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Old 08-27-2017, 04:59 PM   #26
Dash_Martino
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Member#: 78728
Join Date: Jan 2005
Chapter/Region: Tri-State
Location: Jim Chunk, PA
Vehicle:
04 STi
PSM

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Finally tracked down a hoist and engine stand! Time to get to work!!



Wrapped up the intake manifold with a rachet strap.



Jack stand under the tranny to reduce load to the input shaft.



After a little pump to raise the motor, time to separate using thin bladed screwdrivers and a hammer.
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Old 08-27-2017, 05:03 PM   #27
Dash_Martino
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Member#: 78728
Join Date: Jan 2005
Chapter/Region: Tri-State
Location: Jim Chunk, PA
Vehicle:
04 STi
PSM

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More pics of splitting the block from the tranny.



It's free!



Bolted to a stand!



Obligatory stand where the motor used to be shot.

Next part of the plan is to set up a meeting with my engine builder and see what all they need from the old motor to start building the new one. In the mean time, I will try to remove some of the parts underneath the car that are rusty and try the whole electrolysis rust removal thing.
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Old 04-07-2018, 05:17 PM   #28
Dash_Martino
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Member#: 78728
Join Date: Jan 2005
Chapter/Region: Tri-State
Location: Jim Chunk, PA
Vehicle:
04 STi
PSM

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Big update!

Yesterday I took delivery of my rebuilt EJ257 from Area 1320 Motorworks in Nazareth, PA.
The motor was rebuilt with a nice list of goodies!
-Area1320 Spun Bearing Special, an OEM loaded shortblock with Manley forged pistons
-Subaru OEM Complete Gasket Kit
-11mm oil pump
-oil pump union
-2.5L oil pan
-Killer B Ultimate oil pick up
-Aluminati TGV Delete Housing
-Perrin 02-07 Subaru STi Black Turbo Inlet Hose
-Timing Belt Component Kit with Water Pump
-Comp Clutch Sti Subaru Steelback Brass Plus Clutch Kit
-Matching Flywheel Resurfacing
-Matching cylinder head
-Misc Hoses






Now that I have the motor, I've got some work to do underneath the car with mild rust removal and some extra parts like a new radiator, new subframe (which is rusting out), a few extra hoses, sensors and belts while the motor is out.

Looking forward to the next couple months!
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Old 05-25-2018, 03:36 PM   #29
Dash_Martino
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Member#: 78728
Join Date: Jan 2005
Chapter/Region: Tri-State
Location: Jim Chunk, PA
Vehicle:
04 STi
PSM

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Weather's getting nice, a couple more parts and goodies are trickling into my mailbox. Time to get to work.

Installed new STi Motor Mounts:





Also, I went to put my new clutch in but stripped a pressure plate bolt head when torquing them down. Luckily my buddy's left handed drill bit spun it right out!

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Old 05-25-2018, 03:38 PM   #30
Dash_Martino
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Chapter/Region: Tri-State
Location: Jim Chunk, PA
Vehicle:
04 STi
PSM

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Also took the front subframe off. It's getting pretty rusty thanks to NEPA winters and salt on the road.



It wasn't the worst shpae I've seen for a subframe after searching the internet, but I figured while the motor was out I would replace it before it rotted away and prevented me from passing inspection.



The subrame bolts were relatively unpleasant to get out. One broke.

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Old 05-25-2018, 11:44 PM   #31
rayd3rz
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Join Date: May 2018
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2011 STI
Matte White

Default Love it!

Quote:
Originally Posted by Dash_Martino View Post


More pics of splitting the block from the tranny.



It's free!



Bolted to a stand!



Obligatory stand where the motor used to be shot.

Next part of the plan is to set up a meeting with my engine builder and see what all they need from the old motor to start building the new one. In the mean time, I will try to remove some of the parts underneath the car that are rusty and try the whole electrolysis rust removal thing.
This thread definitely gives me the motivation I needed to get to work on mine I have a 2011 sti and want all the goods in an 05 because that is my dream car keep it up and canít wait to see the end results!
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Old 07-03-2018, 12:38 PM   #32
Dash_Martino
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Location: Jim Chunk, PA
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PSM

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Update time!

Vacation time for me, got a few days off. It's hot as hell, but it's somewhat shaded in my garage, so time to get to work!

Time to put the clutch in, no broken bolts this time.

