4g63t / AWD 7g Build

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Originally Posted by the_boogiman

Definitely an awesome job on the conversion. Massive props. Not the first though. There's myself and I've heard of one more somewhere.

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That's cool. I'm just happy to have done it :thumb: I'm curious how you handled the conversion. What did you do for the drive shaft(s)?

I got the new rear calipers in last night, stuck my speed bleeders in and bled 'em out. After that I had a little brake fluid under the front tires so I had to move the car... around the subdivision a couple times :bouncy: (Private roads so no tags = ok). So first impresssions = totally awesome. The exhaust is a little louder than I'm after but very deep. I couldn't really get on it since I haven't been able to tune yet. I could build a couple psi and then it'd buck on me. I'll ditch my old maps as soon as I get it street legal and start tuning.

Oh, I also double checked the exhaust to drive shaft clearance. I should be good. If I really smacked the driver's side of the exhaust right by the center flange I could make it tap the drive shaft but it stayed clear with firm nudges. I'll keep checking it regularly though just to be sure.

Awsome work!!! I am very jealous of your car. Keep up the good work and post another vid once its on the road

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Originally Posted by the_boogiman

Definitely an awesome job on the conversion. Massive props. Not the first though. There's myself and I've heard of one more somewhere.

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he's the first as far as i'm concerned. As i don't recall you ever posting pics.

hahaha i agree with john. I thought he was the first this whole time though. i know a couple people have tried but haven't finished it.

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Originally Posted by the_boogiman

Definitely an awesome job on the conversion. Massive props. Not the first though. There's myself and I've heard of one more somewhere.

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ur AWD? why you no post? pics! vids!

Very Nice to see you pull it off eclipsh... I wonder how wide you can go with rims ... I would luv to see some beefy tire setup on a 7g, or something with a deeeep lip....

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Originally Posted by phizzalot

Very Nice to see you pull it off eclipsh... I wonder how wide you can go with rims ... I would luv to see some beefy tire setup on a 7g, or something with a deeeep lip....

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Thanks :) Right now I've got my summer wheels on, Evo 8 Enkie's with 245/40-17 Kumho SPT rubber. There is very little in the way of clearance for them and they are as wide as I'd want to go. I went too far towards track car with my 1g and made it so my wife didn't like riding in it (and never made it to a road course, just auto-x!) I need to strike more of a balance on this project and just make a fast street car which also includes not running super-wide, low-profile tires.

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Originally Posted by eclipsh

Thanks :) Right now I've got my summer wheels on, Evo 8 Enkie's with 245/40-17 Kumho SPT rubber. There is very little in the way of clearance for them and they are as wide as I'd want to go. I went too far towards track car with my 1g and made it so my wife didn't like riding in it (and never made it to a road course, just auto-x!) I need to strike more of a balance on this project and just make a fast street car which also includes not running super-wide, low-profile tires.

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NICE on the 245. I'm running evo9 enkie with 235/40/17 Goodyear Eagle F1, and I LOOOOOOOOVE the grip. Never felt so confident with my handling, and the ride is the best its ever been.

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Originally Posted by DOHCstunr

NICE on the 245. I'm running evo9 enkie with 235/40/17 Goodyear Eagle F1, and I LOOOOOOOOVE the grip. Never felt so confident with my handling, and the ride is the best its ever been.

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It is all about wearing the right shoes. :rockon: My stock 1g swirlies have a set of 205/55-16 Nitto SN1 snow tires that are amazing in the winter too. Can you say doughnuts? ;) That'll be an interesting experience with the longer wheel base and new suspension geometries. I'm very excited to see how it really handles.

Very nice... Ive been thru the Yokohama Advan235/40/17, Sumitohmo 235/40/r17, and currently Continental Contact Pro 245/40/r17 on my Evo9, and each have a different feel and driving experience to them.

I'am sure the the wider rubber on your awd 7g will truly bring out the power and response of the swap and motor...

I've got some 205/40/17 on my 7g now, which are a nice change from my previous sunflower chromez lol..

I think i will be in the market for some awd parts after hearing your satisfaction of the swap... Can't wait for some rolling pics or vids...

It's been a while, time for some updates.

This morning I finally finished repairing my fuel pump sending unit which the previous owner cut off. I ended up cutting the sender off the Galant unit and using a 5/16 double compression fitting from the hardware store to splice them together. At idle there are no leaks so I think I'm good to go on that front.

