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  #11 (permalink)  
Old 09-12-2014, 10:12 PM
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The shift shaft has a hole that needs to be filled in. On the side of the rear case there is a half moon shape that must be closed in. On the upper smaller circle is a bolt hole that must be filled in.
Subaru Gears Product Review and assembly procedure-20140912_175758-800x600-.jpg
Also, the big shiny suba-plug on the back must be welded in.



On my main case I have a pin hole I have to get fixed (my tranny had it when I bought it), and Due to it being a TY52 case and not a TY55, 57, or 75 case The clearancing cut through just below the input shaft between some webbing.
Subaru Gears Product Review and assembly procedure-burn-through-1-ty52-800x600-.jpgSubaru Gears Product Review and assembly procedure-burn-through-2-ty52-800x600-.jpg

The TY52 is thinner in this area than the TY55, 57, or 75 which is why it is recommended to use them instead. Also if you use a TY52 (much cheaper) you will have to source up a replacement TY55, 57, or 75 center diff case like I did.
All small jobs, and maybe an hour or so's worth of welding work.


So far about two full work days worth of work on the case modifications.

Last edited by ydeardorff; 09-12-2014 at 10:27 PM.
  #12 (permalink)  
Old 12-14-2014, 02:01 PM
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The TY755 turbo transmission has arrived. If anyone wants me to document how this conversion is done, I can. It will take a lot longer to document it, than just do it. Ill wait and see if I get any interest, before I decide.
Its a really easy mod to do, just a few tools, and a grinder/cut off wheel.
So let me know...

For starters:
Here is a comparison between the turbo transmission (TY755) and the non turbo transmission (TY752)

Subaru Gears Product Review and assembly procedure-20141213_143413.jpg

The turbo transmission is on the right, and the non turbo transmission is on the left.

The bolt patterns are the same, only the turbo has more attachment bolt points than the non turbo.
The turbo also has more webbing radially to make it stronger, and the case is thicker.
The turbo transmission also has a hydraulic slave cylinder for the clutch, where the non turbo has a cable operated clutch.

Subaru Gears Product Review and assembly procedure-20141213_143008.jpg

Here you can see the difference between the unmodified turbo transmission and the modified non turbo. The rear case is discarded, and the center case section is the one that's modified.
Its only 8 bolts and the whole rear of the transmission comes off. Just dump out the guts, and keep the case and shift rod.

Last edited by ydeardorff; 12-14-2014 at 09:11 PM. Reason: adding a picture
  #13 (permalink)  
Old 12-18-2014, 08:10 AM
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Quote:
Originally Posted by ydeardorff View Post
The TY755 turbo transmission has arrived. If anyone wants me to document how this conversion is done, I can. It will take a lot longer to document it, than just do it. Ill wait and see if I get any interest, before I decide.
Its a really easy mod to do, just a few tools, and a grinder/cut off wheel.
So let me know...

Yes! I'd definitely be interested in the details of the mods required. I thought there was some welding required too? With the new engine adapter, this trans can be used with the VW engine too - so a viable alternative for anyone wanting a 5-speed but keeping the VW (or T4) engine.
Jeff
  #14 (permalink)  
Old 12-18-2014, 12:04 PM
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Subarugears makes an adapter for the type 4 engine.
Subarugears
Also, he offers the the two main pieces on eBay here for 1300 USD:
VW Transmission Reversed Ring Pinion for 5 Speed Subaru Trans Fits VW Cars | eBay

Todd, Treibler has a quick run down on his site:
Assembly

However, I took some photos of my progress: If they are blurry I apologize (it was cold out):

Subaru Gears Product Review and assembly procedure-conversion-step-1-.jpg

Subaru Gears Product Review and assembly procedure-conversion-step-1.5-.jpg

Subaru Gears Product Review and assembly procedure-conversion-step-2-.jpg

Subaru Gears Product Review and assembly procedure-conversion-step-3-.jpg

Subaru Gears Product Review and assembly procedure-conversion-step-4-.jpg

Subaru Gears Product Review and assembly procedure-conversion-step-4.5-.jpg The last gear on the shaft can be damaged using vise grips etc, you will be tossing it anyway, so its fine to grab at this point to help remove the nut.

Subaru Gears Product Review and assembly procedure-conversion-step-8-.jpg

Subaru Gears Product Review and assembly procedure-conversion-step-9-.jpg

Subaru Gears Product Review and assembly procedure-conversion-step-9.5-.jpg

Subaru Gears Product Review and assembly procedure-conversion-step-10-.jpg

Subaru Gears Product Review and assembly procedure-conversion-step-11-.jpg

Subaru Gears Product Review and assembly procedure-conversion-step-12-.jpg This part is really simple its only a shaft inside a tube. You cant mess up the gearset here. So dont panic.

Subaru Gears Product Review and assembly procedure-conversion-step-14-.jpg In this picture you can see a large bearing, a washer, and a flat needle bearing that must be transferred to the new pinion shaft. This can be done by hand, or via a press. It take only light pressure to remove and replace them. just take them off, and put them back on in the same order.

Subaru Gears Product Review and assembly procedure-conversion-step-15-.jpg

Subaru Gears Product Review and assembly procedure-conversion-step-16-.jpg

Subaru Gears Product Review and assembly procedure-conversion-step-17-.jpg

Subaru Gears Product Review and assembly procedure-conversion-step-18-.jpg

Subaru Gears Product Review and assembly procedure-conversion-step-19-.jpg

Subaru transmission manual is available
If you would like it, email/pm me.
I didn't get any pictures of my welded up, and modified mid case. But Ill get those done and post it up here.

Next Ill document the transmission clean up, and case clearancing. Again not difficult, you just need to understand how to use a grinder/sander and take your time.
The case clearancing takes the most time. It is done to the side of the case that does not have the starter hole in it.

