Torque Converter Rebuilders Association November 2010 Issue 2, Volume 9 [email protected] www.tcraonline.com PLATINUM SPONSORS: Monthly publication of TCRA newsletter provided by Melissa Hall T orque converter rebuilders have been reporting an increase in the number of failed ring gears on Mitsubishi Galant converters. Most of the failed ring gears are found on 2006-2008 vehicles equipped with V6 engines, and the failures seem to occur soon after the vehicle’s starter has been replaced. Prior to the ring gear failures, most customers report hearing a noise during startup followed by a starter non-engagement condition. In most vehicles, the starter ring gear is located on the outer diameter of the flex plate; when a ring gear fails, the flex plate must be replaced. On most Mitsubishi Galants, the ring gear is mounted directly on the converter, which makes it more difficult and much more expensive to replace. If the mileage of the vehicle or the appearance of the ATF makes the condition of the transmission questionable, replacing the converter and overhauling the transmission may be a better option than simply replacing the converter. If it is a low-mileage vehicle and the ATF appears to be in good condition, it is possible to replace only the ring gear. Unfortunately, the location of the ring gear on the Galant converters makes it impossible to replace the gear without disassembling the converter. The welds used to secure the ring gear to the cover are too close to the TCC reacting surface to allow the ring gear to be replaced with the converter still assembled. A ring gear typically can be removed from the converter by machining the welds off on a lathe. On some models of the Galant the ring gear is mounted to the outer diameter of the converter cover. On the 2006-2008 Galant, the ring gear is mounted to the front of the cover directly adjacent to the four mounting pads. The close proximity of the ring gear to the mounting pads makes ring gear removal more difficult. On those converters, a milling machine is a better option than machining the welds off on a lathe. If you are only removing one ring gear, you can secure the cover directly to the bed of the milling machine, see below. If you are removing more than one ring gear, you may want to mount your cover to a turntable. To remove the weld, plunge into the weld until the milling bit contacts the ring gear (the ring gear is harder than the weld and has a different feel on the cross feed). Do not force the milling bit into the ring gear. If you do, the bit will quickly become dull. Why did the OEM ring gear fail? While the cause of the ring gear damage is not totally clear, all known failures have been in vehicles with aftermarket replacement starters. The OEM replacement starter cost about $160, so customers often elect to go with an aftermarket starter that is about $40 less. In the short run, these customers did save $40, but in the long-run they also had to pay for the R & R of the converter, the cost of the replacement converter and opted to go back to the OEM replacement starters to prevent a repeat failures. Ed Lee ©2010 Sonnax NEWS BRIEF TCRA member awarded 2010 BBB Integrity Award C ertified Transmission is proud to have received the 2010 BBB Integrity Award. Since 1995 the Better Business Bureau serving Nebraska, South Dakota and southwest Iowa has presented the prestigious BBB Integrity Awards to recognize those firms whose business practices and related activities exemplify the BBB’s mission and principles which include honesty, commitment and accountability. The BBB Integrity Awards recognize companies that go above and beyond in serving their customers and communities. Unlike other awards, the BBB Integrity Awards focus on demonstrated ethical business practices, rather than a company’s growth, profitability or popularity. The BBB Integrity Award applications are not only nomination based. All businesses, organizations and charities located in the BBB’s service area, that have been operating under the same ownership for three years or more, are eligible to apply. Independent panels of judges from the business and academic communities select the award winners. TCRA says ‘goodbye’ to Robert Mock T he TCRA has received word of the recent death of Robert Mock of Mock’s Transmission in Cottage Grove, Oregon. Bob was 64. He is survived by his wife, Carol and two children. Bob was a long time member and supporter of TCRA and he will be missed. A memorial donation has been sent to the American Cancer Society in his name. The business will continue to be run by their son Bob, who has been recently trained in converter rebuilding, in addition to being well trained in transmission rebuilding. Premature Failure Of Mitsubishi Galant Ring Gears The cover can be secured directly to the bed of the milling machine when removing only one ring gear.