TMZPerformance

The Stage #1 rebuild is a basic rebuild of the 1990-1999 DSM AWD, Galant VR4 and Mitsubishi Evo 1-3 transfer cases.

The replacement parts are OEM Mitsubishi parts unless stated otherwise:

*New Drive Gear Tapered Roller Bearings
*New Driven Gear Tapered Roller Bearings
*New Input Sleeve Seal
*New Tailshaft Seal
*New Side Cover Bolts
*New Mid Housing Bolts
*New Tail Housing Bolts
*New Shims for Bearing Preload Setup, Gear Backlash Setup, and Proper Gear Mesh
*New Side Cover O-Ring
*New Mid Housing O-Ring
*New Transfer Case Breather Bulb
*New Inspection Plate Fasteners
*New Fill Plug
*New Fill Plug Gasket
*New Magnetic Drain Plug
*New Drain Plug Gasket

*Transfer case is fully degreased, chemically cleaned, bead-blasted, cast iron is epoxy coated and cast aluminum housings are ceramic coated for a brand new look!

*Stage #1 Upgrades and Extra Parts Costs:
*NEW Transfer Case Mounting Bolts (Add $36.00)
*ADD Shot-Peening Services to the transfer case gearset (Add $80.00)

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The Stage #3 transfer case rebuild is a capable setup for handling less than 750 AWHP. This transfer case rebuild adds a machined driven gear with beam welded 300M output shaft, machined tail housing with larger shaft bushing, and uses a larger Sonnax Forged or Spicer Cast 1310-Series 25-Spline yoke designed for usage with the 25-Spline yoke DSS Driveshaft. Shot-Peening services to the gearset, along with setup for proper gear mesh, backlash and bearing preloads. This is a transfer case service, you need to supply a functioning transfer case for the work to be done.

The replacement parts are OEM Mitsubishi parts unless stated otherwise:

*UPGRADED 300M Output Shaft On Factory Gearset, Modified by Liberty Gears
*Machined Tailhousing with Large Bushing and Seal
*Upgraded to use with a 25-Spline 1310-Series Sonnax or Spicer Slip Yoke (Not for use with OEM drive shafts)
*Shot-Peening of Gearset
*Includes NEW Installation Bolts
*New Drive Gear Tapered Roller Bearings
*New Driven Gear Tapered Roller Bearings
*New Input Sleeve Seal
*New Tailshaft Bushing and Output Seal For 25-Spline Slip Yoke
*New Side Cover Bolts
*New Mid Housing Bolts
*New Tail Housing Bolts
*New Shims for Bearing Preload Setup, Gear Backlash Setup, and Proper Gear Mesh
*New Side Cover O-Ring
*New Mid Housing O-Ring
*New Transfer Case Breather Bulb
*New Inspection Plate Fasteners
*New Fill Plug
*New Fill Plug Gasket
*New Magnetic Drain Plug
*New Drain Plug Gasket

*Transfer case is fully degreased, chemically cleaned, bead-blasted, cast iron is epoxy coated and cast aluminum housings are ceramic coated for a brand new look!

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The Stage #4 transfer case rebuild is the most capable setup handling above 750 AWHP. This transfer case rebuild adds a machined driven gear with beam welded 300M output shaft, machined tail housing with larger shaft bushing, and for use with a Sonnax Forged or Spicer Cast 1310-Series 25-Spline yoke designed for usage with the 25-Spline yoke DSS Driveshaft. Shot-Peening services to the gearset, and the Frontline Fabrication billet aluminum machined transfer case brace, along with setup, clearancing, and associated fasteners for installation. This transfer case brace DOES NOT FIT 1990-1991 transfer cases that are either completely cast aluminum (1990-style) or units that do not have additional mounting bolt holes in the mid-housing or tail-housing (1991 models).

