1991 SS, and a trip.

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1982gl4
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Joined: Tue Oct 18, 2011 8:40 pm
Location: Worcester, VT

Re: 1991 SS, and a trip.

Post by 1982gl4 »

I love that knob. Weighs a lot, but it has such a good feel, not that I have tried it in the car yet. A lot of progress has been made so far. I have all of the rear parts swapped over, diff, axels, spindles. The Sti e-brake cables work great in the legacy after I moved around some of the brackets. Front spindles are in. I got the drive shaft sorted. Ran into an issue on Saturday, the clutch throwout bearing will not stay snapped into place so I ordered a new clutch today. It should be here tomorrow. The rear rotors came in today, I have yet to try them on the hubs, but they look to be correct. This weekend it should be up and driving around.
1991 SS
1993 SS part's car, dead due to rust
1992 Legacy L wagon
1984 subaru GL wagon
1986 Brat (work in progress)
Several Air cooled VW's
1982gl4
First Gear
Posts: 127
Joined: Tue Oct 18, 2011 8:40 pm
Location: Worcester, VT

Re: 1991 SS, and a trip.

Post by 1982gl4 »

Got the rest of the swap installed today. All fluids, exhaust back on (still need to get the 6 speed hanger for the down pipe hopefully I can get one from subaru) Got the rear rotors installed after painting the hubs to keep them from rusting. Torqued everything and took it for a couple of drives this afternoon. The car drives amazing now, no wines from the trans, no grinding, no bad noises of any kind with exception of the chopped tires, I rotated them, and they are chopped on the front now, I want to get new tires at some point soon anyway, I never really liked these. The car feels a bit heavier, but feels much quicker than it used to. The closer gears of the 6 speed go very well with the 2.2t. Now I'm just waiting on the shift boot, and the dccd pro and I will be done with the drivetrain swap.
1991 SS
1993 SS part's car, dead due to rust
1992 Legacy L wagon
1984 subaru GL wagon
1986 Brat (work in progress)
Several Air cooled VW's
Legacy777
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Re: 1991 SS, and a trip.

Post by Legacy777 »

Good deal! Congrats on getting it all swapped and back up and running :)
Josh

surrealmirage.com/subaru
1990 Legacy (AWD, 6MT, & EJ22T Swap)
2020 Outback Limted XT

If you need to get a hold of me please email me rather then pm
1982gl4
First Gear
Posts: 127
Joined: Tue Oct 18, 2011 8:40 pm
Location: Worcester, VT

Re: 1991 SS, and a trip.

Post by 1982gl4 »

Thanks man! Your pics made life so much easier! What did you end up doing for the 6 speed down pipe mount? Took it on another drive today, and still can't believe its a 6 speed now. I love being able to drop down several gears from cruising in 6th!

Also got my ej swapped brat running for the first time in 4 years today so it's been a busy weekend!

Image
1991 SS
1993 SS part's car, dead due to rust
1992 Legacy L wagon
1984 subaru GL wagon
1986 Brat (work in progress)
Several Air cooled VW's
1982gl4
First Gear
Posts: 127
Joined: Tue Oct 18, 2011 8:40 pm
Location: Worcester, VT

Re: 1991 SS, and a trip.

Post by 1982gl4 »

Got my shift boot in today. I got to install it along with the trim ring, and bolts. Redline makes a great product, I'm very pleased with how it looks, and how it fits. Modifying the center console was as simple as trimming some plastic, and making some mounting tabs. Also ordered the exhaust hanger. it should be tomorrow and then I can put that on. All I have left after that is the DCCD.

Image
1991 SS
1993 SS part's car, dead due to rust
1992 Legacy L wagon
1984 subaru GL wagon
1986 Brat (work in progress)
Several Air cooled VW's
beatersubi
Fifth Gear
Posts: 2385
Joined: Tue Mar 13, 2007 12:56 am
Location: 10-9-oh(!), wa

Re: 1991 SS, and a trip.

Post by beatersubi »

That shift boot and surround look awesome. I'm jealous of all your progress.
That brat must be a hoot, as well.
93 legacy wagon L, 22T swapped (TW imitator) now with five forward speeds. (Gone, but never forgotten)
johndrivesabox wrote: Rally, my kyboard is brok, his has nohing o do wih h liquor.
Originalcyn wrote:Apparently everyone hates Gabe.
Legacy777
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Re: 1991 SS, and a trip.

Post by Legacy777 »

Yeah the STi shifter knob, surround, and boot do look good! I'm hoping to do something similar to mine.

