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Old 11-18-2006, 10:37 AM   #51
xcntrk75
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I Spy the SUPER MULTI JUNCTION (SMJ)... You're going to want that...
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Old 11-18-2006, 04:53 PM   #52
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Like you know what you are talking about Anthony.



Ben
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Old 11-19-2006, 12:40 AM   #53
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Originally Posted by Wiscon_Mark View Post
Me!45
It's yours! Available for pickup anytime! It even comes with two dented doors and a mangled rear hatch


The engine and tranny came out of the legacy today.

Turns out the steering column and front sway bar from the WRX will swap over, so we tossed in some hardened bushing and put that in the Legacy.

One of the CV boots on the WRX axles is torn. I doubt Subaru would do anything for us if I hauled the whole axle into the local dealership and threw it on the counter, so we're taking all of them to be refurbished so that we won't have to deal with them ever again. If we had noticed before the accident it would have been covered by warranty.

Christophe was still prying away trying to get the dash and wiring harness out, but I succumbed to too much dirt in my eyes and came home. We'll get pictures up later tonight or tomorrow.
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Old 11-19-2006, 03:02 AM   #54
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Just got home after 16 hours of wrenching and here's a quick photo update!

Both motors pulled!

WRX cross-member and steering rack installed, though I know realize that I forgot to check if the input shaft splines match the legacy steering column. I'll find out tomorrow!

It took Kevin and I four (*&(&*#$@#$ hours to get the legacy dash, HVAC, and heater core free. I hope I can get all of it back in!


It's time to hit the sack- tomorow will be a long day!

Last edited by ten80; 01-22-2007 at 02:27 PM.
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Old 11-19-2006, 07:08 AM   #55
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Oh man, nice project and pictures
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Old 11-19-2006, 08:35 AM   #56
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Mate this looks sweet, Can't wait to see the finished product.
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Old 11-19-2006, 10:15 AM   #57
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Looking good... That dash is a PITA, not to mention it will always squeak a little once reassembled. Nothing like a factory install…
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Old 11-19-2006, 10:20 AM   #58
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No squeaky dash for us, I'm going to use excessive amounts of double-sided tape and sticky-backed foam. I'm off to the gym then back to the garage for another long day. I should have some interesting updates tonight
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Old 11-19-2006, 11:43 PM   #59
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Another productive day in the marathon swap project. I'm going to post some pictures and then Christophe's going to post later the nitty gritty details of the problems we've run into. He's currently washing the anti-seize out of his hair

First off, from yesterday, some nice new bushings in the WRX steering rack and front crossmember:

Which bolts up nicely.

Here's me, trying to figure out how to get the glovebox out:

Because, you know, action shots are key.

As for today, I think there's some sort of vermin breeding in the kitchen:

We may need to look into that. I'm pretty sure it's on the agenda for tomorrow.

Bilsteins!


And it's a sad day when a WRX is primarily used for the storage of stuff you think you'll need again but aren't sure and don't want to leave out in the driveway:


Other things we did today were change the sparkplugs, install the pedals from the WRX, start the timing belt changing process, changed the rear differential and driveshaft, and cleaned the engine bay.
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Old 11-20-2006, 12:12 AM   #60
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Ok, we've had a few glitches so far. First, the legacy CV boots are all leaking, torn, or about to blow. No biggie, right? Well, it turns out the WRX boots aren't doing so hot after only 52k miles, and there's no warranty on them any more. I'm going to drop them off to have the boots replaced tomorrow. Additionally, my 1lb dead blow isn't enough to bust the axles out of the hubs, so I have to have mineke press them out for me.

The WRX clutch/brake/gas pedals bolted up to pre-existing holes in the legacy firewall, though not without some dremel action to enlarge holes in the pedal assembly. Bye bye auto tranny parts!

The good news is that the wrx front crossmember bolts right up with swaybar, control arms, and steering rack. Bad news is that the wrx steering rack has different splines than the legacy steering column. I have to check and see if the wrx column will work, otherwise I'm going to have to make a hybrid wrx-legacy rack to column U-joint assembly. Fun.

