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Do you remember the length and spring rate of the detent springs you installed, I would only need one for first gear though, might wait until another one gets weak. I don't know if you are looking for better traction like VDC but I am trying to find a way to install a traction control, for off road use only, based on Arduino. http://rcarduino.blogspot.ch/2013/06/rc-arduino-traction-control-traction.html?m=1

Thats excellent news, finally fixed !

Happy you have recovered ! Now imagine you had a snow storm on top of that...

Can't see the vids here but watched them on youtube, some cool footage, thanks ! Did you finally get up the ultimate climb ?

I can't see another SUV or 4x4 being lighter than a Subaru. If you install a body lift (1-2"), you can also gain some up travel and won't hit the underbody as often. Limited slip diffs front and rear are available for our Subarus, and even an Eaton/Harrop E-locker since Rally modified a front Nissan D40 he installed at the rear of his Forester in a R180 diff, report to come....

I'll wait until you make a steep down hill review before changing for similar springs ! And sorry, can't help about the headlights.

Impressive ! You go 2 wheels on some portions...its hot !

Can't see the vid...

Nice ! Do you have the same spring rates on both the Outback and Forester ? The Forester seems to jump more over the bumps. Maybe some softer springs or more damping (rebound) would help.

Dedman on offroadsubarus built a box with 1,59:1 and 4,44 but he did take some more meat off the ring gear.

As for the diff lock EJ box, you can put a DCCD center, its plug and play ! Another option is a 20kg center, hard to find and won't lock as well as the DCCD.

Can't remember...do you have a 1,59:1 low range ? Because normally, the 4,11 ring gear clears the 1,447:1 low range, its standard on EUDM and AUDM. I too have first gear popping out driving down rough grades while engine braking...if you find stiffer springs, let me know !

Yes, reverse is quite fragile on manual transmissions when low range is engaged... To "strengthen" your gearbox, you should swap your diff ratios to 4,44.

You can go for a EUDM or AUDM EJ box, change the 1,447:1 for the 1,59:1 from your EA82 and swap the 4,44 final drive from an SG XT. Its not plug and play but has already been done.

I too have a long travel suspension setup (HotBits), but not as custom as pontoontodd's. My setup is more for "crawling" and because the wheels stay longer in contact with the ground it sure offers much better traction as there still has no locking diffs for our Subarus (Rally on offroadsubarus.com is actually making one)

Honestly, doing a lot of work on a severly rusted car is not ideal. I don't know on what budget you are but maybe find another Outback in a better shape and keep this one for bits and pieces. Here in Switzerland, you can find many Outbacks for relatively cheap on www.autoscout24.ch www.ricardoauto.ch www.anibis.ch and also in France on www.leboncoin.fr (easier for you as you are in the European market)

Nice Outback ! I like the way you reinforced the chassis, it should resist a few winters of salt. Is your rear suspension lifted with springs or blocks ? Because if you've lifted it with springs (Kings, Dobinsons...) it makes your self-levelling struts not work properly.

There aren't any lockers for the r160 but a few alternatives are available. I have Quaife helical diffs f/r, and some Subaru owners have plated diffs (Kaaz, Cusco). Few other makes are on the market as well. A rear locker on a 5mt is nearly useless because the center viscous diff is not strong enough. But you can upgrade with a DCCD. The best option for the 4eat is to upgrade the MPT for a VTD. "Rally" on offroadsubarus.com is actually trying to fit a rear locker in his Forester http://offroadsubarus.com/showpost.php?p=97910&postcount=404

If I remember last time I did it, it was something between 0,12 and 0,18 mm and 0,10 mm preload on the diff bearings.

Gear mesh seems good. Have you already changed all the bearings or just swapped ring and pinion from another gearbox ? Back lash can be verified from the drain plug hole after the gearbox is assembled.

Could be the back lash of the front ring and pinion, or not enough/too much preload on the diff bearings

Don't push too hard in low range especially with the H6... Now you have to install a DCCD and you're done !

Think you will find spare parts for your dual range easier and cheaper in Australia rather than Europe. Check on www.offroadsubarus.com

I drove to Sète then took the ferry (38h) to Tanger. Wife and kids took the plane to Marrakech.

I have a few on youtube !