DSM Transfer Case Staged Rebuilds:

All rebuild pricing below reflects the cost of labor and parts only.  All shipping costs are additional.  WI sales tax rate is 5.1% for in-state sales.  Return shipping costs typically are $40.00-$50.00 for insured FedEx Ground shipping, packaging and materials.  If you are interested in only purchasing the parts listed in each staged rebuild and doing the transfer case rebuild yourself, subtract $125.00 from the staged rebuild price for the parts cost.  If you do not have a transfer case to send in, core transfer cases are $200.00 extra fee if cores are in stock.  All shipping costs are additional, and WI in-state sales are subject to 5.1% sales tax.  All Paypal or Credit Card purchases have an additional 3% fee to the total shipped price to cover associated costs of the service.  International Paypal transactions are 4% to the total shipped price!

Stage #1 Transfer Case Rebuild

Stage #1 Transfer Case Rebuild:                              $715.00

DSM Tcase 1

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 Shaft Nut
*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 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!

*Stage #1 Upgrades and Extra Parts Costs:
*NEW Transfer Case Mounting Bolts (Add $27.00)
*ADD Shot-Peening Services to the transfer case gearset (Add $50.00)

Stage #2 Transfer Case Rebuild w/ Frontline Fabrication Case Brace

Stage #2 Transfer Case Rebuild:                            $1,275.00

DSM Stage 2 Tcase 1

The Stage #2 transfer case rebuild adds 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:

*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 Seal
*New Shaft Nut
*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 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!

Stage #3 300M Transfer Case Rebuild

Stage #3 300M Transfer Case Rebuild:                              $1450.00

DSM Stage 3 Tcase 1

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 a Spicer 1310-Series 25-Spline yoke designed for usage with the Drive Shaft Shop (DSS Product Page Link Here) 950HP Heavy-Duty Driveshafts. 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
*Machined Tailhousing with Large Bushing and Seal
*Upgraded 25-Spline 1310-Series 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 Seal
*New Shaft Nut
*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 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!

Stage #4 300M Transfer Case Rebuild w/ Magnus Brace

Stage #4 300M Transfer Case Rebuild w/ Magnus Billet Side Cover:     $1700.00

DSM Stage 4 Tcase 2

The Stage #4 transfer case rebuild options are 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 a Spicer 1310-Series 25-Spline yoke designed for usage with the Drive Shaft Shop (DSS Product Page Link Here) 950HP Heavy-Duty Driveshafts. 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. This option has the Magnus Motorsports billet aluminum machined transfer case bearing side cover installed, 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).

The replacement parts are OEM Mitsubishi parts unless stated otherwise:

*UPGRADED 300M Output Shaft
*Machined Tailhousing with Large Bushing and Seal
*Upgraded 25-Spline 1310-Series Spicer Slip Yoke (Not for use with OEM drive shafts)
*Magnus Motorsports Billet Aluminum Machined Transfer Case Bearing Cap
*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 Seal
*New Shaft Nut
*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 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!

Stage #4 300M Transfer Case Rebuild w/ Frontline Fabrication Case Brace

Stage #4 300M Transfer Case Rebuild w/ Frontline Fabrication Billet TCase Brace:     $1950.00

DSM Stage 4 Tcase 1

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 a Spicer 1310-Series 25-Spline yoke designed for usage with the Drive Shaft Shop (DSS Product Page Link Here) 950HP Heavy-Duty Driveshafts. 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
*Machined Tailhousing with Large Bushing and Seal
*Upgraded 25-Spline 1310-Series 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 Seal
*New Shaft Nut
*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 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!

Stage #5 300M Transfer Case Rebuild w/ Boostin Billet Mid Housing and Frontline Fabrication Billet Brace

Stage #5 300M Transfer Case Rebuild w/ Billet Mid Housing and Frontline Fab Brace:     $2600.00

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. Drive Shaft Shop (DSS Product Page Link Here) 950HP Heavy-Duty Driveshafts. 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 25-Spline Output Shaft
*Machined Tailhousing with Large Bushing and Seal
*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 Seal
*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 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!

Stage #6 Billet Brena / Magnus Gearset w/ Billet Magnus Front Housing and Billet Boostin Mid Housing Transfer Case Rebuild

Stage #6 Billet Gearset Transfer Case build w/ Billet Front Housing and Billet Mid Housing:     $6045.00

The Stage #6 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. Drive Shaft Shop (DSS Product Page Link Here) 950HP Heavy-Duty Driveshafts. 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
*Upgraded 25-Spline 1310-Series 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
*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!

 

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