ONE *^&%* control arm bolt was stuck in the rear hub so I had to pull the entire rear subframe. Then, I noticed that the rear diff studs from the wrx diff are too short. I used the double-nut method to remove the longer, threaded studs from the legacy diff and installed them in the WRX diff. WRX diff then bolted right up to the legacy subframe and I was able to somehow get that heavy assembly back in place without any help!

Lastly, the legacy cruise control unit looks like it will hit the exhaust downpipe and the AC hard lines are in the spot that is normally used by the WRX cruise control box. Some rigging is going to happen here

That's enough wrenching for tonight- some homework, a little sleep, and I'll be back at it tomorrow.
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Old 11-20-2006, 08:00 AM   #61
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Awesome! Looks like you're making some great progress. And you have no idea how much it helps to have someone fully document this swap.
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Old 11-20-2006, 10:26 AM   #62
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Quote:
Originally Posted by ten80 View Post
Ok, we've had a few glitches so far. First, the legacy CV boots are all leaking, torn, or about to blow. No biggie, right? Well, it turns out the WRX boots aren't doing so hot after only 52k miles, and there's no warranty on them any more. I'm going to drop them off to have the boots replaced tomorrow. Additionally, my 1lb dead blow isn't enough to bust the axles out of the hubs, so I have to have mineke press them out for me.
If I were you; get all the WRX axles overhauled (boots, lube, bands) and use them instead of the LGT axles, they work fine and are stronger. You can use a 2/3 jaw puller to pop a seized axle out of the hub splines. Just throw it on there and use the jaws on the hub and the piston on the axle, it should pop free pretty easily with the puller.

Quote:
Originally Posted by ten80 View Post
The good news is that the wrx front crossmember bolts right up with swaybar, control arms, and steering rack. Bad news is that the wrx steering rack has different splines than the legacy steering column. I have to check and see if the wrx column will work, otherwise I'm going to have to make a hybrid wrx-legacy rack to column U-joint assembly. Fun.
+1 for using the wrx column! Put if it doesnít work, the hybrid joint is a great idea and what UTciv did with his sti rack and lgt column.

Quote:
Originally Posted by ten80 View Post
Lastly, the legacy cruise control unit looks like it will hit the exhaust downpipe and the AC hard lines are in the spot that is normally used by the WRX cruise control box. Some rigging is going to happen here
In the BD model, these are in the same spot and clear just fine. It looks tight but once everything is in place thereís plenty of room. As for the CC, youíre not using the LGT system? (why do you need the wrx CC box)?
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Old 11-20-2006, 10:27 AM   #63
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Quote:
Originally Posted by ten80 View Post
Ok, we've had a few glitches so far. First, the legacy CV boots are all leaking, torn, or about to blow. No biggie, right? Well, it turns out the WRX boots aren't doing so hot after only 52k miles, and there's no warranty on them any more. I'm going to drop them off to have the boots replaced tomorrow. Additionally, my 1lb dead blow isn't enough to bust the axles out of the hubs, so I have to have mineke press them out for me.

The WRX clutch/brake/gas pedals bolted up to pre-existing holes in the legacy firewall, though not without some dremel action to enlarge holes in the pedal assembly. Bye bye auto tranny parts!

The good news is that the wrx front crossmember bolts right up with swaybar, control arms, and steering rack. Bad news is that the wrx steering rack has different splines than the legacy steering column. I have to check and see if the wrx column will work, otherwise I'm going to have to make a hybrid wrx-legacy rack to column U-joint assembly. Fun.

ONE *^&%* control arm bolt was stuck in the rear hub so I had to pull the entire rear subframe. Then, I noticed that the rear diff studs from the wrx diff are too short. I used the double-nut method to remove the longer, threaded studs from the legacy diff and installed them in the WRX diff. WRX diff then bolted right up to the legacy subframe and I was able to somehow get that heavy assembly back in place without any help!

