Input for OBS rebuild.

[s'ko]

I need some input from your.

I have a 2k OBS w/rod knock and messed up 2nd gear synchros. With my wife & I expecting, I need fix this 4 door as the baby mover. Other vehicles is an SVX, RX & BRAT. My wife will most likely be driving this around. She has expressed that she would like to make it a bit taller so it is more SUV like. That means more power and better torque to turn the bigger tires. I have Forester struts right now & it can comfortably fit 225/60/16’s. Power with those tires & the stock Ej22 was pretty anemic. I am thinking EJ25/22head High Compression Frankenstein build with a EA82 5 spd D/R tranny.

Parts List:

1996 EJ25 DOHC pulled from junkyard with 167k

a set of EJ25 head gaskets.

a set of EJ22 Cometic HGs

cams with a torque grind from DeltaCams

EA82 DR 5 spd 3.9 less than 100k

Rear LSD 3.7

High Performance Clutch

I need input in the following areas

1) head gaskets.

The EJ25 gaskets that I have are not OEM and I don’t know if they are designed to fix the phase 1 HG problem. I have a set of EJ22 cometic HGs. The bore difference is 1.35mm radius. Do you think these will work or should I should get some EJ25 hybrid ones?

2) Transmission,

Should I go through the trouble of swapping this in? Does anyone foresee problems with the high HP and the High performance clutch in 2wd holding up. Part of the reason why I think this might be ok is that my wife will be the primary driver. She is not hard on cars. Or should I yank the Fulltime 4WD DR from the RX? Or source an EJ tranny or maybe do an auto swap. (remember mostly wife driven)

3) Clutch

What kind of clutch? I know that a 6 puck clutch is good for high power applications. Will that be too harsh for the Mrs?

The Pressure plate will have to be heavier that stock. With the cable clutch of both the stock tranny and the EA tranny do you think this is going to be too hard for the wife’s leg?

4) go up more?

With the Forester strut lift & the 225/60/16 tires, I am taller than a stock Outback. What’s the biggest tire people have put onto the strut lifted OBS. I remember seeing a thread about OBS’ using the rear trailing arm mount from a Lego or Outback to allow for a more centered wheel after the lift. I have a set of the mounts to try out.

I figure if I want to go taller, I will need lift blocks. Are 2 inch blocks going to affect the camber up front?

That’s all I can think of for now.

BW

[Numbchux]

IIRC, the cylinder hole in the head gaskets is larger than the bore by a bit. so 2.2 HGs will still clear the bore just fine. but don't quote me on it.....I've got some info on hybrid builds somewhere, I'll dig...

 

 

I wouldn't bother with the EA82 trans. limits your clutch selection quite a bit, and FT4WD/AWD is much nicer in mediocre weather (where FWD just won't do, but 4WD is overkill). upside is, you'll see better good-weather mileage in FWD. the torque of a high-compression 2.5 would make the low range entirely unnecessary.

 

also, since this is a daily driver. I'd think twice about a high-comp hybrid. they're a bit high-maintenence, and will require premium fuel. maybe get another 2.2 and throw some cams/TB spacer/exhaust at it. might get you the extra power you seek without sacrificing reliability and cost.

[idosubaru]

sticking with the EJ trans sounds the way to go to me as well.

 

a Phase I Ej25 will be an interesting swap into a Phase II EJ22 equipped vehicle. do you know all the intricacies of that? that's not nearly the swap that the 1998 and earlier stuff is. 1999+ is another ball game.

 

a 2000 EJ25 into a 2000 EJ22 is more difficult than earlier years. add to that a cross-phase swap - 1996 Ej25 into a 2000 Phase II, that's not going to be simple.

 

the EJ25's move rather nice, they power the wagons just fine. go drive a wagon and see how it feels, the impreza will feel even better being lighter and smaller.

 

if you think you can get the Phase I EJ25 to work in the Phase II vehicle, then i'd just keep it stock. they have good power. use Subaru head gaskets and call it a day.

 

_______________________________

changing gears a bit...might want to think about this.

 

as a current OBS owner and owner of a 5 month old you might want to consider a legacy.

