Offroad gearbox build

NachaLuva said:
I've been told to get the complete DCCD assembly as well, housing, diff & esp the input shaft. Don't forget the input shaft!
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Yes, that is it, explained better by NachaLuva, sometimes I'm a bit lost with the english words...:iconwink:
 
Thanks. Yep I a hoping to get a compete DCCD box to get the bits out of. Just waiting to find one at the right price.

NachaLuva said:
Don't forget the input shaft!
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What do you mean by input shaft? Do you actually mean the shaft the drives the diff (which is what I think of when I hear input)? Or do you mean the front pinion shaft that takes the torque from the centre diff to the front diff? Or do you mean the rear output shaft that has the transfer gear on it to that sends drive the rear wheels?

On another note I also agree with Bennie about the L series 5th gear not working, after taking it apart there is no way it will work in the AWD box.
 
Dedman said:
What do you mean by input shaft? Do you actually mean the shaft the drives the diff (which is what I think of when I hear input)? Or do you mean the front pinion shaft that takes the torque from the centre diff to the front diff? Or do you mean the rear output shaft that has the transfer gear on it to that sends drive the rear wheels?
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Good question, shame I can't give a good answer! :lol:

Venom had trouble with his Dccd which he bought without this shaft. It took him a while to find one on eBay, which he said he was very lucky to find! Best way is to buy the complete DCCD assembly.

If you do find a complete DCCD assembly while you're looking for your DCCD gearbox, please keep me in mind :iconwink:
 
Haha Im pretty sure its the rear shaft then. To change the input to the centre diff means taking the whole box apart. Ill keep you in mind for sure although in a month of looking I have not seen a single 5 speed DCCD which is not still in a complete gearbox :( and the one complete box I found in the right price bracket someone beat to :(

On another note do DCCD wear out? From what I can gather they are clutch type LSD with an electro magnet to control the lock. Does this mean the clutch plates can wear out?
 
Yes, they wear out but seem to be very resistant.

An other aspect to lookout is to control the magnetic resistance (ohm) to make sure that the diff works, have a look on www.DCCDPro.com
 
Only the 06 6 speed DCCD's onwards have the plated LSD as well apparently
 
Back to your L series LR, was it out of a 5spd? Aparrently the 5 spd LR will fit the EJ DR 5spd box better than the L series 4 spd LR
 
NachaLuva said:
Back to your L series LR, was it out of a 5spd? Aparrently the 5 spd LR will fit the EJ DR 5spd box better than the L series 4 spd LR
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1852 5 speed first box to come out with the 1.59. No 4 speed came with 1.59:1 I think they were all 1.468 or something like that. In terms of fitting I have both and they look identical to me. Never measured or tried to fit them so I could be wrong.

Also I finally found a good description of how the electromagnetic clutch works in a DCCD. Definitely wear parts in the clutch plates but perhaps they are very durable.

https://igotasti.com/vBforum/showthread.php?263-DCCD-info-and-FAQs
 
If it moves, it can wear out.
 
Thats a great article. Although when explaining how the cams & planetary carrier all work together is a bit too complicated for me lol.

So its both a helical & plated diff...interesting!
 
Rally said:
If it moves, it can wear out.
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Yes that is true but some parts are designed to not wear out by lubricating everything to reduce friction and limit wear where as some parts (such as clutch plates in a dccd) utilise friction in the way they work and thus one would expect them to wear out far more quickly.

NachaLuva said:
Thats a great article. Although when explaining how the cams & planetary carrier all work together is a bit too complicated for me lol.

So its both a helical & plated diff...interesting!
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Well it is not a helical diff as it does not produce a torque bias when a rotational speed difference occurs whilst in open mode. Whist in open mode it more closely behaves like an standard open diff just with an uneven torque distribution.

The clutch part of the diff is to create varying amounts of lock up. The electro magnet produces a small force in a secondary clutch arrangement. This friction causes makes the balls shown in the pictures try to roll up the cams which creates a force on the primary clutch locking the diff. The higher the current supplied to the electromagnet the more the cams will activate and the more the diff will lock. Very hard to explain. I also have no idea how the diff creates the 65:35 torque split as that part is not well explained.
 
Dedman said:
I also have no idea how the diff creates the 65:35 torque split as that part is not well explained.
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Could that not be created by the helical gears? Look at the 1st pic in post #3. That looks exactly like the helical diffs I've seen diagrams of
 
L series low range conversion finished.

I finished putting the L series gearing in my forester box on the weekend. :ebiggrin: Currently it fits with no modification to the 4.11 crown wheel so I am hoping I will be able to get the 4.44 crown wheel in with only a small amount of shaving.

Using my ingenuity I have managed to do the whole conversion accurately in a suburban backyard using nothing more advanced than an angle grinder and a drill. Everything is running true and seems to shift between low and high without issues.

14424698668_17a3da4f2a_z.jpg


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^ Beautifully cleaned, DM :) :cool:.

That will certainly stand you in good stead in the long run. After all, these aren't LC gearboxes (same principles, but far simpler and crude as all get out) ... :iconwink: :lol:. More like a precision item like a sewing machine.

Your photo is actually an excellent example of how synchro rings work as well as constant mesh gears. Do you mind if I use it at some stage for that purpose?

Please keep up the photos of how it goes back together. You can't have too many photos (you can always leave some out ... ), but it's bloody easy to take one too few - usually of some critical part of the process! :shrug: That's life, I guess.

Thanks.
 
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