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Guest Message by DevFuse
 

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Project EJ22 Hatch continues


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147 replies to this topic

#1 Pooparu

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Posted 05 May 2009 - 03:58 PM

I sure that some of you are familiar with my Project EJ22 Hatch (if not follow the link below to my car domain page). Well with the weather starting to improve I've set some goals on my Hatch.

1. Add power steering

2. Add reverse lights

3. Clean up some wiring

4. Get my intake relocated

So the first thing I'm going to do is add the power steering. While I'm at it I'm going to replace most of the suspension components too. I pull a cross member & rack from a 1983 wagon at the junkyard. The car had a ton of miles on it and the rack & cross member were covered with 26 years of oil and dirt. I'm going to pull it apart, clean, repaint and rebuild everything.

Here are some images of the begining process. I'm using Krylon Silver Hammer paint.

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Right now I'm waiting on the parts to rebuild the pump and rack. I'll post more photos when it's all back together.

#2 carfreak85

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Posted 06 May 2009 - 07:25 PM

I'm going to be doing the same thing on my hatch soon. Could you give me a lead on where to find those parts you plan on using for the rebuild?

#3 Pooparu

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Posted 07 May 2009 - 09:40 PM

I've got all the hardware painted now. I just need to wait for the new parts to arrive. Tie rods & tie rod ends & rebuild kits.

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#4 Pooparu

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Posted 08 May 2009 - 07:10 PM

So while I'm waiting on parts I decided to put everything back together so I didn't forget how it went. Here's everything painted, cleaned and put back together:

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#5 monstaru

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Posted 09 May 2009 - 12:17 AM

i remember asking for that info the last time this was brought up.......i have checked out a couple of places with no luck.and by a couple i mean a bajillion......cheers, brian

#6 Pooparu

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Posted 09 May 2009 - 10:24 AM

Here's where you can get the power steering rebuild stuff: Lithia Subaru of Oregon City #113. They don't sell a kit, but the parts are available individually.

#7 Pooparu

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Posted 10 May 2009 - 09:16 PM

I mounted some reverse lights yesterday. I haven't wired them up yet, but they should be much brighter then the stock ones:)

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#8 GeneralDisorder

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Posted 14 May 2009 - 08:40 PM

Let us know what grease you use for the rack and pinion gears. I checked into it a few years back and the grease was insanely expensive IIRC. It looks like a lithium base as it's white. It's also quite thick. When I talked with Lithia they had no clue as to the grease I should use as they claim to have never rebuilt one as they almost never fail and when they do they are replaced, not rebuilt.

I would be very careful about the installation of the teflon hydraulic seals as well - mine leaked worse when I put it together after an investigatory dissasembly than it did before I touched it. The rack tube may need to be honed or replaced if it's got any grooving or pitting damage. Also remember to order new lock washers as you will be destroying most of them in order to get the rack apart.

GD

#9 Pooparu

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Posted 15 May 2009 - 03:17 PM

Ya, I was starting to second guess rebuilding the rack. I'll probably just do new tie rods & end. That should be good. I'll also rebuild the pump and freshen up the rest of the front end.

#10 PoorManzImpreza

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Posted 17 May 2009 - 11:43 AM

I've rebuild a couple power steering racks and what they don't tell ya is you need a press to get the rack assembly back together..it was the only way I could get the new inner seal to go into its seat. The pinion shaft was easy with sockets and a press as well. The grease I used was a crc extreme pressure marine grease was red, thick and nasty. So far so good..zero leaks now, would go through a quart of atf in a month before.
hth
Kaz

#11 Pooparu

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Posted 18 May 2009 - 07:12 PM

I've decided not to rebuild the rack, but I did install some new tie rods & ends.

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#12 Pooparu

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Posted 21 May 2009 - 11:16 AM

I just ordered a set of these hood latches for my hatch. I can't wait to install them.

