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Old Fri 27th March 2009, 07:14 PM
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EJ Dual Range AWD 1.19:1 Lo range upgrade to 1.59 {56k warning}

G'day,
Since I am starting this thread for EJ gearboxes only...

My task is to upgrade this useless 1.19:1 low range in 5speed EJ gearboxes that are found behind EJ22 Liberty, also known as Liberty Dual Range boxes. I am planning to take out 1.59:1 ratio gearset from L Series gearboxes and fit it in Liberty's EJ box - It'll be interesting! (Free to comment in here!)

What you need is: Good mechanical knowledge (that you would be able to remember reverse order), 2 gearboxes - donor EA Dual Range from L series and EJ Dual Range box to work on.

Tools Required:
- 10mm ring spanner
- 12mm ring spanner/socket
- 14mm ring spanner/socket
- Circlip pliers fairly big/strong ones (inner and outer)
- Pointy Nose Pliers (to remove pins)
- 6mm nail punch/pin pusher
- Soft Hammer (NOT HARD hammer!!)

NB:
Gen. 1 Liberty has 3.9:1 ratio Dual Range.
Gen. 2 Liberty & Outback has 3.7:1 ratio Dual Range. (don't know about Gen3 etc)

Here is pictures below -

EJ Gearbox Side:


Gearbox Front:


Centre Diff (bottom):


Transfer Case removed - notice 5th Gearset:

After cracking the box up... one side and other side... Notice Dual Range section above the diff..




Main Shafts -
Top one is L series Shaft
Bottom one is EJ AWD Shaft - pretty much identical except first cog differences (that is 1.59 & 1.19 gear set)...



Upto now, I called it a day from what I noticed and learnt tonight, Is that you cant "just swap" the cogs over as they're both in different sizes.... question is can both dual range section be swapped over without disassembling whole shaft to suit... (shown in red box below)


What can I do about using L series dual range selector in EJ box - obviously I need to modify it to fit with ball bearing to stop from getting out of gear? EJ people who have converted in theirs, what have you done and how?

The Input shaft holder are both different between EA and EJ boxes, the EA one is smaller than EJ one, same goes with the bearing behind the imput shaft (I think its 6205?).

Cheers
AP
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Subarus that I have/had:
1995 Liberty "Rallye" - 5MT AWD, LSD - *written off 25/8/06 in towing accident.
1996 Liberty Wagon - SkiFX AWD 5MT D/R, Lifted.. Outback Sway Bar, 1.59:1 Low Gearing see thread: 1.59:1 in EJ Box Page
Sold at 385,000kms in July 2011.
2007 Liberty BP Wagon, 2.5i automatic

Last edited by AlpineRaven; Fri 1st May 2009 at 10:24 PM.
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Old Fri 27th March 2009, 08:31 PM
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Quote:
Originally Posted by AlpineRaven View Post
G'day,
Upto now, I called it a day from what I noticed and learnt tonight, Is that you cant "just swap" the cogs over as they're both in different sizes.... question is can both dual range section be swapped over without disassembling whole shaft to suit... (shown in red box below)
If you remove the circlips in front of the low range gears they just slide off the shaft.

Quote:
What can I do about using L series dual range selector in EJ box - obviously I need to modify it to fit with ball bearing to stop from getting out of gear? EJ people who have converted in theirs, what have you done and how?
I remember someone saying they modified their leaver in the car to have a detent rather than modify the gear selector.

Quote:
The Input shaft holder are both different between EA and EJ boxes, the EA one is smaller than EJ one, same goes with the bearing behind the imput shaft (I think its 6205?).
If you're lucky you might be able to get a new bearing with the right od and id to fit the EA shaft. When I did my Foz box I ended up using the EJ bearing with a spacer to fit it to the EA shaft.
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Old Fri 27th March 2009, 08:35 PM
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Quote:
Originally Posted by PeeJay View Post
If you remove the circlips in front of the low range gears they just slide off the shaft.



I remember someone saying they modified their leaver in the car to have a detent rather than modify the gear selector.



