Dual range swapping my Subaru!

In this video I convert my XT forester transmission from a standard 5 speed to a dual range 5 speed to give my subie some much needed low range to hit the trails!
To do a dual range swap in a Subaru you will need the following parts:
- Dual range transmission (With wiring)
- Push type clutch
- Push type clutch slave
- Dual range spec centre console trim piece
- Dual range lever assembly (including bracket around shifter)
- Rear diff with matching FD ratio (if dual range has a different FD ratio to current box)
To source a dual range transmission:
In Australia -
Get one from a wrecker. SF Forester boxes have the best low range. They were available in all non-turbo manual foresters between 98-2012, and should mate up to any Subaru in this range of years. Newer models may require an adaptor plate.
Otherwise see ADS for all your transmission needs! www.alldrivesubaroo.com.au/ge...
In USA -
thezfdesign.com/transmissions... foximports.weebly.com/subaru-... There may be more but this is all I could find.
Rest of the world -
I haven't done much research here. Some countries may already have these models otherwise try importing a gearbox from Australia.
* Please note I cannot confirm fitment or the exact parts you need for this job. This is purely a guide to help you on your dual range swapping journey and you should seek additional information and talk to a professional before attempting this task. Ignition Offroad and its creators will not be held responsible if you purchase the wrong parts for your build.
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Big shoutout for the help from Lachy! Check out his channel here: / @lachytactor3477
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[@mauriciovalverde4729]

In Costa Rica all non-turbo forester (SF SG SH) have dual range gearbox 💪

[@fourbyforester]

you are unbelievable starting and finishing this job. Thank you for sharing this.

[@softroadingthewest]

When you said you were switching to the R180 diff, my instant reaction was: but what about your Torqlocker?? Which you immediately answered, LOL. This whole setup is very very interesting. I think I would have to drive someone else's converted Forester offroad to decide if this seems worth the expense and hassle for my uses. I just almost never encounter trails/tracks that are on par with what you have down there. Anyway....you're well on your way to once again having one of the best offroad Foresters on the planet. Looking forward to seeing it in action once you're able!

[@ignitionoffroad5028]

Thanks! Yeah wasn’t a fan of the torq locker. I think it’s good when you spend most of the time on the dirt, but for me there’s often many km of road to travel before I even hit the dirt so a selectable option seems more suited to my needs.

[@FerrariLamborghini24]

@@ignitionoffroad5028 is there a dual range 6 speed manual transmission

[@ignitionoffroad5028]

@@FerrariLamborghini24 no, there were only 4 and 5 speed dual range transmissions released with Subaru.

[@philipkemp7510]

I understand life, God this blokes still my legend 🙏🏽

[@therootedprogress]

Niiiiceee one man! Can't wait to see you own some ruts in the new subie! Loved that gunshot transition in the beginning. Great info in the beginning man. How long did it take you to gather up all that info. Wonder how much it'd be to convert my outback.

[@ignitionoffroad5028]

Most of it was info I gathered over the years of off-roading subies. Just call up ZF and see what they quote you. I can’t see it being super expensive if your just getting a standard gearbox and do the work yourself.

[@NotSoFlatAdventures]

Going to be a weapon, will all be worth the effort.

[@ignitionoffroad5028]

Yes, it’s all coming together now 👌

[@v26224]

the 4eat auto is ok for most of what i do. the 4.44 final drive also helps.

[@ivanvalverde1155]

I agree, 4EAT in 1st speed is Lo as needed.

[@soundsolutions]

@@ivanvalverde1155 it holds my SG down steep tracks, also I have a bad back and don't like using a clutch anymore.

[@veganpotterthevegan]

@@ivanvalverde1155 It's definitely not as low as needed when people with real crawl gears need even better aftermarket crawl gears. It can be good enough for your area. But there are plenty of times where my 4eat doesn't cut it and wouldn't with a 1st gear that's even 50% better

[@lachytactor3477]

Stoked to finally see this come together for you mate! Can't wait to see the rig out on the tracks.

[@ignitionoffroad5028]

Cheers again for the help mate! You’ll see this beast in action soon enough 👌

[@Kacpa2]

I wander if 6speed could be fitted with dual range. Legacy 3.0R spec b could be even more fun to thrash around in Lo. 2.0R versions got 5mt dual range so it would be possible to get the interior trim and lever

[@VwManiacwV]

Great video! Only downside subaru's dual range gearboxes are that low range is still way too high in my opinion to compare something like pajero or land cruisers low range.