As for the down pipe exhaust hanger I modified the hanger to get the proper fitment.
Josh

surrealmirage.com/subaru
1990 Legacy (AWD, 6MT, & EJ22T Swap)
2020 Outback Limted XT

If you need to get a hold of me please email me rather then pm
1982gl4
First Gear
Posts: 127
Joined: Tue Oct 18, 2011 8:40 pm
Location: Worcester, VT

Re: 1991 SS, and a trip.

Post by 1982gl4 »

beatersubi wrote:That shift boot and surround look awesome. I'm jealous of all your progress.
That brat must be a hoot, as well.
Thanks! I'm really happy with the way the swap has turned out so far! The brat seems quick for as much as I have driven it. It runs pretty poorly right now kind of a given with a swap like this. I still have a bunch of issues to sort out. But I can say I'm impressed by the torque I built a 2.5/2.2 hybrid for it, cant wait to get it running better!
Legacy777 wrote:Yeah the STi shifter knob, surround, and boot do look good! I'm hoping to do something similar to mine.

As for the down pipe exhaust hanger I modified the hanger to get the proper fitment.
Thanks! I love everything I bought for the interior portion of this swap. I figured out the hanger. My six speed didn't come with one, so I just ordered a new one for a 6 speed from Subaru. 3 bolts later we are all good :smt023
1991 SS
1993 SS part's car, dead due to rust
1992 Legacy L wagon
1984 subaru GL wagon
1986 Brat (work in progress)
Several Air cooled VW's
1982gl4
First Gear
Posts: 127
Joined: Tue Oct 18, 2011 8:40 pm
Location: Worcester, VT

Re: 1991 SS, and a trip.

Post by 1982gl4 »

Dccdpro has been ordered. Now I just have to find time to install it after it comes in.
1991 SS
1993 SS part's car, dead due to rust
1992 Legacy L wagon
1984 subaru GL wagon
1986 Brat (work in progress)
Several Air cooled VW's
1982gl4
First Gear
Posts: 127
Joined: Tue Oct 18, 2011 8:40 pm
Location: Worcester, VT

Re: 1991 SS, and a trip.

Post by 1982gl4 »

Pulled the spare 22t today. The black car gave a bit of a fight, nothing some torches couldn't take care of. I guess its expected with 270k and a very salty northeast life. I took it for its last drive yesterday. Started right up after jumping the starter. The drive was super sketchy with bald summer tires, 3 inches of fresh snow, and no brakes. I'll be starting the engine build soon! I'm sure I'll have some questions along the way. I'm still undecided as to what exactly I'm going to be doing as far as the build. I'm aiming for 300whp at least. I'm doing a lot of research as I go along. I took a couple photos from today, but my phone went dead after a while due to no cell signal in the shop, I'll be sure to take more as I start tearing down the engine.

Image

Image

Just a bit of rust.
Image

One I took last year, just so I can remember it in its prime.
Image
1991 SS
1993 SS part's car, dead due to rust
1992 Legacy L wagon
1984 subaru GL wagon
1986 Brat (work in progress)
Several Air cooled VW's
beatersubi
Fifth Gear
Posts: 2385
Joined: Tue Mar 13, 2007 12:56 am
Location: 10-9-oh(!), wa

Re: 1991 SS, and a trip.

Post by beatersubi »

Its tragic what your roads do to cars, up there.
I say forged slugs and 20g heads.
93 legacy wagon L, 22T swapped (TW imitator) now with five forward speeds. (Gone, but never forgotten)
johndrivesabox wrote: Rally, my kyboard is brok, his has nohing o do wih h liquor.
Originalcyn wrote:Apparently everyone hates Gabe.
1982gl4
First Gear
Posts: 127
Joined: Tue Oct 18, 2011 8:40 pm
Location: Worcester, VT

Re: 1991 SS, and a trip.

Post by 1982gl4 »

Yeah i know. I felt bad taking it apart, but there is nothing I can do with that shell. I'm planing on forged everything, and was looking into the 20g heads.
1991 SS
1993 SS part's car, dead due to rust
1992 Legacy L wagon
1984 subaru GL wagon
1986 Brat (work in progress)
Several Air cooled VW's
1982gl4
First Gear
Posts: 127
Joined: Tue Oct 18, 2011 8:40 pm
Location: Worcester, VT

Re: 1991 SS, and a trip.

