Nikolaus.Conrad's 1996 Outback GT. End of the Road.

[nikolaus.conrad]

I just remembered today, I bought my first Legacy in July of 2009 and it was two years ago yesterday it was totaled. Two days later I bought my silver Legacy and last year when that wouldn't pass May Inspection due to rust I retired it and bought the Outback. The 11th of May will be the day when I have had my Outback a year!! I think I'm too excited to have a car for more than one year lol. It and I have come a long way.









I really didn't do anything to the 91 Legacy, except fix/bandaid broken parts (Transmission, starter, heater core). at the time the only forum I was a member of was LegacyCentralBBS, which I rarely went on. I planned to clean up the headlights, throw on new fenders, new tires, and new exhaust but never got to it. I wanted to do a Manual AWD swap from the Auto FWD setup it had, but looking back on it now there is no way I could have done it in that point of time. The 96 was a problem when I first had it, it would start and run fine until it got warm and it was shut off, then it wouldn't start. The problem was the Crankshaft position sensor, after I replaced that it ran great! At some point the ABS unit short circuited and would put the car into Limp/death mode when it was plugged in, So I just ran it without ABS. I joined SLi a month after I had the car and did some light mods, GT bumper, mesh grill, GT wing, 'new' wheels from the 91, and a new radio. When I retired the 96 I carried over the GT front bumper, mesh L grill, and headlights. I'm going to be using more bits from it when I do my transmission swap Soon I hope.

[nikolaus.conrad]

Minor update: today I hit the 203k mark, and my speedo and tach were all over the place. Both would hit zero then come back on then the speedo would read as if it were the tach. The ABS light would come on then turn off, also my radio kept turning on and off by itself and switching through CD/AUX/and radio. But my car would still run and drive normal, but with only a small decrease in power I think I need a new battery or alternator, the car was dead and needed to be jumped after I got out of work. Two weeks ago I jumped a co-workers Civic, then last week my friend's Buick died, and now mine. Every week the parking lot claims another car! lol

Car problems aside, since school has ended for the semester I've had the chance to work on projects. Last night I finally removed the transmission from my old car and started tearing it apart. I've always wanted to take apart a Subaru transmission to see how it's made, It's little things like this that I love doing, No wonder why I'm still single lol. The syncros are pretty shot, once I accidentally shifted the car out of gear by bumping my arm into the shifter. If something gets screwed up on this, it's no big deal. It's kind of practice before I touch the transmission I'm going to use for my swap

Almost but not quite dismantled transmission


Moar pics soon! I also have some exciting news for another ride thread of mine More details soon!

[nikolaus.conrad]

Yesterday I split the old transmission, it was a lot easier than I thought it would be. It was pretty straight forward and only took me about 2 hours total. Sorry about the super crappy pics lately, I only have a cell phone camera at the moment



Also, yesterday I received a lightweight flywheel in the mail from Huffer, Thanks again!

[GTDrifter]

Can't wait to see it this semester.

[nikolaus.conrad]

Thanks Harry! This semester? Are you going back to Wilpo in the fall?

Edit: 600 posts!!

[nikolaus.conrad]

My plan for my transmission swap is this; I have two transmissions, one from and L and one from and Outback. My plan is to combined both to make a custom transmission to be easy to install and work as if it's from the factory. The Outback transmission has low miles (Only 8,000 miles) but the wrong gearing, the L has the gearing I'd like to use except the syncros are shot. The biggest reasons why I'm not just using the Outback transmission alone is because of the taller 5th gear. Having a tall 5th gear gives the engine a higher RPM at highway speeds making it easier to tow, but I'm not going to be towing anything with my car. I can borrow my father's truck for something like that I'd like to have a lower RPM for highway speed, I feel this will increase my fuel economy and help keep the wear on my engine and transmission parts down a bit. I also don't want to fork out money left and right since I'm on a college budget, so price is also playing a huge part in this build.

This is where the madness starts...

Gear ratios for all North American AWD 5 speed manual Subaru transmissions are about the same. Chuck the Admin gave me a wonderful site with the gear ratios and final drive ratios of most JDM and UDSM subaru 5 speed and 6 speed transmissions, but I can no longer access it :smt010 These numbers are from my head and I feel are relatively similar.

Transmission Ratios
1st gear = 3.545
2nd gear = 2.111
3rd gear = 1.448
4th gear = 1.088
5th gear = .871 (Outback)
5th gear = .781 (L)

Final Drive Ratios
L, LS, LSi = 3.9
GT, Outback = 4.111

Parts I plan to use for the build:

Outback Transmission
1st 2nd 3rd 4th gear
Syncros
Front diff
Center diff
Transmission housing
Bearings
Shifter linkage

L Transmission
Final drive 3.9 ring and pinion
Mainshaft
rear transmission casing
5th gear

In a nutshell, what I'll be building is a transmission with new internals, a lower 5th gear, with a 3.9 final drive ratio, which boils down to pretty much a modified L transmission preforming like an Outback transmission. With the 3.9 FD I'm going to be using smaller tires since the final drive and tire size is directly related. My new tire size with 3.9 is going to be 215/55R16 and this should give me the same results as the 4.11 and 205/70R15 (And better lowering capabilities ).

