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Brumby conversion: EJ22, hybrid AWD center lock, SUCCESS!!!

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Edit: SUCCESS!!! Read down page 6!

 

Alright.. I've been keeping pretty quite on this because I knew it would take forever to get it done. What I am doing is putting a EJ22 in my Brat/Brumby with a Subaru Liberty(Legacy) gearbox casing, which is running a normal EA82 diff with 23splines and a normal EA82 gearset, but it is running the ring gear, pinion shaft and centre diff locker from a turbo EA82 car. This gives me AWD on road and 4WD offroad so the EJ22 doesn't just burn rubber. I am also going to have something different for the rear diff, but I'll talk more on that later when it's underway (I run a welded rear at the moment, and am not looking forward to going back to open.)

 

So, this all started about 5months ago. I had a Subaru Liberty wreck sitting in my driveway with a good running motor and gearbox noise for a few months and my mates "are you doing to do the swap yet" questions were getting on my nerve. See, I had decided that I was happy with my car... But well, I'm doing the conversion now.

I started looking at the FT4WD gearboxes because I like on-road driving and plenty of people say EJ22 in FWD is kinda interesting. So I decided if I'm running a EJ22 it's either with a t-case (totally illegal here) or it's with AWD.

Now the LSD centers on the dual range EJ gearboxes aren't any good for anything but road and sand. So It had to be 4WD.

After seeing lots of pictures of the FT4WD gearbox (thanks to this forum) and after removing the EJ22 and gearbox from the Liberty I relised the gearboxes look the same!!

So then after about 2months research I figured it had a 99% chance of working and I got one of those jap import FT4WD gearboxes. On a side note here, the gearbox I got was not a normal turbo diff locker box. It had already had the center diff locker rear end bolted to a normal EA82 gearbox. I think they done this because the diff locker was from a single range gearbox. So this is why I stuck with the EA82 23 spline front diff.

I pulled both the Liberty and the modified turbo box apart and found it was going to work. I also found the problem noise in the Liberty box which I thought was a bearing it turned out it was the nut on 5th gear input side, it was lose.

So after making the EA82 low range lever work with the detent, welding and some drilling with some grinding, I had the gearbox going back together.

To torque the diff properly and pinion shaft I done it home workshop style. I used the pinion shims from the Liberty casing in the Liberty casing with the EA82 gears and pinion. I then set the left side diff cap so the back lash was just feelable. Then I tightend the right side one. I done this over and over till the diff felt the same as the other 5sp gearbox I had and had a tiny bit of backlash as recommended by manuals. This was after 5 or so hours of research finding out how to do this properly (which is done with 3 Subaru special tools.) Some might tell me this won't work, but I can't see why not. We removed a mates 5sp and the left side diff caps was loose! And because this had the tooth washer holder we figured the gearbox would of have to of been like that for more then 12,000km and this mate of mine is VERY rough with his gearboxes. Also that gearbox had no noises, only removed it because the synchros were going.

Here comes the fun bit, making the diff locker work. This took us ages to figure out why once we had the gearbox together that it too 50 - 60Nm to engage the diff locker. The vacuum solenoid could only push and pull about 20Nm. After pulling the back off the gearbox 5 or so times and making three different lever and mount designs (box didn't come with original mount for the actuator cable) we figured out it was 2 missing alignment pins between the front two piece section of the gearboxs and the rear section which holds the diff and engager lever. Once those pins were installed it worked with only hand pressure on the lever. And the vacuum solenoid works great!

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Now we are upto yesterday. 6th of February 2007

 

Then engine is out with gearbox as well. So is the welded rear diff and all the gear linkages. I have the EJ22 engine sitting there with the EJ flywheel ready to go on the EJ dualrange with EJ clutch and center diff locker with EA82 mounts.

So my first problem here was... The EA82 mounts are different to the EA81. I never remember hearing about that! So now it's time to go do some research to find out how people do that. I will post some pictures in a minute.