[@ignitionoffroad5028]

Yes, definitely still an issue with the low range. Proper low range would be way better

[@Tahu2323]

Where can you go to get the linkage? I’m in america and they’re hard to find. Know anywhere that might have one they’d be willing to ship to the US?

[@c-martz2846]

Dude you do not owe apologies. You’re persistence gave viewers the opportunity for a final product. Thanks for sharing because it’s always been my curiosity to install one in my Baja turbo

[@HomebrewSubaru]

The lever and center console trim make it look all OEM. Very nice setup man

[@ignitionoffroad5028]

Yep, super clean as if it rolled out of the factory like that! Only difference is I don’t have the low range light come up on the dash when I engage it. (Could do it but way to much work for me)

[@pinzone4358]

Now I know what you've been doing all this time. I'm glad you could swap the drive line over, even though it took some time. I deliberately bought the manual to get the low range, it's not as low as 4x4's, but still great to have. You have gone the extra mile with your's and have a very versatile setup.

[@ignitionoffroad5028]

Thank you! Even though the standard low range isn’t great, when upgraded like mine it certainly makes a difference out on the tracks.

[@bruceyyyyy]

I love the idea of the Air Locker R180! Are custom axles not an option? They're not as expensive as some people think. At least here in the states.

[@ignitionoffroad5028]

Custom axles are an option but I have no idea where to start in terms of getting hold of any. I’ve just been trying wreckers without luck. I know subaru will sting the wallet if I go new but it might be the way to go.

[@ivanvalverde1155]

Great mod! Now your Forester is unstoppable!

[@v26224]

awesome mate, are you within the ring of steel or not. if so you must be killing to hit the tracks

[@ignitionoffroad5028]

Na I’m outside it. I’ve been on the tracks plenty for work but certainly am keen to get the foz out!

[@Chill_Mode_JD]

Man that’s badass, I bet she’s a beast now! So what style center differential is in that dual range trans? I just swapped out my MPT in my 04 XS for a 07 VTD and wow what a difference! Especially with the factory 4.44 and rear VLSD! Chugging through the Florida swamps like a boss 😅💯

[@ignitionoffroad5028]

My centre diff is a 20kg viscous coupling by AllDriveSubaroo.

[@Chill_Mode_JD]

@@ignitionoffroad5028 🤘🤘🤘

[@tjrentfro8514]

Awesome job, man. What was the hangup that stopped the trans from mating up on the ground? I'll be doing this swap on a friend's 04 fxt soon and don't have access to a lift. Hoping it can be done on the ground

[@ignitionoffroad5028]

It’s just the process of trying to align the clutch and all the studs on the engine. You need to muscle the transmission into place a little and I just didn’t have the room under my setup. You could luck out and it all lines up perfectly for you. Good luck with the swap!

[@dilshanari1061]

great video- but when you lift the car did you put large bricks etc behind the rear wheels?

[@ignitionoffroad5028]

No, I just relied on the handbrake. Probably something I should do in future however.

[@jwlycra]

Your're a very committed man! :-) On your webite it says your have a longer 5th gear. Any advice on getting that done? 5sp Man subies wiht 4.44 rev way too high on the open road at 110km/h. Cheers

[@ignitionoffroad5028]

The longer 5th is a must with the 4.44. I believe it was from an early model sti, but best to ask AllDriveSubaroo for more details on it.

[@jwlycra]

@@ignitionoffroad5028 Thanks. Alldrivesubaroo advised that mine is already running the tallest 5th they make :-/. What Rpm do you sit on @ 110km/h? Mine is about 2850.

[@ignitionoffroad5028]

@@jwlycra I think mine is the same. I think it works well for me though.

[@v26224]

last time i had to remove the axes i chose to remove the lower ball joint as that way i dint mess up my alignment

[@ignitionoffroad5028]

Yeah true, that’s not a bad way of doing it

[@brianlipke1668]

I so wish I could do this in Ruby!

[@sniperjj1077]

I wonder if this swap is possible in an 05-09 outback. That would be sweet!

[@ignitionoffroad5028]

Subaru is like Lego. Pretty good chance it will fit, otherwise you might need to buy an adapter plate from the engine to gearbox.

