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Modified 5 speed Subaru transmission into a 2ltr bay

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

  1. paul77

    paul77 Well-Known Member

    Messages:
    1,024
    Location:
    Brisbane
    Do the Subaru trans have the crankshaft sitting higher? If so, how we would that affect tinware and carbs etc for the type 4?
     
  2. rstucke

    rstucke Well-Known Member

    Messages:
    1,808
    Location:
    Wamberal NSW AUS
    In the last couple of weeks I pulled the motor and transmission out of my kombi and mocked up the subi trans housing attached to a conversion plate and 2ltr set of cases and moustache bar (done this while the subi transmision was in bits) into the chassis.
    The bell housing on the Subaru transision is larger than the 091 trans. For the 2lr to sit in the correct position creates some challenges (but I think do able).
    The bell housing sits closer to the crossmember above it. Can't use the clutch slave cylinder. I'm designing a bell crank arrangement to mount it lower or use existing clutch cable an a bell crank (preferred), not sure yet. The starter motor solenoid fowls the cross member which was almost a deal breaker (I'm not prepared to chop anything)but have found a starter with the solinoid off to one side. Not a direct fit so had to modify the starter flange on the Subaru Bell housing. Will put up pics of the mod in the next few days.
    The Subaru transmission is slightly longer when attached to the 2ltr compared to the 091 box, it must sit closer to the rear beam and needs a small mod to the lower part of the sloped panel which is under the rear seat/r&r bead. Front gearbox mount has also been redesigned to allow the box to sit closer to the beam.
    Because the gear change rod in the box is off to one side, I'll be using a couple of small steering uni joints which I've seen working on a Bay window with a full Subaru conversion (need to think how to not butcher the gear change rod (or swap it out)
    Because the crownwheel is amboid not hypoid (ie. pinion above crownwheel centre) the drive flanges sit lower than the 091 tranny so the CV joints are nearly parallel but works without altering drive shafts (seen on full conversions)
    The throttle cable tube is in the way which I have re-routed
    I've put the the 2ltr and 091 back in Blitz and the re-routed throttle cable, works fine.
    The rest of the conversion will be done when the next engine I am building is ready to go in (next year)
     
  3. tillis

    tillis Well-Known Member

    Messages:
    361
    Location:
    gold coast
    you are a brave man...i have been painting my house but soon will do the opposite to you...fitting a VW 094 box to my kombi... yes i realise need to move engine 50mil back but no problem cos i got no cooling tin...so who is the most traitorous to VW purism? you yes VW engine and Suby G,box and me VW box but Holden engine? Ha I,m not losing any sleep over it!
     
    onetrackwonder and rstucke like this.
  4. AC-T3

    AC-T3 Well-Known Member

    Messages:
    1,098
    Location:
    Woy Woy
    Liking the journey here. Reminds me of the hunt for a 3rd and a 1/2 gear for my 091. More easily sorted with an air cooled T3. Cut 20mm from the gearbox mount, move the engine 30mm rear and bolt up an 094. Still 100% VW and loving the 1st gear under drive.
     
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  5. rstucke

    rstucke Well-Known Member

    Messages:
    1,808
    Location:
    Wamberal NSW AUS
    @tillis
    We are both impurests
    Hated by the old guard
    looking for a better experience
    finding performance in technology without showing it
    who cares (I don't). Do what you're gona do
    A big cheers.
     
    Last edited: Sep 9, 2021
    onetrackwonder, Elsie 76 and oldman like this.
  6. rstucke

    rstucke Well-Known Member

    Messages:
    1,808
    Location:
    Wamberal NSW AUS
    @tillis
    I've got 2 of those boxes if you need them
     