 

here are serveal pictures of the EA82 turbo crossbred gearbox (basiclly just all about the center diff locker)

http://offroadingsubarus.com/images/ea82gearbox_centerdifflock_onbench.jpg

http://offroadingsubarus.com/images/ea82gearbox_centerdifflock_onbench2.jpg

http://offroadingsubarus.com/images/ea82gearbox_centerdifflock_rearremoved_center_diff.jpg

http://offroadingsubarus.com/images/ea82gearbox_centerdifflock_rearremoved_diff_engager.jpg

http://offroadingsubarus.com/images/ea82gearbox_centerdifflock_rearremoved_diff_engager_frontview.jpg

http://offroadingsubarus.com/images/ea82gearbox_centerdifflock_fithgear_selectors.jpg

http://offroadingsubarus.com/images/ea82gearbox_centerdifflock_casingsplit_leftside.jpg

http://offroadingsubarus.com/images/ea82gearbox_centerdifflock_casingsplit_rightside.jpg

 

here are some pictures from a few months back when I pulled the EJ22 and striped the wiring loom (which I hope works, not tested yet)

http://offroadingsubarus.com/images/ej22swap_engine_crane.jpg

http://offroadingsubarus.com/images/ej22swap_wiringloom2.jpg

http://offroadingsubarus.com/images/ej22swap_wiringloom4.jpg

http://offroadingsubarus.com/images/ej22swap_wiringloom1.jpg

http://offroadingsubarus.com/images/ej22swap_wiringloom3.jpg

http://offroadingsubarus.com/images/ej22swap_wiringloom_finished.jpg

 

and some photo's of the detent mod to the low range shift lever, so when you shift into low or high range it holds in and doesn't pop out when on really bumpy terrain

http://offroadingsubarus.com/images/lseries_liberty_gearboxhybrid_lowrangeshiftforks.jpg

http://offroadingsubarus.com/images/lseries_liberty_gearboxhybrid_lowrangeshiftforks_detent.jpg

http://offroadingsubarus.com/images/lseries_liberty_gearboxhybrid_lowrangeshiftforks_detent2.jpg

http://offroadingsubarus.com/images/lseries_liberty_gearboxhybrid_lowrangeshiftforks_detent3.jpg

http://offroadingsubarus.com/images/lseries_liberty_gearboxhybrid_lowrangeshiftforks_detent4.jpg

 

 

I will be editing then write up here to go on my site when I get the time.

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Thanks guys!

 

I'm working on cutting up a EA82 gearbox crossmember to fit the EA81. This is because I don't have any good EA81 mounts and never in my life have seen any good ones. Where most of the EA82 mounts look good. I have pictures, but can't upload them right now.. I'll update on that later, gotta make sure it works first.

 

I've also pulled the left drive shaft again (second time this year) to fix the stupid boot clip things and clean the dirt out of the rubber to metal joint.

 

Other then that, not much has happened, but that's because I am lazy... Hopefully I can fix that before the weekend :)

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I've also pulled the left drive shaft again (second time this year) to fix the stupid boot clip things and clean the dirt out of the rubber to metal joint.

 

Big ol' Stainless Steel Hose Clamps FTW!!! :banana:

 

a parts guy suggested it, and so I tried it, and it worked great! I'll never use anything else again.

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Yeah, I tried it, but the only ones I had big enough had to big of a screw, so it was going to rub on the caliper my brother said. Maybe I'll find some smaller ones that will fit later on.

At the moment I am just using zip ties, as the original somehow pulled itself off :confused: This time I put some silicone between the rubber and the cup, we'll see how that goes.

 

 

And some more pictures!

 

Here is the striped out Subaru Liberty GX I got the motor, gearbox casing, and wiring loom from.

http://offroadingsubarus.com/images/ej22swap_donor_libertygx1.jpg

http://offroadingsubarus.com/images/ej22swap_donor_libertygx2.jpg

 

Here is the striped out Subaru Brumby that's getting the Ej22 and funky swap box that I built.

http://offroadingsubarus.com/images/ej22swap_striped_brumby_underneath.jpg

 

And here is an unexpected problem..

I was jacking the car up to remove the plate that bolts the gearbox crossmember to the body (or in my case, the lift blocks.) Mayeb this is what was making that noise I thought was a bull joint that I replaced not so long ago...

http://offroadingsubarus.com/images/ea81_suspension_mount_broken.jpg

 

I gotta get some pictures of my custom bracket for hte diff locker lever next. I warn you though, it is very cheap looking...