[@user-ns2hs7dr2u]

👍

[@Lulu-st1og]

Really good Job , do you know if the trans is solid enough for the xt? I think i heard that the low range part is a little fragile.

[@ignitionoffroad5028]

I would certainly be careful about how I treat the transmission. The standard turbo 5spd has been nicknamed a glass box so one from an N/A would be no different. AllDriveSubaroo have treated gearsets before to improve their strength so that is something I may look at in future.

[@torreVs]

​@@ignitionoffroad5028 Compare engine power and *torque* curves, N/A vs Turbo engine, and see where *torque is overlapped* . That's is a safe rpm number for transmission specially with low range activated. Check engine temperature when driving in low range. Reduce transmission maintenance, at least yearly. Excelent transmission oil selection. ZF TE-Ml 05 aftermarket.zf.com/remotemedia/lol-lubricants/lol-en/lol-te-ml-05-en.pdf Enjoy it!

[@ignitionoffroad5028]

I use Cusco LSD oil in my trans. At $45/L it should be the best oil I can get for it haha

[@mattbozzo6910]

Great to see you supporting Movember Miter!

[@ignitionoffroad5028]

This one is just a trial run, but I have been talking about doing it with a group this year. Will see but definitely want to do it one day!

[@FRFOverland]

What were your thoughts on the Torq Locker. I've heard mixed reviews. Would love to go the R180/ARB + Dual range route, but for the overlanding we're doing here it's not worth it so I'm debating 4.44's, Torq Locker, 4EAT swap my 5spd. 🤷‍♂️

[@ignitionoffroad5028]

Torq locker was fantastic offroad, but loud and clunky on road. As I do a lot of driving on the black stuff to get to the tracks I chose to remove mine. If your going the 4eat route, I would just buy another subie with the 4eat already in it

[@FRFOverland]

@@ignitionoffroad5028 I end up doing a good amount of travel on the tarmac before getting to the trails as well. Was it just tight corners that you found it struggled with? I also heard it was a bit unpredictable in wet corners at high speeds?

[@ignitionoffroad5028]

@@FRFOverland so really tight corners I actually had the rear lock up, but otherwise it was just loud and uncomfortable. It’s great the product exists but it’s not for me.

[@FRFOverland]

@@ignitionoffroad5028 I see! Thanks for the heads up. I was looking for some fist hand objective criticism of it so I really appreciated it! 👍

[@DavidNieuwenhoven]

I have a 04XT auto. Thinking of getting a dual range or if available a 6 speed auto? Plan is to tow a light caravan 1100kg dry around Oz. I would also add a dual range tank. So its $3500 ish for gearbox? I wouldn't be doing any extreme stuff as my car is already very good offroad. Just need lower gearbox and a bit more strength. I diesel would be good but I would miss the power.... I can afford to spend $10,000 k to make the car ready and I'm still way cheaper than a large 4WD. Thoughts?

[@ignitionoffroad5028]

The auto and XT is a pretty good combo and for the driving you do I don’t think the swap would be worth it. Only other gearbox to look at would be the 5eat (5speed auto trans). 6 speed auto would be one of the new CVT transmissions and from what I’ve seen would not recommend for off-roading.

[@DavidNieuwenhoven]

​@@ignitionoffroad5028 Ok. Im not worried about the cost as it's still way cheaper than a large 4wd. We already do some pretty serious 4wding in the 4 speed auto with limited mods but having a dual range would be way better or at least an extra gear. I have seen those new 6 speed autos in for example the Amarok go up some big hills. I wouldnt be doing the high country Victoria but going up some steeper hills we be good and more gears for economy as it sucks juice when towing :)

[@Tavo-TECH]

ADS sell the dual range pinion? Or the complete transmission?

[@ignitionoffroad5028]

They sell both. I think they have the gear sets for sale on their website

[@roscored1000]

I have been curious watching some of your earlier videos when you still used the XS did you ever consider a supercharger conversion for the XS? Would that have been worthwhile? I believe there is someone on the gold coast that does them. Great videos

[@ignitionoffroad5028]

Yes, I initially wanted to supercharge the old foz with a raptor supercharger kit (made in QLD). I’m happy with the turbo now though 😁

[@roscored1000]

@@ignitionoffroad5028 ok I thought about it too for a while but I just like changing things around from stock, miss my old turbo RS though. keep up the good work

[@nyambatbegzjab5191]

Hey 👋 that's looks good. Did you change some gear ? Since engine is turbo.

