EJ Dual Range AWD 1.19:1 Lo range upgrade to 1.59 {56k warning}

Everything Engine, Gearbox, Diffs & Driveshafts for the EJ series models - NA & Boosted
User avatar
PeeJay
Junior Member
Posts: 685
Joined: Tue Oct 04, 2005 10:00 am
Location: Riverstone, Sydney
Contact:

Post by PeeJay » Tue Apr 20, 2010 6:03 pm

Mine is still going fine. Just installing an electronic boost controller to run 15psi so we'll see how it goes now :)

User avatar
AlpineRaven
Senior Member
Posts: 3682
Joined: Wed Oct 19, 2005 10:00 am
Location: Melbourne, Victoria, Australia.

Post by AlpineRaven » Tue Apr 20, 2010 10:13 pm

dibs wrote:so hows the box going you still smiling????????????????????

dibs
Yep mate it is still good...
On other day about 4 weeks ago, I had to pull up an Commodore on a car trailer on my mates farm where he couldn't pull it up with his Rodeo (would loose traction on grass) so I wacked in low range and pulled it up - works like a treat - he was gobsmacked..
Cheers
AP
Subarus that I have/had:
1995 Liberty "Rallye" - 5MT AWD, LSD - *written off 25/8/06 in towing accident.
1996 Liberty Wagon - SkiFX AWD 5MT D/R, Lifted.. Outback Sway Bar, 1.59:1 Low Gearing see thread: 1.59:1 in EJ Box Page
Sold at 385,000kms in July 2011.
2007 Liberty BP Wagon, 2.5i automatic
Image

User avatar
dibs
Junior Member
Posts: 658
Joined: Wed Mar 21, 2007 6:33 am
Location: sunshine coast QLD

Post by dibs » Tue May 04, 2010 7:13 am

thanks m8 i got a forry box now need a doner box and get to it

dibs
[SIGPIC][/SIGPIC]

User avatar
RSR 555
Elder Member
Posts: 6951
Joined: Sat Nov 10, 2007 10:42 am
Location: ATM... stuck in Rockingham

Post by RSR 555 » Tue May 04, 2010 1:25 pm

Hey AP..

I have a 8 bolt Outback gearbox (99 model) here that has bearing problems and wish to pull apart at some stage.. Do you think the EA D/R internals will fit?

Cheers,
Paul
You know you are getting old when the candles on your birthday cake start to cost more than the cake itself.

RSR Performance
Home of the 'MURTAYA' in Oz
Subaru Impreza WRX based Sportscar
[SIGPIC][/SIGPIC]

Disclaimer: Not my website but hyperlink here to Subaru workshop manuals

User avatar
El_Freddo
Master Member
Posts: 12487
Joined: Tue Oct 04, 2005 10:00 am
Location: Bridgewater Vic
Contact:

Post by El_Freddo » Tue May 04, 2010 9:46 pm

RSR 555 wrote:I have a 8 bolt Outback gearbox (99 model) here that has bearing problems and wish to pull apart at some stage.. Do you think the EA D/R internals will fit?
Paul I'm pretty sure the internal layout is still the same, just the number of bolts to mount the engine have changed.

If it's a 4.11 or 4.44 diff ratio, to fit the L low range you'll have to shave some meat from the crown wheel. I'm not sure which section needs to be removed as I've not done it or seen it done myself. Peejay will be able to elaborate more I'm sure.

Cheers

Bennie
"The lounge room is not a workshop..."
Image
El Freddo's Pics - El_Freddo's youtube

User avatar
RSR 555
Elder Member
Posts: 6951
Joined: Sat Nov 10, 2007 10:42 am
Location: ATM... stuck in Rockingham

Post by RSR 555 » Wed May 05, 2010 12:07 am

El_Freddo wrote:Paul I'm pretty sure the internal layout is still the same, just the number of bolts to mount the engine have changed.

If it's a 4.11 or 4.44 diff ratio, to fit the L low range you'll have to shave some meat from the crown wheel. I'm not sure which section needs to be removed as I've not done it or seen it done myself. Peejay will be able to elaborate more I'm sure.

