241 replies to this topic

[Evo-00x]

Excellent.
I'll come back to here when I've done some weighing and pricing for shipping.
Thankyou.

[BRUSHED]

Done well Rob, thanks for putting up all the info needed, it makes it a lot clearer for people not to switched on about gearboxes, myself included

[Evo-00x]

Weighed the parts up tonight. Please see pic descriptions and weight in kilograms. This should help guys work out postage for themselves for wherever they live.
I even checked the calibration with one of the kids 25g bar of el cheapo muesli bar. The digital scales measured it as only 24mg!! We got ripped off 1mg!! lol
Actual weights may be +/- a few small grams to factor in chipped teeth or still some oil and grit on some parts that haven't been cleaned properly yet.
Note: The double synchro for 3rd gear and 4th gear are the same so I only took one pic and just the one measurement obviously.

4th gear only upgrade
2850 grams = Intermediate shaft
510 grams = 4th gear
119 grams = 4th double synchro
Total weight = 3479 grams
Say 3.5kg + add extra weight for whatever you're going to wrap and post it in.
Realistically say 4.5-5kg will cover it.
For 4.5-5kg Australia Post Express post international includes signature on delivery and tracking = $138.45 one way.
Other postage options and pricing for 4.5-5kg is in attached pic.

3rd and 4th and Centre Diff upgrade
2850 grams = Intermediate shaft
511 grams = 3rd gear
119 grams = 3rd double synchro
510 grams = 4th gear
119 grams = 4th double synchro
3207 grams = Centre diff housing including cover, minus internals and minus bolts
160 grams = Centre diff cover bolts ( 8 x 20 grams each bolt = 160grams)
Total weight = 7476 grams
Say 7.5kg + add extra weight for whatever you're going to wrap and post it in.
Realistically say 8.5-9kg all up will cover it.
For 8.5-9kg Australia Post Express post international includes signature on delivery and tracking = $215.25 one way.
Other postage options and pricing for 8.5-9kg in in the attached pic.
__________________________________________________________________________

OK, I went through my parts today and I found the following parts suitable for doggy styling
2 x (CD5A GSR, CD9A EVO I, CE9A EVO II & EVO III are all the same) intermediate shafts with chipped teeth on 3rd gear and 4th gear = suits the 3rd and 4th gear dogbox upgrade.
1 x CE9A (EVO II & EVO III) double synchro 3rd gear still good, but it must be sacrificed = suits having the synchro section cut off to mate to a new 3rd dog gear.
3 x CE9A (EVO II & EVO III) double synchro 4th gears with chipped teeth = suits having the synchro section cut off to mate to a new 4th dog gear.
2 x used but good double synchro sets to suit CE9A 3rd gear and 4th gear.
1 x centre diff housing I was saving for my spare box.

Hmmm... but looking at those prices and as my car is mostly street I think I'll go back to just wanting the 4th gear upgrade.
Any of you guys going to get the 3rd and 4th gear upgrade still have good 3rd gear teeth on your intermediate shaft?

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[ENGINR]

<sup>I'm going to get the 3rd and 4th gear upgrade done Rob, but have decided to get the centre diff housing machined here locally (to save on postage) when the gearbox is apart.

PM me prices for what you want on

1 x (CD5A GSR, CD9A EVO I, CE9A EVO II & EVO III are all the same) intermediate shaft with chipped teeth on 3rd gear and 4th gear = suits the 3rd and 4th gear dogbox upgrade.
1 x CE9A (EVO II & EVO III) double synchro 3rd gear still good, but it must be sacrificed = suits having the synchro section cut off to mate to a new 3rd dog gear.
1 x CE9A (EVO II & EVO III) double synchro 4th gear with chipped teeth = suits having the synchro section cut off to mate to a new 4th dog gear</sup>

Edited by ENGINR, 12 September 2013 - 11:31 PM.

[BRUSHED]

I'll get all 3 upgraded and should still have a good 3rd gear that's ok

[Evo-00x]

Shayne, Ive got all the bits for you to get the 3rd & 4th & centre diff upgrade done.
* Intermediate shaft
* 4th gear
* 3rd gear
* Double synchros
* Good oem centre diff housing including cover
Don't be silly, I don't want any money for the parts from you mate. All I will need from you is your oem centre diff housing when you pull your gearbox down to replace the centre diff housing I'm sending to Matthias on your behalf.
That sorts you out right now so its ready to ship as soon as I pack it up

I just want the 4th gear upgrade done so I have a 4th gear and synchro ready to send. But I don't have an intermediate shaft that still has good teeth on 3rd gear.
As soon as I get one I will ship both of our parts together as it should come in under the maximum 20kg allowance.