[@ignitionoffroad5028]

When I had the gearbox built originally it was strengthened a bit. I’m still careful with it though and want to get the gear sets treated before I start really abusing it

[@adambaldwin2946]

Hey mate dumbest question. Buuut I have a 2011 plate forester. Just wondering if you know if they are as liftable. Its an auto. I know you have a manual and thebolder model but im just wanting to convert to something that will be purely for beach driving. Anyway hope you're doing very well. And I don't know if dual range would be needed.

[@ignitionoffroad5028]

So a lift kit is definitely still worth it. You won’t get as much clearance as an older model but it’s still useful. The auto will be perfect on the sand, you’ll love it!

[@_Epictetus_]

So I am now trying to find a dual range and can't seem to even find pricing for over. Is this transmission unachievable now?

[@ignitionoffroad5028]

What country are you in? Outside of North America these gearboxes are easier to come by. Within USA you will have to get one imported. ZF Design is the go to shop in the states to source dual range gearboxes

[@69foz]

Hey bud just wondering what throwout bearing and fork did you use?

[@ignitionoffroad5028]

I believe it was all OEM Subaru. I had the gearbox completely reconditioned and built up by AllDriveSubaru less than 5000km ago, so didn’t change anything for the swap.

[@69foz]

@@ignitionoffroad5028 yeah righto just having issues with my clutch I got a feeling I'm running the wrong flywheel or something. Yours just a standard na flywheel or a push type turbo flywheel?

[@ignitionoffroad5028]

@@69foz I’m running a push type clutch setup however I went with a heavy duty clutch that AllDriveSubaroo installed. They did replace the flywheel as well but I’m not sure if it was a standard or something else.

[@daleoldfield7961]

I got the gearbox priced at alldrive Subaru around $3500AU I'll get one,one day

[@soundsolutions]

Wow, that's $1,000- more than my XS2.5 SG cost me. In good condition too. They want to give you a decent unlimited warranty for that sort of money.

[@daleoldfield7961]

@@soundsolutions that is with an extra low dual range gear and main gears that can handle a turbo engine. You'd think it would be cheaper if I give the company my turbo box plus a dual range box to use parts from but guy I spoke to wasn't real sure

[@Tavo-TECH]

Low range transmission can handle turbo engines?

[@ignitionoffroad5028]

Depends how you treat the car. I would not launch the foz with this gearbox as it was designed for a car with 110kw. I would like to have the gears modified one day though to be able to handle more power.

[@anthonynonya]

As I'm about to buy my first Subaru, a Forester XT, I've found this channel extremely informative. That said - am I the only one who finds those jack stands insanely sketchy for doing a transmission R&R? A tire rotation or a brake job sure, maybe even risk a light duty oil change, but damn I wouldn't want to be doing heavy duty work under those skinny pillars. Stay safe dude, you need to keep making videos! ;-)

[@ignitionoffroad5028]

Yeah that was 100% sketchy when I pulled that trans out, hence why I tried not to put my body under the vehicle. I do not want to see anyone do as I did. Hopefully in a few months time I can get back into making videos

[@ryansyl]

How about the 5EAT?

[@ignitionoffroad5028]

Yes I know one guy who runs a 5EAT offroad and he seems pretty happy with it. I’ve never used a 4EAT or 5EAT so I can’t comment too much but knowing that I have low range feels like a better option than relying on just high range gears of the autos.

[@Anime0x0x]

Hey I have a standard Subaru like the standard one am I still able to do mods and take it off road.. I've only really seen mods done with the higher end ones ..

[@ignitionoffroad5028]

You can mod any Subaru. I would recommend modding the cheaper ones for offroad anyway.

[@nathanturner2482]

What did it take to get lined up?

[@ignitionoffroad5028]

Literally just that extra room under the car and 2 guys muscling the gearbox into place was all. With the limited room on jack stands I think I just couldn’t get the angle right for it to line up.

[@nathanturner2482]

@@ignitionoffroad5028 yeh, I'm not looking forward to it

[@1mach28914u1]

When I did a clutch on my liberty years ago I put a bottle jack at the front of the engine to get the angle right.

[@wc7568]

awesome content bro, im starting a suby offroad channel here in the US and would love to work with you in the future!

