el_freddo Posted May 20 Share Posted May 20 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 1 Link to comment Share on other sites More sharing options...
SuspiciousPizza Posted May 20 Author Share Posted May 20 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 :] Link to comment Share on other sites More sharing options...
czny Posted May 20 Share Posted May 20 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. Link to comment Share on other sites More sharing options...
el_freddo Posted May 21 Share Posted May 21 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 Link to comment Share on other sites More sharing options...
czny Posted May 21 Share Posted May 21 (edited) 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 May 21 by czny Link to comment Share on other sites More sharing options...
el_freddo Posted May 26 Share Posted May 26 Any autopsy pics? My popcorn is going cold Cheers Bennie 1 Link to comment Share on other sites More sharing options...
SuspiciousPizza Posted May 26 Author Share Posted May 26 No transmission work done this weekend, I had a graveyard shift Saturday and Sunday so I stuck to interior work. Also going through all the nuts and bolts. De-rust, ultrasonic clean, and sorting the damaged ones out. And cleaning all the emissions and coolant plumbing. The pedal box is also getting cleaned up and lubed. I just stuck to work I could do in my pajamas and not get all greasy. On a transmission note - One thing I did notice was my two Loyale ('91 & '93) SR4WD also have those two upper dowel holes. Even more interesting that the '85-'90 parts manual I have doesn't show those dowel holes on any of their transmission diagrams. I found a shop in town to get my D/R resealed and synchros bead blasted. I had to go through and make a list of all the seals, o-rings, bearings, and bushings. I bought all the seals and o-rings I could. Pretty cheap to buy all the seals (sans 2 o-rings and the weird "top hat" seals I believe). Think it was around $50. I'm taking the transmission in this week. The RTV on the spare trans is going to be an issue. They really laid it on thick, I cannot get the T-case cover off. :] Link to comment Share on other sites More sharing options...
SuspiciousPizza Posted Tuesday at 12:29 PM Author Share Posted Tuesday at 12:29 PM I have a question regarding axles. My D/R transmission has 23 spline hubs, I've been looking around and I found two axles that according to the photos would fit, turns out they're 25 spline axles. The neverending joy of finding the right axles. Is there any parts interchangeability between axles? Could I use the 25 spline axles for their inner or outer joints? Or are they differently sized parts? Or could I put the 23 spline inner races on the 25 spline axles and use a beefier axle? I'd assume they're completely different, but still worth asking. Thanks :] Link to comment Share on other sites More sharing options...
moosens Posted Tuesday at 05:39 PM Share Posted Tuesday at 05:39 PM Archives should have answers on mixing ends. I seem to recall folks swapping ends but be sure to verify. There should also be a reference chart that I recently saw. Link to comment Share on other sites More sharing options...
el_freddo Posted Wednesday at 08:19 AM Share Posted Wednesday at 08:19 AM Depends on the splines on the axles that the races live on. These could be different between the axles. You could try just swapping the inner cups but this usually results in a noisy cv joint. The 25 spline shafts are no thicker than the 23 spline shaft, just the spline count changes and the diff stub axle is thicker on the 25 spline units. You could swap your gearbox for the MPFI box with the 25 spline diff stub axles… Cheers Bennie Link to comment Share on other sites More sharing options...
SuspiciousPizza Posted Wednesday at 12:38 PM Author Share Posted Wednesday at 12:38 PM Interesting... It'd be interesting to see if it's possible to remove the splines themselves from the axles. It looks to me like the splines were broached and then pressed into the inner DOJ race. I wonder if they can be removed from the race, get a custom 23/25 spline insert machined or broached, and then pressing that back into the DOJ race. What I'd mainly be interested in swapping is the outer joint, as this is what seems to be making noise on tight turns (getting out of parking, etc). But swapping in a new axle and keeping the inner race does the same thing. I'll be experimenting with swapping axle parts this week. At the minimum they all need to be regreased. Haven't heard much from the transmission rebuilder, just that I may use my spare as a parts transmission if they end up needing parts. I gave em all the seals I could get ahold of and a copy of the FSM. I'll keep y'all updated with photos if I can snap a few. Thanks for hanging in there along with me :] 1 Link to comment Share on other sites More sharing options...
SuspiciousPizza Posted yesterday at 12:09 AM Author Share Posted yesterday at 12:09 AM The inner DOJ races cannot be swapped between 23 and 25 spline models. The 25 spline axles are a larger diameter (0.944" vs 0.896" measured on the axle shaft) and use a larger DOJ race, ball bearings, and carrier. Also the splines are most definitely NOT pressed in. Modifications to the inner DOJ race to convert a 25 spline race to a 23 spline race would take a fair amount of machining. It'd be interesting to see if a 95AC23 DOJ race can be swapped with the D/R's 87AC DOJ race. :] Link to comment Share on other sites More sharing options...
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