  7. tillis

    tillis Well-Known Member

    Messages:
    361
    Location:
    gold coast
    Thanks but have a good one and the Weddle shift mechanism...cant wait! WP_20210220_001.jpg
     
    oldman and rstucke like this.
  8. rstucke

    rstucke Well-Known Member

    Messages:
    1,808
    Location:
    Wamberal NSW AUS
    Modified the flange where the starter sits on the transmission
    The standard Subaru starter fouls the crosmember over the bell housing
    The starter I found that will solve the problem couldn't be modified so modify where it sits on the transmission
    Not an easy Job. Needed to open the access hole from 65mm to 75mm and move it away from the flywheel by 1.5mm
    Made up some special jigs and looks like it worked (won't know till tomorrow when I marry it all up and hit the starter button)
    Anyway you can see how much lower the solinoid is now

    42.jpg 44.jpg 41.jpg
     
  9. Elsie 76

    Elsie 76 Well-Known Member

    Messages:
    227
    Location:
    Caves Beach
    My head’s spinning. :confused:
     
    oldman likes this.
  10. rstucke

    rstucke Well-Known Member

    Messages:
    1,808
    Location:
    Wamberal NSW AUS
    so is mine
     
    oldman likes this.
  11. Wiz

    Wiz Well-Known Member

    Messages:
    392
    Location:
    Near Ballarat
    So is the starter motor.
    PR
     
  12. T1 Terry

    T1 Terry Well-Known Member

    Messages:
    1,704
    Location:
    Mannum South Australia
    A somewhat off topic question, are the gears on the pinion shaft keyed or fixed to the shaft so they turn when the pinion turns .... therefore spinning the gears on the input shaft, even if the input shaft is stationary?
    The reason I'm asking, I want to flat tow my Kombi but the pinion shaft does not spin the gears themselves, so no oil splash from the gears if the input shaft is not turning and the bearings end up running dry .....

    T1 Terry
     
  13. mackaymanx

    mackaymanx Active Member

    Messages:
    386
    Location:
    Mackay
    What is that replacement starter out of?
     
  14. rstucke

    rstucke Well-Known Member

    Messages:
    1,808
    Location:
    Wamberal NSW AUS
    That's a yes Terry but there's a fair bit of oil flogging around on over run with the engine off
    If it was me I would remove or at least disconnect the drive shaft from the wheel axles and tie them up
    If it's a short distance I don't think its's a problem
     
  15. rstucke

    rstucke Well-Known Member

    Messages:
    1,808
    Location:
    Wamberal NSW AUS
    BRZ Subaru (later model) or Toyota 86 sports
     
  16. T1 Terry

    T1 Terry Well-Known Member

    Messages:
    1,704
    Location:
    Mannum South Australia
    Not a short distance job and disconnecting the driveshafts means the vehicle can not be moved under its own power, a real problem if reversing is needed at any time.
    Early next yr we are planning a trip to Tassie to do an off grid install, then down to the BIL's place on the side of the Huon Valley and return up he west coast .... so we will need the Kombi to carry the gear as well drive it onto the ferry and off again each side .... costs a lot less than towing a trailer.
    The alternative is to carry on with the planned EV conversion and flat tow Kombi in 4th gear

    T1 Terry

    T1 Terry
     
  17. oldman

    oldman Super Moderator Staff Member

    Messages:
    10,481
    Location:
    Avalon Beach NSW
    Reconnection isn't that hard if all you have to do is move it a short distance Terry......
    A cordless drill/driver with the correct torx/hex bit will have it moveable in 10 minutes if you're only doing up the wheel ends.
    Just a thought.
    Cheers,
    Mark
     
  18. T1 Terry

    T1 Terry Well-Known Member

    Messages:
    1,704
    Location:
    Mannum South Australia
    Certainly quicker than doing an EV conversion or gearbox swap I guess ......... I'll try a practice run .... I'd need to drop both shafts, the planetary set in the diff wouldn't handle that much of a work out .... maybe later I could look at adapting a dog clutch set up for each shaft ..... but then I'd need to shorten them to fit it in ......

    T1 Terry
     
    oldman likes this.
  19. rstucke

    rstucke Well-Known Member

    Messages:
    1,808
    Location:
    Wamberal NSW AUS
    David H likes this.

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