idosubaru

If it’s not an installation error, it’s the sprockets. Check the timing marks? Fuel lines didn’t get mixed up? Swap the crank and drivers side timing sprockets.

Well shoot, I'm unsure about the SVX The SVX has a rear LSD, I wonder if those axles are different. My guess is you swap the rear diff guts. Which isn't hard nor does it take long...but I've never done it with an SVX so I'm unsure on what can be done or best approach. Here is what you need to end up with from swapping the guts between the two differentials: 1. The ring and pinion from the forester (for the proper 4.44 gear ratio to match the transmission) 2. the rear diff chunk from the LSD (because it'll properly receive your axles). I'm just not sure which housing to use, either: A. install the Forester ring and pinion into the SVX housing. The pinion bolts to the housing and the ring bolts to the (SVX) diff chunk. In this case you'd want new pinion seals and side seals. or B. install the SVX guts into the forester housing with it's original Forester ring and pinion. If you do this - you keep all the side caps, shims, everything identical in the SVX and swap them to the forester. In this case you'd want new side seals. B would be easier because you don't have to mess with the pinion which is kind of beastly and then you probably need to replace the pinion seal and maybe that messes with preload on the R&P? It might be better to keep the R&P within it's own housing....just a wild guess but that's also what I've always done. The non-LSD housings (the forester) have little bumps inside you grind down so the larger SVX LSD chunk can clear the housing. It's not as hard as it sounds. Try to install the LSD chunk and you'll see it hits the bumps inside. Knock that down with a grinder until the LSD fits. It's not much and doesn't take long. Another option might be some kind of axle swap or frankenstein axle, but I'm unsure if that's even possible. I've done these types of rear diff gut swaps to change gear ratios or swap LSD chunks, but I've never done it with an SVX or due to axle problems, so that's why I'm unsure.

Doesn’t look Subaru

hold onto the bad trans until you know the donor trans pan isn’t dented and it doesn’t have toque bind. And it’s not missing the torque converter, stubby shafts, or shift switch on the passengers side. Usualky they just come with all that stuff but I’ve seen all of those missing or damaged before too. but in general, Nope. They’re basically the same trans with slightly different guts inside and all that stuff usually stays with the trans Torque bind isn’t uncommon so if you wanted you could save the rear extension housing (it’s like 6 or 8 easy bolts and it pops right off). It has the 4WD clutches and solenoid. Or just hold onto the trans At least until you drive it and verify the donor trans doesn’t have torque bind. Then throw it away or keep the rear housing if you have room. make sure he knows how to properly seat the torque converter, if you don’t the oil pump will crack inside the trans. The torque converter and flex plate should not touch when the trans is bolted up to the engine and installed. The flex plate bolts will draw them together.

Should be.

-50F haha, wow. The first question is - There’s lots of Subarus in Alaska I doubt they’re all replacing boots annually. Maybe they’re coastal and more moderated temps? I’d upgrade to OEM 00-04 OBW axles and new Subaru boots. No need to reinvent the wheel if those work. You can feel a difference between the 00-04 outer boots and 90s boots as soon as you remove them from the box. The material is way different and very robust. If yours is lifted,colder, both, or otherwise stressing the boots more than other Alaskans, I’ve seen a company years ago that made silicone boots from dimensions you send them. Don’t recall the name. The linked heavy duty axle is not a good axle. Might get lucky but They aren’t the first company that tried to sell a Subaru axle marketed like this and they won’t be the last.

Yeah it’s been awhile but 99 Outback/Legacy SUS is odd. The 95-99 Outback legacy engines all swap. so it’s hard to imagine the trans doesn’t swap. But - I think those 99s have the Phase II trans. If the trans has a spin on filter then it’s phase II. 95-98 didn’t have that. also 95-99 all EJ25s swap except the 99 Forester and Impreza RS. And all 95-98 EJ22s swap electotncialky but the 99 EJ22 doesn’t for any of them even though the 99 EJ25 does swap with esrkier models for legacy/Outback. Just the 2.2 doesn’t in 99. thoroughly confusing year.

Subaru OEM boots? They’re way better than standard aftermarket. They don’t break in a year. I reboot my Subarus when I get them and never have to do it again even after 100,000 miles. That never happens with aftermarket. if you’re using 90s axles upgrade to 00-04 Outback style axles. the boot material is better, particularly the outer boot, it’s “stiffer” and the outer boot has more convolutions. They have the tone ring on them, just tap it off with a hammer it just sits on the ridge. They can even be left on but I remove them. They’re a direct swap into 90s EJ vehicles. I’ve seen silicon boots for sale but I forget where. Google should find some.

