Graham, i have spent alot of time just looking at the thing and working out how it all goes together and comes apart. I have had the assistance of some nice manuals located here:

http://206.13.93.15/STi_Stuff/STi_Manual/sti_dir.htm

They are for the 2004 Sti but the 5Mt is exactly the same.
It's all nuts and bolts at the end of the day. So many things are a black art until you do a bit of reading up and work it out.
I still wouldnt have the fogyest idea where to start with suspension though!

The diff is a new item from Rallispec in USA. Should be the new type helical from the latest generation sti.

 

Great thread Danny.

I was there that day @ Scoobyclinic, Think I remember you.

My car came third that day and im still on the std Gearbox, So keep the info/pics coming as I reckon i shall be needing it soon.

p.s. Any chance you can PM me, Where from & how much you paid for the Gearset.

Thanks
Andy

 

Danny, are you sure that the front diff from the 6 speed will fit in a 5 speed case?

 

Yes, measured it up yesterday and its exactly the same size, pic looks a little different because the new one has no crown wheel, bearings or stub shafts on it yet.

Off to the tool shop thismorning to buy a bearing puller and a big vice

 

69WRX i was there, probably at the back being quiet

This Kit is from PPG in Australia, i imported mine directly as i had an unmissable opertunity on the shipping however Pavlo at Zen Performance is the official UK importer and having since spoken to him via e-mail about prices i was genuienly surprised at what he was able to offer.
If you fancy going the gearset route he will be able to give you all the cost info you need to know, but be warned it is expensive!, more expensive than the Subaru 6 speed option. But weighing up all the pro's and cons i think for me this will be the better way.

Dan.

 

Brave man doing the gearbox I think I'll be doing the same at some point too

I turn my back for a minute and there's more projects than you can shake a stick at Great! Trouble is it makes me want to start stage 4 - and no more economy mods...

F

 

Don't get sucked in!
Graham...resisting for another 11 months.

 

Tools procured, hopefully more progress today, still waiting on a few seals from subaru though

 

Just to let you know Danny, i recieved the Datalogit yesterday morning. Cheers.

 

Dave, wrong Danny Boy. There seems to be a few of us round here!

Ill take the credit anyway though, Ta

Dan.

 

Double Post

 

Sorry bud. Will now go in hunt of the right bloke.

 

Been busy in the freezing workshop today.

New front diff with crown wheel and bearings attached next to original front diff


I have new stubb shafts but i have not attached them yet so i can still roll the box over and they dont get in the way.

 

So onto the main side casing of the box



Stripped out the forks ready to prep the casing for paint.


Mono Jack barrels work nicley to hold the selector shaft interlock plungers in place.


Standard forks and shafts


Comparison of standard forks against the new billet forks


Main casing side in the 'spray booth'

 

Reverse idler and new billet forks installed on original shafts


Front Diff Installed


Original gears reinstalled to dry assemble the box (5th gear syncro is still missing)


Box and transfer case dry assembled ready to go to Pavlo to get the presswork done.

 

I'm impressed!
All that and without a Haynes manual! You must be at 10 Spanner level
Graham

 

it's all coming flooding back, i remember seperating the transfer case was a pain if you didn't know what the hell you were doing

 

http://bbs.scoobynet.co.uk/showthread.php?t=98502

my exploits might be of some interest, but i doubt it

 

The haynes Manual is dead, long live the PDF file

 

Tricky to take into the oily garage?

Wish Haynes did actually do a manual.

 

Not too tricky when its on a laptop and the internet is on a wireless connection. Just have to wipe the keyboard after i have finished

Completed box is now in two pieces in the boot of the car and will be dropped off with Paul first thing monday morning for finishing off.

 

Excellent, 10/10. The first real gearbox build I've seen on SN (not that I've seen all threads of course).

Great pictures Danny.

F

 

As its my first project thread i thought i better dive in the deep end in true british fashion and do it properly, or is that bodge it properly?

 

OK Update time, the box has been off to see Paul at Zen Performance for my PPG kit to be installed and is now currently sat in my garage awaiting fitment to the car, just work getting in the way of progress now as usual


Finished built up half of the box complete with a new 5th gear syncro assembly, thanks paul


Comparison of standard 3/4th cogs with PPG 3/4


You can also see here the differences in the syncro tooth design.


Comparison of the tooth profile.


Close up on the diff


And the finished product


I have booked some time in with a local friendly mechanic round the corner from my parents place who is willing to rent me out his 4post ramps for the day so hopefully that should make my life a bit easier for my first gearbox change

Just need to aquire a lightened standard flywheel from API and then im all set to go.

Would you reuse the standard flywheel retaining bolts, or get new ones? and would you use threadlock on the bolts as well?

Cheers

Dan.

 

Nice one Dan

Re use (unless threads look fecked), and threadlock.

 

Dan, if you want a lightened and balance standard flywheel I have my old one, lightened to 8.4kg also with an Exedy uprated (short throw, stronger springs) cover plate that was balanced to it yours for 50 quid plus delivery or collection from Kent. It did about 30k miles before it came out for the new engine build and the billet 5kg flywheel

 

Danny, I'm impressed!
Those gears are looking almost JCB in proportion.

Graham

 

Tim thanks for the offer, might take you up on it. If you could find out a postage cost that would be great.

 

Royal mail charge 11.65 for up to 20kg, I'll ask my dad what ANC charge him for sending the same (or less!) weight

 

Thanks Steven hope they arn't fecked as, as far as i know ill be the first person to see them since the little man in Japan who put them in

Graham, as long as they dont sound like a JCB ill be happy
You know you want some