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Old 12-13-2015, 08:35 PM   #1
HairySheep
Scooby Newbie
 
Member#: 108912
Join Date: Mar 2006
Vehicle:
2002 WRX Wagon

Default 04" WRX swap into 96" OB wagon (almost complete)

Im a little late on this, so some of the pictures have been lost or accidentally deleted over the last year.
But my buddy and i are on the bottom leg of swapping 04' WRX engine and complete drivetrain into his 96' OB Wagon.
His OB had was nearing the 230k mile mark. The tires were bald and the struts were blown out from rough trail riding. This had been a plan for a while, but it got to the point were if we didnt do it now, he was going to have to put a lot money into the OB to keep it driveable. So he pulled the trigger, picked up a totaled 2004 WRX 5spd wago, completely intact.

Here is his 96' OB wagon and my 02' WRX wagon


LET THE DEMOLITION BEGIN!!
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Old 12-13-2015, 09:10 PM   #2
HairySheep
Scooby Newbie
 
Member#: 108912
Join Date: Mar 2006
Vehicle:
2002 WRX Wagon

Default

Initial tear down on the 04' WRX began in early spring last year. We flew right on through it, working a couple hours at a time, one or two nights a week. Although from the get-go ive been certain the EL header on the wrx was going to give us trouble. It hangs down way to low, we wont be able to mount a skid plate or anything with it.

So after a couple of months and lots and lots of beer, we had completely strippd the WRX to basically the bare frame. So we picked it up with the tractor and tossed it out!

We waited a few weeks for him to be ready to tear into the OB, it was his daily after all. Here is his other daily.
[IMG][/IMG]

So we begin again, pull the OB in the garage and commence destruction!
This one went much slower, half the bolts either broke off or had to be cut out with a grinder. Luckily no bolts that mount to the body broke off. She was a good ole' gal, but it was time to give her new life.
Here she is stripped down to her skibies
[IMG][/IMG]
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Old 12-13-2015, 09:28 PM   #3
HairySheep
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Member#: 108912
Join Date: Mar 2006
Vehicle:
2002 WRX Wagon

Default

Once the motor came out it was basicly now just a waiting game. The good folks at http://www.iwireservices.com/ have been amazing for us. They merged the two harnesses together for us and have been excellent with their customer service and answering our technical questions. If the wiring had been left to us, we might honestly have given up because we would be so lost.

They took a couple of months with the wiring, so that time was most spent waiting and doing final prep work to get the body ready for reinstall. Slowly we did thing like put in place the complete rear subframe. He purchased new OEM springs and KYB GR2 struts as well as new OEM parking brake, rotors and pads. Whats the kicker? It got a new set of shoes, General Grabber AT2s 215-65-16.

Once the wiring harness came it, it was back to balls to the wall! Oh... wait, WTF are we doing?? This is when it becomes clear that weve never attempted anything like this before. The harness when in fairly smooth, went in just as the old one came out. Now it was time for the motor.
When we took the motor out we had trouble with it on the subframe, so we actually dropped the motor in place before doing anything else. It was very simple this way, there was nothing to run into and it slid neatly into place. Once the motor/5spd trans were in place we then installed the trans bracing. We were amazed tat the WRX brace simply bolted right in place. Sfter that we put the front subframe under the motor and bolted it to the frame under the motor. Then we could let the motor off the lift and finally bolt it in place.

Home free right?
WRONG!
This is were we began running into problems.
We had to swap the 5spd speed sensor for the OB 4EAT speed sensor. Problem? The WRX sensor is plastic and broke off in the tranny, we spent about 4 hours and several beers digging it out piece by piece. Once it was out though the new one went right in.
Next! We put the OB radiator in and began hooking it up when we realized, we have no way to hook up the turbo reservoir. So we took it all out to swap the WRX one in, but the fan plugs were differant, so we cut them off and swapped them with the OB plug and began to install the WRX radiator. Quickly we realized, of snap! this thing wont fit at all, its like 2" taller. So we did some research and discovered the proper way to do it.

You run your radiator overflow line to the turbo reservoir, then run that overflow back to your overfill tank and voila! Thats it! It helps to do the research first so you dont have to waste your time like we did.

Last edited by HairySheep; 12-13-2015 at 09:54 PM.
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Old 12-13-2015, 10:13 PM   #4
HairySheep
Scooby Newbie
 
Member#: 108912
Join Date: Mar 2006
Vehicle:
2002 WRX Wagon

Default

I keep making seperate post because i afraid ill type all this out and lose it somehow.

Finally we got everything plugged up, brakes bled, newly installed clutch slave cylinder bled and it works like a champ. The dash is together and wired up and things are looking great, so we put the battery in to see if shell turn over.

She cranks a couple times and FIRES! it RUNS! This was just last night and at the end of our night so we didnt get any further than that. It didnt run smoothly, it idled very rough, shaking around and it didnt rev very fast. The CEL was on, as expected, but we dont have a scanner to see what its reading.

Major problems we have right now:
-Very rough running. I feel like it could be in vacuum leaks or line in the wrong place.

-No air box. The WRX had an AEM short ram which we will not be using. I believe we are going to try and find a OEM WRX air box to put in. Its running open ended right now, so obviously not helping our running situation

-WRX steering rack spline shaft and 96' OB steering column spline end are completely different. Im going to cut the bottoms off the connecting shafts and weld the WRX bottom to the OB shaft

-Driveshafts for a 5spd OB wagon are impossible to find! Our 4EAT shaft will "work" kinda, not really. It will fit in but it leaves half the spline end hanging out. So it will be weak and probably wont keep a seal.
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