Last edited by ydeardorff; 12-18-2014 at 03:33 PM.
  #15 (permalink)  
Old 12-26-2014, 10:10 PM
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Case clearancing:

Now that the Ring and pinion have been installed, it is time to get the case half clearanced. Remember this is done to the case half that DOES NOT have the starter hole in it.

Here are some of the tools you will need:
Subaru Gears Product Review and assembly procedure-ty755-case-mod-tools-needed.jpg

The first step is to grind down the webbing flush with the cases inner surface. Grind this down to just about the height of the central bearing boss. The black marker is where I marked the edges of the ring gear mount with the bolt head sticking through.
Subaru Gears Product Review and assembly procedure-ty755-case-mod-marking-second-clearance-step-1.jpg

Now carefully grind the webbing down far enough for the ring gear mount and bolt heads to clear the webbing.
Subaru Gears Product Review and assembly procedure-ty755-case-mod-cutting-notches-step-2.jpg

Here you can see how far down this ring gear mount and the bolts stick out. The bolts must not hit anything while the bearing is sitting evenly in the bearing race.
Subaru Gears Product Review and assembly procedure-ty755-case-mod-ring-gear-depth-profile.jpg

Subaru Gears Product Review and assembly procedure-ty755-case-mod-ring-gear-depth-profile-2.jpg

Here you can see the webbing ground down to allow the center diff and its bolts to spin freely. The shiny surface was made by using a dremel with a wire wheel on it. It burnishes all the edges and smooths them out.
Subaru Gears Product Review and assembly procedure-ty755-case-mod-burnished-edges.jpg

Here is another shot. Do your best to smooth out any sharp edges or gouges created by the grinder. You want to prevent any sharp edges. You also want to not grind on any bearing surfaces, or the main bearing boss in the center of the diff case. Once I was finished here, all grinds were smooth with no sharp edges.
Subaru Gears Product Review and assembly procedure-ty755-case-mod-burnished-edges-2.jpg

In this photo is the breather vent hole that must be added. The breather vent part number is available on the subaru gears website.
Subaru Gears Product Review and assembly procedure-ty755-case-mod-9-.jpg

A quick video of the ring gear spinning smoothly in the newly clearanced case half.
http://youtu.be/VyGF-lJlY_o

Finally the gear shafts have been laid back in place and tested for mesh.
http://youtu.be/HKSUg4G4w90

Here is a quick couple of shots using my borescope to check the clearances
Subaru Gears Product Review and assembly procedure-my-snapshot3.jpgSubaru Gears Product Review and assembly procedure-my-snapshot11.jpg
The shapes are still fairly jagged, and could be smoothed out. I may go back apply my OCD to them later.

Now the next step will be to set the pinion depth, check and adjust the mesh, install the breather vent, and fluid level hole.

Then on to the final assembly...
More to come...

Last edited by ydeardorff; 12-26-2014 at 11:25 PM.
  #16 (permalink)  
Old 12-27-2014, 06:55 PM
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Output shaft seals reversal:

Once your getting ready to start putting things together, and make everything final, youll need to either replace the seals and put the left in the right side (and vice versa), or if your seals are good, you can swap sides with them.

Subaru Gears Product Review and assembly procedure-20141227_141236.jpg

Use a wrench to remove the keeper
Then use a hammer and a flat tip screw driver to tap the ribbed section counter clockwise until it can be spun by hand.

Clean your parts and now place the left on the right side, and vice versa.

Screw them back into place, until the plate is flush with the surface of the transmission body.
Now assemble the transmission. Youll need to tighten these evenly. So move them a little at a time per side until the central diff spins, but with a small amount of drag on it.
  #17 (permalink)  
Old 01-05-2015, 01:31 PM
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Link to manuals:
Index of /automotive/forester/fsm/MY03-04/3 - Transmission/Manual and Differential

Pinion assembly:
http://www.ludicrous-speed.com/autom...20Assembly.pdf

Differential assembly:
http://www.ludicrous-speed.com/autom...20Assembly.pdf
  #18 (permalink)  
Old 01-22-2015, 03:34 PM
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A Note on my previous post:
Try not to use a screw driver and hammer is you can. You can buy the differential side cover tool, or make one. The ribs on the side covers will not tolerate being hit too hard, or too much.

I was using a spanner wrech designed for pluming.
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Its not ideal, but it works ok.

Im in the process of making a wrench out of a metal filter housing.

Right now homework for this quarter is taking precedence so when I can Ill get this posted up.

The transmission just recently came back from the shop after getting a really good bath. So things are very clean now and ready to be assembled. Its just waiting for me to get my butt back in the garage now.

Pretty soon, it will be time to tear into the motor.

Last edited by letterman7; 02-15-2015 at 03:41 PM.
  #19 (permalink)  
Old 01-22-2015, 06:39 PM
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Will your transmission use hydraulic clutch actuator or a vw cable? Also do you know if 2008 trans out of non-turbo impreza can be used for this build? Also in your opinion which year and model trans is the best for this conversion? Thanks
  #20 (permalink)  
Old 01-22-2015, 07:23 PM
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Since I will be using the WRX pedal assembly, I will retain the Hydraulic clutch on the transmission.
For information on what transmission to use see here:
FAQ

Also get ahold of Todd Treibler from subaru gears.com sales@subarugears.com and ask him about more of the specifics. I know you will need an AWD manual 5 speed transmission for this that is 1999 or newer. My TY75 is from a 2000 JDM WRX. My TY52 is from a 1995 Legacy but can be used on non-turbo subaru engines. Since Im using the WRX 2.0 turbo engine I had to get the TY75. You using the single cam engine have more transmission options.

Last edited by ydeardorff; 01-23-2015 at 04:03 PM.
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