EJ 4.11 with 1.59

Hi Phizinza,

I have read your 1,59 conversion with a lot of interest, you say you had a bit of machining because it's a 8 bolt gearbox, does this mean that with a 4 bolt gearbox you have no machining ? Thank you for sharing, nice write up !
 
Yeah, the newer 8bolt gearboxes use a larger bearing (I guess to support more power) and therefor you need a sleeve to sleeve the older (ea82) shaft to the larger bearing size. The ea82 internals are almost identical to the old Liberty EJ internals so with the older 4 bolt gearboxes the bearings and shafts all interchange. I machined my sleeve out of brass. You see that on page 2 of the write up. Seem to of worked out fine and the gearbox is still going good 30,000+km later.
 
Thats good news ! So it should just be a swap of the internals...:)

Next week, I'll go to the wrecker and exchange the Vortex for an EA82 unless someone is interested by the Vortex.
 
If you want to keep the EJ centre diff you'll only need the lowrange gearset. You keep the EJ gears on their shafts but replace the input shaft+gear, low range shaft + gears and the last gear of the low range which is on the top half of the actual gearset. I might be able to dig up an image and highlight the parts you would need to swap.

Just a side note, I haven't played with a 4 bolt forester box, I am only assuming they are the same as the Liberty box only with a different pinion gear for the 4.11 ratio diff...
 
In fact, I wanted to put the Vortex center diff in my box but El Freddo told me how to do it and its not that easy...and Venom is going to swap his Vortex center diff for a DCCD and it seems to be quite simple, so i'll go for a DCCD.

And because I can get a EA82 box in standard exchange with the Vortex box, I wanted to do the 1,59 conversion at the same time.

Yes, I would be pleased to have an image of all that, thanks Phizinza for your help.
 
Thats nice Phizinza, you explain it so well, looks like Lego ! And i played a lot with Legos !
 
Subaru's remind me of Lego a LOT! It's like all the interchangeability that the old EJ engines had. EJ18 heads on EJ22's. EJ25 blocks used in EJ22 engines including using different pistons to get different compression ratios for either turbo or NA. It's all just grown ups Lego!
 
I opened my EA82 box today, it was quite easy thanks to Phizinza.

I'm now waiting for a 5MT DCCD (not found yet) then will do the whole swap.
 
Great write up Phiz!

Where the 1.59:1 synchro has to be machined down 3mm to clear the 4.11:1 ring gear, do you think it would be possible to get it to clear 4.44:1?
 
Great right up mate, I'd be looking at doing this soon in my 8 bolt Forester box...
The 1.447.1 just isn't quite low enough!
How does it go with the EJ25 Phizinza? Plently of power and good gearing? Can't wait to get my EJ25 in the old Foz too :D
 
Yeah, the Ej25 has a lot of low end power already, heaps more than the EJ22. To be honest I've only needed the low range twice. I still don't have decent tyres so won't be doing anything that needs it for a while yet.
 
Hi Phizinza !

Do you think that i should go for the 4,444 ring gear so i wouldn't need to machine 3 mm off like Stilson says ? I can't find the information on the web...
 
Yes, but thats more work to remove the 4,11 ring gear and I don't know if the 4,444 will fit my rear locker...
 
Setting the differential backlash can be very time consuming and if you don't have the right tools it can also lead to a very clunky gearbox. You would have to do this if you change the ratio. Personally I like handling so I am not interested in huge tyres. And I like economy, so I like lower revs at highway speeds. I'm happy with my 4.11, that's all I'm saying.
 
Just doing some rough overall calculations.

3.545 1st gear with 1.59 low range with 4.10 FD = 23.10ish overall drive
3.545 1st gear with 1.59 low range with 4.44 FD = 25.02ish overall drive
3.545 1st gear with 1.44 low range with 4.44 FD = 22.66ish overall drive

For reference i once worked out the overall drive of a landrover defender in 1st gear low and it was 66.XX or something crazy!

But yeah our Subies need all the low gearing they can get so why go half in? :P
 
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