kimokalihi's 91 SS EJ20 Swap

[kimokalihi]

you do know that you can open the center shaft section yoke up and swap the two.

but there is one thing, my father did it five years ago and i forgot how he did it. i know there is a plastic cup or steel cup and once you remove it there is a bolt that splits the yoke. i just cant remember it all, but ill find out for ya.

Wait are you talking about the driveshaft or the differential? What is a yoke?

I just ordered the mounting flange for the rear diff for $75. I was going to go to the junkyard and get one but the weather is shitty, I work nights so I would have to get up early and it would be a bitch to get off a car in the junkyard.

I didn't want to take anything off the 91 LSD because I want to sell that.

[kimokalihi]

tank was good to go?

Yeah sorry I forgot to tell you I picked it up 3 miles down the road from my house and it looked good to me. Was that from a turbo or NA?

I put it in and hooked it all up but I'm sure it'll be a long time before I know if those sending units and pump are good.

[Airgne]

came out of a turbo.

[NICO]

you do know that you can open the center shaft section yoke up and swap the two.

but there is one thing, my father did it five years ago and i forgot how he did it. i know there is a plastic cup or steel cup and once you remove it there is a bolt that splits the yoke. i just cant remember it all, but ill find out for ya.

Wait are you talking about the driveshaft or the differential? What is a yoke?

I just ordered the mounting flange for the rear diff for $75. I was going to go to the junkyard and get one but the weather is shitty, I work nights so I would have to get up early and it would be a bitch to get off a car in the junkyard.

I didn't want to take anything off the 91 LSD because I want to sell that.

the yoke is the center of the driveshaft, i think that is the right term for it.

but if your going to sell it you wont need to split it up to make a working shaft for your self.

[kimokalihi]

Man sounds a lot easier to change the shaft than it will be to swap out the mounting flange on the diff. I'm just hoping that I can get the axles back in, pull the Ebrake really hard and it will hold strong enough for me to break loose that big nut holding the flange on the diff.

But before I do that I have to wait for my parts order to arrive. I ordered new inner hub seals because I found out mine are shot and while the axles are out I might as well replace them.

[logan9691]

What year did your forester lsd come from and whats the ratio?

The studs on the forester rear LSD were way too long so I ordered the 91 legacy rear diff studs and picked them up at the dealership.

Part number 800912040

Used the double nut lockwasher sandwich method to remove the studs that were too long. Worked great.


Finished bolting the crossmembers back up and all that other suspension crap and a heat shield for the gas tank. Bolted the rear diff in. Then I went to bolt in the forester driveshaft because the bolt pattern is different than the legacy bolt pattern on the rear differential end and that's when I found out the forester driveshaft is too short. By 2"-3". So that's not going to work. I think my only other option is to unbolt the input shaft mounting plate on the rear diff and swap it with my legacy one. If that's possible. Problem is I don't have a big enough socket for that. I'll need a compressor since the legacy rear diff is not in the car anymore and I don't have way of holding the axle stubs still while I torque on it.

[kimokalihi]

Could I ask you to edit that quote for me and remove the pictures? I post a lot of pictures on each page and it already takes a long time to load them all when viewing the thread so if you could do that I'd appreciate it, thanks! It also takes a lot more space up on the page meaning a ton of scrolling.

To answer your question, it came out of a 97 JDM forester. The ratio, I'm told, is 4.444. Came with the tranny and engine swap.

[kimokalihi]

To compliment my 8mm phenolic intake spacers and throttle body coolant passage bypass I ordered these nifty coolant tank insulator mounts.

http://carldavey.co.uk/

He's got some pretty cool custom parts and he just sold his really nice RS. Prices are a bit high though.

Haven't put them on yet. Just got them earlier today and I'm sick now. I'm also waiting on some parts in the mail before I get back to work on my car. May need to buy a propane heater too since it's getting down into the 20's at night now.










I thought my 8mm spacers were pretty big but apparently they make bigger ones. 20mm

[mike-tracy]

Hey stay motivated Kimo. Your ride is gonna be so sweet when it's done. I'm in a long build myself, well, I'm learning everything as I go along, with work and school being my bigger priorities.

I've been to a couple of Subaru meets, and the get together with Josh and the others at the pizza joint last month really helped me confirm my reasons for doing the build - the knowledge gained and the cool people to meet!

Hopefully I can see your beast some day.
Mike

[kimokalihi]

And hopefully I may see your beast someday....no homo lol.

I think the bulk of it is behind me now. Just little things remain in my way. For instance, inner hub seals need to be replaced before I can install the axles. Also in the same parts order I'm waiting on there's the rear diff flange and nut I'm waiting on so I can bolt up my stock driveline to the forester LSD.

I wish I could have gone to the subaru meet up in Seattle last week but I had to work that night. I would have felt dumb showing up without a subaru though.

