Subaru Dual Range Transmission

What is a Dual Range Transmission

Dual range gearboxes allow the driver to select between higher and lower range of gearing; introducing a new level of versatility when lower speeds would be more suitable to the terrain. The high range is generally used in normal driving conditions, and the low range is selected when the terrain requires higher torque at slow speeds.

The Subaru dual range gearbox is recognised as one of the most effective and versatile AWD transmissions in the automotive industry today. The hi/lo range setup allows for comfortable daily city driving with the option to easily adapt to more demanding off-road terrain.

Although Subaru’s symmetrical AWD system is outstanding in off-road conditions, the low range gear reduction drastically reduces gear speeds; implementing an effective engine brake down steep hills and making it easier to slowly navigate obstacles with more precision and control.

Call an ADS consultant now on 02 9915 9900

ADS Dual Range Gearbox Conversions

Although the dual range is widely available in many naturally aspirated 4-cylinder models, Subaru never optioned the dual range box to their turbo or H6 model Range. Considering the demand for an adaptable transmission to suit both on and off-road applications, ADS technicians have developed a conversion kit for all EJ turbo and EZ single-range models.

This isn’t an off the shelf kit removed from another vehicle; each dual range conversion is enhanced, revised and customised to allow for an effective synthesis of practicality, driveability and durability. By utilising a range of turbo and NA internals, along with our revised selectors and shifters, the ADS dual range conversion is guaranteed to help you navigate through the most demanding terrains with ease.

ADS Closed Decking Machining Procedure

ADS Dual Range Image Gallery

ADS Dual range transmissions can be assembled with the added strength of shot peening and ISF treatments. This is a vital step in the process when pursuing durability and strength dual range conversions for turbo models.

The Shot peening Process compresses the outermost layer of the treated component via high pressure metal sphere bombardment. This treatment introduces a strengthened outer layer which reduces the possibility of crack formation on a surface.

ISF is a polishing process which reduces friction whilst improving gear fatigue resistance. As friction is reduced, so is the operating temperature of the gearset.

Front and rear Cusco LSD units are also available for those pursuing ultimate off-road traction. These are available in a range of options and can be systematically adjusted to suit your specific off-road application.

Every individual gearbox component is laid out and inspected before assembly commences. The dual range transmission consists of an additional hi/lo gear cluster, so they can be quite complex when assembling.

Our transmission team consists of three specialist trained technicians, one of which has over 30 years experience in Subaru gearboxes.

Every transmission housing is Hydro blasted, hot tank cleaned and pressure washed in our 4000psi cleaner for a like-new appearance; we don’t paint our gearboxes.

Every gear set is assembled with all new components and lock nuts to strict ADS specifications. Tooth profiles and side clearances are all checked, amongst adjustments.

Front diff unit is assembled with the Cusco hemisphere and new genuine bearings. Subaru transmissions require Special Service Tools (SST) to correctly adjust the diff preload.

Input and output gearsets are installed; Meshing and backlash is checked and adjusted as required.

The dual range cluster is now installed with a final control check before sealing and closing the gearbox

If all checks are a pass, the housings are sealed, assembled and torqued to spec

Transfer case is assembled with an RS20kg centre diff unit. An upgraded 12/20kg centre diff increases driving response and durability, while traction on loose surfaces is significantly improved.

Transfer gear heights are measured for the correct shim clearances; once the correct shims have been installed, the transfer case is sealed, assembled and torqued to spec.

The transfer case is then installed to the gearbox housing.

The transmission is torque checked again, cleaned and bench tested. Once testing has been finalised, the transmission is ready for install!

ADS Dual Range Buy Options - Get a Quote

The Off Roader 119: Standard conversion with 1.196 HI/LO, std front diff and 4kg VC

  • Part#: ADS/OR.119
  • Low Range ratio: 1.196
  • Centre diff: 4kg
  • front diff: factory open diff
  • Supported Power: rating of 250bhp
  • Availability: In stock

The Off Roader 119 Assembly Includes:

  • Largest first & second Gear possible
  • Turbo 3rd and 4th gear set
  • Longest 5th gear possible
  • New 1st/2nd ball bearing sliders
  • 1.196 Low range ratio
  • New gearbox bearing kit
  • Serviced front differential
  • Dual synchronisers for 1st 2nd & 3rd Gears
  • New revised centre differential bearing kit
  • High advanced bead blasted gearbox housings
  • New OEM gasket and seal kit
  • Complete serviced fork and rod kit
  • New revised 4 kg viscous coupling
  • Assembled and set to strict ADS specifications

Price: $895 + GST

Description:

The ADS Off Roader Dual Range is our entry level conversion designed for the driver pursuing low range drivability without compromising reliability.
The assembly process starts off with a 5mt dual range housing which is glass bead blasted, pressure washed with our 5000PSI cold wash system and then processed through our chemical hot tank for the cleanest possible finish. After the desired driving ratios have been confirmed, the gearset is assembled with the strongest available main shaft, turbo 3rd and 4th gears with the strongest 5th gear possible. This assembly also consists of a 1.196 low range, dual synchronisers and ball bearing sliders for improved rolling 1st gear engagement, a new revised 4kg viscous coupling and new bearings and seals throughout the entire transmission assembly. ADS gearbox technicians measure and assemble the transmission to our unique specifications and clearances to guarantee quiet, smooth and durable operation.