After that I got around to cutting the plastic bumper up a bit so it would fit around the FMIC and then attached the bumper cover and installed the whole set. It is still fugly and missing the lower section of the bumper cover but it is on there and I have at least some crash protection.

Right now I'm taking a lunch break, drinking a beer and a nice man in my garage is putting a new windshield into the Galant. He just called me out to tell me there was a minor defect in the glass. Turns out it is two tiny dots in the tinted section at the top. They offered to get a perfect one or knock $50 off the price. I chose the latter.

I have a set of prothane bushings for the rear end headed my way as well as a new JAW 1.041 unit. My 1.04 bit the dust and won't talk to my computer. On the plus side the 1.041 will come with a third display for me and the option of incorporating an EGT sensor. I'll need to add some wires to the harness again but it'll be worth it. I'm just not sure where I'll add the third display at this point.

Aside from that, most of the interior is back in and cleaned. I still need to take a steam cleaner to the seats but I already hit the carpet with some cleaner and a scrub brush. Not quite good as new but clean enough for me.

I have a few wiring issues that still have to be resolved. I don't have the fans connected yet and for some reason my tach isn't working with the rewire I did. Of course my priority is the fans. DOHCStunr if you can recall how you wired yours I'd love to copy you. Otherwise I'm going to pick up a 1g radiator temp sensor and plumb it into the system to trigger the fans.

That is it for now. I'll be sure to post up more as the project comes closer to hitting the road. Thanks again for reading and for all your support.

Does the 1g radiator fit our cars or the lower mounts need to be relocated?

as for the Tach, Seth98est had this exact same problem and to be honest I don't think he ever corrected it.

I believe it has something to do with the difference between distributor and distributorless.

My car is a GS and originally it already had distributorless ignition. I never had to add or change any of the wires for the coil packs/transistor pack.
My tach worked from day one.

Perhaps the instrument cluster between the GS and the rest are different, maybe due to an inverted signal, idk.



I had problems with my Speedometer for years not working, eventually I fixed it lol. If you have any issues with that, just let me know.

http://www.vfaq.com/mods/wayback/2gcoolingfan.html
I essentially took this idea and modified it to use the 1g coolant temp switch to ground the radiator high circuit(instead of a toggle switch to bridge the connections)
I see no point in using the radiator low. and have never overheated as a result of this mod.

I pulled out to spin the car around for room to work on bushings and noticed the speedo isn't working. What'd you do to fix it?

I should get my 1g fan switch in at the Zone today. I'll find a place to plumb it in and get that working on my next day off.

Well I've replaced the left rear knuckle bushing that was blown out with a new urethane one. Definitely a PITA to install. I think I'll wait on the rest. I've got my fan switch. Unfortunately it is a metric 14x1.5 thread and I don't have a tap that size nor did the hardware store. I'll have to run around and see if I can find one after I figure out how I'm installing the sensor.

Tomorrow is the big day for getting my salvage title. I'll be trailering the car down across the border to New Mexico where I bought it, weighing it and then sitting in their sorry-excuse-for-a-DMV for hours. Wish me luck.

No tach here either. I've tried some different ideas, even went and got a tach out of a 1g to see what the difference was. I'm sure it does have something to do with the signal being inverted. Plus the way the back side of the gauge cluster runs wires. I was trying to mess with that and took out the ground screw of the tach. Now i get the tach to sit at 1000 rpms and not move at all, but everynow and then it'll shoot down past 0!

Good luck at the DMV, i do know it's usually better to go at the beginning of a month, rather than the end with all the procrastonators

If I have time today I may pull my gauge cluster and see if I can modify the setup enough to get the 2g DSM electronics into it. I looked into it before and they were pretty different but I hadn't really looked at hybridizing them. I'll be sure to post up my results.

I pulled the guage cluster and there is no way the two will ever be compatible. I'll have to see what I can work out to get the ones I have functioning.

I also took the car down to the New Mexico DMV today. Man are they awful! I won't bore you with details just know they suck more balls than a porn star and not in a fun way.

I also got to weigh the Galant. As it sits with 1/4 tank of gas it comes in at 3120 lbs. That is less than the Talon I used as a donor and no weight loss program.

Thanks to the idiots at the DMV, who have no clue what customer service is, I don't have the salvage title yet. I'll have a few more hoops to jump through before that is done.

