RSR L.Series Offroader

guyph_01 · Post by **guyph_01** » Tue Jan 11, 2011 4:40 pm

I mean what the first mods you are planning to do on it:)

RSR 555 · Post by **RSR 555** » Wed Jan 12, 2011 1:12 am

El_Freddo wrote:Drools!

Wish I'd found a touring wagon THAT neat! Bonus that you got the lift with it too!

Looks like it'll be a great unit once you put it all together. Its killing me not being able to build up my project L - and that someone else is about to beat me to what I thought was going to be a pretty original setup! But don't let that hold you back

How quickly will this build move along now?

Cheers

Bennie

I just got to get the box built then it's all ready to go in.. Dave (Subarino) has done the harness for me and I pretty much have everything else in the shop. I'll keep everyone updated

guyph_01 wrote:I mean what the first mods you are planning to do on it:)

As per the first page of the tread but with this car instead of the white one

Post by **Alex** » Wed Jan 12, 2011 9:50 am

love it, saw the best yesterday, very impressed with how good nick she is!

should be a bloody beast when completed

alex

RSR 555 · Post by **RSR 555** » Wed Jan 12, 2011 10:50 am

Alex wrote:love it, saw the best yesterday, very impressed with how good nick she is!

should be a bloody beast when completed

alex

Cheers Alex.. you when it's done you'll want another one again

Post by **Alex** » Wed Jan 12, 2011 11:00 am

RSR 555 wrote:Cheers Alex.. you when it's done you'll want another one again

mate, just seeing it yesterday was making me want one again.

if only i had space to do a project (probably a good thing i dont have space haha)

alex

YouTube · Post by **El_Freddo** » Thu Jan 13, 2011 9:24 pm

Alex wrote:mate, just seeing it yesterday was making me want one again.

if only i had space to do a project (probably a good thing i dont have space haha)

You know you want to! Go on, I DARE you to start a project

Cheers

Bennie

RSR 555 · Post by **RSR 555** » Thu Feb 17, 2011 6:39 pm

Well a bit of an update..

I've decided to get my "a into g" and get this gearbox sorted. Today with a little spare time on my hands, decided that I'd start putting the EA D/R gearset into my 8 Bolt housing Outback box. I've come across the normal D/R selector fork size differences which I believe to be sorted with a little machining but where I'm kinda stuck is the front input shaft bearing. See pics below.. the L bearing is much smaller than the Outback. Does anyone (AP and Bennie I'm thinking of you guys but anyone is free to jump in) if I can get a bearing that will do the job?

YouTube · Post by **El_Freddo** » Thu Feb 17, 2011 7:44 pm

Yeah I've heard about this but not run into it - and hoping not to with the build of my AWD bastard box either!

Here's APs thread on the L series low range into EJ g'box install - I think he came across the same issue from memory... Worth a read anyway!

Cheers

Bennie

RSR 555 · Post by **RSR 555** » Thu Feb 17, 2011 8:11 pm

El_Freddo wrote:Yeah I've heard about this but not run into it - and hoping not to with the build of my AWD bastard box either!

Here's APs thread on the L series low range into EJ g'box install - I think he came across the same issue from memory... Worth a read anyway!

Cheers

Bennie

Thanks Bennie.. I've read that 100 times but still find it easier to do the job than try to picture it in my head.

RSR 555 · Post by **RSR 555** » Sat Feb 19, 2011 3:54 am

ok.. I have a plan and hope it will work. I have sourced a bearing that will fit the L.Series D/R input shaft and fit inside the 2000 Outback input shaft housing. It will need a 1mm shim to match the thickness of the Outback bearing but locating one may be harder than first thought

My machinist is doing his magic with the D/R selector fork and hope to see that back next Tuesday. I will update some pics as the progress goes further.

RSR 555 · Post by **RSR 555** » Tue Feb 22, 2011 10:39 pm

Ok it's Tuesday and as promised, I'd give you an update...

I received the required bearing today via airbag and pressed it onto the input shaft. It looks the goods and happy with the progress. I couldn't find a 1mm shim with the correct ID/OD so I'm having a good friend machine one up for me. I shall get that tomorrow and try it out. I still haven't received the modified D/R selector fork back but hopefully it's not too far away.

Here's a pic of the L.Series input shaft (on the right) with the new bearing to fit the 2000 Outback Input Shaft Housing.

YouTube · Post by **El_Freddo** » Thu Feb 24, 2011 6:17 pm

RSR 555 wrote:Ok it's Tuesday and as promised, I'd give you an update...