Lastly, the legacy cruise control unit looks like it will hit the exhaust downpipe and the AC hard lines are in the spot that is normally used by the WRX cruise control box. Some rigging is going to happen here

That's enough wrenching for tonight- some homework, a little sleep, and I'll be back at it tomorrow.

Yup, the CC and AC are usually the first to go when people do subaru swaps since they tend to be the ones that differ among the different models. Most that choose to retain CC relocate the CC module on the pass strut tower and extend the rubber hose.
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Old 11-21-2006, 12:52 AM   #64
ten80
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Today's update:

I had six axles re-built: 4 wrx and 2 legacy (rear) with new CV boots today. Turns out that the WRX rear axles won't work on the legacy hubs because they lack the speed sensor splined rings. So I'll be using wrx front and legacy rear axles. Oh well, now I have an extra set of wrx axles for when I swap my TS to rear LSD.

PITA of the day: I managed to strip a couple of threads on the front control arm rear bushing holes. I bet a big-ass 10 or 12mm tap will be expensive. Add that to our already huge list of expenses!

pretty boring day overal, though we have started looking into the wiring. It's going to be VERY complicated as the legacy dash, gas tank, doors, and sunroof have different wiring than on the wrx. We are considering two options:

1. use the wrx harness with legacy bits spliced in
2. use the legacy harness with wrx bits spliced in

for the first option, there will be an ass-ton of splicing to do. For the latter, we have to figure out what aspects of the auto tranny control need to be eliminated or neutralized. Any suggestions are welcome!
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Old 11-21-2006, 03:44 AM   #65
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how will you use the legacy harness with wrx spliced in, you will need the whole bulkhead.

I say option 1 cause i dont see how 2 will work without even greater hassle.

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Old 11-21-2006, 09:12 AM   #66
xcntrk75
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Well I did option-2 with mine; maintained the existing Legacy harness throughout, then integrated the WRX motor, tranny, fueling, and ecu relevant branches. I guess it depends on a number of factors such as; if you’ll be swapping over the wrx dash, cluster, and dash wiring, etc?

Option-2 is pretty strait forward:
  • Breakout and strip down the wrx harness removing all components not related to engine, tranny, ecu, fueling, etc.
  • Prep the new thinned out wrx harness for integration.
  • Remove the ecu, engine, AT-tranny parts from the lgt harness.
  • Overlay the stripped down wrx harness and route all cords to their corresponding locations.
  • Integrate the wrx harness into the Legacy harness with lots of splicing.

Pics of stripped down and prepped wrx harness:
http://66.49.172.173/subaru/swap/swapSPF/Image017.jpg
http://66.49.172.173/subaru/swap/swapSPF/Image018.jpg
http://66.49.172.173/subaru/swap/swapSPF/Image019.jpg

Last edited by xcntrk75; 11-21-2006 at 09:22 AM.
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Old 11-21-2006, 10:58 AM   #67
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xcntrk75- WOW. You might just be my hero of the day. I'm going to look at the wiring today and hopefully your method will do the trick!

we're hoping to use the legacy dash and wiring and the wrx cluster, though I did a test-fit and it seems that the wrx dash would fit pretty closely. Becca is vehemently opposed to that option because the leg dash is much nicer, and I must agree.
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Old 11-21-2006, 06:42 PM   #68
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Nice work man....I was honestly thinking about shadowing your swap....Im in need of a motor in my 00 BH auto


I sent ya PM too....
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Old 11-21-2006, 07:32 PM   #69
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xcntrk75,

I am doing some of the wiring for this swap and have a couple questions. The WRX uses some different sensors etc in the fuel tank, ie it has more. How did you go about this? CEL?

Also, the abs ecu that is located in the abs modulator has a different part number for the auto and manual versions in the lgt. The auto has one more wire than the manual. Did you swap ecu's or just leave the wire out of the circuit?

