a budget offroad gearbox build and BIG tyres.

Your English is good, got the message across.
You are talking about the top left parts in the below image.

14432434717_19038e8fe4_z.jpg


And all the parts back together again.

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When building my box I found out that it was very difficult to get the little synchro keys in place with the c clips during assembly and they come out if you bump the selector ring before its all together.
If the shim under the input shaft is significantly to large this could also be an issue even if assembled correctly.

Good to hear you got it all sorted!
 
Yep dedman that's it!

any thoughts about the speedo sensor wirering somebody?

If possible i would leave the 2 wire senor in the tranny, I'm worried that it will break in 2 parts when i try to turn it loose.
 
The two and three wire speedo sensors output a different signal type and I am pretty sure they can be swapped. You can get electronic converters for the different signal types but they would be more than a second hand sensor I would have thought. Physically I am not sure if the 2 and 3 wire sensors can be swapped either but I would imagine they would be the same.
If your gearbox builder did a good job cleaning everything he should have removed the sensor already so it should be loose. That being said I have pulled sensors out of three different 15+ year old gear boxes which would never have had the sensors removed from new and all came out without and issue using an open ended spanner.
 
You were right dedman.

i bought a 3 wire sensor and that fits with out a problem. Thnx!

today the first testdrive. The "new" engine runs perfect. Gearbox works smoothl, there is a noticeable difference with the high/low gearing compared to my wifes stock forester. All electrics are working fine

So far the good news

sadly there is a strong whining noice when the engine is running. If i press the clutch the sound disappears. The clutch is new and works oke. Now is the question is this sound the clutch or is it the gearbox again? I must say that i'm getting a bit sick and tired of this, i want my subi back on the street again :furious:....
 
Bugger. You are not having a good run...

From your description it is hard to tell clutch or gearbox although I am tending towards gearbox. Answering these questions will help pinpoint it.

Is the noise there when:
- The clutch is lightly pressed but not enough to disengage the clutch?
- When the car is moving?
- In any of the gears when the car is moving (if so which gears make the noise)?
- When idling with clutch out but low range is selected?
- At all engine speeds when not moving?

Was this noise there before you took the box back to the builder?

Hope you work it out soon
 
I'am getting a bit desperate of all this.

the whining noice is there with the engine running in neutral and not thouching the clutch. It changes in tone when i put the h/l leaver from h to l. It's gone when i press the clutch pedal
Imho a bearing isn't good. The sound is stronger than the noice of the engine.

had contact with the gearbox guru and i was a bit mad (understatement).
Anyway i removed the gearbox again a have brought him this bloody tranny for the 3th time.

I'am getting quite handy in removing & mounting a tranny in a forester. That's the only benefit of this mess. Tranny will be ready for 3th time next week and it better be good. Or the gearbox guru has to run for his life. And i'am quite fast at 10km running :twisted:
 
Most likely culprit is the input shaft bearing. Had this myself, thought it was the thrust bearing.
 
Based on what you are saying I have a very strong suspicion of the cause of your problem. Its a very easy mistake for those who are not familiar with Subaru gearboxes and can even happen if you do
In the below image there is a little bearing on the input shaft between the low range section and the main gearbox section. In the first image you can just see a little hole drilled in the bearing casing which needs to be located on a pin that goes through the shaft the reverse gear spins on which you can see in the second image. If the hole and the pin do not line up the pin squashes the bearing making it feel all notchy and I would assume make quite a bit of noise.
PICT6696.jpg


24024085.jpg


Pay close attention to the bearing orientation on disassembly of the box. The bearing will need to be replaced if it was assembled incorrectly.

When putting it all back together the last check before the two halves of the transmission casing go together should be to check that the bearing is located correctly on the pin.

Once the box is together turn the input shaft and select all gears including low range before installing the box in the car
 
The man who build my box thoes only build subaru boxes , most of the time rally and circuit race boxes. The impreza guys are nearly worshipping this men. Well I'm not, I thought that this man would be THE specialist i needed. Sadley it seems that i'm the first one who wants a modified h/l forester box.

Anyway it seems that all the bearings are oke and the problem is that one of the sprockets of the 1.59 is slightly too big in diameter. There is not enough backlash between 2 gears. He ordered a new one, and i hope that it doesn't take 6 weeks as it did the first time. My subi is now 3 months out of order.... :madred:
 
Thats bad luck mate! We had to machine and grind a few parts in my box to fit the 1.59 gearing with the 4.11 ring gear. The first time the box was together I had to stop to shift between low and high range as there was too much play between both synchro's and the synchro hub. Thats now been rectified and is spot on.
 
Sounds like he's great with normal gearboxes but not as good with dual range boxes. I hope it doesnt take too long...
 
I don’t have much luck with this conversion.


I made the appointment that my gearbox would be ready last Saturday.

It was, but when I checked the box, the gearleaver of h/I was stuck and the shaft which goes in the clutch turned very heavy. (don’t know the right name for this shaft.) You couldn’t turn it by hand.


Because this guy only has 1 hand, I helped him yesterday evening with dismantling this gearbox. At first there was nothing to see and every thing looked oke. We decided to put everything back together and constantly checking if the leaver was still working and all axels were moving without too much friction.


Everything seem oke, until….
When I mounted the 3 bolts which mount a cast iron part in the bellhousing (is that the right word?) It holds the input shaft. After mounting these bolts the H/L leaver and the shaft got stuck. When turning these bolts lose I needed more the 5 mm and the it felt oke again. We found the problem and now looking for the solution.


:furious::furious::furious::furious::furious::furious:


I must say that I’am getting sick and tired of it. My fozz is now more then 4 months out of order and I miss the off-road events.
 
Sorry to hear sbout your continuing troubles.

That sort of thing really gets me going too, Casper. I've had my fair share of it!

Sounds as if something is not seated properly, or a thrust washer has the wrong clearance, but it's probably something else. I'm sure as heck not an expert on gearboxes!
 
casperfromholland said:
Everything seem oke, until….
When I mounted the 3 bolts which mount a cast iron part in the bellhousing (is that the right word?) It holds the input shaft. After mounting these bolts the H/L leaver and the shaft got stuck. When turning these bolts lose I needed more the 5 mm and the it felt oke again. We found the problem and now looking for the solution
Click to expand...

Sounds like a synchro ring hasn't seated properly or the new low range's synchro hub needs a modification to fit properly - which also has me wondering how it was secured with the clip. Mine had 4.25mm removed from the spline to make it fit on the EJ shaft:

IOvmqe.jpg


More details here: https://www.ausubaru.com/forum/showpost.php?p=118407&postcount=13

I reckon this is where the issue is.

Also I know your pain about down time - 8 months to get my gearbox back in the subi after a number of hurdles!

All the best.

Bennie
 
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