a budget offroad gearbox build and BIG tyres.

Believe me I checked everything 4 times or more. There is 2mm play between the high/low gear and the crown wheel, everything moves like it should so i have good hopes.

about the center diff. I checked thw wrx-sti tranny and there is sadly no wiring from the inspection plate. Also the number on the tranny says 9R-TY752VBCAA. It is surely from a RHD japanese import Sti from 1997.
Can somebody tell me wher i can find the specs from this tranny?
 
1) set the diff up properly then check for room between the crown and the low range setup ;)

2) I'm 99% sure all standard centre LSDs are a 5kg rating anyway. The STi's are rated higher but I'm not sure what rating they are.

Any 5mt centre LSD (with exception to the L series AWD locking centre diff) will work so long as it's in the housing it came in from factory.

So either centre diff will work on your gearbox.

I'm glad it's coming back together! Which low range did you end up going with?

Cheers

Bennie
 
After all the troubles with the so called gear box guru, i have the stock h/l. The only change is the 4.444 final. With this i can run bigger tyres with out power loss.

today i remounted the gearbox and made a stupid mistake.

how about:mounting a tranny, you finanly have all the bolts fitted, and come to the conclusion that you forgot the clutchbearing. Took the tranny out again.

I'm getting really handy in getting the transmission in and out :redface:
 
Yes my Fozzy is does drive again! shifts smoothly and the 4.444 is quite noticeable.

There are some gremlins left.
High/low works good but not with the leaver in my forester. Looks like the cable is 3 millimeters too short to push the leaver on the tranny in the Hihg gear position. The cable isn't adjustable on the tranny side.

Is it possible to adjust the cable on the leaver in the car?
 
Hey, that's great news, Casper.

Either the cable should be adjustable, or maybe the mounting plate is ...

Have you lubricated the linkages properly?
 
Maybe be the little bits of plastic at either end of the cable are gone, so that may means less movement. The in cabin lever, and transmissions mounts may be a little different across models. Lever, tranny mount for the cable etc should all come from one/car.
 
Pull off the center console - the lever should be adjustable (cable bolted in a slot).

Correct procedure is to put in high range (lever down), loosen bolt so it falls in its natural position, then tighten.

EDIT: I'm a little confused, if cable is too short, it should have trouble shifting into low range, not high (normal).

also found a picture of the mechanism - you can see the cable end bolted (big gold coloured nut) in the slot under the LR lever.

b7bu.jpg
 
Is it possible to build a cheap offroad gearbox? No

my first gearbox guru messed up, there by killing the extra low high/low gearing.
I opened the gearbox myself mounted the stock high low and solved the problem with the 4.444 final.

I drove my foz for a month without a problem. I bought bigger tyres, 225 75 15. And with the 4.444 the foz makes just at much rpm's as with the stock tyres. For me important because my foz is also my daily. Fuel consumption is the same as with the stock tyre size. So far so good.

But... after a week the tranny started to pop out the second gear, becaming so wotst that i had to held the gearleaver in place with my hand. Otherwise the second was useless.

I took the gearbox out again (the fourth time this year.. ) and brought it to a wellknown gearbox specialist.
Who was advised to me by several other gearbox companies.

After 2 weeks received the box back and install it again... And guess what? The second gear is still not oke. I am getting a bit desperate, did somebody voodoo with my gearbox?
 
Very sorry to hear that! What an absolute nightmare for you, Casper :cry: :puke:.
 
Casper, this really sucks mate!

This is also one reason why I learn how to do my own stuff, then I've only got myself to blame!

One thing you can check is the dedent ball and spring. On the LHS side of the gearbox are three 12mm bolts. Behind these are a spring and ball. Check them as one spring might be broken.

I can't remember off the top of my head which one does 1st and 2nd, I think it's the lowest one, 3rd/4th in the middle and 5th/reverse up the top.

I hope it's as simple as a busted retainer spring, I can't see it being anything else other than internal springs on the synchros and selector hub - but you'd know about that!

Also a good idea to drain the oil then see if you can feel any loose bits in there if nothing comes out in the oil. This will give you a good idea of the health of the internals - and allow you to check the ball and spring without dropping oil everywhere. You will need a little hook to pull the spring out ;)

All the best, I really hope it's a simple issue!

Regards

Bennie
 
To day I brought my forester to the gearbox shop. He will take the box out and fix it. I didn't had the energy anymore to do it a fifth time this year. He start working on it upcoming week, so wait and see.

well i do have to take the gearbox out of my wifes 02 forester. The clutch of that forester is slipping and i'am quite experienced now with this kind of work.
 
1 week after i brought my forester i could pick it up. Gearbox is oke now the only thing that the garage forgot was to tighten the front wheels properly. After 40kms driving on the highway with 140km p/h my forester starts to shake that became severe in a few hundred meters. I stoped and found out that on the leftfront wheel only one nut was still tighten, the other 4 i could turn easily with my hand. At the right frontwheel 2 nuts were loose. After re-thigten the nuts my forester is finally ready.


what i now have thnx to the 4.444 final is a fozzy with 225 75 15 wheels which drives likes a fozzy with stock tyres. But man what a troubles it gave.
 
Finally it works ! Cool !

Hope I'll never break down in the Netherlands...
 
Great to hear, Casper. At long last! What a trial it has been for you!

Glad you realised the wheel nuts were loose before things got really ugly ...
 
I'm sorry you had such problems getting the gearbox you wanted, I'm very glad its done now!

very lucky with the wheel nuts! :eek:
 
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