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Hellosubaru's EA/EJ build/rebuild thread

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If the dates don't make sense in this post, it's because I copied this build thread from another local Subaru forum I run. I figured people on USMB would like to see this too.

 

So, I've never really done a build thread before, so I figured, hey, why not?

 

Before the build/rebuild part starts, here's a little history on the car:

 

I purchased this '86 GL for $150. Both front hubs were stripped, so I had a RWD soob for a while. The one tire fires in the rear were awesome. It came with the stock 1.8 carbed EA and the DR 5spd.

 

Fast forward a few months. Both hubs are replaced, and it runs pretty decent.

 

020.jpg.

 

After the lift went in, it needed a little more gusto. My friend Andy found a guy getting rid of a whole '93 Legacy for $150. He had punched a hole in the torque converter, and was done with the car.

 

So out with the EA:

 

IMG_3733.jpg

 

The same day I picked up the EJ, I found a guy in the Seattle area (I think Suberdave?) getting rid of a whole EJ turbo swap (turbo, heads, DP, lines, etc.). After all said in done, in with the turbo EJ:

 

DSC_0030.jpg

 

At the same time, it got a fresh coat of bedliner:

 

IMG_3741.jpg

 

IMG_3729.jpg

 

So here's how it stood:

 

2011-01-11_23-23-39_614.jpg

 

2011-01-11_23-24-04_146.jpg

 

This concludes our history lesson. Now for the rebuild and upgrades. :headbang:

Edited by hellosubaru

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09/04/2012, Andy and I got the EJ22E-T pulled from the GL:

 

952012-08-299519-30-3595616.jpg

 

IMG_20120829_193221.jpg

 

IMG_20120829_193249.jpg

 

IMG_20120829_221613.jpg

 

Yesterday, Andy measured tolerances and put the pistons in the freshly machined block (thanks to Adam at NWRS):

 

IMG_20120904_214034.jpg

 

IMG_20120904_213914.jpg

 

More next week.

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09/11/2012 we got the long block mostly assembled:

 

IMG_20120912_133022.jpg

 

IMG_20120912_133035.jpg

 

IMG_20120912_133049.jpg

 

And a few pictures of some of the parts I've been collecting for this build over the past year:

 

IMG_20120911_161404.jpg

 

IMG_20120911_161409.jpg

 

IMG_20120911_161413.jpg

 

IMG_20120911_161417.jpg

 

Next time we should finish the long block, and start working on all of the EJ drivetrain parts.

 

 

09/18/2012, Engine is now fully built:

 

IMG_20120918_221948_zpsc814d8a5.jpg

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Well, not much happened this week (10/02/2012), I got the EA diff out, and compared it with the EJ diff. They are pretty much identical on the outside. It's amazing that these were manufactured 14 years apart from each other:

 

IMG_20121002_192120.jpg

 

IMG_20121002_192135.jpg

 

I just need to figure out how to get the EA axles splined to the EJ diff. I think I'm either going to swap the carrier from the EA (since it's an LSD) to the EJ, so I can bolt the stub shafts in and use the EA axles, or use EJ inner cups with the EA axles, I'm not sure yet. So if you have an opinion, let me know!

 

EA:

IMG_20121002_192225.jpg

 

EJ:

IMG_20121002_192201.jpg

 

Here's the EJ trans mocked up in the EA:

IMG_20121002_192342.jpg

 

Hopefully there will be much more progress next week!

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The last three weeks (10/02 - 10/16/2012), we've been working on the trans mount/guard for the EJ trans. It's now complete, thanks to my friend Alex:

 

IMG_20121016_193530.jpg

 

IMG_20121016_193538.jpg

 

IMG_20121016_193605.jpg

 

Next up is re-gearing the trans, swapping around diff parts (carriers and gearing), and figuring out the driveshaft and linkage.

 

 

Not much has happened in the past few weeks (10/23 - 10/30/2012). I've done a lot of wiring, and we started on the rear disk swap last night.

 

IMG_20121030_200922.jpg

 

IMG_20121030_200929.jpg

 

IMG_20121030_201050.jpg

 

IMG_20121030_201128.jpg

 

IMG_20121030_201218.jpg

 

-Jason

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11/04/2012, my bros and I finished up the rear disk swap and 6 lug conversion:

 

IMG_20121104_181112.jpg

 

11/06/2012, my friend Andy tore down and rebuilt the 5spd trans with 4.44 gears.

 

Old gears:

IMG_20121106_203357.jpg

 

New:

 

IMG_20121106_210828.jpg

 

Also, my other friend Marcus, and I, did a bunch of wiring for the control panel and in cabin winch controls, along with new power distribution.

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Well, it's been a few weeks. Work has been extremely busy, and the Thanksgiving weekend was thrown into the mix, but progress has been made.

 

The transmission is rebuilt, and installed in the car:

 

IMG_20121113_210436.jpg

 

The rear end has also been re-geared:

 

3.70 LSD

IMG_20121113_210202.jpg

 

is now a 4.44 LSD

IMG_20121113_210253.jpg

 

The LSD swap was quite simple. I had a 4.44 open diff out of an Outback. We just took the ring and pinion out of the Outback diff, and swapped it into the GL diff with the LSD.

 

Also, the switch control panel was finished:

IMG_20121117_125008.jpg

 

The shift linkage has also been shortened, and the driveshaft is at Driveline Services getting shortened as well.