When I get it going I plan to participate in some meets though. I'd like to talk to people who know and love subarus. I don't ever see anybody else who likes subarus.

[kimokalihi]

Got a box in the mail today. Actually I guess it came on saturday but the mail lady is a bitch and won't honk the horn when there's a package that needs to be signed for or won't fit in the mailbox. We have a gate for the dogs and somehow they have a rule that if you have a gated driveway they will not honk, but if you don't have a gate, they honk? WTF? That makes no sense! I'm ALWAYS home when the mail comes too, I'm just sleeping. I'd gladly wake up if she honked and run out and get my package rather than waiting until the next business day to drive down to the post office and pick it up.

I called and complained but they don't care. They're sticking to their stupid rule. The old mail lady used to honk.

I traded one of my turbos + $20 to jdmleggy97 for this airbox which was extremely hard to find.

I'm excited to finish my intake.

[dropdfocus]

Excellent!! I'm sticking with a panel filter for the time being on Trixie until I install something larger than a TD04 and I'm needing more air flow from an open element filter. By then I'll have installed a heat shield around it & have fresh air coming in from outside the car to feed it.

[kimokalihi]

Got my offset resevoir today from New Zealand, yay!

[07Evolved]

wow man, you certainly know how to find rare parts!

[AWD_addict]

To compliment my 8mm phenolic intake spacers and throttle body coolant passage bypass I ordered these nifty coolant tank insulator mounts.

http://carldavey.co.uk/

Apparently his prices only include shipping within the UK. How much did he charge for shipping to the US?

[kimokalihi]

It was included in the price. Unfortunately the exchange rate is horrible. 1 GPB = $1.58 So I paid $25.53 for them instead of 15 GPB.

[kimokalihi]

Finally got my hub seals, rear diff driveline flange and locknut from subaru after nearly 2 weeks or processing and 1 day to ship it.








It was 15*F and I froze my ass off. By the time I was done I couldn't feel my toes. Only thing that kept me alive was this propane heater I borrowed. It worked pretty well when I wasn't under the car but it got no heat under the car because it was too tall and that's where I was the majority of the time.








Ripped out the old seals which were all intact and fine except the passenger side outer hub seal which was in 2 pieces.










I tried installing the axles and that's when I found out you can't install them without dropping the differential. Not fun, I installed it for nothing last time.

Finally got it back in with the axles installed and I must say I think I like the axles with the pins that hold them on and the male axle stubs off the diff.

Then I decided to install my new airbox but found out both of my MAFs do not fit. The bolt holes don't line up.

Impreza MAF








91 Legacy SS MAF







Here's a shot of my intake all put together except the MAF isn't bolted in.








Quick comparison of my new offset clutch resevoir.

[kimokalihi]

Forgot to mention that I could NOT get that bolt off the rear differential that holds the flange on which the driveshaft mates up to. It won't budge. It's not corroded at all, infact it looks new. I put a breaker bar on it and jammed the eBrake as hard as I dared to and the eBrake couldn't hold it still. So I got out my chain wrench and wrapped it around the flange and tightened that sucked down good and must have put at least 150ft lbs of torque on that thing as hard as I could push under the car and it won't break loose!

I sprayed it down a couple times before I left with parts blaster so maybe that'll help next time but I doubt it.

Any other ideas? I need that thing off to finish putting my drivetrain in.

[kleinkid]

I better look at the air box I am going to use and check MAF bolt holes also. Probably same as your situation.

[kimokalihi]

Yeah, I need an MAF now. I don't know which ones will fit either.

[Legacy777]

Do you have access to an impact wrench? If so, I'd try that on the rear diff.

[dropdfocus]

Agreed with a starting point of 120psi on the air tank.

[evolutionmovement]

Or at least the poor man's version—apply pressure on the bolt and tap the handle rapidly with a small hammer. The point isn't heavy blows, but to send vibrations through. Another trick is to just keep a slow steady pressure on the bolt. It takes a little feel for what's too much (and could snap it) and what's the right amount of stress. A long enough bar makes it easy to do by hand, but you can also use a weight or something to load the handle your using and leave it, overnight if necessary. And of course, there's also heat.

[kimokalihi]

I have a nice 1/2" craftsman impact gun which cost me a pretty penny earlier this year and shortly after buying it I found out the compressor was recalled due to some of them rupturing and they came and took it away and gave my parents $100. Since then I've been without a compressor which I only used for a week or two.

I've never had the luxury of power tools. Always done everything by hand.

I don't have a torch either. I should buy one though since they're not too expensive.

[dropdfocus]

Oh dear God!!! I would have NEVER gotten my project to the running condition it is as of this week without my beloved air tools!!!!!!!!! I am very sorry for your loss Kimo.