Split the box yesterday, but didnt have time to post up any pics. Current findings:

1 tooth smashed off the input gear of 2nd, plus a few good chunks and graunches.
2/3 teeth knocked of the output gear of 2nd, plus a few good chunks and graunches.
Hub/carrier? for the 1st/2nd Selector has a chunk knocked out of it.
Bits of metal about the place but not as much as i was anticipating.

Will do pics tonight.

 

Good news then

 

does sound that way.. I was expecting debrie damage to other gears..

 

Pics
Box on engine stand ready for stripping


Transfer case and output shaft together with selector


Centre diff housing


DCCD


End of main case, with 5th gear visible


One half of case with selctor rods and forks in situe, sorry forgot to take one with gears still in


A bundle of bits including modena front diff


A bit blurred, but one tooth hidden in casing


More shrapnel burried up here


Input gear missing one tooth


And again, together with one tooth!


Output gear with 2 teeth missing


And again


Chunk removed from carrier for selector fork


Still not decided on which way to go, dog or syncrhro.

I was thinking dog this morning, but swinging back round to synchro now, due to difference in cost, allbeit marginal, and the relative ease to swap over.

Steven

 

Big lumps of hard steel...

I'll be very interested to see which way you go in the end.
I think a full dog box on the road would be murder and need a good fettle every 12 months?

Also:

Straight 1st 2nd and semi helical 3rd 4th, stock 5th?
or the other way round?
Weird oil.

Graham

 

steven, personally Id go syncro, then if you want to go dog sell the box.. just remember your goal was a fast road car, not a drag special.

 

Steven, count the teeth on the reverse/selector ring, I may be able to give you one, save you a couple of quid (assuming you stay Syncro)


Graham, Thats Redline Shockproof.

Straight cut 1st,3rd & 4rth
Semi Helical 2nd
Standard 5th

---john---

 

Just sat and read this in one go

Really great to see it develop and really sad to see it go as well

Just out of interest how much is one of those sumps?And what is it made out of?

Cheers

Danny

 

Good to hear it was not that bad, but why would it break, weak matierals? or too much power? or a extreme driver....?

 

At least 2 of the above I would say

 

There speaketh drop gear smasher extrodinaire Mr. Andy Forrest

 

Does he not possess all 3 of the above?

Is shock proof oil ok in an 'old' box for road/race use?

John: (#607) why is that semi helical in 2nd? for good downshifts?
Do you have occation to drop from 2nd to first in a hill climb to boot-out of a corner?
I have just one corner at Prescott where I HAVE to do this in my Sti.
Graham

 

Graham,

The semi helical gears have no impact on shaft quality. The 1st and second are from a PAR set of 4, which were semi helical 2-4 with straight cut 1st. John Stevenson's box is a dog box.

 

Graham, what Paul says !! I don't know why Steven has a mix and match gearbox, probably circumstance, Steven ?

Yes 1st used at both Forrestburn and Fintray.

---john---

 

Yes Cirumstance. Dropped on a 1st and 2nd PAR kit, plus PPG 3rd and 4th considerably cheaper than the full PPG kit. This was thought to be pretty bullet proof (as far as you can get), and given that i had abused the hell out the identical setup on the Lateral car, with well over 100 more horsepower and torque, i was pretty confident it would hold up.

However, its seems a combination of events have surprised me, and quite a few others.

When it initially happened i thought the engine had gone, and then a drive shaft, but soon realised it was 2nd

Funny as hell at the time, and still funny now, but concern is now in my head as to what to do.

John, i will have a count up later on and get back to you.

Steven

 

Blimey oh riley, I was going to give you a bell to catch up (I still will do) but at least I've saved a fortune on the phonebill - if I'd have asked "so what's been going on with the car" then I think we'd still be on the phone next week

 

So, for me and my hillclimb/road car:

Sti v3 donar box (currently inperfect condition)
PPG semi helical synchro on 1/2/3/4 and a UK 5th for cruising (Sti is a bit revvy at 80mph)
Impact oil
5 blade paddle from Lateral with sprung center

Avon slicks.

Wonder if it is better to get a slave box as the donar and sell the Sti box to off-set some cost?
Is this a DIY/While you wait at Paul's place...?

 

John, 40 teeth

 

Chiark, we must meet up for a beer one lunchtime, maybe next week?

Graham, see if you can source a duff box as a donor and go from there. Should get one for between 50 and 100 quid.

Steven

 

Graham that's exactly what i did with mine, sourced a broken box.
Then gives you the time to be able to get the box built up without the car off the road. Or strewn about the drive in many bits

 

Thanks!
Graham

 

Graham,

Whats up, you were recommending API 800 quid rebuilds earlier.. now you recommend paul

Make your mind up..

David

 

PS And building a box isnt a DIY thing! not unless you have a press and a few tools and know how to set the preload etc.

David

 

I meant:

Drive the car to Zen
DIY to help/do the gearbox out of the car @ Zen (even i can do that)
Zen do the box
911 puts back in to save a few $$$

Or: Get a duff box (ie v6) and take loose box to Zen.
Go shopping with the wife for brownie points and come back for the box that day.
Fit box at home, struggle on your back on your own.

API do gearbox rebuilds, could get the kit off Paul and go there for same action (API much closer to me). API have a good link to Zen.

I'm going through all this as I expect the box may start to complain soon and there is only a 2 week gap between races now till end Sept.

Boy Scout stuff: Be prepared

Graham

 

In that case graham,

find a front diff now, find a donor casing now.

Buy the billet forks one month.

buy the bearings, seals etc another..

doesnt cost as much then

 

Or doesn't feel as if it does!
The gearbox fund is started and will grow.

Getting the doner will be a case of ebay i think as people on here tend to know what is the good stuff...
I have a pre-occupation to keep the stock stuff so being able to put it back to stock when I'm done with the Impreza thing (ie hill climbing).

The Impreza is getting close to being out classed soon with some of the stronger cars coming in later in the year.

Thanks to all for the input!
Graham

 

Any update on the gearbox Steven?

Joe.....

 

Of course you need a few tools (ya spanner) nothing special though, I've built a few boxes with just basic hand tools and a bearing puller.

Andy

 

What did you use to press the stuff back onto the shaft?

Waiting for parts to arrive Joe.

 

Probably a big scottish screwdriver! To tight to pay for a press