Project Slow Evolution
02 January 2006, 08:02 PM
#31
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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.
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.
02 January 2006, 09:00 PM
#32
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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
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
03 January 2006, 08:45 AM
#34
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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
Off to the tool shop thismorning to buy a bearing puller and a big vice
Last edited by Danny Boy; 03 January 2006 at 08:56 AM.
03 January 2006, 08:54 AM
#35
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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.
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.
04 January 2006, 10:24 PM
#36
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
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
05 January 2006, 10:40 AM
#38
05 January 2006, 05:05 PM
#40
There seems to be a few of us round here!
07 January 2006, 02:04 PM
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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.
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.
07 January 2006, 02:20 PM
#44
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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'
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'
07 January 2006, 02:43 PM
#45
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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.
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.
07 January 2006, 03:24 PM
#47
\m/ ^_^ \m/
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
07 January 2006, 03:32 PM
#48
\m/ ^_^ \m/
http://bbs.scoobynet.co.uk/showthread.php?t=98502
my exploits might be of some interest, but i doubt it
my exploits
might be of some interest, but i doubt it
07 January 2006, 07:06 PM
#51
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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.
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.
07 January 2006, 07:50 PM
#53
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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?
25 January 2006, 06:17 PM
#54
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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.
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.
25 January 2006, 07:19 PM
#56
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
26 January 2006, 01:51 PM
#58
26 January 2006, 03:22 PM
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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
Graham, as long as they dont sound like a JCB ill be happy
You know you want some