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Modified 5 speed Subaru transmission into a 2ltr bay

Discussion in 'Engine & Transmission' started by rstucke, Sep 5, 2021.

  1. rstucke

    rstucke Well-Known Member

    Messages:
    1,804
    Location:
    Wamberal NSW AUS
    I’ve been toying with the idea of swapping a 2007 Subaru legacy transmission into Blitz. There’s nothing wrong with the 091 transmission, just want another gear.
    The VW 5 speed (that I have 2 of) is way too long and would mean moving the engine back more than 50mm which is out of the question.

    The Subaru transmission has to be modified so it will run backwards and the all-wheel drive to the rear needs to be disconnected and removed. There is also some clearancing work to be done on one side of the transmission case to accommodate the new crown wheel which is placed on the other side of the new high torque pinion. I’ve also got a new torque biasing diff carrier to go in as the front carrier is very open and looks a little weak considering it is used on the front wheels of a Subaru and now has to push a 2 tonne kamper.

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    I’ve modified 5 other Subaru transmissions like this for kombis but all have been married up with Subaru engines. To fit behind a 2 ltr type 4 motor requires a conversion plate which is quite thick (a Subaru engine has part of the bell housing on it) and a modified flywheel to take the Subaru starter motor and heavy duty clutch and pressure plate.
    All this stuff is available through Subarugears (except the clutch, bearings, seals etc.) but as Todd informed me it has never actually been done for a 2ltr air cooled motor.
    What could possibly go wrong?
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    Last edited: Sep 5, 2021
  2. rstucke

    rstucke Well-Known Member

    Messages:
    1,804
    Location:
    Wamberal NSW AUS
    First step get Todd to modify the conversion plate. The vw transaxle has 2 frog eye mounts on top of the bell housing to hold it and the engine to the chassis the Subaru transmission doesn’t. I could put a bar under the transmission but I don’t want to butcher anything to make this all happen. I got Todd to extend the top of the conversion plate so I could cut and shape it to fit into the existing mounts (maybe).
    Next step determine the gear ratios I need and the crown wheel and pinion ratio. This transmission will be going on a larger type4 engine that I haven’t been able to start on yet.
    I’ve used the 091 box and ring and pinion ratios as a guide. I don’t want to go faster, Blits sits on the freeway comfortably at 115kph without overheating but I do want a better spread between 3rd, 4th, 5th and 5th slightly lazier than the 091 4th gear.
    The ring and pinions available are 3.90:1, 4.11:1, 4.44:1 and 4.86:1. After doing the calculations and real time runs and gear change points on a few web sites that have speedo, tacho, gear change intervals for each ratio on animated gauges I know 4.11:1 would be disastrous for an air cooled engine (1st, 2nd & 5th way to tall). Not even sure it’s good for a Subaru engine in a bus and 4.86:1 is out of the question, maybe good for a std type 1 engine.
    The 4.44:1 gives 1st and 2nd nearly the same. 3rd slightly under vw 3rd, 4th slightly under vw 4th and 5th slightly over vw 4th.


    So
    Strip the transmission, remove the, crown wheel, carrier, pinion from the gear train and the whole back half.

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    Bit of work to clearance the case with die grinders


    10.jpg

    Measure the clearances in the gear train as per manual. Fit pinion and torque pinion nut. Fit crown wheel and torque biasing carrier and torque crown wheel bolts.
    Reassemble transmission, measure and adjust backlash, adjust the preload.

    It's important to pre set the pinion depth gauge correctly must be vertical

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  3. rstucke

    rstucke Well-Known Member

    Messages:
    1,804
    Location:
    Wamberal NSW AUS
  4. rstucke

    rstucke Well-Known Member

    Messages:
    1,804
    Location:
    Wamberal NSW AUS
    Check tooth contact pattern, drive and over run.
    Replace seals and o rings



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  5. rstucke

    rstucke Well-Known Member

    Messages:
    1,804
    Location:
    Wamberal NSW AUS
    Transfer components to new nose cone
    Seal the transmission.
    Store under the bench for later problems I'm going to have
    when installing non vw transmission into kombi
    The engine build thread (hasn’t happened yet) will have the final install


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  6. Barry

    Barry Well-Known Member

    Messages:
    5,844
    Location:
    Abbotsford NSW
    Watching with interest!!!
     