If you're lucky you might be able to get a new bearing with the right od and id to fit the EA shaft. When I did my Foz box I ended up using the EJ bearing with a spacer to fit it to the EA shaft.
Yep, Now I've figured out tonight (5mins ago!) and I'm relieved about that, will work on that tomorrow or Sunday.
Thanks mate
Cheers
AP
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Subarus that I have/had:
1995 Liberty "Rallye" - 5MT AWD, LSD - *written off 25/8/06 in towing accident.
1996 Liberty Wagon - SkiFX AWD 5MT D/R, Lifted.. Outback Sway Bar, 1.59:1 Low Gearing see thread: 1.59:1 in EJ Box Page
Sold at 385,000kms in July 2011.
2007 Liberty BP Wagon, 2.5i automatic
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Old Fri 27th March 2009, 08:40 PM
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The only bearing I replaced was the one on the input shaft, only because I couldn't be bothered getting the old one pressed off the shaft. I probably should have replaced the needle bearings as well, but never actually did.

ps. You may want to clear out some pm's - your inbox is full!
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Old Sat 28th March 2009, 09:49 AM
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Looking good there AP! Don't forget to let us know how difficult (or easy) it is to remove and install the low range gears that mount on the gearbox casing beside the input shaft

Keep up the good work - very useful info!

Also, with taller tyres (27 inch), which 5th gear ratio is best to use and which gearbox do you find it in?

Cheers

Bennie
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Old Sat 28th March 2009, 10:49 AM
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Went to garage this morning, pulled apart further:

Left side is Liberty's Dual Range section
Right side is L Series Dual Range section

I need to pull off the bearing off from Liberty's shaft and put on L series shaft (i will get new bearing anyway)

Dual Range selector section differences. (left is Liberty and right is L series)

I'm still working out but its long way at the moment, I need to start fitting the L series dual range onto EJ main shaft then I'll put it back in casing then will work out from there.. Might mill some off on the selector - but again its long way off.

Hoping to do this once the family goes home this afternoon..
Cheers
AP
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Subarus that I have/had:
1995 Liberty "Rallye" - 5MT AWD, LSD - *written off 25/8/06 in towing accident.
1996 Liberty Wagon - SkiFX AWD 5MT D/R, Lifted.. Outback Sway Bar, 1.59:1 Low Gearing see thread: 1.59:1 in EJ Box Page
Sold at 385,000kms in July 2011.
2007 Liberty BP Wagon, 2.5i automatic
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Old Sat 28th March 2009, 10:54 AM
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Quote:
Originally Posted by El_Freddo View Post
Looking good there AP! Don't forget to let us know how difficult (or easy) it is to remove and install the low range gears that mount on the gearbox casing beside the input shaft

Keep up the good work - very useful info!

Also, with taller tyres (27 inch), which 5th gear ratio is best to use and which gearbox do you find it in?

Cheers

Bennie
I'm running 26.5" tyres at the moment, with 3.7 diff & 0.871 5th it revs around 2600 rpm at 100kmh and to what I think its reasonable... But I would be interested to try out 0.825:1 5th gear, I think Turbo's 0.780 or 0.738 is too low for N/A.. Problem is to find 0.825 is pretty slim.. Unless someone tells me if its easy to find?
Cheers
AP
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Subarus that I have/had:
1995 Liberty "Rallye" - 5MT AWD, LSD - *written off 25/8/06 in towing accident.
1996 Liberty Wagon - SkiFX AWD 5MT D/R, Lifted.. Outback Sway Bar, 1.59:1 Low Gearing see thread: 1.59:1 in EJ Box Page
Sold at 385,000kms in July 2011.
2007 Liberty BP Wagon, 2.5i automatic
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Old Sat 28th March 2009, 01:12 PM
discopotato03 discopotato03 is offline
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I tend to think 2600 at 100 is pretty good , it beats 3200 at 100 .

BTW the tooth counts for the overdrive 5ths is 32/41 for 0.780 and 34/39 for the 0.871 .
If you want the gear tooth counts for the other four ratios (close and wide versions) I can post them if you like .
From what I can tell 5th gears are the rear most set , besides the transfer pair that take drive back up to the rear output shaft .
Something to look out for is how tall 5th gear ratio is in relation to 4th because the taller 5th gets the wider the the gap inbetween becomes .
If you have a heavy vehicle or one thats a bit peaky torque delivery wise sometimes the revs drop too much and the engine struggles to pull 5th below certain road speeds .

I find with my RX L that the short 0.87 5th (3.7 diffs and 185/60/13 rubber) is great for hilly country but a bit buzzy on the expressways .
My sort of fix will be a higher 8.6 CR and VF10 turbo so the slightly higher revs (and exhaust gas throughput) won't choke off an engine that would normally be reving less . If I had the time and money I'd open my box up and fit the taller Turbo L 0.78 5th but for 2-300 revs its hardly worth it when its rarely driven over 100 . Easier to play with tyres when the 16s go on .

