497 replies to this topic

[allpaw4]

If you need a spare man, I have just pulled an NA 2l manual dual range box out of my GX. I found it easier to pull the manifold the first time. Just make sure that only 3 of the 4 go back onto the AC bracket. Initially this is your only real choice. It's not that difficult I found to just lift the manifold once the 8 bolts are off, especially considering you'll likely have to remove the intercooler etc to access the bell-housing bolts on the top of the engine.

[duncanm]

Managed to get at it with a wobbly extension once the other three were off and the bracket rotated a little.

 

Oh - I'm pulling the engine rather than dropping the trans.. as I have an engine crane.  Rocker cover gaskets need doing, too, so I'll knock those off at the same time.

[duncanm]

well.. it doesn't take a rocket surgeon to work out what went wrong.

 fork.jpg   141.55KB   0 downloads

 

Spigot bearing had also crapped itself - for some reason it looks like water was getting in there, as the bearing was very dry and rusty.

 spigot.jpg   113.94KB   0 downloads

[El_Freddo]

Good effort there!

My sister recently (last year or so) had a clutch issue, it wasn’t fun to drive, clutch inoperable and a nasty squeaking noise. Our issue was the throw out bearing decided to deform and do weird things.

I can’t remember if we threw a new bearing in there or if we put a clutch kit in. I reckon we would’ve just gone with the new bearing. Spigot was also dead like yours. Maybe that’s the cause...?

Good idea on engine maintenance while it’s out

Cheers

Bennie

[RX25SE]

Yep, she's forked!

 

 

Any noise from the spigot before the fork shat itself?

[duncanm]

well... there was a bit of a squeak in the engine bay.. but I'd put that down to an idler. 

 

Really thought by the look of that bearing that it'd be making all sorts of noise. The thing came out fully disassembled.

 

Cam covers all reinstalled with new gaskets, half-moons and rubber washers. I was pleasantly surprised with the cam surfaces. Look like new, even though the donk's done almost 250k now.

[Barbbachello]

Common thing on those push style boxes. Even on the later model turbo ones. 

I think you can get an aftermarket fork that fixes it. Probably isnt cheap and would be ex USA. Otherwise a brand new oem will probably last another 20 years if you look after it

[duncanm]

new clutch kit buttoned up.  New release lever/fork.

 

I'll wrestle with the engine install tomorrow. 

 unforked.jpg   150.16KB   1 downloads  clutch.jpg   188.31KB   1 downloads

[duncanm]

Anyone have an idea about power steering pump bracket compatibility?

 

My bracket is busted and I don't know what's compatible. Local Subaru wrecker reckons a local turbo variant may fit, but didn't have any around to check.

 

PN is 22870AA001 or 002. 

 

A couple of 'where used' parts list give me

- circa 2002-03 USDM Impreza 2.5NA  models.

- JDM 2000-2000 GD S204 -- fat chance of those being around

 

 

AUDM B4's (2002-), SF GT Foz, and lots of later Imprezas are mostly 22870AA110.. so maybe that'll work?

[Barbbachello]

afaik all the pump brackets are the same. EJ blocks are the same externally (for the most part) so they all bolt up to the block the same. Pretty sure they all mount with the same 3 bolt setup on the front too

 

If you get really stuck i have a D-E pump and bracket that are stuck together with a snapped bolt. Removed it for a GC8 pump setup so was working when i removed it

[duncanm]

Thanks for the info,

 

I didn't really understand why there were so many different variants. As you say, the blocks are all the same, pump mounting all seems the same, and there are only two or three different pumps (or just reservoir setup?).

 

D-E will be the '110 part. I should be able to find one of those at the local pick a part - thanks for the offer, and I may hit you up for it if I have no success there.

[allpaw4]

Got a couple spare here in Ararat should you need one Duncan.

Cheers,
Ben

[El_Freddo]

Only the early brackets are different when the PS pump was the same unit from the EA82 in the XT4 turbo Vortex models. The only thing that changed was the mounting bolt pattern between the pump and the bracket. The later model stuff should all be the same, shape or location of the reservoir are the only physical changes.

Cheers

Bennie

[duncanm]

thanks for the tips on the bracket guys. I'll check out the pull a part.  

 

Engine went back in this evening after work. Usual 40 minutes of fuckery jiggling the thing around to get it to mate to the gearbox.. in some rain, of course!

 

Another evening should have it buttoned up and running again.

[El_Freddo]

A few evenings passed, any good news?

Cheers

Bennie

[duncanm]

yeh - all good.

 

Took Thursday off to finish it up. Just bolted the slightly broken PS pump bracket back on - it holds fine, so I've got some time to sort out a replacement.

 

I need to go back and put on the clutch lever rubber boot which only came in the mail Friday, and at the moment its only got water in it, so I'll need to change to coolant, but she fired up first go has that oh-so-light new clutch feel.

[allpaw4]

How's this coming along Duncan? Get everything sorted out?

Cheers,
Ben

[duncanm]

Well.. good and bad, Ben. Clutch boot and everything else back.

 

Couple of little hiccups.  I've had a weird intermittent power failure - like someone clicked off the ignition switch momentarily. Everything off, and sometimes with a reset trip and clock (ie: the power to the dash got cut).

 

Figured I must have missed a ground wire or something when the engine went back in.  Dug around on Sat morning and cleaned up all the engine bay grounds and cleaned and re-plugged the two large connectors near the main fuse/relay box.

 

I think that's sorted it, I suspect one of those plugs wasn't fully clicked in, as it took a bit of wiggling to get it to seat. No weirdness after two reasonable drives this weekend, so crossed fingers.

 

More of a concern is the clutch I put in. I cheaped out and went for a standard EJ25 clutch, and its not up to the task. It slips at full boost from about 3k up.

 

I must have got lucky with my previous exedy clutch which coped just fine.

 

I'm going to have to buy a stronger clutch and do it all again some time.

 

Bollocks.

[El_Freddo]

Why not swap the old pressure plate back in? That’s the clamping bit and it should be fine still. The disc is the wear item.

Could be worth swapping the pressure plate back to the old one. I’d pull the box out to do it, no coolant and many less electrical connections to deal with.

Cheers

Bennie

[duncanm]

Why not swap the old pressure plate back in? That’s the clamping bit and it should be fine still. The disc is the wear item.

Could be worth swapping the pressure plate back to the old one. I’d pull the box out to do it, no coolant and many less electrical connections to deal with.

Cheers

Bennie

 

yeh - I'd try the old pressure plate &/or clutch if I hadn't chucked it .. but I figure hours of my time futzing around with the car is worth a new clutch kit.