 

the OBS is really tight with kids. with the car seat i can't put the front seats back as far as i want and i'm only 5'10".

 

i also have a 1996 Legacy sedan which is much nicer than the OBS. the added few inches make all the difference with the safety seat and i can put the seat right where i want it.

 

maybe your child seat will be smaller and not an issue since your wife is driving mostly. we take long trips and i hate sitting all up close and not being able to sit back normal or take a nap. doesn't feel safe either, but that's just in my head.

 

i think the 2000+ legacy's have beefy safety rails that went from like 0.8mm to 2mm thickness, making a significant jump in safety with the redesign.

 

the legacy's are nicer too, more comfortable, smoother, quieter, safer, rear disc brakes, nicely trimmed.

 

all of this made me buy a 2002 OBW just a few weeks ago to get rid of the OBS.

 

as talented as you are, i'd imagine you could pick up a legacy for next to nothing....probably one needing work for less than what you can sell your OBS for.

[Numbchux]

^he's talking about a hybrid. the phase I EJ25 shortblock with his 2.2 heads/intake. that's plug and play.

[idosubaru]

^he's talking about a hybrid. the phase I EJ25 shortblock with his 2.2 heads/intake. that's plug and play.

roger that!

 

back to hybridizing!

[Skip]

the only thing I see missing

from your most excellent list

is

High test gas

Doesn't this result in about a 11:1 comp ratio?

[Gloyale]

As far as a transmission, unless you're wife is going to be wheelin' this thing, I'd just replace the synchro on the trans.

 

Split the case yourself, then take the main shaft to a trans shop with a press and have them fit the new synchro.

 

Probably spend less than $100 bucks. At anyrate alot less than an adapter plate, a mix matched clutch set, and all the work of modifying the linkage and lengthening the driveshaft.

[s'ko]

the only thing I see missing

from your most excellent list

is

High test gas

Doesn't this result in about a 11:1 comp ratio?

 

Yeah. I think 91 will work though.

 

I wouldn't bother with the EA82 trans. limits your clutch selection quite a bit, and FT4WD/AWD is much nicer in mediocre weather (where FWD just won't do, but 4WD is overkill). upside is, you'll see better good-weather mileage in FWD. the torque of a high-compression 2.5 would make the low range entirely unnecessary.

 

also, since this is a daily driver. I'd think twice about a high-comp hybrid. they're a bit high-maintenence, and will require premium fuel. maybe get another 2.2 and throw some cams/TB spacer/exhaust at it. might get you the extra power you seek without sacrificing reliability and cost.

 

Good point.

 

As far as a transmission, unless you're wife is going to be wheelin' this thing, I'd just replace the synchro on the trans.

 

Ahh yes, bit I might be tempted to wheel it.

 

But, back to point. wow, that would be 2 firsts for me. Rebuilding a engine and doing tranny work.

oh wait make that 3... having a kid

 

bw

[s'ko]

Gary, I used the OBS to get a signature loan for the invitro. So I can't get rid of it. :-\

 

So after reading your posts,

 

Here is what I am thinking.

 

1) take the 2.2 out of the OBS, diassemble, bring it to a machine shop and have them inspect the crank. Get bearings and rings and rebuild the short block.

 

2) take tranny apart and have the synchro replaced.

 

now the question it what to do with the 2.5 I just pulled.

 

BW

[subaru360]

the only thing I see missing

from your most excellent list

is

High test gas

Doesn't this result in about a 11:1 comp ratio?

 

It might be even more, the 96 EJ25 pistons are different than the 97-99 ones.

[subaru360]

Gary' date=' I used the OBS to get a signature loan for the invitro. So I can't get rid of it. :-\

 

So after reading your posts,

 

Here is what I am thinking.

 

1) take the 2.2 out of the OBS, diassemble, bring it to a machine shop and have them inspect the crank. Get bearings and rings and rebuild the short block.

 

2) take tranny apart and have the synchro replaced.

 

now the question it what to do with the 2.5 I just pulled.

 

BW[/quote']

 

I don't think it makes sense to rebuild EJ22 shortblocks. They are a dime a dozen and cheap to buy, we get them for $60 used here. Th same shortblock works in 90-98.