Post by 1982gl4 »

Dccdpro came in! Now I need to install it. I may fool around with it a bit this weekend, but I think I'm going to start pulling apart the 2.2, and I need to remove the cylinder head on my datsun because the valves are sticking.
1991 SS
1993 SS part's car, dead due to rust
1992 Legacy L wagon
1984 subaru GL wagon
1986 Brat (work in progress)
Several Air cooled VW's
1982gl4
First Gear
Posts: 127
Joined: Tue Oct 18, 2011 8:40 pm
Location: Worcester, VT

Re: 1991 SS, and a trip.

Post by 1982gl4 »

I disassembled the 2.2t down to the short block today. All was going great. Pulled the valve covers off.
The engine looked super clean.

Image

I pulled the intake off without any problems, as well as the goose neck I've had the bolts break off in the block, and that usually turns into a bad time.

Image

Had a check engine light for knock sensor, I can't imagine why.
Image

And then I had a bad time. I didn't even try with it, and it just snapped off.
Image

Right now I have the broken bolt soaking in penetrating oil, my dad as a knack with this sort of thing, and he thinks we will be able to get it out. He had a couple of tricks we will be trying. But I'm still open to suggestions. I've taken 100's of ej engines apart, and never have had a head bolt break. Guess I should buy a lottery ticket.
1991 SS
1993 SS part's car, dead due to rust
1992 Legacy L wagon
1984 subaru GL wagon
1986 Brat (work in progress)
Several Air cooled VW's
Legacy777
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Re: 1991 SS, and a trip.

Post by Legacy777 »

Yeah....that sucks!

Hopefully the threaded part in the short block is not seized to the block and can be removed.
Josh

surrealmirage.com/subaru
1990 Legacy (AWD, 6MT, & EJ22T Swap)
2020 Outback Limted XT

If you need to get a hold of me please email me rather then pm
1982gl4
First Gear
Posts: 127
Joined: Tue Oct 18, 2011 8:40 pm
Location: Worcester, VT

Re: 1991 SS, and a trip.

Post by 1982gl4 »

It does suck. I'm going to spray it some more today, and heat it up a little hoping it will let the penetrating oil seep in even more that it normally would and let it soak another few days. I'm going to contact the machine shop that has a couple of my other engines right now, and see what they suggest for it.
1991 SS
1993 SS part's car, dead due to rust
1992 Legacy L wagon
1984 subaru GL wagon
1986 Brat (work in progress)
Several Air cooled VW's
cj91legss
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Re: 1991 SS, and a trip.

Post by cj91legss »

That happened to me. Roopair told me to get a 3/8" reverse drill bit. With the reverse bit on the broken stud, sometimes they get lucky enough that the bit catches it and unthreads it out.

If that doesn't work then it may need a time-sert.
91 L-TW Wagon with a full Swap -RIP
92 SS Prefaced, GD dash swapped, 22T/205 Hybrid 20 psi - BEAST!
93 SS Bone Stock Gone!
94 TW Bone Stock Gone!
91 SS 4EAT Sold!
98 LGT 4EAT
98 LGT Wagon 4EAT
beatersubi
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Joined: Tue Mar 13, 2007 12:56 am
Location: 10-9-oh(!), wa

Re: 1991 SS, and a trip.

Post by beatersubi »

^this.
I've had good luck with reverse drill bits, albeit I've never had to remove a Subie head bolt. The heat definitely helps to get the penetrating oil into the threads. Get her nice and hot, then soak it with the lube.
Last edited by beatersubi on Sat Jan 03, 2015 3:02 am, edited 1 time in total.
93 legacy wagon L, 22T swapped (TW imitator) now with five forward speeds. (Gone, but never forgotten)
johndrivesabox wrote: Rally, my kyboard is brok, his has nohing o do wih h liquor.
Originalcyn wrote:Apparently everyone hates Gabe.
cj91legss
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Posts: 6317
Joined: Fri Jun 20, 2008 8:17 am
Location: Lakewood, Wa 98439
Contact:

Re: 1991 SS, and a trip.

Post by cj91legss »

I wasn't that fortunate tho. But I didn't heat the block up. Hadn't crossed my mind. But roopair did the time-sert for me. Halves are on a shelf waiting for a new crank and some wisecos.
91 L-TW Wagon with a full Swap -RIP
92 SS Prefaced, GD dash swapped, 22T/205 Hybrid 20 psi - BEAST!
93 SS Bone Stock Gone!
94 TW Bone Stock Gone!
91 SS 4EAT Sold!
98 LGT 4EAT
98 LGT Wagon 4EAT
1982gl4
First Gear
Posts: 127
Joined: Tue Oct 18, 2011 8:40 pm
Location: Worcester, VT

Re: 1991 SS, and a trip.

