2.5 Legacy conversion - done at last!

[ricp]

Finished at last. I have completed my 2.5 legacy upgrade to my T25 Camper. What a difference it makes - we can go up hills without being reduced to 2nd gear and it is even slightly more economical than before. However now feels a bit undergeared.
So I thought I'd give all a bit of a summary.
Thanks must go to RJES for all the bits, which fitted off the shelf, and make for a much less stressful experience but as importantly, the advice. Also to the Haynes Motor Museum, who did most the spanner work for a very reasonable rate. They even knocked some of the hours off as it was a voyage of discovery for all. The cost was more than hoped but most of this was due to doing all the gaskets and seals on the engine before it went in as a precaution and the their desire to make it as professional a job as possible down to placing all the wiring in new conduit, re-undersealing the underneath where the cross member was attached, sorting an oil leak on the gearbox, etc, etc. It looks a fantastic job and worked straight from the box, which says a lot for all parties work, but I paid for it!
Also thanks to the Subaru guys at Used Subaru Parts nr Cullompton for second-hand bits.
In total, the Legacy with FSH and 53K miles was £700 plus £300 to deliver from Newcastle to Someset.
RJES stuff was £2000 approx inc exhaust
Haynes gave 50 hours approx at £50/hr to remove VW and Legacy engine, recon and then refit the Legacy engine and parts etc.
There was other stuff that gets paid as you go along but you get the idea
I got £600 for the VW engine and £250 for the remains of the Subaru.
Was it woth it - financially probably not, I guess the van is worth more but as a keeper to use, yes. It has made it much easier and more relaxing to drive especially 4 up with bikes and kit, running cooler and further, rather than having to cane the 1.9 VW engine within an inch of it life constantly.
Next to do is to go up a size in tyre profile to try to raise the gearing a little before looking at gearbox ratios possibly.

[R0B]

has your insurance premium stayed the same.as its now a modified van..

[ricp]

It has gone from £240 to £330 ish with the 2.5 engine. This does include UK and European breakdown cover for the whole year though.

[jamesc76]

I have the 2.2 ej22 scooby lump and have just fitted a tweeked Ainden special gearbox makes massive difference, its a 4 speed with 4th swaped out for the taller 5th from a 5 speed box uprated syncros and few other bits and bobs runs lush now!

[ricp]

What rpm does it run at for 70mph? I think, looking at the Legacy ratios and torque curve, 3200ish would be about right rather than the current 3700. How much was the gearbox conversion although all these things are done for love rather than financial benefit overall!

[jamesc76]

gearbox is circa £780, dont know what revs its doing as dont have a rev counter! but it aint struggling at all and sounds about right!

[toomanytoys]

What rpm does it run at for 70mph? I think, looking at the Legacy ratios and torque curve, 3200ish would be about right rather than the current 3700. How much was the gearbox conversion although all these things are done for love rather than financial benefit overall!

With the amount already spent it would be daft not to speak to Aidan and get the box freshend up and gearing sorted, its now the weak link in the conversion..

[ghost123uk]

And where are are the pictures

[ricp]

Pictures to follow, only another £800 for the gearbox. It is the weak link but may have to remain so until next year If she-who-must-be-obeyed finds out, I'm proper in the poo.

[silverbullet]

Go for broke and bin the 094 for the legacy gearbox that you've just sold for scrap #doh!#
Seriously - save up another £1500 or so for a reverse crownwheel and pinion from matey in Australia, then you can use a Legacy AWD saloon trans (important- no dual range gubbins like in the estate boxes to get in the way) locked for 2wd operation, and you can go for a 4.1 diff or even a 3.9 if you think the engine will pull it with a full camping interior (probably not) You'll then have a rjes bellhousing surplus - sell it and get some £££ back
That'll improve the gearing, but the EJ's are happier at higher revs than WBX's anyway. A healthy 2.5 with an unrestricted exhaust like rjes will make something like for 180 bhp at 6500-odd and keep going to 8000 if it needs to
I'm hoping to go this route with my Microbru, but AWD, using all the Legacy drivetrain from the donor and some syncro front end parts. Mad? Yes.

[KarlT]

Hi Fella.
I'm thinking of going down this route. Its been eventful already & I haven't raised a spanner in anger yet!! Where are you? Would like a good poke around!!

[IainG]

Definately going down the Subaru route as the 2.1 is painfully slow - I'd better start saving!

I was initially thinking just the 2.0, but perhaps that's not worth the bother???