I still have a few other things on my to-do list. So far:

Get gauges working
Find out why the TPS is reading 12%-8x% rather than 10-100 and fix it.
Build new WBO2 controller and get it in.
Get a shift boot and surround.
Get radiator fans working.
I did take a buddy out for a spin and showed it off at the salvage yard where I bought it. They were definitely liking the conversion and impressed that almost all of it was done in my garage.

I am also thinking I need to make a new exhaust sooner rather than later. I heard an odd rubbing sound going around a corner tonight and suspect it may have been the drive shaft and exhaust meeting. I think things might shift around enough that they can touch. I think 2.5" through the tunnel and reusing the 3" bends to a good muffler will be the way to go. As always I'll keep you updated.

Very nice.. I think the weight is surprising, Mainly becasue a quick google puts a 7th Gen around 3980 lbs. An evo9 is around 2,888–3,285 lb.. I wonder how much weight can be removed ie rear bumper bar/spare tire/rear seats/ac..

Nice work eclipsh, what type of showing of did you do? launches? 360's? or a myabe a quick burnout? Just wanted to hear about what this setup is going thru so far :)

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Originally Posted by phizzalot

Very nice.. I think the weight is surprising, Mainly becasue a quick google puts a 7th Gen around 3980 lbs. An evo9 is around 2,888–3,285 lb.. I wonder how much weight can be removed ie rear bumper bar/spare tire/rear seats/ac..

Nice work eclipsh, what type of showing of did you do? launches? 360's? or a myabe a quick burnout? Just wanted to hear about what this setup is going thru so far :)

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Uh... 2755 lbs actually. But 3980 was close ;) http://consumerguideauto.howstuffwor...i-galant-8.htm

So about a 400lb weight gain. I'd say it is worth the trade. Oh and that was with the spair in too.

For the showing I just showed the salvage guys while it was on the trailer and fired it up. For my buddy just some basic laps around the subdivision. It isn't tuned enough for burnouts yet ;)

I had my 98 FWD w/4g63t swap weighed at a truck stop once and it pushed the scales at about 31xxlbs if I remember correctly.

Just for reference a 7G VR4 weighs at 3315lb... With the complications of 4WS is the most likely reason for the weight increase from ur conversion. the 6A motor is only heavier than the 4G by a feather.

Got the TPS issue more or less resolved this morning. Turned out the stop under the gas pedal was the problem. I cut the section off that rises up above the carpet and now I see 12%-98% throttle. I'm still missing 4% but even without the cable moving the throttle I get those readings so it is probably the sensor at that point.

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Originally Posted by eclipsh

Got the TPS issue more or less resolved this morning. Turned out the stop under the gas pedal was the problem. I cut the section off that rises up above the carpet and now I see 12%-98% throttle. I'm still missing 4% but even without the cable moving the throttle I get those readings so it is probably the sensor at that point.

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just an FYI the 2g non cruise cable will work

If I can I plan to use the cruise since this is going to be my family's road trip car.

On a completely different note, the Colorado DMV once again proved themselves better organized than the NM DMV. I gave them a call this morning to see if I could get temp tags for the Galant. After listening to my situation they sold me a set of 60 day tags for $6.20. So the Galant made it's first debut on public streets this afternoon. It definitely needs some tuning as the car was running pretty lean. In the mean time I'm poking around and working on getting the speedometer functional. I have confirmed that I have a good connection between the sending unit and the gauge cluster as well as a good connection within the cluster. Oddly enough I'm seeing a steady 4.5v going to the speedo. I am off to do some more diagnostics now. DOHCStunr did give me some advice as to what may be wrong but I'm going to dig around a bit before hacking at my wiring. Wish me luck!

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Originally Posted by eclipsh

If I can I plan to use the cruise since this is going to be my family's road trip car.

On a completely different note, the Colorado DMV once again proved themselves better organized than the NM DMV. I gave them a call this morning to see if I could get temp tags for the Galant. After listening to my situation they sold me a set of 60 day tags for $6.20. So the Galant made it's first debut on public streets this afternoon. It definitely needs some tuning as the car was running pretty lean. In the mean time I'm poking around and working on getting the speedometer functional. I have confirmed that I have a good connection between the sending unit and the gauge cluster as well as a good connection within the cluster. Oddly enough I'm seeing a steady 4.5v going to the speedo. I am off to do some more diagnostics now. DOHCStunr did give me some advice as to what may be wrong but I'm going to dig around a bit before hacking at my wiring. Wish me luck!