Piston rings. Not ideal to have another shop do it for a litany of reasons. Unless they’re very experienced in Subarus subaru doesn’t even fix it, they just replace the entire short block $2000 new block and $3,000 for new headgasket and reassembly. Costly but at least you get a good warranty out of the new block instead of just 12,000 miles and 1 year from a typical shop repair the good news is they come with a 36 month unlimited mile warranty. Used to be 36,000 miles now I think it’s just 3 years no mileage limit. That’s just the block, everything else, which practically speaking is just the headgaskets, would have the standard 1 year 12,000 mile warranty Best fit solution: schedule a reasonable check and top off schedule you do routinely, don’t keep using the dash light. Top it off every Sunday or night you’re home or gas fill up, I see people checking oil at gas stations (I travel a lot), you’re already waiting for the pump anyway. When you change the oil, overfill it a 1/2 quart. The top fill line is extremely forgiving - if it wasn’t then every mountain, curve, steep boat ramp, hard braking causing the oil to rise on one side or slosh around would damage the engine. Pro tip: none of those damage the engine. Use thicker 40weight oil. 10w40. Shoot as a test I’d run 20w-50 and see what happens. But that freaks out the inexperienced oil nazis. Either way - don’t use the recommended 0W-20 garbage

It looks like a bolt and nut to keep with a chain for lifting engines, etc. 14mm old gen bolts: suspension: ball joint, cross member. Most are 12 but some engine accessory bracket hold down bolts - like A/C bracket, P/S, Alt are 14mm. bellhousing and head bolts but this isn't one of them.

If it does work, the rear transfer solenoid bits are different and need swapped over. Those changed in 03/04 The TCU won’t need swapped if the trans swap works 99 is an odd year. Outback engines are the same as 95-98 Outback engines. But I think the trans may have went to phase II in 99.

Check wiring for rodent or prior engine work damage - just the exposed, easily visible wiring, that's what they'd typically find first as well. Follow the wire back from the solenoid as far as you can. Are you sure you're addressing the correct side, there's two right? Make sure you're looking at the right one.

I’ve rebuilt a ton of totaled cars which many people claim is hard, terrible, and fraught with danger and potential rejection or unknown problems and the state is out to get you. I’m an untrained DIY guy, never had shop classes or been in auto business. Never had a problem rebuilding a totaled car and getting a real title for it. It’s not a big deal. I haven’t done a title-less car but after the rebuilding process I wouldn’t be deterred if the right situation presented itself. I’ve seen the process listed looking at potential buys and other car protocols. The state tells you what to do - go do what they say. In my experience the inspectors and people involved aren’t as bad to deal with as many claim. They just want to see the I’s crossed and T’s dotted and nothing sketchy and you’re good.

Wow, "you've entered the Twilight Zone" 500,000 miles!!!! wowsers. how many engines/trans so far? any door sag or adjustments after all those miles?

Nice work Brucey. That's cool trying things. Keep it up. The guys at Hartsells on University got a kick out of inspecting the legacy I converted to FWD automatic just to do it. You did the hard work but hindsight being 20/20 It seems risky to have an unforgiving data point downstream of the final drive output. I've got a 14 Forester parts car I was wondering if I could swap the trans into an outback....looks like it would work on what you're doing. I ran into a police officer at the local highschool a week or two ago and he said "Dude I saw an XT6 just like yours, look at this picture".....it was mine. Lol.

Could oil consumption be breaking in? Maybe it'll reduce over time by 20K? The smells don't sound good though. Keep an eye on coolant levels and that should tell you if you're actually losing coolant.

run whatever you want, they're dead men walking anyway? and hey I get it, it's not like it's easier to daily drive my XT6 than our 2016 outback.

I’ve repaired a few rodent damaged harnesses. Besides diagnosing and tracing them to under carpet wiring, or hidden areas, they were all easy repairs, never had repeat issues. One or three are broken completely, another is abraded, splice them all, wrap, and on your way. Good luck!

Is it covered under your insurance policy? That's in a very bad area and good chance it's causing the codes. Splice the broken wires to repair or replace the entire harness, Subaru will have those in stock (i think). Subaru will only replace the entire wiring harness, they will not repair the current harness. At least all the dealers I know won't, maybe there's a few willing to "break the rules".

I don’t know either. It’s my understanding it should run but I haven’t investigated it.

Taking it apart - can you check continuity from the connector wiring harness side to a point on the circuit board of each pin as far down stream of the connector as possible. maybe also why wiggling or pressing it to the side so to speak. If you have access to any used Subaru parts All 1995-1998 4 cylinder 2.2 liter and 2.5 liter, Outback legacy Forster Impreza TCUs all readily swap.And 99 Outback’s and Legacys. I think even a FEd TCU is plug and play lol

just putting this here for my own reference, but something like this in the right size, this is too big: https://www.akr-performance.com/p/srs-exhaust-donut-flange-pipe-635mm25-flange-a

I want to keep the stock exhaust manifold/header and replace the rest. Is there a flange adapter that bolts up to the stock header and donut gasket?

Read the owners manual. You can run any reasonable oil. It would be fine. I’d probably avoid 5W on EA engines but for no reason. For what it’s worth GDs shop superior in Portland runs 5w-40 synthetic as a rather standard oil for various non turbo applications, I think including EA engines. Of course hotter temps will be less ideal for thinner oils and that’s a good reason to check the manual like prior post mentions.

Are there any engine codes (check engine light)? Not saying this to be mean but for clarity: running well isn’t important - are there any check engine engine lights or codes? Check if the ATF pan is dented. It can cause problems much easier than a dented engine oil pan. You can attempt to extract the AT codes: some newer Subarus like 2005 ish I think but I forget the years, I have a very easy way to read the codes without any scanner. Not sure it applies to 2002 or the classic schizophrenic multiple personality disorder meth smoking strategy Subaru employed here which you can do yourself with no scanner: