Venoms lifted H6 Gen2 Lib

Hey guys,

Thought i might share the details of my car around on here ;) I bought this in March. Flew up to Al's from AMAutos place in QLD and drove it back to Victoria with my girlfriend co-driving. This was Als personal car which he converted to a EZ30D. Pit-stop at Bennies to show off on the way back of course. I had a month wait to get into the engineers, which was worth it. Only changes required were a padded steering wheel and a quieter muffler, easy :D I had to change to stock shocks and springs for the RWC which i wasn't happy about because they were engineered.

Current specs are:
2003 Outback H6
V3 STI gearbox
4.44 ratio diffs
Front LSD, clutch pack Rear LSD on my desk
277mm WRX front brakes

Fuel use has so far averaged 9.53L/100km over 5 tanks of fuel. It is very efficient on the highway and around town if driven appropriately.

Plan is to build this into an off-roader.

H6Gen2007.jpg


These are Als pics from the sale and his posts on the conversion process.

H6Gen2001.jpg


H6Gen2002.jpg
 
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Okay the 705mm drive shafts didn't work out. Ball joints weren't even close to going into the hub.
 
Venom said:
Ok so in gear, handbrake on i can grab the tailshaft and rotate it a fraction of a turn (maybe 1/16th - 1/8th a turn or more). Is that normal? It seems excessive.
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Sorry mate, I completely forgot about checking mine.
Just checked it (hand brake on, in gear DCCD unlocked) and it does rotate slightly I would say 1/16 of a turn tops but very hard to estimate with any accuracy. If done fast it does make a bit of a clonk sound from the rear diff which is just the backlash between the ring and pinion in the diff. The rear diff is 100% what is limiting the rotation and not the gearbox. If you are getting up to 1/8th of a turn maybe there is something wrong with ring/pinion in the rear diff, wear in the diff internals or in your rear cv joints. Of course my rear diff is a suretrac which AFAIK does not contain spider gears but some form of black magic where as your clutch style diff not only contains spider gears but these gears are mounted on a shaft that is not rigidly fixed relative to the ring gear. Im guessing that this is where the extra movement may be coming from and may be perfectly normal.
A better check for gearbox play might be to repeat with both back wheels in the air so the rear diff can not limit things. You will find significantly more movement in this situation but again determining what is normal will be very difficult.

Ratbag said:
There is at most maybe 1/8th inch rotational play in mine
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Ratbag how can you measure a rotation with a linear unit of measurement?? :poke: This makes no sense to me unless you are some how listing a tangential distance travelled in which case you would also need to list the distance from the centre of rotation to the position that this distance is being measured
 
Gidday DM

Dedman said:
Ratbag how can you measure a rotation with a linear unit of measurement?? :poke: This makes no sense to me unless you are some how listing a tangential distance travelled in which case you would also need to list the distance from the centre of rotation to the position that this distance is being measured
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Easy, mate.

Hold a tube of a known diameter that's supported at both ends in one hand, then turn circumferentially. Estimate circumferential distance travelled by heuristic ... .

Mapping of globular objects on to flat surfaces cause a similar problem if one wants a precise measurement. Great circle route distances that navigators have used for centuries do this with considerable precision ...

Other than that, my micrometer does the translation (in reverse) with very great precision - 0 to 25 mm accurate to 0.01 mm for my dear old clunker.

:poke: :lol: :cool:
 
Ratbag said:
Hold a tube of a known diameter
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Yes that was the missing information I was getting at earlier . I had no idea where exactly you were measuring as there are different diameters on different sections of my tail shaft and I don't know if all Subaru ones are exactly the same diameter anyway. Also a micrometer is slightly different using a precision screw thread to measure a linear movement but that's going on a bit of a tangent here. Anyway now that I know what you meant I estimate that as around 1/40th-1/50th of a turn which is less than mine although this could be as a result of different amounts of torque being applied in testing. Now to stop clogging Venom's build thread.
 
New driveshafts fitted, the old ones certainly have some play. Hard to say at this stage as the gearbox fluid is hot, but it seems to have improved the behavior of the front LSD. That in turn is reducing the instances of the bunny hop problem. Going up the ridiculous hill in my street on a cold morning will really be telling.
 
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A little bit of movement in my tailshaft. Not sure how much but some. Hope your new axles help with the bunny hopping
 
Mmmm.
IMG_20150203_202719.jpg


2005 STI Liberty 5MT that's done 130,000kms. Complete with short shifter, full push type hydraulic clutch assembly, tail shaft and drive shafts. Oh, and an LSD.

This should cure my drive-train issues, seriously. And preps the car for an SG based dual range to go in at a later date.
 
The turbo libertys of that era had a 6 speed... don't know where the 5 speed is from??
So another gearbox build?? Got his cars almost into double digits for gearboxes.. lol

My box is almost done and I found a 92,000km 07 outback box(same as SG)..
 
Nope 05/06 STI Libs still had the 2.0L turbo and 5MT, 07/08 was the 2.5L and 6MT.

My dual ranges have done alright to handle the torque of the H6 and all the added strain of the DCCD and plated diffs. It's asking a lot.
 
So your using the gearset out of it on a two piece input/main shaft? That'll only have a single piece main as its single range..
When I destroy this new box a year or two down r he track I'll prob go with a set of straight cut PPG gears with dual range and the works.. atleast then it will handle the grunt of my new motor at the same time.
 
So a quick update, this epic shudder/jerking problem is still on-going. Imagine the drivetrain acting like a jackhammer, that's the best description for it.

Stock SF gearbox ended up going into the car. 1.447 and 4.11 for $300 from Jollys. This saw no change to the problem, but needed to be done anyway since 1st in the old gbox was howling. Stock tailshaft in, no change.

So the car spent some time at the mechanic, conclusion is it's the rear diff. Lots of backlash play. At this stage I'm not sure whats worn or why. The KAAZ is still functioning beautifully. It's not making any noise, so it seems unlikely to be crownwheel/pinion wear. Stock diff will go in soonish, most likely the KAAZ will go into the 06 Lib LSD housing with some new bearings and seals. Then the KAAZ and DCCD can go into the car further down the track.
 
Mines doing it too, I find giving it more revs stops it. I worry what the jerking motion does to the drivetrain...
 
jf1sf5 said:
Hmmm, bad news…

Could it be the flywheel ?
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Unlikely, I installed a complete DMF conversion kit with brand new clutch and flywheel when I fitted the SF gearbox. It made no difference.
 
Sounds very odd Venom. Did you try sticking a camera under there at all and film different components to source the vibration? Seems strange that the rear diff would develop excessive backlash without noise as you would need either excessive gear tooth or bearing wear to cause this. Being set up from the start incorrectly on the other hand very possible but then the problem would have always have been there.

NachaLuva said:
Mines doing it too, I find giving it more revs stops it. I worry what the jerking motion does to the drivetrain...
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Do you mean more revs or more speed? If its just when you are taking off or crawling along then could be slightly bent trans mounts. That was the exact symptoms mine had and bent trans mount was the cause.
 
Do you feel the shudder on the seat meaning it comes from the back of the car or in the steering wheel which would locate it in the front.

The problem could also be caused by a bent axle where the 5 bolts hold the wheels, sorry, I don't know the english word…

Hope you'll find out.
 
Are the tailshaft uni's lined up properly.?
 
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