Maybe I should have just left the auto in my 84 turbo wagon as it seems that every thing that I touch turns to poop. With that said I have installed a 86 dualrange 5 speed trans from my turbo sedan donor car the 25 spline axles are about 1 1/2" longer than the 23 spline axles that were in the 84 turbo wagon. So I dissembled one each of the axles to see what I could swap around to make something work and nothing looks like it will work. My question is I can't be the only guy that has had this problem, so what have you other guys done to make this work?

What you want is turbo axles for an 83 or 84 turbo wagon or brat, and wap your 25 spline doj cups to that. 

Thanks MilesFox, Let the search begin.

Well I am back to square one again, as it seems that the 83-84's never had 25 spline axles. So do I need to look for an earlier transmission or is there someone who is modifying early 23 spline axles to fit the dual range 25 spline stubs. Or I just might scrap the whole project, but it is such a nice car.

Change the transmission stub shafts/drive shafts on the transmission

 

http://www.ultimatesubaru.org/forum/topic/144724-transmission-stub-shaft-swap-who-has-done-it/

http://www.ultimatesubaru.org/forum/topic/87305-easy-transmission-front-seal-replacement/

It would be far easier to swap the inner axle cups than the stubs from the transmission. There are some old (10ish years ago) posts on the forum that detailed how to do it and which specific axles were needed. I myself made a set in 05 from 2wd ea81 axles and early legacy inner cups.

^^ this. It may be some unicorn combunation of parts. What you need is the measurements for like 5 different axles and size them up. It will iklely take pieces form 2 types of ea81 axles combined with ea82 axles. I myself have never accopmplished this for lack of parts to try out.

 

typically 2wd axles are larger diameter than 4wd for ea81. 

 

Otherwise have a machinist shorten up an ea82 25 spline axle at the spline end, or chop and welded together with a sleeve. Perhaps you should search on the australian subaru forums.

Best of my memory it wasn't a terribly hard couple of combos to come across. I know the 2wd ea81/legacy works, I actually did doj and cv ends to make an ej knuckle 5-lug 25 spline axle. I'm thinking the 4wd and ea82t cups will interchange as well, best way to find out is to get your hands dirty like we did in the old days, or search some old retrofitting threads for our old dirty work lol.

 

 

edit, I do remember the 2wd axles HAD to be oem, aftermarket replacements were/are the same as 4wd.

Edited October 1, 201411 yr by 86BRATMAN

Thank you all for your very helpful information. I really don't mind doing the stub swap, but am going to the wrecking yard this week and look at possible axle combos. Really want to get the wagon back on the road.

So how did this work out? I am about to embark on the same mission...  Did you end up swapping stub axles?

He should just get a Non-turbo five speed that will have 23 spline stubs.

 

stock axles.

 Yes I swapped the axel stubs, the only problem that I had was finding new seals for the transmission. Between my auto parts store and the local Subaru dealer, I now have the transmission ready to reinstall in the wagon.   I have already built the transmission cross member and modified my shift and transfer case linkages. You are right Gloyale it would have been easier to find another transmission, but it might have needed seals also. I hate oil leaks. ShankinPickle get all of the seals and gaskets first it will save not having the transmission sitting around dissembled.