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I cleaned the engine bay today. And drilled out the engine mount holes. I would post pictures, but the engine bay is still dirty looking (not as bad as it way, but) and the holes look terrible.. ahhaa, not trying to hard. But they will do the job and you won't be able to see them so that's alright..

 

My major goal is to make it look like that engine and gearbox was made for the car, eheh.

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My major goal is to make it look like that engine and gearbox was made for the car, eheh.

 

Nice!Great job.Good job on the pictures,since many of us :slobber: while looking at your project brumby are over 15,000 miles away!:)

 

Looks like it will be loads of fun!

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Yeah, I tried it, but the only ones I had big enough had to big of a screw, so it was going to rub on the caliper my brother said. Maybe I'll find some smaller ones that will fit later on.

At the moment I am just using zip ties, as the original somehow pulled itself off :confused: This time I put some silicone between the rubber and the cup, we'll see how that goes.

 

Yeah, zip ties work alright, I've used them before with no dramas. just get the big chunky ones that you can swing off to get it nice and tight.

 

Never tried big hose clamps, might do so next time I need to open a boot.

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Anything must be better then my stock on. It broke in under 200km on the outer boot, lucky most of that was road stuff... Back to zip ties, if I need to change one I can in about 15mins. As there is no need to take the axle off. And I've already got my axle changing down to about 45mins :rolleyes:

 

As for how the car is going... Nothing new since last post.. I have cut the gearbox EA82 cross member to match the mounting of the old EA81 style, and now it needs a little welding and maybe a bit more grinding to make it fit, plus some holes drilled in it. I'm also replacing my steel 2" lift blocks with alloy 2" lift blocks while I have the plates off that hold everything back there.

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excellent, form what you can tell much difference is there between the ej trans mounts and the ea82's

 

got any pics

 

Heres the best I can do for now.

 

EJ gearbox mounts

http://offroadingsubarus.com/images/ej22gearbox_vlsd_casing.jpg

 

EA82 gearbox mounts

http://offroadingsubarus.com/images/ea82gearbox_centerdifflock_onbench2.jpg

 

 

But what I am doing is converting a EA82 gearbox crossmember to fit where the EA81 one does. I am doing this because EA81 mounts suck, and I think modding the EA82 one in is better then modding the smaller looking EA81 one to fit the EA82 mounts.

I will have pictures of that soon I hope.

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The swap you are doing is almost exactly what I'm working on, with the exception you are able to work on yours lol, and mine isn't lifted. I'm just trying to look into ever option I can for the mounting of the transmission without much modifying to my trans tunnel. I know i'll end up having to get the bfh out on a few spots none the less. I can get ea82 trans mounts pretty cheap from a friend of mine with connections, since the ej's i have are a little worn out.

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The swap you are doing is almost exactly what I'm working on, with the exception you are able to work on yours lol, and mine isn't lifted. I'm just trying to look into ever option I can for the mounting of the transmission without much modifying to my trans tunnel. I know i'll end up having to get the bfh out on a few spots none the less. I can get ea82 trans mounts pretty cheap from a friend of mine with connections, since the ej's i have are a little worn out.
I haven't been following your thread as of late, what trans do you plan to use? AWD EJ?

Know anyone with a TIG welder?? You could weld on some new places to bolt the EA82 mounts to the AWD box, ehehe. Probably easier to just make a custom gearbox crossmember. Do you have one of those to compare/mod to your Brat? I can get pictures of mine and the stock EA81 one.. I'll see what I cna do.

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I haven't been following your thread as of late, what trans do you plan to use? AWD EJ?

Know anyone with a TIG welder?? You could weld on some new places to bolt the EA82 mounts to the AWD box, ehehe. Probably easier to just make a custom gearbox crossmember. Do you have one of those to compare/mod to your Brat? I can get pictures of mine and the stock EA81 one.. I'll see what I cna do.

