Whoohoo! The axles are shipping this week! Finally!
I spent the last week and a half working on the wiring and I'm almost done. I have a hangup trying to determine how the transfer case 'range detection switch' works as the FSMs seem to contradict themselves, but hopefully I'll be able to figure that out tomorrow.
I got the wiring diagram for the old 2000 PCS TCM translated to the new 2800 and cross referenced to the Winters shifter and Sport's PCM. I stumbled across a PCS-2000 wiring diagram for the old European AW3 from the Eclipse which helped a LOT. Other than cross referencing a about 40 wires and one call to tech support to clear up the wiring on the transmission output sensor, it was pretty painless. Very time consuming but painless.
(The PCS diagram was for the old AW3 with a reed switch, rather than the magnetic A/C sensor that the newer Jeeps, Mitsus and Toys used. The reed switch needs a +5v pull-up where the magnetic sensor doesn't. Which I already knew but had forgotten. Doh!)
The Toy A340E and the Mitsu Turbo AW3 use a line pressure solenoid instead of the mechanical 'throttle cable' setup to regulate transmission line pressure. The line pressure 'throttle cable' is the cable visible on the DR side of the transmission in earlier transmission pictures. It is -- NOT -- a 'kick down' cable as is erroneously reported in numerous threads on the internet.
Having a mechanical line pressure 'regulator' is a good thing and a bad thing. If like me you are replacing the TCM and have to program a new TCM, not having to figure out line pressure is a huge plus. That's where 99% of the issues come in - and also where you're most likely to trash a transmission, I am told. The three remaining AW3 solenoids are not 'linear', they're strictly on/off - there's no position(s) in the middle like newer transmissions. The FSMs contain detailed shift and TC charts and information so its very clear how to program the tables for the three solenoids.
The downside to having the mechanical throttle cable setup is that the 3.5L throttle bodies don't have the second attachment point for the transmission throttle cable. The 97-99 3.0L throttle bodies do, but they are not quite the same animals. After spending several days researching this, I've come up with some possible avenues -
1) Install the cruise control box from the old style cruise with the separate vacuum control. This is basically the box on the '97 Sport bolted to the firewall that all the cables run into. Run the cable from the pedal and the throttle cable into the box and the accelerator cable out the box to the TB. The same way it worked originally.
2) Change TB from the 3.5L to the 3.0L. I know they'll bolt up because I have a 3.0L TB on a '02 3.5L manifold and it works peachy. I just don't know if the IAC will work. I seem to remember that the two IACs are not the same. But, if the plugs and electronics are the same, this would be the simplest solution. All that would be required is a 3.0L accelerator bracket or to fab up a bracket.
3) Figure out how to put the second cable attachment on the 3.5L TB. I'm waiting for a new generation 3.0L TB with the cruise built onto the TB to see if this is even remotely possible. The TB comes with both attachment points but ... there are a lot of 'buts' in this possibility.
I'm keeping my fingers crossed for #2.
I was really impressed with PCS' tech support. Very helpful. This is unfortunately going to be a one-off thing, though. PCS kindly informed me that I shouldn't have even been able to buy their controller. Apparently, they don't sell their controller if they don't have a CAL file for the TCM. I ended up with mine because of an error on the part of one of their sales channels. I'm not going to go there right now, but once I get this all working satisfactorily, I'm gong to see if I can pester them into selling me a spare for emergencies.
Anyway, the axles should be here late this week or early next. Then its time to drop everything at the shop and get started.