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      01-03-2010, 05:01 AM   #89
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The rear diff is back together. I took 5 hrs, mostly messing with the setup to get bearing preload, pinion engagement and ring gear runout all within spec at the same time.
Did you use paint on the teeth to check the contact patch location?
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      01-03-2010, 06:32 AM   #90
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Originally Posted by m_thompson View Post
Did you use paint on the teeth to check the contact patch location?
zinc oxide
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      01-03-2010, 04:10 PM   #91
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Progress today: Last rear brake, hub/knuckle, rear drive shafts and differential are all in. Still need two bolts from Subaru before it can sit on its own four tires.
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      01-03-2010, 07:03 PM   #92
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zinc oxide
Protects against sun burn too.

I used to change the ring and pinion in muscle cars to lower ratios. You are right, it was a pain to get the pinion depth and ring gear position just right and still have all of the preloads correct. We went through a lot crush sleeves in the process.
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      01-03-2010, 07:21 PM   #93
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You are awesome. I'm checking this thread a lot, haha.
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      01-03-2010, 09:30 PM   #94
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Quote:
Originally Posted by m_thompson View Post
You are right, it was a pain to get the pinion depth and ring gear position just right and still have all of the preloads correct. We went through a lot crush sleeves in the process.
Even harder was that we were trying not to (and didn't in the end) touch the pinion or change the load on the crush washer. There was a lot of swapping of shims from right to left but we ended up back at the factory shim configuration minus a couple of thousandths via shim sanding. We started with about a 0.010" of runout on the ring gear and zero on the side bearings (spec'd at 0.0040" to 0.0080") and a reasonable contact patch to locking up the side bearings to 0.004" on the ring gear and a acceptable but not preferred contact patch to 0.006" runout and a good contact patch. The nice thing about using zinc oxide is that it in not impacted by oil residue on the gears.


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You are awesome. I'm checking this thread a lot, haha.
Thanks! I'm starting to feel an itch to go drive this thing, especially with some snow around.

Here's a pic of the diff back in the car. Note the lack of support under it!
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      01-06-2010, 09:22 PM   #95
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Have fun... and rebuild it again after we roll it in a couple of years. As you know, I've got the spinning down. It's time to work on rolls.

Here the final vent install and the test fit on the vent scoop.
Aah you have a vent scoop on yours. I was in Charleston SC last week and saw a Subie that I thought looked like yours to be.
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      01-08-2010, 06:52 PM   #96
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No progress to report this week. I'm hoping that tomorrow is productive.
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      01-08-2010, 08:58 PM   #97
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No progress to report this week. I'm hoping that tomorrow is productive.
Posting this so that we keep on your back about continuing?

If so, GET TO WORK!
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      01-09-2010, 09:13 PM   #98
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GET TO WORK!
Ok! The t-braces that tie the lateral lateral links together and back up to the rear cross member went in today, as did the front lower tie-brace. The front tie-brace ties the control arms together in the front crossmember via the jacking plate. The fuel filler neck went in back in today, too. Total working time today was about 3-1/2 hours, just enough to freeze my hands. While I got the air temp up to about 50 deg in the garage, the tools were still at about 30 deg! If I can figure out how to get some decent angles, I'll get some pics of the new parts up tomorrow.

Next up will be getting the e-brake hooked back up to the handle for when the car heads to the body shop.
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      01-10-2010, 08:18 AM   #99
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Thats it? slacker. Maybe you should invest in a garage heater. That would speed/ease up the process.
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      01-10-2010, 08:27 AM   #100
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Pics of roller or ban! Brakes all bled?
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      01-10-2010, 09:34 AM   #101
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Thats it? slacker. Maybe you should invest in a garage heater. That would speed/ease up the process.
Actually, getting the braces in was a complete pain. To a large extent, both the front and rear crossmembers had to be disassembled and reassembled.

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Pics of roller or ban! Brakes all bled?
I guess you'll just have to ban, then. I'm still waiting on Subaru for two bolts before it can roll. Brake fluid showed up last Thursday. I can bleed the brakes now but I haven't done it yet. Maybe tonight since it doesn't require much planning or setup.
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      01-10-2010, 09:48 AM   #102
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Quote:
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Actually, getting the braces in was a complete pain. To a large extent, both the front and rear crossmembers had to be disassembled and reassembled.



I guess you'll just have to ban, then. I'm still waiting on Subaru for two bolts before it can roll. Brake fluid showed up last Thursday. I can bleed the brakes now but I haven't done it yet. Maybe tonight since it doesn't require much planning or setup.
Love to see the progress though, Mike!! Scoobydoo is taking their sweet time with this bolts.
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      01-10-2010, 03:41 PM   #103
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Evidently coming from Japan... seriously
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      01-11-2010, 08:17 PM   #104
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Thanks to Andy's help, the brakes got bled tonight. I also tried to hook up the e-brake... and quickly found that I had swapped the cables left-to-right when I reassembled the rears. So, now I have to disassemble the rear brakes to swap the cables. That's a job for another day, maybe Thursday.
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      01-20-2010, 01:25 PM   #105
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Ok Larry, you asked for it. UPS was just here and dropped off the long awaited box of parts. Tomorrow night should be a work night.
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      01-20-2010, 03:13 PM   #106
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Sweet! Hope that's the only stuff you'll need to order from overseas from Subaru. That took quite a while.
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      01-21-2010, 03:42 PM   #107
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      01-21-2010, 03:58 PM   #108
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We're working on the car tonight. I don't like the way the stock lug nuts contact the seat on the new wheels, so the car won't be on the ground tonight, even though it should be ready when we're done. New lug nuts have been ordered and should be here either Saturday or Monday.
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      01-26-2010, 08:23 AM   #109
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      01-26-2010, 09:33 AM   #110
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Hopefully I'll have something good later today.
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