    Wiz likes this.
  7. cbus

    cbus Well-Known Member

    Messages:
    13,433
    Location:
    sunshine coast
    The ability to do things properly can be a two edged sword :D
     
    oldman likes this.
  8. rstucke

    rstucke Well-Known Member

    Messages:
    1,804
    Location:
    Wamberal NSW AUS
    yep but
    needed to do something to alleviate the boredom of lock down down
     
    Last edited: Sep 5, 2021
    Elsie 76 and Barry like this.
  9. oldman

    oldman Super Moderator Staff Member

    Messages:
    10,461
    Location:
    Avalon Beach NSW
    Our apprentices are truly missing out on your experience and skill, Rick.
    Loving your passion for perfection.
    I would love to sit around a fire when yourself and Andrew (1500king) have had a couple of cleansing ales…;)
    My head would explode trying to understand the dialogue!
    Cheers,
    Mark
     
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  10. rstucke

    rstucke Well-Known Member

    Messages:
    1,804
    Location:
    Wamberal NSW AUS
    Thanks for the thoughts Mark
    But I may be setting myself up for a major fail
    There's hurdles to overcome that others haven't been able to overcome
    I've sorted some around throttle but need to sort out ctutch (I think I've got gear change sorted)
     
    Last edited: Sep 6, 2021
    onetrackwonder, David H and oldman like this.
  11. Wiz

    Wiz Well-Known Member

    Messages:
    384
    Location:
    Near Ballarat
    Great work.
    I like the bench you are using to move the gearbox around. Dimensions please?
    PR
     
  12. oldman

    oldman Super Moderator Staff Member

    Messages:
    10,461
    Location:
    Avalon Beach NSW
    It's about the size of an overhead projector trolley........;)
    Cheers,
    Mark
     
  13. Wiz

    Wiz Well-Known Member

    Messages:
    384
    Location:
    Near Ballarat
    Should be in the "who remembers" thread then. o_O
    PR
     
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  14. rstucke

    rstucke Well-Known Member

    Messages:
    1,804
    Location:
    Wamberal NSW AUS
    Shhhh! they might want it back
     
    oldman and David H like this.
  15. rstucke

    rstucke Well-Known Member

    Messages:
    1,804
    Location:
    Wamberal NSW AUS
    I'll measure and post here
     
  16. Wiz

    Wiz Well-Known Member

    Messages:
    384
    Location:
    Near Ballarat
    Thanks, I've been contemplating whether to build or buy one.
    PR
     
  17. oldman

    oldman Super Moderator Staff Member

    Messages:
    10,461
    Location:
    Avalon Beach NSW
    Ha ha ha….I have my spies on the lookout for me back at the millstone …….I can do with one now !
    Apparently, they were binning them by the dozen not so long ago.
    Cheers,
    Mark
     
    rstucke likes this.
  18. rstucke

    rstucke Well-Known Member

    Messages:
    1,804
    Location:
    Wamberal NSW AUS
    That's how I got mine.
    They were putting up for tender a whole heap of stuff in Kempsey, commercial sewing machine, tables and chairs, timber cupboards, metal cupboards, trolleys, C & j electrical tools saw horses etc. not sure why they didn't move the stuff to Tafes that needed it.
    Can't believe the waste happening through government departments.
    When I started at Glendale as senior Head teacher I was told on the first day to clear out a storage area
    3 dynomometers, 2 diesel fuel injection test beds, engines in test beds, cupboards, benches, etc.
    What a monumental waste. Sent some to other Tafes. Gave alot away.
    When I retired I took posession of a gas powered steam cleaner that was destined for the tip, I kept it for a week then drove it up the hunter to Cesnock Tafe and gave it to the auto section who were greatful to receive it.

    By the way Mark
    Think you were at Seaforth, Did you know Dick Flint, in auto, that section is gone now (good friend from the past)
     
    Last edited: Sep 8, 2021
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  19. oldman

    oldman Super Moderator Staff Member

    Messages:
    10,461
    Location:
    Avalon Beach NSW
    The waste is beyond belief and still occurring today……
    I’m sure we could trade stories all night.
    I was at Brookvale so no, didn’t meet Dick Flint….
    Cheers,
    Mark
     
  20. rstucke

    rstucke Well-Known Member

    Messages:
    1,804
    Location:
    Wamberal NSW AUS
    trolly.jpg
     
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