gearbox was dropping out of 3rd and 4th ----christmas tree of filings didn't look good - so stripped the box down to find the main bearing was shattered and filings distributed right through the box
so....decided to replace all bearings (right down to the little needle rollers) about $1000 in parts including a taller 4th gear I sourced this neat bearing retainer plate from TH Parts in Germany to solve the floating halfmoon key that pops out - this locks the whole bearing in place rather than just half of it being held in place by the case.
Meanwhile, pulled the heads on the suby motor, replaced gaskets and seals, water pump and timing belt and torqued it all back together. Then started sorting the wiring [/ATTACH] Busaru are a wealth of info on this but it's still a tedious pain in the butt! next time I'm paying someone else to do it!
I bought the RJES bell housing - this uses the original vw clutch friction plate inside a suby clutch housing thingy -
engine and gearbox in - I mounted it all up with the box mounts in and the engine on jacks so I could fab a carry bar Rocky Mountain Westy exhaust arrived (4 days via UPS from the states) - my local exhaust bloke is booked solid for months with people spending their super! this cost me 995 aud landed - took 10 minutes to bolt it on! Cat and muffler soon to come!
yes I know, the standard sump messes my ground clearance - i'm saving up to get the shortened sump then I can get my skid plates back on and go "Syncroing" again! I started all this in may 2019 and have SERIOUS Syncro withdrawals happening here!
Nice work. Yes that sump needs to go. Not sure you will get the syncro skid plate on with that cross member unless its cut and welded on either side?
Also kudos to the guys at Northside Transmissions in Sandgate whose expert help got me sorted on the more difficult parts of the box rebuild!
Ok it's on the road (i drive it to work most days) performance is AMAZING! so much more power. for comparison: driving over the gateway bridge i'd be back to 2nd gear doing 60kph with a bunch of frustrated drivers behind me....now i cruise over in 4th gear (i put a taller 4th in it too) trying to hold it down to 80kph! Much better fuel economy too! I get about 450 to 500ks out of a tank full now where it used to be looking empty at 330ks with the old wasserboxer. downside: still having issues with the gearbox despite replacing EVERY bearing - doesn't like going into 1st at times. I'm thinking sooner or later this auto forester in the shed is going to donate the whole drive train and live a better life! apart from that i love it! made it fun to drive again without the constant breakdown anxiety and lack of power. Still have to tidy up some wiring and get the sump shortened to regain some clearance ( backed into the kerb once and dented it! almost a coronary!) Also upgrading my camper set up with new solar panel, charge controller and battery while i'm at it.