 

Yeah i'm using the 5spd awd from a 90 legacy, I've got my stock ea81 x-member and a good picture from rguyver when he put the wrx driveline in his brat. Unfortunately I don't have access to a tig, the shop i work at have only migs, and a lot of extra angle iron and flat bar stock and the like:banana: ...

 

As far as my thread goes i haven't been able to do squat to the actual vehicle in about a month, did get the wiring done though. Stupid winter time, why oh why do I always pick this time of year to do anything involving outside and cars

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Alright.. An update of pictures! Because I found some more! ehhe

 

Starting with the EJ's center differential

http://offroadingsubarus.com/images/ej22gearbox_vlsd_casing.jpg

http://offroadingsubarus.com/images/ej22gearbox_vlsd_casing2.jpg

http://offroadingsubarus.com/images/ej22gearbox_vlsd_apart.jpg

 

Moving on to the rear end of the EJ D/R gearbox with the rear casing removed

http://offroadingsubarus.com/images/ej22gearbox_backend_5thgear_pinionshaft.jpg

 

Now going to my final gearbox setup, EJ FT4WD, lever and vacuum solenoid mount.

http://offroadingsubarus.com/images/ft4wd_difflocker_lever.jpg

http://offroadingsubarus.com/images/ft4wd_difflocker_mount1.jpg

http://offroadingsubarus.com/images/ft4wd_difflocker_mount2.jpg

I know it's rough, but it works a wonder now :)

 

Still no more work done to the car :( I am planning to make some new alloy lift blocks for the gearbox crossmember so I can put it all back together and finish the work the the EA82 boxes crossmember.. Pics of that when it's in and fitted.

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Another update for todays happenings...

 

A fair bit happened today, as it was my brothers day off, or one out of three a week anyhow. So anyway, I got him to work obviously pretty much all day (well about 5 hours of the day anyhow.) Do you think I have said "day" enough times so far? :-\:rolleyes: Enough of that, time to show you some pics, as I know all of you like pics!

 

I'll start in order that things happened. As I needed to pull the gearbox crossmember and the plates it attaches to (because one of the studs that holds the crossmember on snapped off,) I decided to replace the steel lift with the alloy one I had planned to do for a while now. Also because the bolts I bought ages ago were a little to long I got the thread cutters out and cut another 15mm of thread on each bolt (12Mx1.25) then got my bro to cut 20mm off of each bolt.

Results....

http://offroadingsubarus.com/images/subaru_liftkit_alloyblocks_brumby.jpg

http://offroadingsubarus.com/images/subaru_liftkit_alloyblocks_brumby_fitted.jpg

 

Then it was time to move onto the gearbox crossmember. I had already cut the EA82 version down to match the EA81 version a couple of days ago, but it needed reinforcing and some holes drilled. So, out came the angle grinder and 40x2mm bar steel. Then got my bro to weld it up.

Results..

http://offroadingsubarus.com/images/gearbox_crossmember_conversion1.jpg

http://offroadingsubarus.com/images/gearbox_crossmember_conversion2.jpg

http://offroadingsubarus.com/images/gearbox_crossmember_conversion3.jpg

http://offroadingsubarus.com/images/gearbox_crossmember_conversion4.jpg

http://offroadingsubarus.com/images/gearbox_crossmember_conversion5.jpg

Sorry, no pictures of it in as yet as the paint is still drying. So I'll do that tomorrow.

 

Then the last and hardest part of the day. The camber kit... Today we drilled the holes for the lower control arm camber cams. The engine crossmember is VERY tough stuff. With our brand new 22.22mm drill bit ( 7/8ths ) it was still very hard and I reckon the bit needs sharpening now.. Anyway, I wouldn't suggest doing it... It wasn't fun... The first picture is from the other day when I flattened out the crossmember to fit the camber cam which are 40mm by 4mm discs I made with the lathe, angle grinder and a towball. Four cams (discs) are needed in total. Also the cam's need to be drilled with an off center hole, I'll do that later tomorrow.

http://offroadingsubarus.com/images/camber_adjuster_kit_flattening_enginecrossmember.jpg

http://offroadingsubarus.com/images/camber_adjuster_kit_cam.jpg

http://offroadingsubarus.com/images/camber_adjuster_kit_drilling_enginecrossmember.jpg

http://offroadingsubarus.com/images/camber_adjuster_kit_drilled_enginecrossmember.jpg

 

 

Hope you enjoyed this. :burnout:

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nice. that 5th pic of the trans crossmember is showing that you double-layered the metal for reinforcement, right?