The replacement parts are OEM Mitsubishi parts unless stated otherwise:

*UPGRADED 300M Output Shaft On Factory Gearset, Modified by Liberty Gears
*Machined Tailhousing with Large Bushing and Seal
*Upgraded to use a 25-Spline 1310-Series Sonnax or Spicer Slip Yoke (Not for use with OEM drive shafts)
*Frontline Fabrication Billet Aluminum Machined Transfer Case Brace

*Shot-Peening of Gearset
*Includes NEW Installation Bolts
*New Drive Gear Tapered Roller Bearings
*New Driven Gear Tapered Roller Bearings
*New Input Sleeve Seal
*New Tailshaft Bushing and Output Seal For 25-Spline Slip Yoke
*New Side Cover Bolts
*New Mid Housing Bolts
*New Tail Housing Bolts
*New Shims for Bearing Preload Setup, Gear Backlash Setup, and Proper Gear Mesh
*New Side Cover O-Ring
*New Mid Housing O-Ring
*New Transfer Case Breather Bulb
*New Inspection Plate Fasteners
*New Fill Plug
*New Fill Plug Gasket
*New Magnetic Drain Plug
*New Drain Plug Gasket

*Transfer case is fully degreased, chemically cleaned, bead-blasted, cast iron is epoxy coated and cast aluminum housings are ceramic coated for a brand new look!

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The Stage #5 transfer case rebuild options are a capable setup handling above 750 AWHP. This transfer case rebuild adds a machined driven gear with beam welded 300M output shaft, machined tail housing with larger shaft bushing for use with the 25-Spline yoke DSS Driveshaft. Shot-Peening services to the gearset, along with setup for proper gear mesh, backlash and bearing preloads.

This is a transfer case service, you need to supply a good functioning transfer case for the work to be done on your gearset and with good front housing and tail housing. This option has the Frontline Fabrication billet aluminum machined transfer case brace installed with the Boostin Performance billet aluminum machined mid-housing, along with setup, clearancing, and associated fasteners for installation. This transfer case brace DOES NOT FIT 1990-1991 transfer cases that have the cast aluminum front housing.

The replacement parts are OEM Mitsubishi parts unless stated otherwise:

*UPGRADED 300M Output Shaft On Factory Gearset, Modified by Liberty Gears
*Machined Tailhousing with Large Bushing and Seal
*Upgraded to use a 25-Spline 1310-Series Sonnax or Spicer Slip Yoke (Not for use with OEM drive shafts)
*Frontline Fabrication Billet Aluminum Machined Transfer Case Brace

*Boostin Performance Billet Aluminum Machined Transfer Case Mid Housing
*Shot-Peening of Gearset
*Includes NEW Installation Bolts With Longer XXL Bolts Needed for Brace
*New Drive Gear Tapered Roller Bearings
*New Driven Gear Tapered Roller Bearings
*New Input Sleeve Seal
*New Tailshaft Bushing and Output Seal For 25-Spline Slip Yoke
*New Front Housing Bolts
*New Mid Housing Bolts
*New Tail Housing Bolts
*New Shims for Bearing Preload Setup, Gear Backlash Setup, and Proper Gear Mesh
*New Side Cover O-Ring
*New Mid Housing O-Ring
*New Transfer Case Breather Bulb
*New Inspection Plate Fasteners
*New Inspection Plate Gasket
*New Fill Plug
*New Fill Plug Gasket
*New Magnetic Drain Plug
*New Drain Plug Gasket

*Transfer case is fully degreased, chemically cleaned, bead-blasted, cast iron is epoxy coated and cast aluminum housings are ceramic coated for a brand new look!

