Crazyeights

Yes the EA71 pistons do fit in an EA81. I just built mine with a NOS set. I have heard that the EA82 (SPFI) pistons fit an EA81 also and are an even better choice for compression. The Delta cam is certainly an improvement, but your valve train may be considerably noisier even with tighter valve clearances if it's a solid lifter engine. You can also remove about .005" from the deck of the engine block halves and another .020" from the heads (make sure they are the large valve heads). Any more than that and the intake manifold may have to be modified to fit. GD's SPFI conversion is great! I have never tried a Weber carb setup on an EA81 so I can't comment on that. If I keep my foot out of it I get about 18-20 mpg city and 25-30 mpg on the freeway. That's with 15" pugs and a 3.9 ratio D/R FT 4WD 5 speed.

Looks GREAT:clap: Must be about an 84, does it have a 4 speed or an auto? What color is the interior? Congrats!

Sweet! So the 2.2 tensioner bracket goes on the 2.5 block and the rest of the timing components are all 2.2? How much clearance do you have on the drivers side at the frame area? Can't quite see from the photos. Lots on the pass side by the looks of it.

I just went through this on my '83 wagon and it was a combination of the connector/headlamp relay (in the dash by the headlamp switch connector near the steering column). I am beginning to wonder how reliable those 20 year old little round style relays are:rolleyes: Hope you get yours fixed.

I recently bought a set of the first gen reproduction lugs from a member here that was making them and they fit perfectly. I had the VW adapters before. GD is right about the safety concern with those. The repros are WELL WORTH the money. They are perfect and the second run was even plated if I remember correctly. Just my 2 cents.

Forgive me, I don't know your Brat. Is it lifted at all? Is the suspension totally stock? Certain combinations of front end lift parts will eat axles FAST. The best axle made (MWE?) won't last any longer than the ones he is putting in if the suspension geometry is what is eating them up. Are the front hubs and bearings still good? Good Luck

I have an Hybrid 3.9 RX/XT6 D/R CL Diff box in my EA81 wagon using the stock EA81 23 spline front axles. The D/R-S/R 23 spline stubs fit right in the XT6 or R/X front diffs. Fair amount of work but you get the chance to re-seal it at the same time:grin: The above links are EXCELLENT! I probably wouldn't have tried building my trans without them. Also, search for the thread on replacing the front trans bearing. GREAT tear-down instructions with good pics.

Brilliant shortcut! I have done the last couple the hard way:rolleyes:

Well, I know there is at least module and a sensor at the base of the steering wheel involved on the XT6. I saved an extra pump, controller, and lines when I sold my XT6. If you figure this out I would love to know. The XT6 FSM has a schematic section devoted to it. I think it is still hosted on the XT6 forum site. Lubegard PS fluid (Sold in the flush kit) seems to work well. About $16.00 for a large bottle I think.

Another successful alternator upgrade:banana: Thanks GD! I actually had the correct size spacer in the "alternator pulleys and spacers" box so I didn't need to grind one down. System voltage seems to be MUCH more stable at lower RPM's than it was before. This is a SWEET upgrade. BTW I took one look at the mud puddle under the Maxima at P-A-P and went for the reman:grin:

Nice work! Is there a special engine paint for aluminum? It seems like no matter how carefully I prep aluminum parts the paint just doesn't adhere like it does to cast iron parts. Love the pics!

That small round headlamp relay was causing LOTS of problems with my dash cluster and gauges. In fact I had given up on finding/fixing it until my low beams went out completely and I had to. Check the connection at the relay connector as well. If you are using used relays try 2 or 3 before you put it back together to make sure you get a good one, or just convert to the newer square style relay. Someone wrote a How-To on here for that. Good Luck. BTW I think this is the first time in a LONG time all my gauges are somewhat accurate now:grin: BTW just re-read your first post. My lamp relay is in the dash near the switch. No idea what that other thing is you are talking about.

You can also build a pretty respectable performance EA81 and it bolts right in (the hard part may be finding a good core). The more miles I put on my new build the more I like it. Just another opinion, but an EJ swap of ANY type will be more time and money. Listen to GD and the others that have done it both ways and then decide. It will also depend on your budget and level of mechanical experience.

Not sure yet what to do with the left over XT6 gear set. Might put a 3.7 XT6 box back together as a spare or put it behind a "Franken" in a Bad A** street Hatch.

1-5 gears are from the RX (closer ratio I think than the XT6). The final drive ring and pinion are from the XT6 (was 3.7 before). The current low range is stock RX - not as low as the 1.59 in the D/R part time trans. That is why I was wondering if I could swap in the 1.59 front section. This would be the ultimate combination for me, but It's really sweet now as it is. The car is street driven mostly and has 15" pugs/tires on it with an SJR 4" lift.

Great info, Thanks!

Yes, it is a SWEET combination. Each low range gear right now is roughly half way in between the 5 high ones. Like a passing gear if that makes sense). If I build another one with the lower low range I'll probably start with a different R/X box so I can leave this one together. I only had 53k on it when I got it (before I modded it) and I think it's the only 5MT trans I've ever had with good first gear synchros:grin:

I think I would pull it out and do it again. Like GD said you don't want to block any drain holes that may exist. A new seal is only another $20.00 and you be kicking yourself if you have to pull it all back out again.

I bought a low mileage used FT 4WD 3.7 ratio Dual/Range trans with a center locking diff and changed the final drive (ring and pinion) to 3.9 using a gear set from an XT6 trans. You must take care setting up pinion depth, backlash, end play, ect. I also opted to remove the 25 spline stubs for the front axles and replace them with a 23 spline set from a single range push button core at the local P-A-P. Now my stock EA81 axles fit right in. The RX trans does indeed have the 2 piece input shaft just like the D/R part time trans does. I was just wondering if I could use the 1.59 Aux trans (low range) in my current set up. I wasn't sure this was going to work so I didn't try it the first time I had the case split. This combination turned out so nice though, it would be nice to have the slightly lower low range set. We just had some snow in the PNW and with the custom trans and the LSD in the rear it tracks incredibly well:grin: This trans build wasn't all my idea, thanks to those that helped privately with ideas, you know who you are:banana:

Call Jerry to be sure, but I specified 51" of tubing when I had mine made.

I built a FT 4WD RX trans with 3.9 gearing from a core XT6 trans and 23 spline stubs so it will fit in my '83 EA81 wagon. So far I have about 1500 miles on it and it works great, no noise, no metal on the drain plug, ect. I took great care in setting it up properly. I REALLY miss the 1.59 low range from my old D/R. Can I gut the 1.59 low range section from a P-A-P D/R and swap them in to my current trans config? Yes I know it's a lot of labor but it might be worth it. It's seems like it would be a good combination. What do you think?

I measured mine (piston diameter) and I think one pair I had was 30mm and the pair I chose to rebuild was 33mm as I recall. Hope this helps, I do know for certain there are at least 2 different sizes.

I just ordered a caliper rebuild kit from Subaru. It came with piston o-rings, piston dust boot seals, and the rubber bellows (1 kit is enough for 2 rear calipers). I think the seal kit was less than $30.00. BTW your powder coating looks REALLY nice.

The powder coating looks great:banana: I just rebuilt mine too but it's a rattle can job.

If these are standard front Gen 2 EA81 seat rails I have a complete set. Make offer via PM