMoto
Back to business. Now, the output shaft from the transfer case runs through the transmission, and you have to pull this shaft out before you can remove the transfer case. Might as well get this done early. I went the EvoMoto route here and picked up a dent puller from the car parts shop, and picked up a M8x1.25 bolt from the hardware store. Weld the bolt to one of the nuts provided with the dent puller and you'll be able to thread it into the output shaft and give it a few good whacks. Boom, off in two hits. Custom tool:
Said nut and bolt, ready to be welded:
Tool inserted:
Output shaft out:
Also, your old block may now be used as a temporary workbench with the head removed.
As for the only hard part of the process... When removing the transmission from the engine, you need to pop the throwout bearing off of the wedge collar (connected to the pressure plate) or you won't be able to pull it off. This is done through the inspection hole on the tranny and was a PITA. I decided to drop the engine/tranny down (after 30 minutes of laying underneath the car) and do it in a position where I could sit on a stool. I win.
You can see a pic of the wedge collar on EvoMoto's site. I'd insert it here, but they're tricky and won't let you right-click on the image to find out the link, and I'm too lazy to find a work-around. (just kidding EvoMoto, I would never do such a thing).
Engine/Tranny removed:
Wedge color (all F'd up after I had to use a giant pry bar to get the damn TOB off. I bet Mitsu has a one-off tool for that.
With the block off, you get a nice view at all of the lovely cooling passages the rods added after they strayed from their respective pistons.
Bearing seats = copper ground mess.
Timing belt = lunch. Oil pump belt = lunch.
Crank took a BEATING.
Haha. ah.
Tranny = cracked
Transfer case = cracked
Transfer case = dented too
Now its starting to look like a garage.
Thats about all I have for now, more to come...........
Last edited by Stew; May 14, 2006 at 07:12 PM.
May 14, 2006, 07:18 PM
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wow... dont worry my T case is cracked also. When I was doing the clutch install, my uncle tried to stuff it back into the hole. As he tightned it I was not paying attention and it cracked.`
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May 15, 2006, 08:00 AM
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Thanks guys. I need to pick up a manual to make sure all the torques are correct when I re-install, but other than that its not too bad of a project. An extra set of hands is key, but with a little research the process is fairly straight forward. The Evo is a delight to work on after my last VW 
May 15, 2006, 09:32 AM
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Originally Posted by JaReDbOy
what the heck did you do to your car that everything is cracked??????
May 15, 2006, 12:20 PM
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Nice write up. I like the humor you threw in there.Those two rods are champs to survive that. They aren't F'in around, those rods should be donated to Boeing to hold a fighter jets wings on. + They are cool enough to kick it with Bud, right?
Edit: GO STEW!