Ive been busy upgrading and rebuilding my F5M42. I replaced all the syncros, bearings, worn gears, hubs and selectors. I decided to install a kaaz LSD option and set it to 60% grip. Did the preloading on the diff was fairly straight forward, I got lucky and was able to reuse the original one. So I got to putting everything back in and tested the transmission by rotating the input shaft and moving through the gears. So, some how with the output shaft bearing " facing the bell house" pressed all the way in, the gears on the shafts rubbed up against each other. Combed over the manual and it mentions nothing about having to adjust it, Just press and bottom it out making sure its facing the right direction. Didnt see any mention of a shim that needs to go in either, Although I don't recall one being there. So, I pulled the bearing out from the casing just enough to stop the gears from rotating against each other. Spun the transmission and shifted through the gears and the issue was resolved. Now everything is installed into the car and I can hear them gears again, rubbing against each other or that's what it sounds like. In neutral you can ever so slightly hear it, More so when you move up them gears when driving but nothing crazy. Is there something im missing here? Im getting ready to drop the trans and inspect it to make sure everything is right before it gets damaged. Anyone have any I durs on this subject ? Ill put up some images of the work that I have done during this whole pandemic rebuild. Rebuilding during this time has been a challenge on finding availability and availability.. lol ..

Thanks, Guys !

 

Parts list so far
Fidanza 161111 - Aluminum Flywheel
Comes with ARP Bolts for the 4G94
ACT MB8HDSS - Heavy Duty Street Single Disc Clutch Kit
Not sure if they make ARP bolt for the pressure plate
F5M42 5 Speed Transmission Bearing Kit with Synchro Rings, BK497AWS
- allstategear.com <-- No inventory " Promp refund"
-Transmissionpartsdistributors.com <--- Dont waste your time, Sent me a box of junk.
- www.vividracing.com <--- Has the kit but uses 3rd party parts ( Great customer service though )
There are NO Carbon kits headed our direction for the F5M42, What I was told from Synchrotech.com ( Shiiieeet ... )
KAAZ - DBM2050 - Lancer CK4A – Mirage CJ4A / CK4A – Hyundai Tiburon 95-01 (1.8L)- 01+ (2.0L Front 1.5 Way "Super Q"


Build your own rebuild kit, Parts that I used except selector hubs, Selector Sleeves . 5th gear,revers.

(Output shaft Syncro's and syncro key's )
-----------------------------------------------------------------------
RING ASSY,M/T 1ST SPEED GEAR SYNCH ($85.73 Japan)
Genuine Mitsubishi (MD770149) - Assembly:29,30,27

SPRING,M/T SYNCH KEY($2.97 Japan) 1st gear syncro key
Genuine Mitsubishi (MR581389) - Assembly:28
------------------------------------------------------------------------
RING ASSY,M/T 2ND SPEED GEAR SYNCH ($105.15)
Genuine Mitsubishi (MR483024) - Assembly:23,22,21

SPRING,M/T SYNCH KEY($2.97 Japan)
Genuine Mitsubishi (MR581389) - Assembly:24
-------------------------------------------------------------------------
RING,M/T SYNCH ($29.37 Japan) 5th Gear syncro
Genuine Mitsubishi (MR581382) - Assembly:10

SPRING,M/T SYNCH KEY ($3.03 Japan) 5th gear syncro key
Genuine Mitsubishi (MR581383) Assembly:
-------------------------------------------------------------------------
RING,M/T SYNCH ($29.37 Japan) Reverse Gear syncro
Genuine Mitsubishi (MR581382) - Assembly:6

SPRING,M/T SYNCH KEY ($3.03 Japan) Reverse gear syncro key
Genuine Mitsubishi (MR581383) - Assembly:7
-------------------------------------------------------------------------

(Output shaft bearings)
BEARING,M/T OUTPUT SHAFT ($33.64 Japan)
Genuine Mitsubishi (MD747707) - Part Spec:Roller,70 assembly:35

BEARING,M/T OUTPUT SHAFT ( $10.54 Japn ) 1st gear needle roller bearing
Genuine Mitsubishi (MD744536) - Part Spec:NEEDLE,58 Assembly:32

BEARING,M/T OUTPUT SHAFT ( $9.33 Japan ) 2nd gear needle roller bearing
Genuine Mitsubishi (MD744537) - Part Spec:NEEDLE,54 Assembly:19

BEARING,M/T OUTPUT SHAFT ($8.51 Japan ) 5th gear needle roller bearing
Genuine Mitsubishi (MD744538) - Part Spec:NEEDLE,49 Assembly:13