The engine RPM is determined by three variables. The transmission ratio, the final drive, and tire size. I've been crunching some values and numbers and have come up with this; here is a list of some quick math using the ratios above, the tire size, and various speeds. These values are not approximate as nothing ever works in the real world as it does on paper.

I used this site to help calculate my values: http://tech.oldsgmail.com/axle_RPM.php

L Engine RPM
Legacy L @ 3.9 FD, 185/70R14 (24.1" diameter), gears 3 (1.488), 4 (1.088), and 5 (.781).

3rd gear @ 30 mph = 2429 rpm
4th gear @ 30 mph = 1776 rpm
3rd gear @ 40 mph = 3239 rpm
4th gear @ 40 mph = 2368 rpm
4th gear @ 50 mph = 2960 rpm
5th gear @ 55 mph = 2337 rpm
5th gear @ 60 mph = 2550 rpm
5th gear @ 65 mph = 2762 rpm
5th gear @ 70 mph = 2975 rpm
5th gear @ 75 mph = 3187 rpm

Outback Engine RPM
Outback @ 4.11 FD, 205/70R15 (26.2" diameter), gears 3 (1.488), 4 (1.088), and 5 (.871).

3rd gear @ 30 mph = 2292 rpm
4th gear @ 30 mph = 1722 rpm
3rd gear @ 40 mph = 3056 rpm
4th gear @ 40 mph = 2296 rpm
4th gear @ 50 mph = 2870 rpm
5th gear @ 55 mph = 2527 rpm
5th gear @ 60 mph = 2757 rpm
5th gear @ 65 mph = 2987 rpm
5th gear @ 70 mph = 3217 rpm
5th gear @ 75 mph = 3447 rpm

I usually go at about 70 mph and I feel that 3200 PRM is a bit excessive, especially if I'm not towing anything. Here is my calculated RPM:

Nikolaus.Conrad's Transmission Build
Modified @ 3.9 FD, 215/55R16 (25.3" diameter), gears 3 (1.488), 4 (1.088), and 5 (.781).

3rd gear @ 30 mph = 2251 rpm
4th gear @ 30 mph = 1692 rpm
3rd gear @ 40 mph = 3002 rpm
4th gear @ 40 mph = 2256 rpm
4th gear @ 50 mph = 2820 rpm
5th gear @ 55 mph = 2226 rpm
5th gear @ 60 mph = 2429 rpm
5th gear @ 65 mph = 2631 rpm
5th gear @ 70 mph = 2834 rpm
5th gear @ 75 mph = 3036 rpm

I'd like to have the lowest engine RPM possible for speeds 55mph and up, and the L transmission seems to deliver this. But since the components are so worn, I feel it's necessary to use the Outback internals with such low miles. When this is all said and done, I expect to see an accurate speedometer, improved MPGs, factory dependability, and many miles for the road ahead. I'm sure there are little things I forgot to mention, if there are any questions, I'll do my best to explain better.

[xoSubieLegacyxo]

TOO MANY NUMBERS!

[nikolaus.conrad]

Yeah I know I feel this is the best way to explain my build, other than I've ran the numbers and it will work lol The RPMs for my build match up to the Outback transmission RPMs pretty close, I'm only off by 50 rpms (Except 5th gear).

[mike-tracy]

Would this help you:

http://forums.nasioc.com/forums/showpos ... ostcount=3

This one is prob the one you saw before:

http://www.northursalia.com/techdocs/tr ... ychart.pdf

[nikolaus.conrad]

Yes, that has excellent information. That is very similar to the site Chuck told me to look at. Thank you!

[Dead91silvia]

I gotta give it to ya! You are one motivated guy! I havent even done that stuff yet...

[nikolaus.conrad]

Thank you! I want to make sure everything is 100% correct since I don't want to tear it apart when it's assembled lol It's not that hard once you work with it for a while, if you need help let me know!

[nikolaus.conrad]

Went to Le Junkyard about about a week ago (haven't had time to update sorry ) and I got a new rear driver's door in the same color as mine for $22, everything was 1/2 off lol. At the time that's the only thing I could think to grab I went back and got parts for my Spitfire since there was a Mark 3 Spitty in the yard. It's updated in member rides 2 and you can click the link in my signature to check that out as well :smt016 I went back a 3rd time to grab a leather wrapped steering wheel from a 2.5RS that had red stitching but I found something better. As you may recall I got wheels from the 2005 Legacy, well I went to see if that still had the steering wheel and it did! So I bought the almost new wheel instead of the one from the 2.5RS. I also got a newer coil pack from a 2004 PT Cruiser and a new serpentine belt, all for $20. The newer coil pack should have less miles on it and it looks to be in better shape than the one I bought before, although I really haven't noticed much of a difference between the two.



