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A few projects have finally come to an end. I'm about to head away for Easter, but couldn't help but share what i've been up to. I'll fill in all the full details when I get back with detailed write ups and photos, but for now you have to guess!

You have 4 clues...

#1



#2



#3


#4
The numbers "37" & "9"

Cheers,
Owen.

didn't you blow up either a front diff in a gearbox or a rear diff ?

I remember that shot of the bits on the drail plug but couldn't find the original thread

perhaps a rebuilt box with modified hi-lo and lsd diff?

TOONGA

I think Toonga is on the money.

Clue 1 being the metal debris on the drain plug

Clue 2 is 2 gearsets and a diff stacked together

Clue 3 is no doubt a plastic hose joiner, but i have no idea what it has to do with the gearbox

Clue 4 is the number of teeth on the crown wheel and pinion wheel, which makes for a 4.111 diff ratio

TOONGA wrote:didn't you blow up either a front diff in a gearbox or a rear diff ?

I remember that shot of the bits on the drail plug but couldn't find the original thread

perhaps a rebuilt box with modified hi-lo and lsd diff?

TOONGA

Rear diff blew up.

Suparoo wrote:I think Toonga is on the money.

Clue 1 being the metal debris on the drain plug

Clue 2 is 2 gearsets and a diff stacked together

Clue 3 is no doubt a plastic hose joiner, but i have no idea what it has to do with the gearbox

Clue 4 is the number of teeth on the crown wheel and pinion wheel, which makes for a 4.111 diff ratio

1 - correct, from the old rear diff after the pinion gear was munched to about 20% of its orginal size

2- pick out a few more details, see if you can figure out what stage of the process it was!

3- see further hints below

4- Correct, the new ration is 4.11

More hints, though you've all pretty much guessed it.

#5



#6

Damn I wish I got here earlier!

Got it: 4.11 diff ratio, L series low range and diff breathers.

Nice. Bet the outback goes well now - I presume you got the gear selector issue sorted??

I got my mates liberty going tonight - this arvo at 12 noon it didn't have an oil pump or radiator Runs very nice and 1st gear no longer clicks

Good to hear someone in vic has got their gearbox project squared away!

Cheers

Bennie

ScubyRoo wrote:
#6

That white fitting looks like a homemade diff breather.

P.S. Don't forget to put the tubing on.

Well after the car's first trip out bush, I can report a few things:

Diff breather wasn't tested (no water crossings), but the hose was clean so that's a good sign as there was lots of sand and mud.

Gearing with 4.11 and 215/70/15 tires is spot on, great to drive and fuel economy has improved... I wonder why they didn't make it 4.11 from factory...

With a VERY loaded car, I can take of in 2nd when in low range (yep, that's how low it is with the 4.11 and the ej25).

You should replace bearings when building a gearbox (see this thread).

Cheers,
Owen.

ScubyRoo wrote:Gearing with 4.11 and 215/70/15 tires is spot on, great to drive and fuel economy has improved... I wonder why they didn't make it 4.11 from factory...

Cheers,
Owen.

Hey Owen.. what sort of RPM was your car doing in 5th gear at 100km/h?

RSR 555 wrote:Hey Owen.. what sort of RPM was your car doing in 5th gear at 100km/h?

Off memory it was about 2800. The speedo is out by 3%, but by my calculations at 100km/h it should be 2750. Was about 3100 @ 110km/h.

I would describe the gearing as very similar to the stock feeling of an early liberty except the 2.5l is far more usable down low, especially with the 4.11. With the way it pulls, matching this box with a H6 or EJ257 with a small turbo would be incredible.

ScubyRoo wrote:Off memory it was about 2800. The speedo is out by 3%, but by my calculations at 100km/h it should be 2750. Was about 3100 @ 110km/h.

I would describe the gearing as very similar to the stock feeling of an early liberty except the 2.5l is far more usable down low, especially with the 4.11. With the way it pulls, matching this box with a H6 or EJ257 with a small turbo would be incredible.

Ok thanks Owen.. I'm thinking my next gearbox build will have to be 4.11

RSR 555 wrote:Ok thanks Owen.. I'm thinking my next gearbox build will have to be 4.11

Of course you are! You know you want to!! I do!

Cheers

Bennie

El_Freddo wrote:Of course you are! You know you want to!! I do!

Cheers

Bennie

Yeah.. thanks to you Bennie Damn you and your ideas :twisted: LOL

RSR 555 wrote:Ok thanks Owen.. I'm thinking my next gearbox build will have to be 4.11

Hi Paul,

If you plan on running larger than say 27.5" tires consider going 4.44. I'll put my 28s (215/70/16) on later this week and let you know what it feels like, although my guess is it'll feel slightly under-driven.

With 28s
4.44 with 0.852 5th is about 2850rpm @ 100kmph
4.11 with 0.852 5th is about 2650rpm @ 100kmph

With 27s
4.44 with 0.852 5th is about 2950rpm @ 100kmph
4.11 with 0.852 5th is about 2750rpm @ 100kmph

Cheers,
Owen.

Hey Owen, I'm not sure what ratio my 5th gear is but I'm thinking I used the smallest one I had from the 3 boxes I took apart (I'm thinking it was from the L.Series box) and the tyres I'm using are 205/70R15 (pictured below)

[quote="ScubyRoo"]If you plan on running larger than say 27.5" tires consider going 4.44. I'll put my 28s (215/70/16) on later this week and let you know what it feels like, although my guess is it'll feel slightly under-driven.

With 28s
4.44 with 0.852 5th is about 2850rpm @ 100kmph
4.11 with 0.852 5th is about 2650rpm @ 100kmph

With 27s
4.44 with 0.852 5th is about 2950rpm @ 100kmph
4.11 with 0.852 5th is about 2750rpm @ 100kmph/QUOTE]

So I guess you're running the 0.852 5th gear ratio I reckon this is what I'm after for my 5th gear in the gearbox I'm looking at building. Just need to find it if I don't already have it in one of the gearboxes I've got for the build - three to be exact! Gen1 (I think) EJ AWD gearbox, L series PT4wd 3.7ratio gearbox and the L series AWD 3.7 ratio gearbox. EJ one for the casing, L PT for the low range and the last, well, you should all know why Should make for a good combo with that fifth gear too.

Cheers

Bennie