I received the required bearing today via airbag and pressed it onto the input shaft. It looks the goods and happy with the progress. I couldn't find a 1mm shim with the correct ID/OD so I'm having a good friend machine one up for me. I shall get that tomorrow and try it out. I still haven't received the modified D/R selector fork back but hopefully it's not too far away.

Paul do you know if this mod is needed when using a gearbox housing from a Gen 1? I know its not needed in a Gen 2 gearbox but AP said something about his input shaft bearing being different when he did his L series low range swap...

I need a shed!

Cheers

Bennie

RSR 555 · Post by **RSR 555** » Thu Feb 24, 2011 7:47 pm

El_Freddo wrote:Paul do you know if this mod is needed when using a gearbox housing from a Gen 1? I know its not needed in a Gen 2 gearbox but AP said something about his input shaft bearing being different when he did his L series low range swap...

I need a shed!

Cheers

Bennie

Sorry Bennie.. it's been a few years since I rebuilt my last Gen1 D/R box and to be honest, I really didn't take any notice of what size the Input Shaft Housing was.. I can't see it being any different to the Gen2 (as both boxes are 4 bolt housings) but you never can tell with Subaru. I'm keeping a detailed list of what I'm doing but this will only be helpful for someone doing the exact same configuration.

Yes buddy.. a shed is a must.. I once built an engine on the floor of my games room but this was well before the ball and chain came along

1111giles · Post by **1111giles** » Fri Feb 25, 2011 8:49 am

RSR 555 wrote: Yes buddy.. a shed is a must.. I once built an engine on the floor of my games room but this was well before the ball and chain came along

hehehe !:mrgreen:

RSR 555 · Post by **RSR 555** » Tue Mar 08, 2011 10:44 pm

Update...

Today I received the dual range selector fork back from the machinist.. it now holds the L.Series selector hub in the Outback fork

with a little extra manicuring it works like a new one

Selector fork in D/R mode

Modified D/R fork

YouTube · Post by **El_Freddo** » Wed Mar 09, 2011 5:32 pm

Very good work Paul,

Have you got a before and after pic to compare the changes to the EJ selector fork? I was hoping that something like this was possible to do...

And what's the pic of the open L box - is this the modified EJ selector fork fitted to see if it operates properly?

Cheers

Bennie

RSR 555 · Post by **RSR 555** » Wed Mar 09, 2011 9:40 pm

Cheers Bennie

Sorry I should have written if differently but the top pic is of the open EJ box (2000 model Outback - 8 bolt hole housing) with the L.Series gear set inside. I have another pic of the open box with the d/r selector in the other position (see below) I was stoked when it all went together nicely.

I thought I did take some pics of the fork before modifing the fork but I can't them

All I did was remove about 2mm off each side of the fork and the grind the centre so it didn't faul as it changed between gears. It should have been done earlier but I left it with another machinist who let me down

I'm off to work for another swing but when I get back I hope to get the L.Series gear set swapped over with the AWD (with centre diff lock) and once done I'll start the conversion.

The selector fork in normal drive

YouTube · Post by **El_Freddo** » Wed Mar 09, 2011 10:30 pm

Dummy fit of the L PT4wd in the EJ casing - Yeah that makes more sense now...

Good to see it moving along. I wish mine was moving along as fast as yours is - I gotta stop pining on your thread!

Cheers

Bennie

RSR 555 · Post by **RSR 555** » Wed Mar 09, 2011 11:00 pm

Yeah sorry Bennie I forget you're not in my head and can read my thoughts.. LOL

but the box is made up of 3 boxes. The first is the 3.9 ratio PT/FWD L.series gear set (because I like the drop down ratio in the d/r gears) which will need to be swapped over on to the 3.7 ratio FT/FWD pinion shaft (because I want the centre diff lock) and the last is the EJ box to join the engine.

I'd love it to be moving faster but I was waiting on the first machinist. I will try this (EA to EJ internals) with another box after my wagon is complete. This one will be in a early EJ D/R box so I'll be able to see the differences. I hope you get yours started soon

YouTube · Post by **El_Freddo** » Wed Mar 09, 2011 11:28 pm

RSR 555 wrote:Yeah sorry Bennie I forget you're not in my head and can read my thoughts.. LOL but the box is made up of 3 boxes. The first is the 3.9 ratio PT/FWD L.series gear set (because I like the drop down ratio in the d/r gears) which will need to be swapped over on to the 3.7 ratio FT/FWD pinion shaft (because I want the centre diff lock) and the last is the EJ box to join the engine.

I'd love it to be moving faster but I was waiting on the first machinist. I will try this (EA to EJ internals) with another box after my wagon is complete. This one will be in a early EJ D/R box so I'll be able to see the differences. I hope you get yours started soon

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