Cheers A .

A .

Last edited by discopotato03; Sat 28th March 2009 at 01:41 PM.
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Old Sat 28th March 2009, 01:52 PM
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Quote:
Originally Posted by discopotato03 View Post
I tend to think 2600 at 100 is pretty good , it beats 3200 at 100 .

BTW the tooth counts for the overdrive 5ths is 32/41 for 0.780 and 34/39 for the 0.871 .
If you want the gear tooth counts for the other four ratios (close and wide versions) I can post them if you like .
From what I can tell 5th gears are the rear most set , besides the transfer pair that take drive back up to the rear output shaft .
Something to look out for is how tall 5th gear ratio is in relation to 4th because the taller 5th gets the wider the the gap inbetween becomes .
If you have a heavy vehicle or one thats a bit peaky torque delivery wise sometimes the revs drop too much and the engine struggles to pull 5th below certain road speeds .

I find with my RX L that the short 0.87 5th (3.7 diffs and 185/60/13 rubber) is great for hilly country but a bit buzzy on the expressways .
My sort of fix will be a higher 8.6 CR and VF10 turbo so the slightly higher revs (and exhaust gas throughput) won't choke off an engine that would normally be reving less . If I had the time and money I'd open my box up and fit the taller Turbo L 0.78 5th but for 2-300 revs its hardly worth it when its rarely driven over 100 . Easier to play with tyres when the 16s go on .

Cheers A .

A .


Yeah I would be interested the gear ratios as well... I think I'll stick what I have on my gearbox, 80% of the time is highway and i find 5th good for overtaking as well..
Cheers
AP
__________________
Subarus that I have/had:
1995 Liberty "Rallye" - 5MT AWD, LSD - *written off 25/8/06 in towing accident.
1996 Liberty Wagon - SkiFX AWD 5MT D/R, Lifted.. Outback Sway Bar, 1.59:1 Low Gearing see thread: 1.59:1 in EJ Box Page
Sold at 385,000kms in July 2011.
2007 Liberty BP Wagon, 2.5i automatic
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Old Sat 28th March 2009, 05:34 PM
discopotato03 discopotato03 is offline
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Hokay

Close..Teeth no .... Wide.. Teeth no .

1. 3.545 39/11 ...... Same .
2. 1.947 37/19 ...... 2.111 38/18
3. 1.366 41/30 ...... 1.448 42/29
4. 0.972 35/36 ...... 1.088 37/34
5. 0.780 32/41 ...... 0.871 34/39

I'm out on a limb after L Series and first gen dual range Lib boxes , AFAIK the Turbo RX L box uses the wide main ratios/1.196 LR/3.7 final drive .
AFAIK 1st G DR Lib has close main ratios/1.196 LR/ 3.9 final drive .
2nd G is a grey area for me but I think I did read that the DR ones were close main ratios 1-4 and tall 0.780 5th/1.196 LR/3.7 final drive . Counting the gear teeth in your box will tell for sure .

Back to Factory specs .
Auxilary Transmission gear ratio (Hi/Lo) .

1.196 - 20/22 x 25/19 . Noted Turbo model .
1.592 - 23/14 x 25/19 .

Hmmm , note how one of the two pairs of Hi/Lo gears has the same tooth count ? It would be real interesting to see how the coupling sleeve teeth are fixed to the side of the 1st motion shaft gear (input gear) because if you could interchange them there is a slim chance that you may be able to retain the Lib style shift fork and detent mechanism . No promises but really need to see close up shots of the two input gears where the high/low coupling sleeves (syncro hubs) engage in direct drive (high range) .

In some Nissan gearboxes what I call the dog ring , which has the gears side cone and short external teeth , is pressed onto a spline on the side of the gear . If they can be removed and the smaller Lib one pressed onto the side of the L input gear all you may have to change is that and the double idler gear itself . Its the need to use the L Series Hi/Lo syncro hub and shift fork that makes this conversion awkward in an EJ style trans because as you can see they are bigger/wider at the fork and a different detent mechanism in the back of an EA82 trans case .

Pics please , cheers A .

Last edited by discopotato03; Sat 28th March 2009 at 05:37 PM.
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