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Phizinza wrote:Ok, I'd say the other part was damaged by being squished because of no shim/gasket. Or because of bring forced out of alignment from having a broken shim/gasket.

Well I will assume that and get the new synchro whenever I can find one and hope it works.

Phizinza wrote:If you have micrometers, measure the ring, tighten them, then turn the ring around while in the micrometers. If they go loose or tight at any point its a fair call to say its deformed/warped.

Just did that and it is as round as it can be.

How I did it, and the guide Rcr used I believe http://offroadingsubarus.com/?p=138 Rcr, can you verify the outer synchro selector slidy thing that had 3mm machine off of it is still 100% round and not warped? I'm 99.9% positive it is round! I can take a picture to show everyone but I don't think th...

Sorry, from the damage it looks like much more than that. Those gaskets are available in differnt sizes, for a reason. Hammer is usually good enough for those gaskets, check elsewhere for load problems. The only thing that seemed off to me was that the brass synchro ring didn't want to spin easily ...

Actually does anyone know where I can get the metal gasket for the input shaft housing? Mine somehow got damaged.

You can buy a bearing that fits the L ID and Liberty OD, saves bushing. The 3 pins that lock the synchro rings, are they the correct thickness as that varies between boxes. As the inner of the synchro ring is not worn evenly across the face, it not sitting in the correct position or is the wrong sy...

RSR 555 wrote:Ok. Did you change the font bearing? Was it the correct thinkness? Sorry I can't remember how Phizinza did his box

Used the ej bearing and a sleeve made to fit the input shaft. Everything was checked in at the right size before I put it together.

RSR 555 wrote:Looks like the clearances were too tight. Have you got the correct shims on the front of the input shaft housing?

Yeah everything was there, I just went back over everything, I put the other synchro from the other side and it felt like it didn't want to turn as easily as it should.

Good points Greg Ok.. Are you saying you got 2 of the same boxes as Phizinza and then built it into one box? We really can only help out if we know all about how and what was done. There is many ways this can be done and we would just be guessing at things without know how and what from the beginin...

Sorry i forgot to say that I did it the same way Phizinza did. I marked each piece that I did not need and moved it to the side.

The length of the rod sticking out of those switches varies, looks you put one in with a rod too long. Measure what you need it to be and fit the correct one. That's the switch that came with the trans, took it out and replaced it with a plug, my car is a us spec single range outback. Now the trans...

Ok thanks for the replies everyone, cracked the box open a couple of days ago and found it was the low range indicator switch, it was bent and blocked the selectors fork from going into high range. http://i1338.photobucket.com/albums/o684/Rcr46and2/image_zpsd3761c88.jpg Don't know exactly want happe...

Hey everyone, just swapped the l series low range in my 4.11 ej dual range box. It lasted about 60km and now it won't shift out of low range, even from the gearbox. Anyone know what's wrong?