Cheers

Bennie
I really hope so.. as for the ratio, I'll grab the number off the box and see. I remember building a 4.4 many years ago and have to skim some of the crown wheel were it bolted to the diff centre flange.. Thanks bud
You know you are getting old when the candles on your birthday cake start to cost more than the cake itself.

RSR Performance
Home of the 'MURTAYA' in Oz
Subaru Impreza WRX based Sportscar
[SIGPIC][/SIGPIC]

Disclaimer: Not my website but hyperlink here to Subaru workshop manuals

User avatar
s3gti
Junior Member
Posts: 19
Joined: Tue Jan 18, 2011 9:32 am
Location: brisbane

Post by s3gti » Mon Jan 30, 2012 12:18 pm

Just curious, is it a certain type of EA D/R box needed to be used as a donor? I bought 2 EA D/R boxes to use on my 2 liberty boxes. The shaft that the 2 dual range counter gears sit on is thinner in diameter than the shaft from my EJ box. I was so hyped to be able to test it in the mud, but now I can't do it & need to buy another 2 gearboxes. Doh. :twisted:

User avatar
El_Freddo
Master Member
Posts: 12487
Joined: Tue Oct 04, 2005 10:00 am
Location: Bridgewater Vic
Contact:

Post by El_Freddo » Mon Jan 30, 2012 7:58 pm

s3gti wrote:Just curious, is it a certain type of EA D/R box needed to be used as a donor? I bought 2 EA D/R boxes to use on my 2 liberty boxes. The shaft that the 2 dual range counter gears sit on is thinner in diameter than the shaft from my EJ box. I was so hyped to be able to test it in the mud, but now I can't do it & need to buy another 2 gearboxes. Doh. :twisted:
G'day s3gti, welcome to the forum!

What year is your EJ gearbox from? And the EA boxes? I've not heard of this happening before.

Have a read in the Subaru Chat part of the forum on how to host images and drop a couple in here to show us what you're talking about exactly ;)

I'm sure we'll nut it out without the need of another set of gearboxes.

Cheers

Bennie
"The lounge room is not a workshop..."
Image
El Freddo's Pics - El_Freddo's youtube

User avatar
s3gti
Junior Member
Posts: 19
Joined: Tue Jan 18, 2011 9:32 am
Location: brisbane

Post by s3gti » Mon Jan 30, 2012 9:33 pm

Lets see if I can do this right, these images should be able to tell the story.

Image

These are hopefully the gears in question. It worked.
Image
These are the 2 sets of low range gears. the liberty is on the right- with the writing on it.

Image
The two shafts side by side

Image
& an end-on pic showing the different diameters.


The liberty gearbox is out of a 91 liberty & the other box is an ea series dual range box. Perhaps it is out of an 1800 wagon, or brumby. I know that it has a final drive of 3.7:1, & that now I have 2 of them in pieces.

User avatar
TOONGA
Elder Member
Posts: 5335
Joined: Sat May 30, 2009 10:15 am
Location: Australind closer to where they divided by zero
Contact:

Post by TOONGA » Mon Jan 30, 2012 10:46 pm

You ned to get an L series 5 speed box and use the low range gears out of that. the brumby/ wagon /MY series gearset will not work.

TOONGA
Image
PJ Gone but not forgotten
JETCAR AKA the sandwedge Rusted in pieces

User avatar
El_Freddo
Master Member
Posts: 12487
Joined: Tue Oct 04, 2005 10:00 am
Location: Bridgewater Vic
Contact:

Post by El_Freddo » Tue Jan 31, 2012 4:32 pm

TOONGA wrote:You ned to get an L series 5 speed box and use the low range gears out of that. the brumby/ wagon /MY series gearset will not work.
Good point Toonga!

s3gti, the gearboxes you've got for the swap - are they a 4 speed or a 5 speed? Got pics of the gearbox casings? I should be able to let you know if it's 4spd or 5spd by the casings if you don't have one that's still together ;)

