subaru gearbox - RWD

[mfrsr]

I've picked up a cheap legacy to swap the motor and box into my SJ410 rough truck project.

I need to convert the AWD box to RWD. it's been done many times before, and i found an article on the net a few years ago, but i cant find it again. does anyone know where there's a step by step (roughly, even just the basics would be nice) guide to doing the mod?


Also, it's a manual box with the subaru hi/lo ratio lever on it. is this a main part of the box, and could i refit it to my ute? i haven't even started pulling the box out at this stage, so this is just theory.


Cheers

Mac

[mercutio]

so does that mean you will have dual transfercase then well a cheap version of

[mfrsr]

that's the plan. pity there's no noticeable difference between the hi/lo when you're driving it. it still launches and wont wheelspin, even on gravel

least now i know the clutch is good and it doesn't overheat. it's always nice to test drive parts cars..

[spanky]

depends on what year legacy it is , on the ej 18s and early ej 20s you dont need to do any thing , but if later model you need to lock the centre diff. i am about to convert a sti wagon to rwd for drifting for a customer at work, will post some pics on this thread when apart.
vaughan

[mfrsr]

it's a 1990 BF. EJ22, non turbo. 5 spd manual.

surprisingly easy engines to pull out...now all i've gotta do is try find the damn computer in it

[mfrsr]

got it all apart. loom wasn't too bad to strip down either.

a few pics of the internals. you could probably do this with the engine and box in place, as all i've done is take the tailshaft housing off.


centre diff on left, output shaft on right


centre diff. got internal splines on both ends


tooth detail



I'm thinking all i'll have to do is weld the teeth up and put it back together.


I found the website i'd been looking for too:

http://www.mrtrally.com.au/performance/docs/112-115_2WDconversion.pdf

[mfrsr]

for a bit of oddball trivia...the link between the centre diff at the back of the gbox, and the front diff at the front of the gbox is a shaft running inside the mainshaft of the gearbox.

So the centre diff is splined onto not only the mainshaft, which turns the body of the diff, but also the front output shaft to the front diff, and the rear output shaft to the driveshaft..

weird. wonder what's gonna happen when i start welding..?

[mfrsr]

I got De-ranged to do the welding for me. Apart from one minor cockup due to me not lookling at it closely enough, it's all back together ok.

there's actually 4 sets of splines inside the diff, 2 at the front, 2 at the back. the fronts are all ok, but the backs were out of line when reece welded it. so when i tried to put it back together, it wouldn't work.

So with some minor modifications, it's all good now. just hope i didn't need that spline and bearing




So let that be a lesson to anyone else who tries this: put the rear output shaft thru the diff before you weld it!

[De-Ranged]

Bugger
Hmmm that weld dosn't look so good now that the head is seperated, you fitted it yet.... if not bring it in one night this week and I'll tidy it up...

[mfrsr]

too late, it's all back together, and i can't be arsed pulling it off again. Those splines on the back of the diff turned into an interference fit after the welding, so took a fair bit of force to assemble, and it'd be worse to pull apart.

i'm happy with it.