BEARING,M/T OUTPUT SHAFT ($8.51 Japan ) Reverse gear needle roller bearing
Genuine Mitsubishi (MD744538) - Part Spec:NEEDLE,49 Assembly:4

BEARING,M/T OUTPUT SHAFT ($20.67 Japan)
Genuine Mitsubishi (MD747740) - Part Spec:Ball,72 Assembly:2
-------------------------------------------------------------------------

(Input shaft syncro's and syncro keys )
-------------------------------------------------------------------------
RING,M/T SYNCH ($29.37 Japan) 3rd gear syncro
Genuine Mitsubishi (MR581382) - Assembly:13

SPRING,M/T SYNCH KEY ($3.03 Japan) 3rd gear syncro key
Genuine Mitsubishi (MR581383) - Assembly:14
-------------------------------------------------------------------------
RING,M/T SYNCH ($29.37 Japan) 4rd gear syncro
Genuine Mitsubishi (MR581382) - Assembly:9

SPRING,M/T SYNCH KEY ($3.03 Japan) 4rd gear syncro key
Genuine Mitsubishi (MR581383) - Assembly:10
-------------------------------------------------------------------------

(input shaft bearings)
BEARING,M/T INPUT SHAFT ($20.84 Japan)
Genuine Mitsubishi MD700207 Sub Part(2526A001) - Part Spec:BALL,68 Assembly:18

BEARING,M/T OUTPUT SHAFT ($8.51 Japan) 3rd gear needle roller bearing
Genuine Mitsubishi (MD744538) Part Spec:NEEDLE,59 Assembly:16

BEARING,M/T OUTPUT SHAFT ($9.33 Japan) 4th gear needle roller bearing
Genuine Mitsubishi (MD744537) art Spec:NEEDLE,54 Assembly:7

BEARING,M/T INPUT SHAFT ($17.83 Japan)
Genuine Mitsubishi (MD717670) - Part Spec:BALL,62 Assembly:2

--------------------------------------------------------------------------

Differential bearing
BEARING,RR DIFF CASE ($13.37 Japan) For FR DIFF side/RR DIFF side
Genuine Mitsubishi, Genuine FUSO (MB393957) - Part Spec:TAPER ROLLER,72.00X18.25-35.00

 

Dropping the transmission

 

Opening the casing and shaft disassembly

 

Assembling the shafts

 

LSD Install

 

Closing up the Transmission

 

Flywheel and clutch install

 

Oil pan reseal

 

Exhaust

 

Suspension

 

Issue's Found

I had to take the transmission out again. The issue was that it was making a sound as if something was rubbing up against each other during testing. The sound turned out to be that the output shaft and the input shaft gears where rubbing up against each other ever so slightly. The offending part "MD747707" was the output shaft bearing that is pressed into the casing. In the manual it says to press the bearing all the way down but this seems to be a mistake. This will lead to this exact issue that im having right now. I had to incrementally press the bearing in and check for clearance. I you over shoot this and have to pull the bearing out you MUST replace it with a new one. DO NOT RE-USE if its been pulled on, There is a very high probability that the function of pulling the bearing out will damage the roller bearing.

 

ECU Tap in

 

[QUOTE=LanceNot;11909722]Parts list so far
Fidanza 161111 - Aluminum Flywheel
Comes with ARP Bolts for the 4G94
ACT MB8HDSS - Heavy Duty Street Single Disc Clutch Kit
Not sure if they make ARP bolt for the pressure plate
F5M42 5 Speed Transmission Bearing Kit with Synchro Rings, BK497AWS
- allstategear.com <-- No inventory " Promp refund"
-Transmissionpartsdistributors.com <--- Dont waste your time, Sent me a box of junk.
- www.vividracing.com <--- Has the kit but uses 3rd party parts ( Great customer service though )
There are NO Carbon kits headed our direction for the F5M42, What I was told from Synchrotech.com ( Shiiieeet ... )
KAAZ - DBM2050 - Lancer CK4A – Mirage CJ4A / CK4A – Hyundai Tiburon 95-01 (1.8L)- 01+ (2.0L Front 1.5 Way "Super Q"


Build your own rebuild kit, Parts that I used except selector hubs, Selector Sleeves . 5th gear,revers.

