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  #1  
Unread 8th August 2018, 01:47 AM
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Post NA SG Low range conversion.

I've got a 2003 (SG) NA manual.

I picked up a spare SG box and have been looking into doing a 1.44 low range conversion. Upon doing some research found that some have done a 4.44 front and rear diff conversion too, using a 0.738 5th gear to keep highway drivability.

Basically was just wondering if someone could help me form a list of parts i'm going to need to get a hold of to do just the 1.44 swap, and maybe also the 4.44 F&R diff swap so i can figure out if that's something that i am going to realistically be able to achieve, or if i should just stick with the 1.44 swap.
I'm competent and mechanically minded but haven't played much with transmissions before so this is going to be a learning curve for me one way or another.

Currently looking at getting:
-1.447 LR gearset (probably from alldrive).
-For the front end, (if i even go down this path) would i just be able to buy a 4.44 gearset+rear diff and swap it straight in after putting the .738 5th gear in?
-Looking at LSD's front and rear while everything's out of the car, advice in this regard would be appreciated too (not worth doing rear LSD if a diff locker becomes available in the next 12 months as i'll just buy that).
-Will be doing throwout bearing and a new clutch while it's out too.

Thanks in advance for reading my wall of text
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  #2  
Unread 8th August 2018, 03:43 AM
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You will need special tools to swap the diff gears over. Not so much the crown wheel but the pinion. May as well stick with Vlsd rear centre till you are ready to get the locker. Keep in mind that for the locker you will need an R180 diff, and nothing from the R160 save the flange will swap over. As for the front, helical/torsen are the most popular, but plated from say Cusco if they are available would be best. For the 5th gear, contact all drive Subaru. Same with the 1.44 gears, unless you did what I did and buy a broken SF box cheap and grab the gears out of it. Of which there are 2. Have you read my build thread?
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  #3  
Unread 8th August 2018, 05:27 AM
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Quote:
Originally Posted by Rally View Post
You will need special tools to swap the diff gears over. Not so much the crown wheel but the pinion.
So does the 4.44 gearset out of an XT for example, swap straight over?
Special tools like a press? Or is there special circlips or such things that need to be removed?

Quote:
Originally Posted by Rally View Post
May as well stick with Vlsd rear centre till you are ready to get the locker.
Yea i figured so much, but worth asking.

Quote:
Originally Posted by Rally View Post
As for the front, helical/torsen are the most popular, but plated from say Cusco if they are available would be best.
I'll look into it. Is there somewhere you know of likely to have the plated Cusco lsd?

Quote:
Originally Posted by Rally View Post
Have you read my build thread?
I have, but i'll likely be reading, re-reading and re-reading, again and again over the next few weeks as i go through the planning/prep phase.
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  #4  
Unread 8th August 2018, 05:35 AM
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The gears will swap over easily on the rear diff, but will need to be shaved to clear the 1.44 low range gears.

I don’t know what actual tools are required. Apparently only diff specialists have it, most mechanics won’t.

Speak to someone like Dave from A1 Tuning and Performance. He can source the Cusco diff.
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  #5  
Unread 8th August 2018, 06:44 AM
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Really appreciate you taking the time to reply mate. Thank you

Last edited by Kevin; 8th August 2018 at 10:02 AM. Reason: Unnecessary use of Quote
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  #6  
Unread 8th August 2018, 08:40 AM
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No special tools required other than some larger than normal sockets. I reckon the 5th gear swap is harder than the diff ratio swap. Namely bedside when I did mine I used a mate's hydraulic hand press that assembled around the gear to be pulled.
The only real difficult bit with the diff is setting the preload and backlash - both are easy enough to do either with the proper gauge or doing it by eye using the coloured grease and the guide found in most factory manuals.

As Rally said, the front diff's crown wheel will need to be shaved to fit the 1.447:1 low range gears. A bit more shaving and stuffing around could see you with the 1.59:1 L series low range and 4.44:1 diff ratio.

Any Subaru 5 speed manual 4.44:1 ratio diff ring and pinion will fit into the SG's phase two gearbox.

Gearbox work is loads of fun

Cheers

Bennie
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  #7  
Unread 8th August 2018, 11:17 AM
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I wouldn't fit a plated Cusco up front because it needs maintenance, a torsen/helical is more appropriate.

What you forgot in your wish list is a DCCD...very effective modification and easy to do.
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  #8  
Unread 8th August 2018, 02:16 PM
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Good point I had forgotten about re the dccd
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  #9  
Unread 9th August 2018, 01:08 AM
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Firstly the gain you get from changing your diffs to 4.44 is immense, it puts the torque is a better speed /rev range and gives far more flexibility in high range. The SG is then far nicer to drive.
If you change the diffs to 4.44 you will need a new speedo drive. I got the yellow one with 32 teeth.
Also Niazi at All Drive can mill the edge of the front diff crown wheel if you get it off him.
You can also buy the rear diff without the hemisphere and reuse yours to reduce cost.
I bought a SF gear box from a car being wrecked for $200 so it is worth looking around.
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  #10  
Unread 9th August 2018, 03:39 AM
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Rally Rally is online now
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Join Date: Jul 2008
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Quote:
Originally Posted by jf1sf5 View Post
I wouldn't fit a plated Cusco up front because it needs maintenance, a torsen/helical is more appropriate.

What you forgot in your wish list is a DCCD...very effective modification and easy to do.
All plated diffs require maintenance, which means regular oil changes. I think considering the performance difference between plated and helical, itís a small price to pay
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