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Old 09-30-2006, 12:14 PM   #1
ten80
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Default 2000 Legacy auto BE/BH to EJ20 2.0L WRX manual complete swap project

Note: the generic title is to help with future searches.

Two weeks ago, my fiancée was driving her manual trans, 03 WRX (Cobb stage 2) and was hit by a Kia that neglected to slow down for a traffic jam. The car was thrown sideways and T-boned by a Mercedes 4-class. Everyone was unhurt. This was the result:



I've always wanted to do a swap project and this is a perfect opportunity- the entire front clip is in mint condition and Progressive allowed us to buy it back with no hassles! My fianceé, Becca, and good friend Kevin (Kbahus on the board) have started the process by buying a 2000 Legacy GT Limited sedan (auto, 125k miles, mint condition interior):



Here is our adventure. I will present as much detail as possible with the goal of facilitating future BE/BH -> USDM wrx swaps in addition to the auto->manual swap. Feel free to chime in with ideas and suggestions, or ask for specific details and photos!

We have a TON of random parts now, Please PM me if you want any of the parts instead of posting This will keep the thread on topic and reduce needless scrolling through tons of pages.
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Last edited by ten80; 01-22-2007 at 02:30 PM.
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Old 09-30-2006, 12:16 PM   #2
ten80
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Step 1. gut interior of WRX, label all wires:


step 2. remove wheels and inspect for damage:

1 bent strut, possibly bent rear subframe. obvious door, frame, and pillar damage, not to mention a few body panels :P

The Legacy suspension is toast and the car rides like a waterbed. We've ordered GR2's and H&R springs, goodridge brake lines, and new strut tops. Hopefull it will all go on next week!

Last edited by ten80; 01-22-2007 at 02:31 PM.
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Old 09-30-2006, 01:28 PM   #3
MitchGT
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Can't wait to see this unfold, hopefully w/lots of pics.

Good call on the gr2/h&r setup. I love mine.
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Old 09-30-2006, 01:47 PM   #4
Wiscon_Mark
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Yes, document everything, it'd be really useful to all of the potential swappers.
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Old 09-30-2006, 01:57 PM   #5
ten80
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Will do! I'm getting the wiring diagrams this week and we'll hopefully pull the engine out of the WRX next week. I enjoy taking pictures and everyone in the legacy forum seems very cool, so this should be a fun thread!
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Old 09-30-2006, 02:12 PM   #6
NMLegacy
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Is the Rex also an auto or are you also doing an auto to manual swap in the Leggie?
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Old 09-30-2006, 02:27 PM   #7
ten80
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We're doing an auto->manual swap, good question.
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Old 09-30-2006, 03:14 PM   #8
Teh Legacy
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I like your Legacy.
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Old 09-30-2006, 03:18 PM   #9
PHATsuby
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You would have made your life a bit easier by getting a manual Legacy but I know they are harder to find. With all the stuff you are doing it wont be a huge deal and you should have everything you need almost from the wrx to make it work.

Very cool project, keep it updated with pics! I like build pics

Ben
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Old 09-30-2006, 03:26 PM   #10
ten80
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I like YOUR build pics! we're trying something a little more straight forward. I'm still trying to figure out if the wrx steering rack will work, quick steering would be very nice!
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Old 09-30-2006, 04:42 PM   #11
Plays_With_toys
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Wow, that sucks about the WRX. Did your insurance let you buy it back and then give you the difference between the wreck cost and the estimated car value or something along those lines?

Is your fiancee alright? What is she getting as her replacement?
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Old 09-30-2006, 07:43 PM   #12
JKirk
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Wow, that's pretty awesome, dude! That's a real nice, Legacy, I like the color.
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Old 09-30-2006, 07:49 PM   #13
ten80
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Yep, the girl's insurance covered part of the wrx and Becca's did the rest, since the girl was under-insured (Never ever hit a Mercedes!). Becca got a nice check for her car and we bought back the wrx. Found the Legacy for less than we bought the WRX back for, so it was a definate deal. My Fiancée had a sore neck for 1 day and two weeks later has had no signs of injury- she's friggin tough!

Probably no more work on the car till next weekend, I just installed new suspension on a 97 outback and school work is beconing.

