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Please # for LHS ?

Sometimes you just need to sacrifice a cheap 10 mm spanner and shape it with a file or grinder, maybe even a hacksaw to make it work. A ring spanner with 12 or note points often gives best choice of short moves before reposition and another turn. I know a wrench only as the awkward shifting adjustable wrench. Hope you have better than this!

is there a blurb I missed on the changed forum format. Curious to know a bit about it. Has a Gmail smell to it

You answered one question there then Bennie. The locating pin that doubles as reverse idler shaft retainer is called a straight pin in the manuals. The straight pin for the pinion shaft is not protruding as much as expected nor the one above it. Some background. I have had this box apart once before, cases together but could not sort the diff bearings out, so pull apart, add some seals for good measure. Now , when the two cases went back together, there was an ever so slight rock centreing over the centre. Torque the bolts fixed that, maybe in more ways than I care ! Its almost as if the straight pin was punched in too far. I am have no choice but to swap the case pair from the 23 splines stubs donor box This is awd dual range but it is not the usual 19 and 23 toothed cogs of the hi lo Only 19 and 20 like later EJ low *cough* range Bloody learning exercise I really don't want or need at the moment. I just wanna get this 12 year old idea done and dusted :( Deal with locating pin first, then diff backlash Thanks Bennie. I know you are a decade ahead of me on gearboxes and EJ conversions EJ22 sits in a sealed box in a shed for old age I suspect I may just have to find a , what was it Greg ? early 2.0 Foz box and give it some EA cases Just pulled my first ex Disco, ex Subareck awd box's centre diff out as when I checked its specs it was nice n tight Only when playing with latest did I suspect something wicked was on with my first awd centre diff Toasted, rooted .....

As I tension up the first bolt of the two half cases the drive pinion starts to become notchy.as i turn it. On first assembly with all locating pins and cross case bolts in and torqued up the drive pinion was stuck fast. I am thinking to remove front diff from equation, or try another rhs housing Everything inside is snug, both halves fit nicely This drive pinion needs to spin smoothly Any experience?

Years since been inside the 4MT but think it does have a circlip holding it back AND people have broken input shaft bearing housing getting it out ! EA PT 4WD 5MT have internal circlip but guess such an interference fit things won't come out easy and yeah that tricky little oil splash guard would not jump back into place. Just got it in, two hands and me nose to guide the dual range selector shaft

IF you were a nube I would suggest the new to you needs a decent replace all replaceable type service first then come back. I ask how many customers got the pcv valve replaced every 24 months as suggested in service manuals when these cars were new? How is yours and its whole breather set up? Choked with carbon? When fuel is low also worth removing sender for peak a boo inside tank

At this age you can find the mild steel barbs the hoses fit to can be corroding away so even a new hose won't fix it. Some drill mild steel out and taper tap 1/16 bspt or 1/8 bspt to add brass or stainless barb to carry on the job Using coolant instead of muddy water is always best to help identify leak sources. Temp sender unit. replacement is good idea too if you can't add a digital gauge to measure block metal temp

I asked about this not long ago, now you have done it ! Do you know just what thread was used as the stud into the captive nut? A small pilot hole above for lube spray may be a good move for anyone not having the access hole Shorter bump stops could be handy. A mate has admired a lower than mine Brumby. Close inspection revealed the factory bump stop clearance of 20 mm has been reduced to nothing. Might have something to do with its 900,000 km as a delivery vehicle

Me? A typo? Maybe? Numbchux you had me doubting self. Wrap this around your grey matter ...my 85 GLTA had the ~ 3.5:1 up front in the auto 3 4WD and 3.7:1 in the arse end !! Silverhelme...funny story

Dual range EA82 input shaft housing O ring 61.7 x 2.4 mm 806961010 Dual range EA82 counter gear shaft O ring - leaks to three bolts input shaft holder inside bell housing 23.5 x1.6 mm 806923030 Dual range EA82 input shaft oil seal. 25 x44 x10 806725090 didn't let the three decades trusted parts manager deter the O ring order just coz no one else gets them. The old O rings hard gone all hard and brittle Reckon they will seal better given how much harder they have been to ' home'

Very tricky sorting pics on this tablet, but think I got some numbers in there to match text in first post. Also found three different size and coloured Speedo drive cogs. Black, blue and white (gone yellow) The white on is smallest diamond to match the larger diameter that drives it via the shaft

Aha. Tap that theory on its head early. Renewing the seal and of course the practice run went well with spare box input shaft slip out of housing. Real thing wants me to go visit a press

The first Brumby box I took apart I needed the jigsaw to get right size socket inside !! Ally swarf everywhere. Balls n springs pop out unexpectedly. Nightmare. Second box I managed without jigsaw.

I want to try plenum delete and run similar to Safari style - one fuel metering device above each head , even if it does look a bit VW...ish I always thought my EA81 with twins sounded like a twin carb Kombi up close. Gannon only gone back to EA82 for race class? Sell my spider ?? Think I promised you first option if the event arose .. injector holes bunged up with 10 mm Welch plugs, was a mess to begin with....

I knew I threw one of these out with its PT 4WD 3 speed auto Now realised I have tossed another Vortex turbo FWD ! At that stage did not want fwd and only wanted the casings for a single range awd box Having now driven fwd for some time now know I tossed a rare thing. Good highway diff

Think this not going to work so need to find synchronised throttle bodies. The WW Stromberg is a contender. I don't want to mess with the spiders casting. Gannon ! WooHoo ! Hardly anyone has been on ausubaru ! Facebook is for the goldfish

An impossible task to replace oil seal on the EA81 4MT DR input shaft without full tear down or break something Looking at the EA82 DR box it looks like the input shaft oil seal and the large O ring can be renewed from the front of the box and not full tear down Nothing in the manuals. Anyone done front seals from within the bell housing ? There was adiscussion on fast paced for the moment media where someone had good advice the seal can be done without teardown on EA81 box. Topic was rightly sorted

I like your handle ausubaru92. No idea where you got that from Next thing iI guess I need to count teeth on the other side.... coming up I've done gearbox repairs and rebuilds before Subaru 4WD 4MT put me off. It is better notneeding to drive gearbox the next day Thought I'd compare the innards of my hybrid 5MT DR AWD EA82 box with standard box also in bits

I have the main shafts of two boxes side by side on some cardboard Looking at the cogs to line up with hi lo counter shaft cogs I have on std dr box 19 and 25 teeth My hybrid has 25 and 22 My std 5MT DR is from a 92 wagon. Teeth count First 11. Hybrid 11 Reverse 12. Hybrid 12 Second 18. Hybrid 19 Third 29. Hybrid 30 Fourth 34. Hybrid 36 Fifth 39. Hybrid 41 Both have 3.7:1 diffs Anyone know how to figure ratio of each cog for the two shafts?

Position of alternator shifts to outer iirc. Once had all the iron mongery but chucked it ;(

play in cv joints andsteering rack ends/tie rods cn also give similar symptoms

I should have added I do not want to destroy, just ' tinker' Thanks for reply

No idea of the difference between big and small valves measurement? I thought is was of little concern like a mm