[@ignitionoffroad5028]

Awesome! Always happy to work with there’s and help out. 🤘

[@ryanroland6426]

Hey where are you located in the us I'm in cali and have a xv crosstrek fitted for offroading if you'd like to hit a trail some time

[@PercyMatthies]

How much you got for the dualrange transmission?

[@ignitionoffroad5028]

If your asking for pricing to have one built, best contact AllDriveSubaroo.

[@mmiller1188]

Didn't ralize it didn't have dual range. Or was that another Forester?

[@ignitionoffroad5028]

My previous forester had the dual range, but they are only found in the natural aspirated models. The forester it went into was a turbo model.

[@Rockerrobin]

Wish mechanics class weren't packed when I was in school this is far beyond my capabilities. Wish I could just take it into Subaru and they would do it as if it was just a new transmission replacement.

[@ignitionoffroad5028]

Your best bet is to find a shop that specialises in modifying and servicing Subaru’s if that’s the route you want to go.

[@MADBONE0]

Join the low range club 🚙👌🏽

[@timfagan816]

I just bought a legacy with low range 5sp manual. How do I engage low range? I pull the leaver, the lo comes up on the dash, but nothing happens!

[@_Epictetus_]

I don't understand why we would swap this over a 5 speed automatic?

[@ignitionoffroad5028]

Because the auto never came with low range?

[@rienkhoek4169]

@@ignitionoffroad5028 true, but isn't an automatic supposed to handle low speed crawling without problems?

[@ignitionoffroad5028]

@@rienkhoek4169 it’s true the auto can crawl pretty good for a 4 speed, but when it comes to steeper terrain, the dual range does it easier and there is actual engine braking, where as the auto relies purely on brakes to stop you flying down steep descents. I need to do a good auto vs dual range video.

[@Rockerrobin]

Not even 700km into owning my lifted 05 forester xt and pretty sure the engine has blown. Got it because all the engine work had be recently done new water,oil pump,timing belt and head gasket. Paid 5k Canadian! Help im not made of money private sale.

[@soundsolutions]

Are you losing engine power? Is it belching white smoke out the exhaust while idling? Any radiator fluid loss? Are you adding engine oil regularly? If non of these are affecting motor running, try adding engine "honey" to the oil... also check the spark plugs and replace if needed, if motor is idling rough.

[@Rockerrobin]

@@soundsolutions nothing like that plugs replaced just before purchase. Found the fuel line was loose and there is an oil line under the car that looks cracked. Not lacking power was seeing a lot of liquid up front around the timing belt and forgot I sprayed some rust release spray on a stubborn bolt earlier in the day. It is getting ripped wear on the cv boots because of the 3 lift. Subframe drop is an option I should invest in alternatively you can swap the Subaru boots with hd Toyota boots not sure if it works but its been tried.

[@gizzyguzzi]

Sorry. The shipping alone is $1500 US on a single transmission. At $3500 for a basic DR trans, that's just not happening. Why doesn't someone in Aus fill a container full of Subaru DR transmissions, and while at it throw in some Land Cruiser full floating rear diffs, lockers, diesel engines, etc. And ship to me in USA!

[@MrScalman]

that low gear is not that low anyways. then if you have money to spend you can make anything from any shit car so that means nothing. why then stay on subaru at first , there are better cars to modify to make them just better bigger for off road. better when you do cheap modifications to get better performance. just putting new parts to car, anyone can do it .

[@ignitionoffroad5028]

Yes the low range isn’t that great but it’s good enough for what I use it for. I also agree that it’s not worth spending the money I have on an offroad Subaru and your better off just doing the basics and transition to a more serious 4wd if you want to go down that route and spend more money, but my subscribers are here to see the Subaru and that’s the focus of my channel so that’s what I’m sticking with for now.

[@soundsolutions]

@@ignitionoffroad5028 I have XS2.5 MY05 auto. Want to go offroad occasionally in Morton National Park. What do you recommend?

[@ignitionoffroad5028]

@@soundsolutions if your after modification recommendations, than a 2” lift kit, sump guard/skid plate and A/T tyres is all you need to start taking your foz offroad.

[@veganpotterthevegan]

It's definitely not that low. I'm building an overlander with one now. It's all cost benefit analysis. I hate how Jeeps drive on the road more than I feel limited off-road in the Forester. There are plenty of things I can't do now. But I'm not miserable every second I'm on pavement