Gearbox conversion

[Gianni]

So I'm slowly plannin on converting cc coupe to awd. Problem is current gearbox has issues.

Solution 1 is replace the gearbox
Problem is when i awd I'll have to again replace it.

Solution 2 is buy a lancer gsr awd gearbox

What I want to know is how do I plug the hole where the tailshaft comes out so oil ect doesn't leak. I don't wanna touch internals coz I then wanna (in the next 6 months) complete awd conversion.

I hope my query makes sence

 

[bazeng]

To go for the awd box running in fwd opinion, you will need to lock the centre diff by either welding the diff or installing a viscous eliminator. I have this type of setup running on the amg galant at the moment. You can just leave the output shaft in as let it free spin.

 

[Gianni]

Doesn't the output shaft run down to the back of the car. I havnt had a good look at the set up yet. Is it hard to lock the gearbox as in how do u do it. What happens if u just leave the shaft in to spin

 

[Rockabilly]

Solution 3 - An lsd fwd.
Cheers !

 

[Gianni]

But once I awd it wouldn't the gearbox need to be replaced. I don't know much about gearboxes.

 

[EVO-00X]

If you are serious about AWD'ing the car at a later date then yes, get an AWD box for now and use a FWD locking spline to make it run in FWD mode for the time being. Its easy to do by removing the rear case off the gearbox and replacing the viscous coupling with an eliminator. Easy 10 minute job and can even be done when in the car. You can leave the ouput shaft (which goes into the transfer case) as it is. It can sit there spinning for the few months whilst you're working on the AWD conversion out the back of your car. Or make up a metal cover for it. Then when you are ready to run it in AWD after your rear floorpan conversion is completed, put the viscous coupling back into the gearbox and bolt the transfer case on.

Pics courtesy of Neil (Vk2kyg) Album

Remove Viscous Coupling from the back of AWD gearbox

Replace the above with this Viscous Coupling Eliminator (aka 2WD locking spline) to make it run in FWD mode (dont worry about welding up the centre diff, this is all you need to do because you plan to go back to AWD later)

Covers made up for GSR AWD box where the transfer case normally bolts onto. There is a specially made cap to cover the output shaft of the AWD gearbox whilst it is running in FWD mode (this is an optional mod for you to do. You can make up something that doesnt have to be as pretty as Neil's work :lol: )

 

[Gianni]

Alrighty. Exactly what I wanted to know. So where do I buy a Eliminator or lockspline from. Would a wrecker beca good place to source lgsr gearbox

 

[EVO-00X]

You can make a locking spline out of an existing viscous coupling (VC) if you can get a hold of one. But if you buy an AWD box you want to keep the VC for when you go AWD later.

CVAP in VIC requires a changeover viscous coupling + $175 for a locking spline. See: http://www.cvap.com.au/?StartAt=15&DisplayNumberItems=15&Display=1&All=0&CAT=0&CAR=Lancer_EVO/GSR/vr4&search=Lancer_EVO/GSR/vr4
Meek in NSW require a changeover viscous coupling + $220 for a locking spline. See: http://www.meek.com.au/index.php?act=viewProd&productId=283
American sellers have them for around $100 + postage outright. Check out Sheptrans: http://www.sheptrans.com/driveline/dsm_awd.htm . There's more, you just need to look for them.

If you give me a couple or so weeks, I'll have at least 2 x GSR AWD gearboxes for sale that Im currently working on.
The gearboxes have been pulled down and inspected by myself, with any damaged items replaced with good ones, or installed new where applicable (eg damaged gears, sliders, forks etc replaced with good 2nd hand ones and any damaged bearings and synchros are replaced with new ones).