Hey Brushed... what's your intermediate shaft like that you are going to send Matthias? lol

[DOUGMO]

ill check my smashed intermediate shaft tomorrow and let you know

[BRUSHED]

Not sure how it all is but hoping its all ok. I'll let you know once it's stripped down

[ENGINR]

I'll try to run my spare gearbox up to Vibert next week Rob.

[Evo-00x]

Cool. Thats all we're waiting on before its off to Deutchland

[GSRWRC]

Damn, would have been keen on a 4th upgrade if I had the funds!

[Hypo]

Because I am lazy what is the landed back here and assembled cost going to be if you have all the required parts.

[Evo-00x]

^{Australia Post rapes us as far as domestic and international parcel post costs go. Other countries should offer a cheaper return shipping cost back to Australia. 'Should' being the operative word.
Installation costs depends on where and who you get to do it for you. If you supply your gearbox to a gearbox rebuilder they probably have about 6 hours worth of disassembly and reassembly work.
Also depends on the existing condition of your other internal parts - synchros, bearings, keys, springs, sliders, seals etc.
You're not going to skimp on something that needs replacing whilst the gearbox and both sticks are apart. Ignoring other parts would be a very foolish thing to do as you could potentially put the gearbox at risk of failure and ruining your dog internals.}

[Andrewv]

I cannot believe that I remembered my password after nearly 4 years.

Over the years I have probably seen inside 40 or 50 evo/gsr gearboxes. I have only seen broken boxes from extreme use. The drag strip is by far the biggest culprit. Side step the clutch at peek power on a gripy surface in a 4wd and something must eventually give.
Keep in mind that these boxes will all eventually suffer from fatigue as they are not getting any younger.
Martins buggy has so much torque that the centre /diff Viscous unit could work out what to do with the drive. It often sent power to the wrong end. The Quafe was the only option and it works really well.
His box will brake at some stage and then I suspect it will get a full straight cut dog drive kit from Drenth. I have seen a few broken PPG and Albins boxes.
Any high HP evo/GSR with a std box has a marginal box for track or Drag work. My final words to anyone in any car with a marginal gearbox has always been "Treat it with a mediocum of consideration" (not sure if mediocum is actually a word). That means dont race syncros, allow the box to change gear, think about the mechanical loads and shock off the line.
As an example I ran a Toyota in the Vic rally championships for 10 + years with a T50 gearbox rated to 165 hp. I had closer to 200hp I never broke a box. Engine had enough power for me not to have to abuse the box. The guy I sold the car could not keep boxes in it. He over drove the box.
If 3rd and 4th are appearing to be a problem then this conversion looks the goods. Keep in mind that this may just shift the problem somewhere else.

[evopwr]

Have you guys explored local gear manufacturers here in AUS land?

Eg: Colgen Engineering Heidelberg?

Just a sanity check I guess..

[Evo-00x]

Alex, Im sending a damaged Cusco centre diff drive gear to a gear manufacturer in VIC this coming week to get them to price up a replacement for me. Thatll give me some indication of what a gear may cost to manufacture locally. Back when Cusco were selling spare parts for their Tarmacs the external bolt on drive gear was near $400. Its at least easy to do as it fits onto the centre diff with heaps of allen head bolts. Would be interesting to find out the price just for that. And thats nothing like Matthias work he has ro do on shafts, gears, centre diff and labour.

[evopwr]

When I was looking at getting some centre diff spline gears made up (I couldn't find 2 more to make the 4-spline conversion at the time) I looked at some local manufacturers.
I was unable to find someone who could make them feasibly (seems like no one wants to manufacture helical gears), but straight-cut gears are a different story as it is much more common to manufacture and all the tooling/machinery is available.
Unfortunately I didn't get budget pricing, but I would have thought it would be cheaper than to have it sent overseas and back for machining services that are essentially available locally.

[ENGINR]

^^ I agree that getting it done locally should always be the preferred option over sending it overseas (or even interstate!!) as nothing beats being able to directly see and talk to the guy doing the job. However given Matthias has done these before he has all the setups and strategies ready to go, which we don't have to pay for. If we were to go to somebody local, there's all the design and setup activities that will have costs which we will incur.

[Evo-00x]

You want to know what a local shop quoted me to make a replacement drive gear for my Cusco Tarmac centre diff? (see pic)

Hi Robert
1 off Helical Gear to sample @ $1493.00 + GST
5-6 weeks
Regards Bill

Ummm... Im getting it sent back to me then Im going to send it to Aldo's friend in Sydney next to see what he can do

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[BMGTZ]

I have a centre diff with a plate slip limiting conversion ......four spider internals. bought it pretty cheap and thought yeah just get another spider. cant find the odd little gear...quoted starting price of a grand to make one.

sits in cupboard.....conversation piece. thought maybe a TAFE or somewhere like that could make it....one day