Calling All Dual Range Owners

[el_freddo]

Hmmm… think I’m looking at EJ cases too much these days, I don’t remember the top of the bell housing being so rounded. 

And those dowel hole up top - never seen that before, maybe a series 1 thing, I haven’t played with those gearboxes before. 

Cool audio clip. Could be many things - crown wheel touching the low range selector ring if they did a diff ratio swap (in which case, have a look at the pinion shaft for a weld mark); reverse gear partially engaged enough to click/grind like that - or a partially engaged drive gear for that matter too. 

So many possibilities of what it could be. Either way, don’t just drop that box in (as established)! 

Looking forward to autopsy pics  

Cheers 

Bennie

[SuspiciousPizza]

I have a 3 day weekend coming up so I'll be taking the time to begin trying to take it apart then. I found a section 1-3 FSM for cheap on eBay so I don't have to wait around to get my other one back. 

I tried taking the T-case cover plate off last night to see if there was anything obvious. The RTV is gonna be a headache, it seriously doesn't wanna budge. Glued, screwed, and tattooed down.

My idea for dealing with the RTV was getting it hot with a torch and gently using a razor blade to cut into the softened sealant. I do worry about residue from burning. I'm just going to have to be very thorough with cleaning the internals. 

I'll be recording as much of the disassembly as I can/remember to. I'll be posting links to the videos when pertinent. 

I'm kind of glad I got a "broken" box, now I can practice servicing one without the stress of potentially damaging a good transmission. 

There'll be more to come

:]

[czny]

Here's some reading for you before you dive in to that "spare".

https://www.ultimatesubaru.org/forum/topic/121582-transmission-reseal-new-bearing-with-pics/

https://www.ultimatesubaru.org/forum/topic/95638-411-awd-dual-range-in-legacy/page/2/

https://www.ultimatesubaru.org/forum/topic/100318-ej-dr-tranny-s-from-nz-ive-read-many-recent-threads-want-newest-info/

Can't recall which long gone member had a complete tear down description, but I think el freddo might know. Gloyale did some, el freddo did some. 

 

 

 

 

 

[el_freddo]

Hmmm, I can’t think of anyone off the top of my head that’s written up a tutorial. It’s one of those things that you just get into and forget to take picks etc as you go. 

Re: silicone. Just lever on the plate, the silicone will let go. The trick is not to damage the mounting face.

Cheers 

Bennie

[czny]

4 hours ago, el_freddo said:

Hmmm, I can’t think of anyone off the top of my head that’s written up a tutorial. It’s one of those things that you just get into and forget to take picks etc as you go. 

Re: silicone. Just lever on the plate, the silicone will let go. The trick is not to damage the mounting face.

Cheers 

Bennie

And, most of the old threads here on USMB lost all pics thru fotosuckit or changes in forum hosting service changes.

PM Crazyeights to see if he still has some pics & such for 5 MT d/r transmissions.

Edited Wednesday at 02:20 PM by czny