WimprezawrX

Hallo,

Here I am back again with a another update on my WRC S7 Replica…

For the build of this check my topic:

https://www.scoobynet.com/members-ga...roject-gb.html

Every one who knows me already, knows that I make update’s with a lot of pictures..

So sit back and enjoy…

Once upon a time there was a guy in Holland…..

No, just kidding…

It started with my other gear box, a JDM STI RA 5 speed with DCCD…







Because I did not have the controller a drove with no power at all on the dccd.
What means that you have 35% traction on the front wheels and 65% on the back wheels…

Here some specs of the Transmission:


JDM Impreza WRX STi RA Ver.II MY96 TY752VB4CA
3.454 2.333 1.750 1.354 0.972
3.416 1.000 3.900 DCCD (35:65)
Open Double-cone 3rd synchro added (RA only)
(also STi RA 555 & RA V-Limited Ver.II MY96)

The gears are very short, and will accelerate as crazy, but top speed end @ approx 240 kmh

This is the link off all the ratio’s of all gearboxes…

The SPDA - Transmission Chart

Now I have a controller that I have to mount first…



This drives very nice, and you can drift with the Impreza at a sure ten height,
because then the wheel with the least pressure will spin…and you will loose traction…

Therefore a Limited slip differential was needed…

Because I’m driving a WRX (MY01) it has the R160 rear diff with 3.54 ratio, what we already changed at the same time as the gearbox to 3.9 (JDM) ratio to come in line with the dccd what is 1:1 and the front diff (3.9).

The plan was to get a spare 3.9 diff, but that was not as easy…
Because the most of the Impreza’s are off course 3.54 and that will not do…

So I found one of a Legacy Turbo with a 3.9 ratio, but there was a lot off rust on the outside
And hoped not on the inside…

So went to a mate off mine and took the diff apart, no probs there…



Take a look in the case…that looked like new…



Next was getting the LSD mounted for my purpose , locking on the gas and unlocking at brake’s…

So we let the Cusco LSD out of it’s box…



We demounted it and hade to reassemble all the parts…



On this picture you can see the teeth of the LSD, that will give you the choice off more or less grip…



And on this one, you can see the ramp who give the choice to come hard in or mildly…



Take a look in the heart off the LSD…





When every thing was back in place, you have a gape in the casing, this is the fore pressure..



Then we bolted it down with 4 M6 bolts…and it ready to mount in the diff casing.



It is important to take a notice (if you mount one) to look at the drive way…

I marked this one for you…





Next we had to get all the old loctite off…



And make them like new…



Then it was time to put the 3.9 Pignon wheel on the LSD…



And bolt it back to one piece… off course we used new loctite to mount it…





When all the bolts where back in place…



It was time to use the wrench to set all the bolts at the same strength…





So that was ready, we put it a side…

Next was cleaning the casing where the gaskets are coming...



Also the bearing housing needed cleaning..





Next we used air pressure to clean the inside of the housing,
and we could continue to mount the Cusco LSD in to the diff housing…



Time to mount the bearing housing, at one side so we could measure the space that we must
Fill up to get the right tolerance on the teeth so we don’t get a wear on the teeth….



We used as a weight , another DCCD unit…

Also you see on the picture, the gap (yellow circle) what we need to fill , but at both sides…

When this was done, we measured the gap’s and adjusted it until it was in to the
OEM Factory tolerances…



When this was acceptable, we finished up and went home…

Because I am not satisfied with the out side off the rear diff, I will get another updates later…

Signing off for now….

Let me now if you all like what you see, and I will continue…

frayz

iTrader: (7)

Carry on fella

WimprezawrX

Hey mate...

Will do...

Stevesbluewrx

iTrader: (4)

More please matey.

Steve

Andy Murdoch

Great work mate. I really like your white Bugeye WRC. Subaru should bring out their limited edition models to reflect a WRC replica rather than a quick raid of the parts dept and a small tacky plaque on the centre console. (22B being the exception as it's the best lookin Scooby ever produced).

Your diff case looks like it came from the Titanic but I'm sure it will be fine with a shot blast a good coat of enamel!!

Keep the updates coming.

finalzero

great attention to detail, look forward to the updates.

Are you going for the full DCCD setup i.e the 5 speed RA box with the uprated diffs front and back or without the dccd (diff-free mode)

finalzero

Painted diff housing would look pretty cool

WimprezawrX

Will do matey,
But today something came up , was not able to go to the workshop...

Ill be working on the diff...

Not sure what you mean at the end, mate...
I already driving with the DCCD 5 speed gearbox, controller and next will be the Cusco LSD.

Yep, thinking off STI (intake) red... what do you all recken...

Thnx to all, for you remarks and kind comments...