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remember, the speedo is all about frequency, not voltage.

if you moved the speedo half a tic forward there wouldn't be any voltage i imagine.

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Originally Posted by DOHCstunr

remember, the speedo is all about frequency, not voltage.

if you moved the speedo half a tic forward there wouldn't be any voltage i imagine.

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In fact you were right. I went through all the diagnostics for a 2g DSM speedo system and checked everything. I also switched back to the M/T speedo sensor from the Talon. After doing some diagnostics and confirming that everything was working ok I gave up for the day and drove to work. That is when the speedo randomly started working. It was very jerky and slow to respond though. So this morning I pulled the speedo plug off the tranny and looked at the connection. The tongues inside each of the connectors were pretty depressed so I pulled them out of the harness and bent the tongues back out to make better contact. I'll see if that resolves the problem.

I was in contact with Alan To regarding my bad JAW 1.041 unit. I shipped it back to him on Monday and will get a new kit sent to me when he gets mine.

I also have a set of Koni Sport shocks and Ground Control coilovers on their way. I found a complete set used on DSM Tuners. They have the hats and everything. It is exactly what I was after, a $1k+ suspension slightly used for $450 shipped. Right now the rear tires are rubbing the fenders on big bumps due to the FWD shocks in the rear lowering it slightly. It'll be good to get it raised back up to factory height and get my alignment done too.

I'm still waiting to be able to tune but I've been driving the car around for a while. I am absolutely loving it. All the work was definitely worth while. I can't wait to get it tuned, get the new suspension under it and really let loose.

[QUOTE=eclipsh;525145]

I also have a set of Koni Sport shocks and Ground Control coilovers on their way. I found a complete set used on DSM Tuners. They have the hats and everything. It is exactly what I was after, a $1k+ suspension slightly used for $450 shipped.
[QUOTE=eclipsh;525145]


That is a killer deal on that suspension setup. Koni and Eibach make a great pair on our cars. A buddy of mine had a 94 GS with Koni and Eibach Sport springs. It rode like a dream!

You have done a great job on this man. Glad to see the DMV gave you a break, I have had my share of fun wth them and have yet to deal with them on my Galant.

It would be really cool if you, Ivory8G and myself could all meet up somewhere in the middle for some fun...I'll be dead last of course lol.

Took the car down to an Albuquerque DSM club meet this weekend and drove up Sandia Crest road with the guys. The Koni's were great and the car handled wonderfully. I did have some overheating issues though. I don't have a problem normally so I suspect it was just the heat and long climb. With the car tuned in right and a little duct work I think that'll disappear.

A few other kinks: my A/C doesn't work right yet. I need to rewire the system as the dash button doesn't trip the A/C clutch right now. When I ran a jumper cable to the clutch the lines didn't cool down so I think it needs to be charged too. Just one more wiring project to tackle. Should've just gone with the 2g harness and an Evo ECU but I'll make it work.

That sounds great eclipsh...If I find a good deal on some rear parts I may not be able to stop myself from buying them, now that I see yours up and running :)

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Originally Posted by phizzalot

That sounds great eclipsh...If I find a good deal on some rear parts I may not be able to stop myself from buying them, now that I see yours up and running :)

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X2

my buddy has a 95 shell hell give me for 400 with the whole rear end but im broke, but no1 wants it so i think next spring this will be my next endeavor

I've had a few requests for the wiring I used. Here's what I've got for notes:

1g ECU : Galant ECU

101 : 13
102 : 12
103 : 60
104 : 26
105 : Custom or N/A (Wastegate Solenoid)
106 : 26
107 : 25
108 : 51
109 : Custom (Tach) - Never got this working

51 : 1
52 : 14
53 : 6
54 : Custom - coil pack
55 : Custom - coil pack
56 : 8
57 : Didn't use = Fuel solenoid
58 : 4
59 : 17
60 : 2
61 : 15
62 : 9
63 : ? (MPI - didn't write this down, sorry)
64 : 36
65 : 22
66 : ? MPI
67 : 18
68 : 5

1 : 42
2 : 43
3 : N/A
4 : Custom (O2 Sensor)
5 : 37
6 : 19
7 : 45
8 : 52
9 : Custom - knock sensor
10 : 70
11 : N/A - ABS on 1g ECU
12 : 34
13 : Didn't write down, fuel pump
14 : 67
15 : 53
16 : 65
17 : 72
18 : 66
19 : TPS - custom
20 : 63
21 : Custom - CAS
22 : Custom - TDC
23 : 61
24 : 72

Of course this will only work with OBD 1 7G and 1g turbo ECU's.