Cleaned flywheel:


Clutch disc with alignment tool:


Cleaned pressure plate:
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Old 07-03-2018, 12:41 PM   #33
Dash_Martino
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Member#: 78728
Join Date: Jan 2005
Chapter/Region: Tri-State
Location: Jim Chunk, PA
Vehicle:
04 STi
PSM

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Ordered new clutch bolts for such a special occasion. Didn't break the bank, they were only about $0.50 a piece:


Pressure plate installed. Bolts torqued to 12 foot pounds, no problem.


Also new throw-out bearing installed. Went relatively easy, was surprised:
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Old 07-03-2018, 12:43 PM   #34
Dash_Martino
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Member#: 78728
Join Date: Jan 2005
Chapter/Region: Tri-State
Location: Jim Chunk, PA
Vehicle:
04 STi
PSM

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Other minor improvements today. Installed a new turbo oil return line, which is much easier with the motor remove from the car:



Also a new positive battery terminal:


That's it for now. Ordered the new subframe, got it for about $350. Glad I checked to see if it was STi specific (it is!)

Right now I could drop the motor in if I wanted, but I'd still like to clean the engine bay and install the subframe before I put the motor in and run out of room to work easily. More updates by the end of the summer!
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Old 07-03-2018, 01:34 PM   #35
Scuby04STi
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Member#: 328635
Join Date: Aug 2012
Chapter/Region: NWIC
Location: Portland*
Vehicle:
2004 STi GTX3076R
Rally Blue

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Well if you wanted to pay the shipping I have one of those U braces off my '04 that's from rust free Oregon, LOL. That is if your able to cancel the one you ordered. I was just about to cut it up and scrap it.
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Old 08-12-2018, 06:58 PM   #36
Dash_Martino
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Join Date: Jan 2005
Chapter/Region: Tri-State
Location: Jim Chunk, PA
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So my buddy helped me build a table for my back porch using a tabletop I found at my house and old EJ motor parts... These are the results:





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Old 08-12-2018, 07:52 PM   #37
Bewrx6
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Location: Watsonville, Ca
Vehicle:
2002 Wrx
Silver

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Quote:
Originally Posted by Dash_Martino View Post
So my buddy helped me build a table for my back porch using a tabletop I found at my house and old EJ motor parts... These are the results:







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Old 08-28-2018, 08:19 PM   #38
Dash_Martino
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Member#: 78728
Join Date: Jan 2005
Chapter/Region: Tri-State
Location: Jim Chunk, PA
Vehicle:
04 STi
PSM

Default

Exciting times! New subframe goes in. Painted it with undercoating spray, got brand new bolts from subaru and torqued them down to spec.


Next up, time to drain transmission fluid and put fresh stuff in. Was able to get the bigger differential bolt off no problem, but the transmission oil pan nut decided to strip no matter what I tried.


Decided to yank the pan and yank the magnet as many people recommended:
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Old 08-28-2018, 08:21 PM   #39
Dash_Martino
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Member#: 78728
Join Date: Jan 2005
Chapter/Region: Tri-State
Location: Jim Chunk, PA
Vehicle:
04 STi
PSM

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New pan from Subaru with an updated strip-resistant drain bolt:


Installed and torqued down:


Fresh Motul 75W90 300 LS!
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Old 08-28-2018, 08:23 PM   #40
Dash_Martino
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Member#: 78728
Join Date: Jan 2005
Chapter/Region: Tri-State
Location: Jim Chunk, PA
Vehicle:
04 STi
PSM

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Sprayed down the engine bay with some degreaser and hosed off the engine bay:






Can't really think of anything else left to do but drop the motor in (but I am willing to hear some suggestions while the motor is out!)


Thanks for all your help and support, stay tuned.
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Old 09-09-2018, 07:18 PM   #41
Dash_Martino
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Member#: 78728
Join Date: Jan 2005
Chapter/Region: Tri-State
Location: Jim Chunk, PA
Vehicle:
04 STi
PSM

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Old 09-10-2018, 01:53 PM   #42
BlueSTI4Me
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Member#: 34361
Join Date: Mar 2003
Chapter/Region: MWSOC
Location: MI
Vehicle:
04.7 STI
WRB

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Nice work on this 2004 STi.
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Old 09-21-2018, 09:55 PM   #43
Dash_Martino
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Member#: 78728
Join Date: Jan 2005
Chapter/Region: Tri-State
Location: Jim Chunk, PA
Vehicle:
04 STi
PSM

Default

After getting the motor in, I discovered that my clutch wouldn't mount to my throw out bearing thanks to the lame two-piece hub ring that broke on installing the motor. Unfortunately this meant that the motor had to come out again. Opted to get an ACT Monoloc:


Highly recommended. If doing a clutch install, pony up and pick one up, totally worth it for the peace of mind.

Motor is in. Again.
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