 

The last thing on the agenda is the turbo swap, and beefy battery cables. After that, it's just buttoning up all the loose ends!

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Very Nice!!

 

I like the bracket you made to put the EJ tranny in there. What did the tranny start as gearing wise, and where did you get your 4.44 gearset?

 

I have a question about your bedliner...That looks like herculiner right? How much did you put on? How many layers? Happy with it? I'm still in the fabrication phase, but after all my exterior stuff is done, I'm planning on putting 2-3 gallons of OD green on the outside and probably 2 gallons on the inside of dark grey.

 

How did you go about masking the windows and other areas you don't want covered? Did you remask your edges after every coat or did you just mask once and carefully remove it when you were done?

 

Josh

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Very Nice!!

 

I like the bracket you made to put the EJ tranny in there. What did the tranny start as gearing wise, and where did you get your 4.44 gearset?

 

I have a question about your bedliner...That looks like herculiner right? How much did you put on? How many layers? Happy with it? I'm still in the fabrication phase, but after all my exterior stuff is done, I'm planning on putting 2-3 gallons of OD green on the outside and probably 2 gallons on the inside of dark grey.

 

How did you go about masking the windows and other areas you don't want covered? Did you remask your edges after every coat or did you just mask once and carefully remove it when you were done?

 

Josh

 

The transmission started off as a 4.11. I purchased the 4.44 gear set from subarugenuineparts.com, the ring and pinion was a direct swap. I have the part number somewhere if you're interested.

 

As for the bedliner, it's worked ok. I don't think I prepped as well as I should have. I did 2 coats, but a lot of it has worn off in one year already. Again, I attribute this to bad prep on my part. I used 2 gallons for the exterior. As for masking, I just masked once, and it turned out pretty good.

Edited by hellosubaru

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what year make model did you use to find 4.44 R&P? It'd be nice to swap that into my 5mt

 

I posted a part number in one of my threads....can't find it now. But the application I used was a 2004 Forester XT. But it's the same part for many models, and the part number for the older jdm 4.444 5MTs has been superseded for the FXT part #.

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I posted a part number in one of my threads....can't find it now. But the application I used was a 2004 Forester XT. But it's the same part for many models, and the part number for the older jdm 4.444 5MTs has been superseded for the FXT part #.

 

The part number I have on file that I used is 38100AB680.

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sweet thanks.. insta-googled it for ************s and giggles. 314 bucks on a random subaru parts website. Price sound about right? They didnt have a picture of the part, just Gear set HYP was the only info the part number had

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sweet thanks.. insta-googled it for ************s and giggles. 314 bucks on a random subaru parts website. Price sound about right? They didnt have a picture of the part, just Gear set HYP was the only info the part number had

 

SubaruGenuineParts has it for $287 if I remember right, and they are legit.

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Finally, an update!

 

In late December, I finished up with installing the new engine/trans/everything else. I took it for a few test runs, and everything was running great. After a few days, I started wrestling with drive-ability issues (erratic idle, misfires, no power, etc). I couldn't tell if the ECU was still relearning, or if there was an issue with one or more of the sensors. It kept going down hill, until it wouldn't start anymore.
 
I finally found out it wasn't running correctly due to it constantly fouling spark plugs. I did a fuel pressure test on the feed side, and had 66psi of fuel pressure. Ouch! I tested the return side, and there was almost 80psi, so it looked like I'd be replacing my return fuel line. I think it was a combo of being a very small (1/8") return, blocked, and possible a pinched hard line. After replacing the fuel lines, the car ran great, and has continued to for about 2-3 weeks now!
 
Here are some pics of the finished product:
 
DSC_0004_zps71a455c3.jpg
 
DSC_0001_zps27652c70.jpg
 
DSC_0002_zpsb4a70318.jpg
 
DSC_0003_zps25d06344.jpg
 
DSC_0005_zpscc224a1d.jpg
 
DSC_0006_zpsdb0bc5e6.jpg
 
DSC_0007_zps510f505d.jpg
 
DSC_0009_zpsba888f62.jpg
 
DSC_0010_zps0b162f99.jpg
 
DSC_0016_zps5b685066.jpg
 
DSC_0011_zpse2a159e5.jpg
 
DSC_0013_zps20b7224f.jpg
 
DSC_0017_zps8adbd7a8.jpg
 
Next on the list of things to do: hood scoop for IC, lighter front bumper, fix exhaust, and give it a little more lift.  :headbang:

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Lookin' good man. Did you rework the wiring looms your self?  I've got my engine hanging in the stand ready to go, it's a 2.2T, goin' into my 88 GL10T wagon.  The wiring's my next hurdle, and I don't know whether to tackle it my self or buy one from someone else.  Whata' you think, I'm so close now, I'm really anxious?  Nice thread, hang in there.  Steve.

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09/04/2012, Andy and I got the EJ22E-T pulled from the GL:

 

952012-08-299519-30-3595616.jpg

 

IMG_20120829_193221.jpg

 

IMG_20120829_193249.jpg

 

IMG_20120829_221613.jpg

 

Yesterday, Andy measured tolerances and put the pistons in the freshly machined block (thanks to Adam at NWRS):

 

IMG_20120904_214034.jpg

 

IMG_20120904_213914.jpg

 

More next week.

is this ej22t closed deck block

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totally digging the pink transmission crossmember!

 

I think I'm going to go and replace my return line with 5/16.My EJ might run better,and my POS ford fuel pump might be a bit quieter.

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