1992 Subaru Legacy/Liberty 2nd gear Single to Double Synchro conversion

grabcad

I replaced my Subaru's faulty gearbox due to a loud bearing and synchro slip problem. I attempted using a double synchro gearset from a 1998 single-range box in my older, single-synchro dual-range unit. All components were compatible except for second gear. The newer second gear with double synchros had a slightly different helix angle than the old single synchro gears. I modified my original gear to fit the new assembly. After 6,000 km, the transmission operates flawlessly. The gear dogs and teeth are depicted for context and as a modelling exercise; they cannot be accurately measured using verniers.