The All Terrain 144: Beefed up with 1.447 HI/LO, STI LSD and 12kg

  • Part#: ADS/AT.144
  • Low Range ratio: 1.447
  • Centre diff: 12kg
  • front diff: Helical Torsen LSD
  • Supported Power: rating of 260kw/350hp
  • Availability: In stock

The Off Roader 119 Assembly Includes:

  • Built with 1.447 Low range ratio
  • ADS Spec first & second Gear
  • Turbo 3rd and 4th gear set
  • Longest 5th gear possible
  • Shot peen gear set strengthening treatment
  • Crack test and demagnetise gear set
  • Isotropic Superfinish treated gear set
  • New 3rd and 5th gear hub and sliders
  • New 1st/2nd ball bearing sliders
  • New synchronizer set
  • New revised centre differential bearing kit
  • Advanced bead & water blasted gearbox housings
  • New OEM gasket and seal kit
  • Complete serviced fork and rod kit
  • Misc. new gearbox bearings
  • New 6 speed helical TorSen front LSD
  • RS12 or 20kg viscous coupling unit
  • Assembled and set to strict ADS specifications
  • Choice of final drive ratio 3.54 3.9, 4.11 and 4.44

Price: $895 + GST

Description:

The ADS All Terrain Dual Range is the next level up within our conversion range.
Our design and engineering team were given a very specific criteria during the development stage; build a transmission that will traverse most off road terrains, whilst maintaining on road practicality, driveability and comfort. Oh, and it needs to comfortably support modified turbo engine power outputs. Using a very unique combination of factory gearbox internals from a range of Australian and Overseas models, our techs have designed, tested and developed the most effective and robust dual range conversion available ANYWHERE.
Although we utilise the same super clean housings as all of our transmissions and same revised bearings and new genuine seal kit used in the assembly processes, that is pretty much where the similarities stop. The All Terrain 144 contains Subaru’s lowest hi/lo gear ratio of 1.447, a Shot Peened and ISF strengthened gearset, New genuine STI front LSD unit, and our ADS RS12 centre diff to compliment the setup. As is always the case, ADS gearbox technicians measure and assemble the transmission to our specifications and clearances to guarantee quiet, smooth and durable operation.

The Warrior 161: Beefed up with 1.61 HI/LO, CUSCO LSD, 20kg/40kg RSVC and SP Gearset

  • Part#: ADS/TW.161
  • Low Range ratio: 1.6
  • Centre diff: 20kg
  • front diff: Cusco performance LSD
  • Supported Power: rating of 290kw/390hp
  • Availability: Built to order - Approximate 2-week turnaround time

The Off Roader 119 Assembly Includes:

  • New Billet ADS 1.61 Low range ratio
  • ADS Spec first & second Gear
  • Turbo 3rd and 4th gear set
  • Longest 5th gear possible
  • Shot peen gear set strengthening treatment
  • Crack test and demagnetise gear set
  • Isotropic Superfinish treated gear set
  • New 3rd and 5th gear hub and sliders
  • Shot peen Crown wheel/pinion, hubs and sliders
  • ISF Crown wheel and pinion, hubs and sliders
  • New 1st/2nd ball bearing sliders
  • New Dual synchronizer set
  • New revised centre differential bearing kit
  • Advanced bead & water blasted gearbox housings
  • New OEM gasket and seal kit
  • Complete serviced fork and rod kit
  • Misc. new gearbox bearings
  • RS20 or RS40 KG viscous coupling unit
  • Assembled and set to strict ADS specifications
  • Choice of final drive ratio 3.54 3.9, 4.11 and 4.44

Price: $895 + GST

Price: $895 + GST

Description:

If you’re the type to seek out a barely recognisable track littered with the burnt out remains of the other off-roaders (Toyota’s, Nissan’s etc) that didn’t quite make it, then The Warrior 161 is the next (really) big upgrade you need. Put simply, we have a saying at ADS: Nothing succeeds like excess.
The ADS Warrior Dual Range transmission will instantly turn your Subaru into a mudslinging, mountain climbing warrior. This unit offers the ultimate versatility and practicality for those who tend to choose a destination off the map and then make their own tracks there. Our design and engineering team weren't given a specific checklist or build criteria for the development of this transmission; they were unleashed with one simple instruction: Build something you’d install in your car. Using the same unique combination of factory gearbox internals found within the All Terrain, our techs decided to ISF and shot peen the front diff crown and pinion, as well as the hubs and sliders in addition to the gearset. The Warrior 161 is assembled with our very own Billet 1.61 crawler gear, a new Cusco RS 1-Way or 1.5Way front LSD unit, and our ADS RS20kg or RS40kg centre diff to perfect the setup.
As is always the case, ADS gearbox technicians measure and assemble the transmission to our specifications and clearances to guarantee quiet, smooth and durable operation.

Get a Quote for The All Terrain 144 - Subaru Gearbox Dual Range

Get a Quote for The Off Roader 119 - Subaru Gearbox Dual Range