Well I got the tach in the Galant working today. I decided I want to use the LED displays from the JAW as a HUD unit (mirror off the windshield). I gave using the tach out of the Turbo DSM another shot and it works. I must have had some wires backwards last time. So I combined the face plate from the Galant cluster with the electronics of the Talon tach. The bolt holes on the rear of the gauge cluster are not the same for the electronics so I had to custom mount the electronics and then run jumper wires to the correct holes. I used the face plate (#'s) off the Galant too. I double checked the RPMs on the Tach VS my logger and it is dead on. The redline is different but it works :)

post up some pics of that cluster. HUD unit in a g would be interesting.

Wow, been a while. I haven't put any work into the HUD system, I've been too busy with school and work this fall. Last Friday I had a surprise while my wife and I were heading home from my parent's house. Something seized with a horrible metallic screech while I was going 65mph. I dove for the side of the road and killed the engine. After digging through my glove box for a flashlight I ducked my head under the car to see if I still had a drive shaft and to look for puddles. Everything looked normal. Thinking that it might be the engine I grabbed a wrench from the trunk and pulled my timing belt cover. The belt looked fine. A quick crank of the ignition and the engine fired right up, happy as could be. I gingerly put the car in reverse and backed further off the highway, turned the heater back on and called my parents to come pick us up.

The next morning I drove the pickup my parents had lent us the night before down to Uhaul to get a car transport. A few hours later the Galant was up on stands in my garage. I started out with draining the rear diff since memory indicated the noise had come from that direction. No shrapnel and plenty of fluid. From there I moved up to the transfer case. The drain plug was wet. I pulled it out and watched as a slow trickle of oil fell into my drain pan. A few seconds later something heavy thunked it's way into the pan. Turns out the plug never got tightened up all the way or worked its way out and let all the oil go. My transfer case was toast.

Thankfully I got a spare when I swapped my 1g DSM for the 2g donor so I set about pulling the transfer case out and installing the new one. While I had the g up on stands with the exhaust and drive shaft out I spent some time bending the heat shields further out of the way and grinding the center flange on the exhaust down. The result is that I now have a bit more clearance in the tunnel.

http://i290.photobucket.com/albums/l...arstuff025.jpg

Turns out it was probably a good thing the t-case went. As I was poking around I also found that both front wheel bearings and a couple ball joints were in bad shape. In my rush to get the car build I didn't realize the condition they were in. I'd seen a torn boot but forgot to check for play. It was bad enough I decided not to drive the car until everything was replaced.

I decided I'd give Mitsubishi a call to see if I could have the ball joint recall performed on my g. As it turns out the Galant had the ball joint recall service back in '01 so I was out of luck. However, when I built the car this spring I switched the knuckles and control arms from the Talon to the Galant and vice versa so I could keep my 5 lug hubs and wheels. I decided to go check my donor Talon and see how the ball joints on it were. They were in great shape, just one little nick in a dust boot that doesn't go all the way through. So I pulled the knuckles/arms off the Talon and with a few blows from a 3lb hammer knocked the hubs out. I should have my new hubs any day now and will put the front end of my car back together as soon as they show up.

I should also mention that the drive shaft held up great as did the custom mount. I couldn't see any signs of damage to either one.

Im glad to hear that it wasnt any major damage!!!! I would love to eventually pull this off. Your build thread made this seem very easy. IYO how difficult was this build? Also you should make some videos of you driving inside the car and also a vid of you driving down the street with the camera outside the car!!!

how the hell did I miss this build?

good work! sucks about the diff. but at least you had a spare

Sprinkle a little DSM pixie dust on a 7g and boom you lose a transfer case. Oh well, at least it was a simple fix.

Yeah i was under my car a while back and just took out the heat shields all together. I didn't really see a point in keeping them.

Needs more pics! lol.

Man im so intersted in this its not even funny.. I wish the JY had a donor 2g AWD!