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#13 Pooparu

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Posted 21 May 2009 - 11:34 AM

I also finally got around to wiring up my 5 speed. I cut out my EA81 plug and wired in and EA82 plug. Just encase anyone else wants to know which wire goes where here is a photo. It wires up the reverse lights and 4WD low light.

So from the EA82 plug to the EA81 Plug:

(4WD low light)
Light Blue with Red line - Black with Red stripes
Green with Black line - Blue with Red line

(Reverse lights)
Black - Blue with Red stripes
Black - Green with Red stripes

The other two wires are not needed. They are for the neutral position sensor.

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#14 Pooparu

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Posted 21 May 2009 - 11:13 PM

Well now my reverse lights are stuck on all the time when the key in on. I'm going to have to crawl under the car and check the switch now. I hope that fixes it. I did manage to get the new backup lights wired up to the stock reverse lights. I don't think that cars would want to drive behind me if the lights were stick on all the time. Hmmmm that might be a good thing:)

#15 Yo'J

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Posted 22 May 2009 - 10:39 AM

I went with Red-Head in seattle, for rebuilders. They were a week out and gave good service. It was easier than getting a new one. Mine was manual and their comment was power models are easier.

#16 Pooparu

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Posted 23 May 2009 - 01:04 PM

I pulled all the parts for a 5 lug swap from an XT6!!! I realize it's a bit of work to put them on my hatch but I'm doin' it.

#17 Jerry DeMoss

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Posted 23 May 2009 - 02:39 PM

I pulled all the parts for a 5 lug swap from an XT6!!! I realize it's a bit of work to put them on my hatch but I'm doin' it.


Now that I want to see! Good luck with that.:slobber:

#18 2.5GL

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Posted 23 May 2009 - 06:42 PM

I may have to come buy and check this show out... the parts look fabulous, want to clean and paint mine???

#19 Pooparu

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Posted 23 May 2009 - 11:03 PM

I may have to come buy and check this show out... the parts look fabulous, want to clean and paint mine???


Ya sure, for a sack full of money.:)

#20 Pooparu

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Posted 24 May 2009 - 02:29 PM

I got my 3rd switch in today. I made some decals to label them as to which set of fog lights they go to. Here's how they look:

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#21 Pooparu

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Posted 28 May 2009 - 12:45 PM

Here's what I've been working on.

5-lug swap

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WRX Rims

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WRX Brakes (cleaning & painting)

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Thanks to the nice weather I've been very busy working on the hatch. I also but new wheel bearings in the front & I blew a set of bearings out in my rear diff, so I'm replacing that too.

#22 RAugur33

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Posted 28 May 2009 - 03:19 PM

Damn Poop,

looks sharp. Maybe I will park my wagon in your driveway when your finished. Just so you don't get bored.

#23 Pooparu

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Posted 28 May 2009 - 03:43 PM

Damn Poop,

looks sharp. Maybe I will park my wagon in your driveway when your finished. Just so you don't get bored.


Sure I'll get to it as soon as I finish the projects on my Hatch, Porsche & BRAT. You can pick it up sometime in the spring of 2020 :lol:

#24 GeneralDisorder

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Posted 28 May 2009 - 07:44 PM

So what have you found out about the 5 lug swap - have you called your driveline guy yet? Checked out ball joint interface issue? This is something I want to do with my Brat at some point but I haven't worked on lining up any of the sources or researching it beyond knowing some of the issues.

GD

#25 Pooparu

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Posted 28 May 2009 - 10:13 PM

So what have you found out about the 5 lug swap - have you called your driveline guy yet? Checked out ball joint interface issue? This is something I want to do with my Brat at some point but I haven't worked on lining up any of the sources or researching it beyond knowing some of the issues.

GD


I'm working on testing some axle stuff out. As soon as I have something that works I'll let you know. As far as the ball joints go I can drill out the EA81 control are to accept the XT6 ball joint and the same goes with the steering knuckle to fit the EA81 tie rod ends. So the only real issue are the axles which I'm working on now. Also I'm working on ether a top hat swap or re-drilling for the shocks.




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