Did you use the factory lgt gauge cluster?

Thank you very much for posting the info on how you did yours! I figured last night that would be the best way and now it is confirmed. I did a jdm swap on my gc but it was far simpler imo.
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Old 11-21-2006, 08:15 PM   #70
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Originally Posted by kbahus View Post
xcntrk75,

I am doing some of the wiring for this swap and have a couple questions. The WRX uses some different sensors etc in the fuel tank, ie it has more. How did you go about this? CEL?
Yeah, the 03+ model was equipped with a ďFuel Tank Sensor Control ValveĒ which is the sensor youíre referencing. Fortunately (luckily) I used an 02í ecu and harness which doesnít have this sensor so I canít help much there. But the topic has been discussed in the swap forum before.

Quote:
Originally Posted by kbahus View Post
Also, the abs ecu that is located in the abs modulator has a different part number for the auto and manual versions in the lgt. The auto has one more wire than the manual. Did you swap ecu's or just leave the wire out of the circuit?
Yes the ABS issue is one which plagued me for over a year until finally getting it fixed. That one wire was previously interfaced with the TCU and communicated when the center-diff was in/out of lockup as it relates to ABS function. Unfortunately nobody could tell me the signal parameters of that line in an attempt to bypass it. If you simply leave that wire disconnected, the ABS will fault and not work. I tried, ground, power, VSS, everything and none of it worked. Finally I just plugged back in my TCU as I still had that entire pigtail present in my harness even though it didnít control anything (no AT tranny any longer). Surprisingly this satisfied the ABS control module and restored the function

Quote:
Originally Posted by kbahus View Post
Did you use the factory lgt gauge cluster?
I used my original dash, cluster, column, and OBD-II architecture. I also retained my original AC and cruise-control setup. Note that in my model (1998) I had an entirely different speed signal system which took a while to get working. Itís basically the difference between the 2-wire VSS versus the 3-wire found on the newer models. You may already have a 3-wire and itís a non issue. If not, let me know and Iíll clarify...

Good luck, Iíve been watching the progress and canít wait to see it up and running!!!
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Old 11-21-2006, 08:18 PM   #71
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this is one of the coolest threads i've ever seen!
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Old 11-22-2006, 01:30 AM   #72
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Quick update:

got the rear brake calipers, rotors, and parking brake lines installed and rear wheels on. If you look from the back, it might almost seem to be a functional car


The wiring extravaganza has begun! Here's Kevin busy chopping out parts of the WRX harness not essential for engine function. We spent 2 hours prior to this just peeling off all the nasty tape and plastic off the wires. I'm off to see family in southern CO and kevin will be working on the harness throughout the week. Hopefully we will have a fully assembled chassis with motor but no wiring by the time that our thanksgiving break ends.


Last edited by ten80; 01-22-2007 at 02:28 PM.
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Old 11-22-2006, 02:08 AM   #73
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Christophe, remember to bring back some pie for him...He's a real trooper for getting that wiring together...during thanksgiving nonetheless
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Old 11-22-2006, 05:11 AM   #74
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This swap wouldn't be happening if it wasn't for kevin and his subaru prowess. Unfortunately, his V2 STi swap is dying (70% leakdown on one cylinder) so we'll be doing another after this one. Hopefully an EJ257

on a side note, I just noticed that the CV boots on my front axles are borked after 52k miles (@#$@#$ cheap subaru boots!). i guess it's no big deal since I'm now proficient in changing axles

HAPPY THANKSGIVING EVERYONE!


Last edited by ten80; 11-26-2006 at 12:05 AM.
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Old 11-22-2006, 08:08 AM   #75
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we're hoping to use the legacy dash and wiring and the wrx cluster.
Going back to my other point about VSS:

It looks like you want to run the WRX cluster therefore will need the 3-wire vss sensor and the wiring. If your legacy MY isn’t already 3-wire then these will need to be carried over from the wrx harness.
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