kimokalihi's 91 SS EJ20 Swap

[beatersubi]

What happened to the diff?!

[evolutionmovement]

There's also an actual black trim tape that you can cover the chrome with. I liked the picture of the new wheel next to the old ones—I think you should have mounted them dually-style. Tell people it's for traction like the old Auto Unions.

[07Evolved]

The setup looks good man. You will have to let us know the details on rolling the fenders.

evolutionmovement, do you know where to get the black trim tape that does the trick?

[evolutionmovement]

I got it at Autozone. It was with the pinstriping.

[07Evolved]

I got it at Autozone. It was with the pinstriping.

Ok thanks man. I need to get some. Is it a better product over just electrical tape?

[kimokalihi]

It's it's any more expensive than electrical tape I wouldn't bother. It works pretty well.

[kimokalihi]

The rear diff is howling bad. Stopped by PIA and Jake was nice enough to throw it on the lift, turn it on, give it some gas and immediately you could hear the diff standing under it making a nasty noise. I must have destroyed it driving it for 200+ miles with no gear oil in it. There was some but when I finally got the fill plug out (stripped it the first time) I couldn't feel any fluid sticking my finger in it.

So now I need a new 4.444 diff in less than 2 weeks so I can make it to the show.

[07Evolved]

Thank you, Kimo.

I hope you get that rear diff soon!

[Mattheww044]

damn dude that sucks man. I hope you can find one, I will certainly keep an eye out. You have to make it to the show! and those wheels are so f***ing badass dude!!!!

[mike-tracy]

There's a 1996 Legacy LSI auto at Lynnwood Pull A Part that's 4.44 FD

[kimokalihi]

I'm assuming that's just a non-LSD.

[mike-tracy]

Right. Only USDM 4.44 FD diffs are in certain cars from the 2000s.

[kimokalihi]

So are there any LSD rear diffs in USDM cars with 4.444 FD? Lookin like ebay for about $250. That's a lot. I only paid $100 for mine. I wonder if it's rebuildable.

[kimokalihi]

So...ebay is lookin like $300 for a 4.444 LSD diff. Shit. Plus I would have to wait for it to arrive. This is cutting it really short. Not a lot of time left.

[Legacy777]

Why not just swap the LSD internals. It's a sealed unit, so it doesn't matter about whether the diff was low in fluid or not.

[AWD_addict]

Keep the shims in order when you take apart the diff, then check the ring tooth contact with some blue dye (or paint or whatever). Also, it may be easier to loosen the ring gear bolts while it's still installed in the housing.

[kimokalihi]

You lost me. lol I don't know my way around the internals of a rear diff. I was wondering if I would be able to EASILY (gotta be easy because I'm short on time) swap my LSD into an open diff 4.444.

[Deride]

Just swapping the LSD is pretty easy, but if you pull the pinion gear it gets to be a pain in the ass. Just make sure not to damage the shims on the side carrier bearings (IE don't use a screw driver or pry bar to take them off) if they aren't coming off easy tap the outside of the carrier bearing with a rubber hammer. Keep the shims in order don't mix them up. Take the diff out, swap the ring gear from the open diff onto the LSD. You *MIGHT* have to take a reamer or dremel to the diff case as the LSD ones are normally notched a bit to get the larger unit into the case. Put some sorta grease or chalk or something on the ring gear so you can rotate it after assembly and check if it is contacting the pinion properly. Also, it is completely normal for one of the bolt holes on the carrier bearing to partially break off... every time I've done one they break in the same spot. So basically go buy a rear diff cover gasket, probably a breather cap, and if your side oil seals look nasty 2 of those as well.

[kimokalihi]

That sounds like a lot of work and parts to source and do in less than 2 weeks when I work at night and sleep all day. I think buying an LSD diff would be much easier.

[SLODRIVE]

It's really not that hard. I'm literally "making" a 4.111 LSD as I type this...the side seals look OK, and I'm using Fujibond instead of a diff cover gasket, so all I need is a little gear lube and I should be good to go.

[kimokalihi]

I've got gear oil left over. 75w90 Redline. Can I reuse the diff gasket?

[07Evolved]

I tried reusing a rear diff gasket one time in my truck...didn't work so well.

I would get another one to make sure and for peace of mind.

[Deride]

Lol like he said it's not that bad, I could have pretty much completed it in the time it took me to type that. I'm guessing your local subie dealership would stock the rear gasket.

[kimokalihi]

Stock it? That place doesn't stock anything I ever need. The only thing they've had in stock that I've asked them for was things like oil filter, coolant, fuel filter and that's about it. On top of that they charge outrageous prices for everything.

[kimokalihi]

I5 Auto down in Napavine (south of chehalis right next to I5) says they have an impreza (I asked if they had a 00-01 impreza 2.5 automatic) there with a rear diff for $225. Just need to clarify something first. 2000-01 Impreza 2.5's were all RS and ALL had the 4.444 rear LSD correct? I don't want to go down there only to end up buying a $225 open diff that I could have gotten for $50-$100 elsewhere.

I'm going by this information I dug up searching the interwebz:

FORESTER 00-02 Rear; AT (4.444 ratio), locking
FORESTER 03 Rear; AT (4.444 ratio), locking (XS model)
FORESTER 04 Rear; AT (4.444 ratio), locking, XS model
FORESTER 04-05 Rear; AT (4.444 ratio), locking, XT model (turbo)
FORESTER 04-08 Rear; MT, locking, XT model (4.444 ratio, turbo)
FORESTER 05 Rear; AT (4.444 ratio), locking, XS & LL Bean models
FORESTER 06-08 Rear; AT, locking, XS & LL Bean models (4.444 ratio)
IMPREZA 00-01 Rear; 2.5L, AT (4.444 ratio)
LEGACY 05-09 Rear; Outback, 2.5L (4 cyl), turbo, MT (4.444 ratio)



Model Year Model Trim Transmission Front Center Rear Rear LSD
1991-1992 Legacy Turbo AWD 5MT 3.900 1.000 3.900 Y
1992-1997 SVX AWD 4EAT 3.545 N/A 3.545 Y
1993-2001 Impreza 1.8L, 2.2L AWD 4EAT 4.111 N/A 4.111 N
1993-2001 Impreza 1.8L, 2.2L AWD 5MT 3.900 1.000 3.900 N
1998-1999 Impreza 2.5RS 4EAT 4.444 N/A 4.444 N
1998-1999 Impreza 2.5RS 5MT 4.111 1.000 4.111 N
2000-2001 Impreza 2.5RS 4EAT 4.444 N/A 4.444 Y
2000-2001 Impreza 2.5RS 5MT 4.111 1.000 4.111 Y
2002-2003 Impreza 2.5RS 4EAT 4.444 N/A 4.444 N
2002-2003 Impreza 2.5RS 5MT 4.111 1.000 4.111 N
2002-2003 Impreza TS, Outback Sport 4EAT 4.111 N/A 4.111 N
2002-2003 Impreza TS, Outback Sport 5MT 3.900 1.000 3.900 N
2002-2003 WRX 4EAT 4.111 N/A 4.111 Y
2002-2003 WRX 5MT 3.900 1.100 3.545 Y