Post by 1982gl4 »

Even though I felt like crap today I decided to get off the couch and do something with my life. I pulled the oil pan off, and the pistons out without a hiccup. I then decided it was time to split the case. As I was heating the bolts/block I was wondering to myself why do I live here. As a car guy I wonder this often.... The northeast is really not the best place for cars. Anyway the thrust bearing looks like it has seen better days, and the crank has worn on the case a tiny bit. Hopefully its still good enough to work with after I get the head bolt out thoughts?

Image

Image
1991 SS
1993 SS part's car, dead due to rust
1992 Legacy L wagon
1984 subaru GL wagon
1986 Brat (work in progress)
Several Air cooled VW's
cj91legss
Fifth Gear
Posts: 6317
Joined: Fri Jun 20, 2008 8:17 am
Location: Lakewood, Wa 98439
Contact:

Re: 1991 SS, and a trip.

Post by cj91legss »

That's the same situation I am in. I dicided I am going to buy a new crank when I can afford it. Get some quotes for machining the halves for #5 thrust and getting the dual drilled we crank.
91 L-TW Wagon with a full Swap -RIP
92 SS Prefaced, GD dash swapped, 22T/205 Hybrid 20 psi - BEAST!
93 SS Bone Stock Gone!
94 TW Bone Stock Gone!
91 SS 4EAT Sold!
98 LGT 4EAT
98 LGT Wagon 4EAT
1982gl4
First Gear
Posts: 127
Joined: Tue Oct 18, 2011 8:40 pm
Location: Worcester, VT

Re: 1991 SS, and a trip.

Post by 1982gl4 »

I was planing on it anyway really. I wanted new everything when I go to put it back together. The only thing that is going to be used are the case halfs.
1991 SS
1993 SS part's car, dead due to rust
1992 Legacy L wagon
1984 subaru GL wagon
1986 Brat (work in progress)
Several Air cooled VW's
1982gl4
First Gear
Posts: 127
Joined: Tue Oct 18, 2011 8:40 pm
Location: Worcester, VT

Re: 1991 SS, and a trip.

Post by 1982gl4 »

Picked up this wrx last week. It looks nice, but it is super, super rusty. The rear strut towers have holes the size of my head in them, and there are no rocker panels to speak of. I have worked on this car for years, and know the history. One owner car, it has been pretty well taken care of. It now has 200k on it so its due for a timing belt. But it has a new cobb turbo back, access port, cobb heat shield. New radiator, front brakes, subframe in the front, control arms, power steering rack, the list goes on. I'm thinking it will be a harness swap for this, I'll be taking some other goodies off from it for my legacy as well! Not sure if I want to try and tackle the dash swap others have done, or have the harnesses merged, anyway a lot of good parts to be used here!

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1991 SS
1993 SS part's car, dead due to rust
1992 Legacy L wagon
1984 subaru GL wagon
1986 Brat (work in progress)
Several Air cooled VW's
Legacy777
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Site Admin
Posts: 27750
Joined: Tue Oct 15, 2002 11:37 am
Location: Houston, Tx
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Re: 1991 SS, and a trip.

Post by Legacy777 »

It's hard to imagine an 2002-2003 era car be rotted out by rust, but I guess if the undercarriage isn't hosed off regularly during the winter the salt goes to town.
Josh

surrealmirage.com/subaru
1990 Legacy (AWD, 6MT, & EJ22T Swap)
2020 Outback Limted XT

If you need to get a hold of me please email me rather then pm
1982gl4
First Gear
Posts: 127
Joined: Tue Oct 18, 2011 8:40 pm
Location: Worcester, VT

Re: 1991 SS, and a trip.

Post by 1982gl4 »

Legacy777 wrote:It's hard to imagine an 2002-2003 era car be rotted out by rust, but I guess if the undercarriage isn't hosed off regularly during the winter the salt goes to town.
You would be surprised. Up here you are lucky if your car makes it 10 years. We condemn cars all the time at work, brake lines, no rockers, subframes bad, frames, the list goes on.

Here is the 97 legacy I picked up last summer. The wrx is a few pot holes away from looking like this... Be thankful you don't live up here....

Image
1991 SS
1993 SS part's car, dead due to rust
1992 Legacy L wagon
1984 subaru GL wagon
1986 Brat (work in progress)
Several Air cooled VW's
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