OPTIONS:

Add Magnus Motorsports Billet Front Housing - $1630.00 (part plus s/h)

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The Stage #6 aka "Stage Eleventy Billion" transfer case rebuild option is the highest we go, with it capable of bottom 7 Second 1/4 mile passes, and all the power.   This transfer case rebuild uses a completely new billet gearset from Magnus Motorsports Fall 2026, coupled with the Magnus Motorsports billet front housing and Boostin Performance billet mid housing, and your machined tail housing with larger shaft bushing for use with the 25-Spline yoke DSS Driveshaft.  Your input sleeve is bead blasted and assembled with the Magnus gearset, along with setup for proper gear mesh, backlash and bearing preloads.  This gearset takes considerably longer to set up than the standard ones so labor cost is higher.  This is a transfer case service, you still need to supply a good functioning transfer case for the work to be done using your good input sleeve and tail housing. The replacement parts are OEM Mitsubishi parts unless stated otherwise:

*UPGRADED Magnus Billet Gearset – 1.090 ratio only - Fall 2026 new batch design / manufacturer
*Machined Tailhousing with Large Bushing and Seal
*For use with 25-Spline 1310-Series Sonnax Forged Slip Yoke (Not for use with OEM drive shafts)
*Magnus Billet Front Housing and Billet Side Cover, Post Machined for O-Ring and Increased Pocket Depth

*Boostin Performance Billet Aluminum Machined Transfer Case Mid Housing
*New Drive Gear Tapered Roller Bearings
*New Driven Gear Tapered Roller Bearings
*New Input Sleeve Seal
*New Tailshaft Seal for Machined Tail Housing and Larger Slip Yoke
*New Shaft Nut
*New Front Housing Bolts
*New Mid Housing Bolts
*New Tail Housing Bolts
*New Shims for Bearing Preload Setup, Gear Backlash Setup, and Proper Gear Mesh
*New Mid Housing O-Ring
*New Transfer Case Breather Bulb
*New Fill Plug
*New Fill Plug Gasket
*New Magnetic Drain Plug
*New Drain Plug Gasket

*Transfer case tail housing is fully degreased, chemically cleaned, bead-blasted, machined for larger bushing and seal, and cast aluminum housings are ceramic coated for a brand new look!

The Stage #6 aka "Stage Eleventy Billion" transfer case rebuild option is the highest we go, with it capable of bottom 7 Second 1/4 mile passes, and all the power.   This transfer case rebuild uses a completely new billet gearset from Magnus Motorsports, manufactured by Brena Corse, coupled with the Magnus Motorsports billet front housing and Boostin Performance billet mid housing, and your machined tail housing with larger shaft bushing for use with the 25-Spline yoke DSS Driveshaft.  Your input sleeve is bead blasted and assembled with the Brena gearset, along with setup for proper gear mesh, backlash and bearing preloads.  This gearset takes considerably longer to set up than the standard ones so labor cost is higher.  This is a transfer case service, you still need to supply a good functioning transfer case for the work to be done using your good input sleeve and tail housing. The replacement parts are OEM Mitsubishi parts unless stated otherwise:

*UPGRADED Magnus / Brena Billet Gearset – 1.090 ratio only
*Machined Tailhousing with Large Bushing and Seal
*For use with 25-Spline 1310-Series Sonnax Forged or Spicer Cast Slip Yoke (Not for use with OEM drive shafts)
*Magnus Billet Front Housing and Billet Side Cover, Post Machined for O-Ring and Increased Pocket Depth

*Boostin Performance Billet Aluminum Machined Transfer Case Mid Housing
*New Drive Gear Tapered Roller Bearings
*New Driven Gear Tapered Roller Bearings
*New Input Sleeve Seal
*New Tailshaft Seal for Machined Tail Housing and Larger Slip Yoke
*New Shaft Nut
*New Front Housing Bolts
*New Mid Housing Bolts
*New Tail Housing Bolts
*New Shims for Bearing Preload Setup, Gear Backlash Setup, and Proper Gear Mesh
*New Mid Housing O-Ring
*New Transfer Case Breather Bulb
*New Fill Plug
*New Fill Plug Gasket
*New Magnetic Drain Plug
*New Drain Plug Gasket

*Transfer case tail housing is fully degreased, chemically cleaned, bead-blasted, machined for larger bushing and seal, and cast aluminum housings are ceramic coated for a brand new look!