(Output shaft Syncro's and syncro key's )
-----------------------------------------------------------------------
RING ASSY,M/T 1ST SPEED GEAR SYNCH ($85.73 Japan)
Genuine Mitsubishi (MD770149) - Assembly:29,30,27

SPRING,M/T SYNCH KEY($2.97 Japan) 1st gear syncro key
Genuine Mitsubishi (MR581389) - Assembly:28
------------------------------------------------------------------------
RING ASSY,M/T 2ND SPEED GEAR SYNCH ($105.15)
Genuine Mitsubishi (MR483024) - Assembly:23,22,21

SPRING,M/T SYNCH KEY($2.97 Japan)
Genuine Mitsubishi (MR581389) - Assembly:24
-------------------------------------------------------------------------
RING,M/T SYNCH ($29.37 Japan) 5th Gear syncro
Genuine Mitsubishi (MR581382) - Assembly:10

SPRING,M/T SYNCH KEY ($3.03 Japan) 5th gear syncro key
Genuine Mitsubishi (MR581383) Assembly:
-------------------------------------------------------------------------
RING,M/T SYNCH ($29.37 Japan) Reverse Gear syncro
Genuine Mitsubishi (MR581382) - Assembly:6

SPRING,M/T SYNCH KEY ($3.03 Japan) Reverse gear syncro key
Genuine Mitsubishi (MR581383) - Assembly:7
-------------------------------------------------------------------------

(Output shaft bearings)
BEARING,M/T OUTPUT SHAFT ($33.64 Japan)
Genuine Mitsubishi (MD747707) - Part Spec:Roller,70 assembly:35

BEARING,M/T OUTPUT SHAFT ( $10.54 Japn ) 1st gear needle roller bearing
Genuine Mitsubishi (MD744536) - Part Spec:NEEDLE,58 Assembly:32

BEARING,M/T OUTPUT SHAFT ( $9.33 Japan ) 2nd gear needle roller bearing
Genuine Mitsubishi (MD744537) - Part Spec:NEEDLE,54 Assembly:19

BEARING,M/T OUTPUT SHAFT ($8.51 Japan ) 5th gear needle roller bearing
Genuine Mitsubishi (MD744538) - Part Spec:NEEDLE,49 Assembly:13

BEARING,M/T OUTPUT SHAFT ($8.51 Japan ) Reverse gear needle roller bearing
Genuine Mitsubishi (MD744538) - Part Spec:NEEDLE,49 Assembly:4

BEARING,M/T OUTPUT SHAFT ($20.67 Japan)
Genuine Mitsubishi (MD747740) - Part Spec:Ball,72 Assembly:2
-------------------------------------------------------------------------

(Input shaft syncro's and syncro keys )
-------------------------------------------------------------------------
RING,M/T SYNCH ($29.37 Japan) 3rd gear syncro
Genuine Mitsubishi (MR581382) - Assembly:13

SPRING,M/T SYNCH KEY ($3.03 Japan) 3rd gear syncro key
Genuine Mitsubishi (MR581383) - Assembly:14
-------------------------------------------------------------------------
RING,M/T SYNCH ($29.37 Japan) 4rd gear syncro
Genuine Mitsubishi (MR581382) - Assembly:9

SPRING,M/T SYNCH KEY ($3.03 Japan) 4rd gear syncro key
Genuine Mitsubishi (MR581383) - Assembly:10
-------------------------------------------------------------------------

(input shaft bearings)
BEARING,M/T INPUT SHAFT ($20.84 Japan)
Genuine Mitsubishi MD700207 Sub Part(2526A001) - Part Spec:BALL,68 Assembly:18

BEARING,M/T OUTPUT SHAFT ($8.51 Japan) 3rd gear needle roller bearing
Genuine Mitsubishi (MD744538) Part Spec:NEEDLE,59 Assembly:16

BEARING,M/T OUTPUT SHAFT ($9.33 Japan) 4th gear needle roller bearing
Genuine Mitsubishi (MD744537) art Spec:NEEDLE,54 Assembly:7

BEARING,M/T INPUT SHAFT ($17.83 Japan)
Genuine Mitsubishi (MD717670) - Part Spec:BALL,62 Assembly:2

--------------------------------------------------------------------------

Differential bearing
BEARING,RR DIFF CASE ($13.37 Japan) For FR DIFF side/RR DIFF side
Genuine Mitsubishi, Genuine FUSO (MB393957) - Part Spec:TAPER ROLLER,72.00X18.25-35.00[/MD747707

 

I'm curious what the difference is between ordering a rebuild kit vs the parts you have listed. I've looked up some of the part numbers and some sites say they are incompatible with the f5m42. Did all of the parts in your list fit correctly? Also, do you happen to have the part numbers for the seals?

Thanks for any help.