-christophe
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Old 10-01-2006, 03:36 AM   #14
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Went to put the Prodrive P7's with 225/45/17 tires on the car and it pulled like crazy to the right. Closer inspection reveals that the right rear tire has severe inside shoulder wear that I hadn't noticed. Hopefully the issue is due to the toe being out of whack and an allignment after the new suspension goes on will fix things. If it's a camber issue, is there any sort of camber bolt that can be used at the top of the rear hub (see picture)? I noticed that whiteline makes camber bolts as small as 12mm, but I've not yet had a chance to look at the rear hub bolt size. Maybe an aftermarket control arm would potentiall work, though I've not been able to locate any.


Last edited by ten80; 01-22-2007 at 02:31 PM.
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Old 10-01-2006, 04:26 AM   #15
MitchGT
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I'm 99% sure you can add camber bolts to the back.
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Old 10-01-2006, 07:52 AM   #16
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Yeah, I run the WL camber bolts and max out at -1.5 in the rear (max for bolts). Of course I also run max toe as well

The WL bolts mount in the top hole of the strut mount and allow the strut to pivot. Only downside to them is they loose their bite if continually reused. In other works, have your suspension dialed in before locking them down.
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Old 10-01-2006, 10:46 AM   #17
ten80
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xcntrk75, I think you are forgetting that the picture above looks nothing like your rear suspension . I'm going to pop one of the bolts out tonight and take some measurements and find some camber bolts- any suggestions on which ones or where to get them would be great!

Last edited by ten80; 10-01-2006 at 11:59 AM.
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Old 10-01-2006, 12:37 PM   #18
PHATsuby
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there are ways of adjusting camber in the rear, I think there are some bolts for adjusting it that connect to the rear subframe, although those may be for toe, I am not totally sure on that. You can't use usual camber bolts I don't think because like you said the suspension is not the same.

JoeT would be a good person to ask on that.

Ben
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Old 10-01-2006, 02:25 PM   #19
ten80
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yep, the subframe eccentric bolts are for toe. I hope that will solve the issue, at least my allignment shop guys are know what they are doing and should be able to pinpoint the issue. 3hrs of searching and I conclude that no BE/BH rear camber bolts exist. I'm still going to see if some camber bolts for another car wil fit, I guess I'm a little stubborn
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Old 10-06-2006, 11:34 AM   #20
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Not to be a vulture but did you WRX have heated seats ? If so (or if the wiring is there as it probably should be) could I get the wiring from you since you will not need it for the swap ? I have WRX seats in my Legacy, have the WRX on/off switches and just need the wiring between the seats to the switch + the relays.

Red Legacy Sedan is hot ! You should try to find some Blitzen wheels for that thing !
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Old 10-06-2006, 06:55 PM   #21
ten80
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Nope, we didn't have heated seats. though the WRX seats are now in my impreza TS! more swap pictures to come this weekend.
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Old 10-07-2006, 11:00 AM   #22
ten80
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I finally got a change to wrench again after a hideous week at school. We're making progress!

Another long evening in the garage...



maybe too long and too many beers- kevin driving an ej20 motorcycle



poor suby is almost naked.


roadkill!

Last edited by ten80; 01-22-2007 at 02:31 PM.
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Old 10-09-2006, 12:38 AM   #23
BeckaSki
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We took a "brake" from pulling apart the WRX today to do some work on the Legacy. It's getting the 11.4 inch WRX front brakes to go along with the 11.4 inch stock rear brakes.

Here's the caliper tree: and removing the brake shield:

The rear caliper brackets were a PITA to get off and Christophe managed to break some bolts.
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Old 10-15-2006, 09:02 PM   #24
ten80
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Nothing much happened on the swap this weekend, though Becca did get a flat tire and I changed the Leg's oil. hopefully there will be more excitement next week. I need to buy some wiring diagrams and start comparing the two cars, find an MT driveshaft, and hope that I can find a vendor with springs in stock. The last two vendors were out of stock and one didn't bother to tell us for 2 weeks. damn setbacks!
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Old 10-15-2006, 11:22 PM   #25
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Why did you remove the brake shield? They didn't get in the way when you put the WRX brakes on there...

Keep up the good work though, can't wait to see the results; BTW, what do you plan to get for the scoop? Baja hood or cutting a scoop in there?
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