Cheers

Bennie
"The lounge room is not a workshop..."
Image
El Freddo's Pics - El_Freddo's youtube

User avatar
s3gti
Junior Member
Posts: 19
Joined: Tue Jan 18, 2011 9:32 am
Location: brisbane

Post by s3gti » Fri Feb 03, 2012 8:17 pm

Pretty sure they are a 5 speed box, same number of cogs as the liberty box. I think it may be like toonga says, the boxes are probably from an 1800 wagon, or brumby. I wish I knew that before I bought the bloody things. Oh well, s#@t happens. thanks for your help.
[SIGPIC][/SIGPIC]

User avatar
El_Freddo
Master Member
Posts: 12487
Joined: Tue Oct 04, 2005 10:00 am
Location: Bridgewater Vic
Contact:

Post by El_Freddo » Fri Feb 03, 2012 8:38 pm

s3gti wrote:Pretty sure they are a 5 speed box, same number of cogs as the liberty box. I think it may be like toonga says, the boxes are probably from an 1800 wagon, or brumby. I wish I knew that before I bought the bloody things. Oh well, s#@t happens. thanks for your help.
Here's the problem - the MY or brumbys only came out with a 4 speed gearbox in high and low range 4wd...

Can you load us up a couple of images of these gearboxes? And if you've got them split a shot like this would help:

Image

:D

I hope you're not giving up on this!

Cheers

Bennie
"The lounge room is not a workshop..."
Image
El Freddo's Pics - El_Freddo's youtube

User avatar
fårwildrajv
Junior Member
Posts: 3
Joined: Fri Aug 03, 2012 4:55 am
Location: sweden

Post by fårwildrajv » Fri Aug 03, 2012 5:19 am

Hello!
you seem to be good at subaru gearbox.
I have a question...
is there a needle bearing on the inputshaft between the HI and LOW speed?
Image

Im sorry if my English is bad and some word get wrong... I live in sweden :rolleyes:

My problem is a bearing noise when i drive in HI but not in LOW so my guess is a bearing between the HI and LOW.

Thanks!
Attachments
vxlsubba.jpg
vxlsubba.jpg (87.31 KiB) Viewed 5575 times

User avatar
wagonist
Junior Member
Posts: 597
Joined: Sun Nov 13, 2005 10:00 am
Location: Sydney

Post by wagonist » Fri Aug 03, 2012 5:40 pm

To the best of my knowledge, the bearings supporting the input shaft are the big wide thing to the right, and the thin one in the wall of the casing behind the diff.
When the synchro is engaged, it locks the 2 pieces of the shaft together.
However, when the synchro is the other way, the load goes via the side shaft via the gears which is hidden behind in that pic.
That short shaft is on bearings also, so that might be the problem area.

Anyone disagree?
Current rides:
JDM GTII Touring wagon
88 RX Turbo Full-time 4wd touring wagon project - 97 Toyota Caldina GTT (turbo 4wd WRX eater:twisted:) - Hyundai Excel Rally Car:confused::???:
Previous rides:
93 Legacy GT wagon - 85 RX Turbo Full time 4wd Touring Wagon - 85 GL AWD sedan
96 Toyota Caldina wagon

User avatar
El_Freddo
Master Member
Posts: 12487
Joined: Tue Oct 04, 2005 10:00 am
Location: Bridgewater Vic
Contact:

Post by El_Freddo » Fri Aug 03, 2012 7:38 pm

wagonist wrote:Anyone disagree?
Nope, I reckon you got it smack on. The issue must be with one of the bearings on the layshafts that the driving gears are mounted to.

What speed/speeds does this noise appear?

There are needle bearings but they're on the other part of the low range setup:

Image

(left one is the L series unit) This is the other gear that completes the low range system, the shaft it's on has the needle bearings but these wouldn't be under load in high range, thus wouldn't be making any noise.

I'd be looking at other bearings or other things on your subi to solve what it is.

