RSR L.Series Offroader

RSR 555 · Post by **RSR 555** » Thu Mar 10, 2011 6:27 pm

El_Freddo wrote:I didn't know you could press the PT4wd gearsets off the pinion shaft and press them back onto the AWD tube - I say tube as from my understanding the lower gearset is on some sort of hollow shaft so that the AWD pinion shaft can move independently of the lower gearset.

I've got all the parts, 3 gearboxes, the 4.11 pinion and ring diff gearset to be put together. What I don't have is the shed space or the knowledge to setup all the preloads - don't know what that's all about so I'm looking into one of Gee's mates to do it for me. I keep meaning to call him but get caught up in my day Plus I don't know what its going to cost yet, hence the need for the call. I would like to put new bearings in and a set of seals will be source (also been meaning to contact FROG on this) to go in. I've got a set of 14 inch scorpion rims on their way so standard offset will be back with 27 inch rubber. Just need this gearbox so I can run on the 27s all the time and have good gearing That's the plan!

Cheers

Bennie

I understand what you say about the 'tube' and I'm hoping (crossing everything) that because both the AWD and PT boxes are L.Series models and they both have the 'tube' then they should just swap over. I will be swapping just the gears over, so I'm 99% sure all will work. I have not built this type (late model casing) of hybrid box before but have rebuilt many Subaru boxes over the years, so time will tell and this is why I'm posting this info up, in the event someone else wishes to do the same conversion?? I will be keeping the 3.7 ratio (hides from the flaming) as I'm looking to keep the RPM to a minimum and also using the PLSD from the 86 RX Turbo. If it turns out to be too much stress on the box then I'll look at different ratios but doing this can create more trouble.. like you say 'preloading' I have all the equipment and tools for this but it's much more work than I want to take on for my Offroader.

I hope you do your gearbox soon

Subafury · Post by **Subafury** » Sat Mar 12, 2011 1:42 am

Nice progress! Extra credit for fluffing about with gearbox bits. Hopefully it will last!

RSR 555 · Post by **RSR 555** » Sat Apr 09, 2011 11:25 pm

Subafury wrote:Nice progress! Extra credit for fluffing about with gearbox bits. Hopefully it will last!

Thx Matt.. Me 2

RSR 555 · Post by **RSR 555** » Sat Apr 09, 2011 11:37 pm

Update: Today was put all the bits of the gearbox back together..

EA82 vs EJ25 Drop Down Gears

Needed some machining to the Dual Range Selector Hub as per what AP did on his box.

Gearbox halfway

and yes I was doing the happy dance Jules

RSR 555 · Post by **RSR 555** » Sat Apr 09, 2011 11:38 pm

Now to put the goodies in it

Install one RXII Centre Diff Lock.. Pics showing open and Locked positions

RH shot of the completed box.. showing the Centre Diff Lock Lever

LH shot of the completed box.. showing the Vacuum Module for the Centre Diff Lock

Now is just finding some more time to put the engine and box together and then into the car

guyph_01 · Post by **guyph_01** » Sun Apr 10, 2011 1:08 am

Hehe, Great work Paul:) Hopefully we can both finish around the same time:)

Post by **TOONGA** » Sun Apr 10, 2011 9:41 am

looking good there, it will be a great box on the road and off the road.

did you stay with the 4.1 gearing as you were saying ?

TOONGA

RSR 555 · Post by **RSR 555** » Sun Apr 10, 2011 8:38 pm

Thanks

Guyph.. you better pull your finger out then cause I'm in overdrive to get this done this time home

Jules.. I did use the Outback gearset but unfortunately there was no way I could use the 4.1 or 3.9 ratio front diff and this was because of the pinion shaft for the Centre Diff

maybe next box will have diiferent ratios

RSR 555 · Post by **RSR 555** » Sun Apr 10, 2011 8:40 pm

I fitted the new clutch today...

Tomorrow it's wash and high pressure clean the box ready to put the engine and box together

YouTube · Post by **El_Freddo** » Sun Apr 10, 2011 8:54 pm

Awesome Paul!

