Disassemble & Fitment of Z27AG Gearbox 4G15 Getrag 5spd - Photos

To view the process see here: /disassemble-fitment-of-z27ag-gearbox.html
I have yet to take the my old gearbox to Mitsubishi and ask for warranty.
So far so good on the gearbox i put together. There are some strange noises. I am wondering if that is coming from the LSD. I want to take in to barbs on the 10/01/2013. But i am waiting for my diff oil to come. I want to change it out again and add the magnetic drain plug.
I also want to rebleed the brakes and clutch.





I used kerosene and a toilet brush to clean out the old gearbox.










The tool you see is a bearing race installer. Its made out of aluminium so it doesn't damage the bearing race. I have also used it to install axle seals. But it is sharp so you should be careful.








New bell housing.
21200 HOUSING,CLUTCH 2960A311
Seen here:
 /possible-solution-to-my-cracked-clutch.html









Note that the housing didn't come with anything. No input shaft bearing or seal. No Output shaft bearing or race. No differential bearings etc.
I had to reuse some of the part from the old case due to a three month lead time.









Bits and pieces.









Heat up the housing for easy install. You can add your bearing race to the freezer as well as heat the case. I lubed everything with some wd40 and attached me slide hammer to the race installer. Much easier!






Soaking in kero




























Installing the ring gear. Some people may have issues. You can add the ring gear to you oven before installing.







I hope the loctite on the ring gear bolts i bought hasn't gone off.

Ring Gear Bolts 2960A304
Input shaft seal 2960A268
Input shaft bearing 2960A269
Outputshaft bearing race 2960A271
Outputshaft bearing 2960A270

I slowly hand tighten all ring gear bolts to pull the ring gear square onto the diff.

Then i hit them with a rattle gun. The extension is a torque limiter. After which i then hand torque each one twice over in a star pattern.

Number the bolts to make it easier for yourself.

Becareful not to crush fingers. I crushed two and the ring gear sliced them quiet nicely! When lowering the diff into the case.

So clean! Installing the bearings and bearing races.

Dont forget to clean the magnet. I used the air gun. Wiping doesn't work to well.

some more of the parts.


RSRS - went a bit crazy at RRP http://rsrs.jp/


---RRP Ultra Light Pulley Kit---

Has been designed aiming to reduce friction loss of engine and engine response with lighter crankshaft pulley and alternator pulley.

7075 adopted duralumin material with the same strength steel material and aluminum material consideration while being thoroughly even strength, cured hard anodized surface by further processing, ultra-hardness have been finished to a pulley.

Aims to further increase the Colt engine response!
Crank pulley genuine  Steel  Weight 2000g (2 km)
Made RRP  ※ duralumin  Weight 1070g (1 kg)
47% compared to normal weight

Genuine alternator pulley  Steel  Weight 182g
Made RRP  ※ duralumin  Weight  84g
54% compared to normal weight

※ RRP are made by using the material duralumin 7075. Materials that are both lightweight and strength comparable to the strength of steel and aluminum, while,
It is ultra-light and strong high-quality materials are also used in aircraft.
CoE-100: RRP Ultra Light Pulley Kit - 39,900 yen

---RRP Racing Water Pump---
Change the rotation ratio pulley, water pump pulley racing radiator cooling we help to reduce the flow rate of cooling water moderately and reduce rotational friction at high rpm while reducing the burden on the water pump. Since the material can also be further reduced weight change, it is lightweight, water pump pulley and also help to combat overheating response up by reducing the friction resistance variety.

Genuine water pump pulley  Steel  Weight 400g
Made RRP  ※ duralumin  Weight 300g
25% compared to normal weight

※ Made RRP is using duralumin material. Materials that are both lightweight and strength comparable to the strength of steel and aluminum, while,
It is ultra-light and strong high-quality materials are also used in aircraft.

CoE-102: RRP Racing water pump pulley - 16,800

---Radiator Cap---
Set to 127kpa valve opening pressure to maximize the cooling performance of the radiator. To prevent vaporization and boiling of the coolant in situations where such congestion in the summer or when traveling circuit-intensive and high load high rpm, water temperature tends to go up, to protect the engine from overheating.

Please working in a state in which the engine is always cold.
If you open the cap when the engine is hot, you might burn coolant is ejected.

CoE-301: High performance radiator cap - 2,310

---RRP super cool gasket insulation--- [on the shopping list]
For gasket for SCI is also favored Colt Colt parts

Super cool gasket insulation insulation gasket is super special material attached to adoption between the intake manifold and the engine. We improve the amount of intake air to lower the intake temperature and reduce the temperature rise of the intake manifold throttle to hardly transmitted to the intake manifold of the engine body heat.
I especially recommended to those who are and those equipped with engine tuning raising salaries are very high compared with normal insulation effect, so also improves further seal.

(One piece 1) RRP super cool gasket insulation: CoE-101 - 9,450 yen








Didn't notice i had made quiet the collection :)

Working late to finish it off for track.

 

Further Reading:
LSD Install with Shims: http://www.focusfanatics.com/forum/showthread.php?t=158224