If you can give us more information about speeds/engine loads when the noise occurs that would be helpful too.

Cheers

Bennie
"The lounge room is not a workshop..."
Image
El Freddo's Pics - El_Freddo's youtube

User avatar
fårwildrajv
Junior Member
Posts: 3
Joined: Fri Aug 03, 2012 4:55 am
Location: sweden

Post by fårwildrajv » Mon Aug 06, 2012 5:53 pm

El_Freddo wrote:Nope, I reckon you got it smack on. The issue must be with one of the bearings on the layshafts that the driving gears are mounted to.

What speed/speeds does this noise appear?

There are needle bearings but they're on the other part of the low range setup:

Image

(left one is the L series unit) This is the other gear that completes the low range system, the shaft it's on has the needle bearings but these wouldn't be under load in high range, thus wouldn't be making any noise.

I'd be looking at other bearings or other things on your subi to solve what it is.

If you can give us more information about speeds/engine loads when the noise occurs that would be helpful too.

Cheers

Bennie
Oh, i will do my best to wright.
So if i get this right, in HI gear the input shaft is one unit. And in LOW gear it split the shaft and the power goes out to this little axle on the side?

The noise is from neutral and most when you have loads at drive train.
If i stand in neutral and releases the clutch you can here the sound change and the when press down clutch it stops.
(bearings in clutch is new)
If i do the same in LOW, the sound don't change.

I thought that it was like in LOW the input shaft was one piece and in HI it split and it was like a over gear on all gears.

User avatar
El_Freddo
Master Member
Posts: 12487
Joined: Tue Oct 04, 2005 10:00 am
Location: Bridgewater Vic
Contact:

Post by El_Freddo » Mon Aug 06, 2012 9:07 pm

fårwildrajv wrote:So if i get this right, in HI gear the input shaft is one unit. And in LOW gear it split the shaft and the power goes out to this little axle on the side?
Correct.
fårwildrajv wrote:The noise is from neutral and most when you have loads at drive train.
If i stand in neutral and releases the clutch you can here the sound change and the when press down clutch it stops.
(bearings in clutch is new)
This to me would point to a faulty throw out bearing, even if it's new. Was the unit new (and a good brand?) or second hand (used?)
fårwildrajv wrote:If i do the same in LOW, the sound don't change.
This leads me off the throw out bearing as the cause... I've got no idea what could be doing this.

Cheers

Bennie
"The lounge room is not a workshop..."
Image
El Freddo's Pics - El_Freddo's youtube

User avatar
fårwildrajv
Junior Member
Posts: 3
Joined: Fri Aug 03, 2012 4:55 am
Location: sweden

Post by fårwildrajv » Wed Aug 08, 2012 5:51 pm

El_Freddo wrote:
This leads me off the throw out bearing as the cause... I've got no idea what could be doing this.

Cheers

Bennie
No it is strange that the noise only is there at HI.
Well i see what to do at this. Im looking for a used gearbox and replace.

Thanks and have fun with subaru :p

User avatar
AlpineRaven
Senior Member
Posts: 3682
Joined: Wed Oct 19, 2005 10:00 am
Location: Melbourne, Victoria, Australia.

Post by AlpineRaven » Fri Sep 14, 2012 8:27 am

fårwildrajv wrote:No it is strange that the noise only is there at HI.
Well i see what to do at this. Im looking for a used gearbox and replace.

Thanks and have fun with subaru :p
Have you resolved the issue you're having? Does the noise appear any gear or specific speed?
Cheers
AP
Subarus that I have/had:
1995 Liberty "Rallye" - 5MT AWD, LSD - *written off 25/8/06 in towing accident.
1996 Liberty Wagon - SkiFX AWD 5MT D/R, Lifted.. Outback Sway Bar, 1.59:1 Low Gearing see thread: 1.59:1 in EJ Box Page
Sold at 385,000kms in July 2011.
2007 Liberty BP Wagon, 2.5i automatic
Image

Post Reply

Return to “EJ Drivetrain”