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- - AWD project (https://mitsubishiforum.com/forum/mitsubishi-galant-13/awd-project-38850/)

Here are some pics of my all wheel drive conversion project using Magna/Diamate AWD parts which are Evo 7 based from memory.

It is about 6-8 months from completion.

The vehicle is a wreck that is being used as a mock up.

The wrecks cost about 1500 dollars here...for that you get everything, engine, interior,wheels,transmission and all airbags intact.

Turnms out with a front side impact the airbag control looms are the first things that get cut....interesting eh?...:(

(the sensors are either side of the radiator support bar)

The car pictured is the Australian 380 which is the same car as the US 9G Galant with PS41 floor pan.

Enjoy...and feel free to comment.

thanks

straight now
http://img152.imageshack.us/img152/8643/dsc01874q.jpg
http://img834.imageshack.us/img834/8955/dsc01885q.jpg
http://img155.imageshack.us/img155/4263/dsc01886uv.jpg
http://img717.imageshack.us/img717/8528/dsc01906l.jpg
http://img259.imageshack.us/img259/3946/dsc01910a.jpg
http://img340.imageshack.us/img340/5048/dsc01913d.jpg
http://img18.imageshack.us/img18/3460/dsc01915fn.jpg

Getting the auto on while out of the car is a piece of cake...

http://img254.imageshack.us/img254/9885/awdautoisin.jpg

But don't expect the support bar to fit under the much larger diff housing on the AWD...so it needs a love tap or some such,
(am still marinating the brain on whether to just grind it or not.)

http://img405.imageshack.us/img405/7...dsmodifyin.jpg

The other big lump of metal of course needs a rework.
Definitely an engineering job for that...it's steering and all that stuff...beyond my panel beating abilities and clearly safety related, so we'll leave that bit for now and have a few beers.

http://img214.imageshack.us/img214/7...yneedsacut.jpg

Still almost too good to be true so far....
http://img214.imageshack.us/img214/5007/dsc01951cq.jpg
http://img402.imageshack.us/img402/3407/dsc01954z.jpg
http://img574.imageshack.us/img574/6258/dsc01958.jpg
http://img194.imageshack.us/img194/3246/dsc01959om.jpg
It's all in there except for one little important shiny thing...lol.......the steering rack.....
http://img547.imageshack.us/img547/8500/dsc01960st.jpg
Still gotta fabricate some 100mm standoffs to mount the rack...
Was thinking of steel tubes with a dual triangular lean section all welded to the x-member should do the trick..
That...will be an engineering job cause i don't have a clue if the steering geometry would be affected.
http://img33.imageshack.us/img33/9743/dsc01962l.jpg
Start with this perfectly good cross member.......Give it a wash with petrol and wire brush else you'll be cursing all the grease...
http://img547.imageshack.us/img547/796/dsc01968z.jpg
Cut this much out...carefully...
http://img812.imageshack.us/img812/7686/dsc01971f.jpg
Don't cut any of the back section for minimal torsional integrity compromise.
http://img524.imageshack.us/img524/9760/dsc01972k.jpg
then wack it all back on the car for the seventh test fit....
http://img256.imageshack.us/img256/5259/dsc01989l.jpg
Looks like a bum in a bucket after a little bit here and there...
http://img221.imageshack.us/img221/9985/dsc01986w.jpg
rear view final...note no rear metal removal in this err...."advanced" re-design...lol
http://img32.imageshack.us/img32/7176/dsc01985ss.jpg
Got the brother ex Tonsley round for a few beers and here are a few suggestions..
Steering rack needs to be in this position...
http://img508.imageshack.us/img508/5240/dsc02038an.jpg
Make a dual box frame and weld it under the crossmember to firm it up.
overall clearance reduction about 50mm
http://img691.imageshack.us/img691/4842/dsc02039xz.jpg
another view
http://img714.imageshack.us/img714/929/dsc02040f.jpg
add plenty of beer and it will all be good...lol
http://img411.imageshack.us/img411/7740/dsc02042m.jpg
We pulled apart the AWD hubs from the AWD and compared to the 380 rears and surprise surprise surprise.
They are interchangeable! All I have to do is get some basic machining done, relocate the ABS sensor ring and fabricate an adapter to bolt the rear diff in and presto! She'll pop the driveshafts straight in with a hole through the hub...
No suspension or chassis modifications , no brake work needed....even handbrake stays stock.
The 10mm shorter track will be taken up by driveshaft splines....
It's too good to be true....so many potential headaches averted..!
See attached pics...the AWD hub is almost a perfect fit (will just require a thin shim)
The longer I plug at this little project the more I am convinced that Mitsi had planned an AWD 380 right from the floor pan design...
These photos are of the drivers' side rear 380 wheel hub and the 380 hub next to each other on the 380 rear axle arm.
Note no hole through hub for the driveshaft spline ...cause in a 380 it's not driven ...lol
The AWD magna/Diamante uses the ABS sensor on the driveshafts whereas the 380 uses it on the HUB...
hopefully it is just a press fit and will move to the AWD hub without any drama....maybe just some heat and a love tap.
http://img30.imageshack.us/img30/9896/dsc02135bb.jpg
http://img339.imageshack.us/img339/4703/dsc02136al.jpg
http://img151.imageshack.us/img151/5059/dsc02137q.jpg
http://img3.imageshack.us/img3/4264/dsc02138d.jpg

Today's effort...had to do some work to pay a couple of bills...
Somethings missing.....lol
http://img3.imageshack.us/img3/5261/...ankremoved.jpg
There it is....only takes a handful of bolts, about 15 minutes and the whole lot drops to the ground
http://img268.imageshack.us/img268/3540/rearaxle1.jpg
Do I see an obvious hole left for a future upgrade by Mitsubishi?
http://img35.imageshack.us/img35/7035/rearaxle5.jpg
What the hell...I can fit any damn diff I like into this thing, as long as the final drive is correct and the driveshaft lengths are good.
Nah...easier to use the magna/diamante unit ...for now...lol
http://img411.imageshack.us/img411/4...le1editted.jpg

Now can someone please post some pics of the Endeavour undercarriage so I can see about a few bits please?

Bad ass!! Very ambitious.

Looks like the Endeavour PS41 rear axle you guys have in the US will bolt straight onto the 9G galant with very little modification.

Almost worth me hopping on a plane to get one...

Here is what it looks like...

http://img801.imageshack.us/img801/6...orrearaxle.jpg
http://img696.imageshack.us/img696/6...rrearaxle2.jpg
http://img688.imageshack.us/img688/5...rrearaxle3.jpg

The Endeavour rear axle definitely fits straight into a 9G.

here's proof....:)

http://img804.imageshack.us/img804/7...xlemockfit.jpg
Uploaded with ImageShack.us