Yes, I used mild steel 40mm by 3mm bar to reinforce the crossmember because after cutting and hammering it split a bit.

We just found out today that because of the extra thickness we needed to also replace those studs that hold the crossmember on. This required grinding the tops off them and hammering out. This of cause would not work in an EA81 with no lift kit...

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I'm working on the fuel side of things now. Still trying to figure it all out. On a side note: Don't look at the fuel hoses while removing them. Fuel + eyes = ****, ****, ****... ARRGGGGHHHH ******* *** !!!!!!

 

Do people really think the surge tank is needed in the EA81? Anyone had problems without one?

I had an idea of making/getting one that would fit right next to/behind the fuel pump under the left hand side of the car. Then running the original fuel pump and original return lines into it and the new fuel pump and return+vent line into the other side of it. Is this just over kill? I reckon I will just take out all the vent stuff on the tank and plug it up.

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More updates!!! :)

 

Yesterday we worked more on the camber adjusters. I still need to put washers with cut outs in them in between the rubber and the 'cam' (in the 22mm hole I drilled basicly) so the rubber on the control arms don't die. Heres some pictures.

http://offroadingsubarus.com/images/camber_adjuster_kit_cuttingcams.jpg

http://offroadingsubarus.com/images/camber_adjuster_kit_cam.jpg

http://offroadingsubarus.com/images/camber_adjuster_kit_welding_final.jpg

Top one is cutting the discs using a lathe on thread cutting speed and an angle grinder. I would of used a cut off bit in the lathe but the tow ball I used was such hard steel the bit could not take the heat so it was doing more cutting to the bit instead of the ball. The angle grinder worked a treat though!

 

Then it was time to put the motor in. When I got it on the crane I relised I may have forgotten to make sure the holes in the new gearbox crossmember lined up properly. I figured the easiest way to measure was to just continue to put the engine and gearbox in.... It worked! All lined out perfectly!!! Wooo hoo!

http://offroadingsubarus.com/images/ej22swap_enginegearbox_crane_ready.jpg

http://offroadingsubarus.com/images/ej22swap_enginegearbox_crane_goingin1.jpg

http://offroadingsubarus.com/images/ej22swap_enginegearbox_crane_goingin2.jpg

http://offroadingsubarus.com/images/ej22swap_enginegearbox_crane_goingin3.jpg

http://offroadingsubarus.com/images/ej22swap_enginegearbox_incar_gearboxmounts.jpg

You may of noticed it was a little tight getting it in.. I think this is because the mounts we held the engine to the crane with were different to the EA81 and so we could not get as much angle on the setup as before with the engine leveler. My brother had to straighten the radiator mounts out and bent that piece of metal back after putting the engine in.. But other wise it fits beautifully!

 

And some other pictures. First off my heater hose pipes. They were touching my vacuum solenoid and the starter motor. So I moved the whole heater valve backwards in the car and pulled the pipes a bit more into the car.

http://offroadingsubarus.com/images/ej22swap_heater_hoses.jpg

 

And heres an interesting one. No one has ever really shown me a picture of said how much room there is for stock cooling fans on the radiator. Heres why you can't use the stock fans in my case.

http://offroadingsubarus.com/images/ej22swap_stock_radiator_clearance.jpg

I plan to use 2 Air-con fans from Mazda 626's on my EA81 radiator.

 

The EJ radiator looks like it would require cutting part of the chassis out, so I think I'll stick with my EA81 version. And if it isn't good enough in the future I'll get a double core one. Although, mine has never had a problem with over heating my EA81dc exepct the few times the cap failed.

 

It's almost time to get the wiring loom out of the box and place it in the engine bay to see if I can start this puppy.. Well I have some exhaust and cooling to deal with first. Also need to weld that center bearing in for the propshaft and deal with the shifter side of things. Oh and make that vacuum solenoid do it's thing.. The list goes on, and on, and on.... :rolleyes:

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