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I guys,
Helping a mate do a gearbox conversion into his SG 2004 Forester.
Now we are putting a SF box in for the better low range gearbox and lightly lower highlands gearing.
Problem is we have put a new Exedy single mass clutch kit in. I have installed the SG clutch fork but now the car won't select gears. The slave cylinder isn't pushing the fork back far enough to engage the clutch.
With the car on a hoist I can use a crescent and engage the fork and clutch manually wIthaca zero issues.
We have installed a new master and slave cylinder as the old one wasn't holding great pressure.
Should I of used the SF fork to match the gearbox?

Any help greatly appreciated as we need this sorted out asap.
If needs be ill pull the engine and change the fork.

Thanks
Taza

Bump

I would of used the fork that came with the gearbox as a matter of course. Not always available but if you've got it give it a go.

The other thing could be a difference in the slave cylinders or the hydraulic system not being bled properly.

Cheers

Bennie

I have a feeling I have read that the clutch fork is different between dual mass and conventional flywheels.

Use the SF fork and you should be sweet

El_Freddo wrote:I would of used the fork that came with the gearbox as a matter of course. Not always available but if you've got it give it a go.

This would be a safer bet. Good luck

Alright thanks guys. Looks like it's engine out tonight.
We tried a SF slave cylinder too with no difference. Has been bleed properly as we had a quality Toyota mechanic handy.
I'll let you know how we go

taza wrote:Has been bleed properly as we had a quality Toyota mechanic handy.

Ok, I think I've found your problem

Cheers

Bennie

Well turns out it was the clutch fork.
We swapped it out yesterday and took the car offroad to test out today.

Great news as the gearbox was going great and the low range was decent until the box blew up! I made a few phone calls and the car is now on a tow truck back to Perth. Will get the box out during the week, strip it down and find out what's going on
It made a loud grind while trying to reverse in soft sand. Got stuck in gear and wouldn't come out, resulting in the gear selector almost bending.
Finely got it out with some rocking and has no 1st, 2nd or reverse in low or high range.
Took a brand new prado, v8 diesel troopy lancruiser and 2 foresters to get it a few km off the beach and to a main road.

Thats aweful after all the work gone into it

And that you didnt do up the bolts for the pressure plate wouldnt help

seriously?

Davidov wrote:And that you didnt do up the bolts for the pressure plate wouldnt help

Umm... How did you manage to do that Taza??

taza wrote:Will get the box out during the week, strip it down and find out what's going on

Got any juicy pics yet???? We're waiting

Cheers

Bennie

Nope no news. Been a week and a half since it was taken to the builder. Wait to hear still.
We are planning for the worst with Brett' s gearbox so we've sourced a few parts for a custom box.

Got a 6 speed sti torsion front diff, 20kg centre diff, l series low range, lower 1st gear and taller 5th gear.should make for a very capable box for Brett' s SG Foz.

Will the 6 speed front diff fit in a 5 speed case?

Gannon wrote:Will the 6 speed front diff fit in a 5 speed case?

I've got my concerns about this too Gannon - my thoughts are that it won't fit - just like almost everything else on the 6 speed...

Cheers

Bennie

Yes it'll fit. I've seen it done. Plus there are people out there go have put them in 5 speed wrx boxes.

Turns out the gearbox is rooted. Main shaft is damaged, 1-2 selector hub, idle bearing, reverse was stripped of its teeth and a few other things.
Estimate 2-3k to fix ouch that hurts

6 speed has a R180 rear diff, would have thought the front would have been equally beefed up.

If Subaru had have been smart, they should have used the same diff centre in the front as the rear. Would have made things so easy

Gannon wrote:6 speed has a R180 rear diff, would have thought the front would have been equally beefed up.

If Subaru had have been smart, they should have used the same diff centre in the front as the rear. Would have made things so easy

Yeah that'd be what I would have thought too. I find it interesting that they've retained the 5 spd front diff in a gearbox they've apparently heavily beefed up. What you say Gannon makes sense in a mass production scenario.

Best of luck with the rebuild - starting with a new box I presume?

Cheers

Bennie