Glad you posted those detailed pics! I was looking over my AWD L gearbox worried that I'd have the wool pulled over my eyes with a single range rear housing on a dual range front casings - I've literally come from the shed after removing the top plate on the box to expose the same thing your centre diff shows (to me).

Very stoked that its all good. I too have to get my finger pulled out. But want to go with new bearings as well so I don't have to pull it apart again!

Can't wait to see it all come together - To be selfish I wish that it was my gearbox going in and together first! Also wish I had the equipment to press new bearings in too (and the know how with diff lash and pre load adjustment). Not much to ask for there!

Looking good mate!

Cheers

Bennie

RSR 555 · Post by **RSR 555** » Mon Apr 11, 2011 2:26 am

Thanks Bennie

That's not selfish at all

hahaha

I too wished I could have fitted a complete new bearing kit but due to my time deadline (SA Trip) I'm losing days almost as fast as braincells at the moment

I was (prior to starting this task) worried that the rear extension casing didn't have the Dual Range rods going through it but the penny dropped after what you said and reading AP's tread (about 1 million times) that the EJ box doesn't need the rear rods cause it's already AWD.. DOH !!

After the assembly of the box, I went through all the gears and also selected high/low range plus the centre diff lock.. all works perfectly and can't wait to have it in the car. I'll run some Castrol VMX-80 gear oil on the first 500kms but after that I'll run the smurf blood. I'm hoping that will save the day

1111giles · Post by **1111giles** » Mon Apr 11, 2011 3:14 am

Looking sweet there Paul ! You have been a busy bee I see

So when is the test day run in the car then ?

RSR 555 · Post by **RSR 555** » Mon Apr 11, 2011 3:23 am

1111giles wrote:Looking sweet there Paul ! You have been a busy bee I see

So when is the test day run in the car then ?

Thanks Giles.. yes way too busy, not even time to go over PMs.. thank god for late nights and Canadian Club

Test run will be right after installation date which I'm hoping is within 2 weeks. I'm 99% sure I have all the necessary equipment to put the engine/box/wiring in the car, then play with brakes/wheels/suspension next time home. I don't have much time left before the trip and I'd love to have testing and licensing sorted out before I leave too

Post by **TOONGA** » Mon Apr 11, 2011 8:55 am

RSR 555 wrote:Thanks
Jules.. I did use the Outback gearset but unfortunately there was no way I could use the 4.1 or 3.9 ratio front diff and this was because of the pinion shaft for the Centre Diff maybe next box will have diiferent ratios

As I understand it they are 3.9 ratioed as is the dual range one I sold you

I will find out about availability today (Memes first visit to the wrecker) make sure you answer your mobile phone will you

TOONGA

RSR 555 · Post by **RSR 555** » Mon Apr 11, 2011 11:31 am

TOONGA wrote:As I understand it they are 3.9 ratioed as is the dual range one I sold you

I will find out about availability today (Memes first visit to the wrecker) make sure you answer your mobile phone will you

TOONGA

That gearbox you sold me is still complete (and leaking oil all over my wrkshop floor) because it's 4 bolt housing and I used the 3.9 ratio from the RXII gearbox.

I have my mobile on and charged

Post by **TOONGA** » Tue Apr 12, 2011 9:51 am

RSR 555 wrote:That gearbox you sold me is still complete (and leaking oil all over my wrkshop floor)

I will bring some degreaser the next time Im in town

TOONGA

Post by **Alex** » Tue Apr 12, 2011 10:17 am

when you start working on the car let me know and i'll come lend a hand

RSR 555 · Post by **RSR 555** » Tue Apr 12, 2011 10:55 am

Alex wrote:when you start working on the car let me know and i'll come lend a hand

Thx bro but you'll be at work when I'm playing but you're welcome to drop in after work

Post by **Alex** » Tue Apr 12, 2011 12:55 pm

RSR 555 wrote:Thx bro but you'll be at work when I'm playing but you're welcome to drop in after work

im thinking about being naughty this week and taking a day off. Got soo much stuff to sort out with cars!

alex

RSR 555 · Post by **RSR 555** » Tue Apr 12, 2011 7:03 pm

hahaha.. no probs Alex.. anytime this week. I might start tomoz pulling the old one out??

Here's today's update (after checking out a prime vehicle for Jules)