The new wheel feels great! I'm still getting used to the spoke in the center at the bottom though lol. Everything still works, nearly. The horn still works and I rigged the cruise control settings since it's the lever from the old wheel. However, I do not have an airbag. The yard wouldn't let me buy it because it's under "explosive charge" That and I''m not willing to try to rig it myself. All my other cars didn't have airbags so I'm not too worried about not having one. I just hope this doesn't bite me in the ass down the road, erm, face. YOLO!

[nikolaus.conrad]

Update: My Outback has been limping ever since Thanksgiving, and now it's on it's last leg. A few days ago I went to Williamsport to see a good friend of mine who was visiting for the day and 1/2 way there my car started overheating. I immediately pulled over and checked my fluids, everything seemed to be in order, I tried to add some water to the radiator but it was full. Upon later inspection my friend Paul pointed out the coolant smelled of oil. Long story short I think my headgaskets are shot. I drove home with the temp spiking occasionally but other than that no problems. I'm seriously thinking about scooping up a 2.2 from my yard and throwing that in when I swap transmissions. I have my eye on a 2.2 with 156k on it.

Also, the Spitfire will get painted this weekend and hopefully I'll bring it home next weekend. And as soon as I get that on the road the Outback is going under the knife for a complete reconstruction surgery. I plan to replace the following:

Engine- 2.5 to 2.2
Transmission- auto to 5 speed
Rear Diff- 3.9
Gas tank- one I can actually fill up!
Exhaust- Kitteh delete
Wheels- 16" Alloys thanks to GTDrifter

More than likely this car will be out of commission for the rest of summer so I might be driving the Spitfire until the fall.

[nikolaus.conrad]

I ran into a problem with my transmission build, can someone help me out? Nothing big, thanks!

viewtopic.php?f=70&t=25034

[nikolaus.conrad]

Leaving soon to go and pull the new heart for the Wagon, will post pics later!

[nikolaus.conrad]

I just realized I became a member of SLi two years ago today, doesn't seem that long ago! Also just realized I forgot pics, don't mind me I'm scatter brained!

I got a wicked awesome farmer's tan pulling this baby, I'm going back to take those folding mirrors!


And since my Wagon is my sports car/hauler, it was only natural to stick the engine in the trunk. A layer of old rubber floor mats and garbage bags and I was all set


It needs a lot of work but I'm confident I can get this running with no problems. I also got the Spitfire home today so that's another project to get done as well! Updates as I go along!

[amgarrety]

Just curious, how much did that engine cost? I wonder if they just have any 255s laying around?

[nikolaus.conrad]

The engine was $205, there are a few 3rd gen Legacys in the yard but most are picked over pretty good. I'm not sure if any have their engines left or not.

[04Legacy]

The engine was $205, there are a few 3rd gen Legacys in the yard but most are picked over pretty good. I'm not sure if any have their engines left or not.

I can get engines from the junkyard i go to for $75-$100.

[redlegacygt]

The engine was $205, there are a few 3rd gen Legacys in the yard but most are picked over pretty good. I'm not sure if any have their engines left or not.

I can get engines from the junkyard i go to for $75-$100.

Is that Harry's u-pull it? lol

[nikolaus.conrad]

The engine was $205, there are a few 3rd gen Legacys in the yard but most are picked over pretty good. I'm not sure if any have their engines left or not.

I can get engines from the junkyard i go to for $75-$100.

That'd be sweet but driving down there and coming back, I would spend just as much as buying one here. Not to mention the headgasket issue my car is dealing with now, the furthest I can drive south is Mansfield.

[nikolaus.conrad]

Update time! Headgaskets have gotten to the point where I can drive about 2 miles and it overheats, been like this for 2 weeks now. Fun. I missed taking the Subaru to a Subaru meet because of headgaskets so I took my father's Volkswagen. The Spitfire is on the road and is being driven right now (check the ride thread, link in sig). I'm borrowing an engine lift tomorrow and yanking the 2.5 out and replacing it with the EJ22 and hopefully I can get it working 100% problem free before the Rhode Island meet on the 28th. The clock is against me but I'm confident I can tear it apart and put it slap it back together to drive 300 miles there then back. This week will be interesting for sure hahaha

[airlia101]

Just found your build here after hearing your post in the RI meet thread. The transmission work sounds crazy (in that fun, tinkering sense lol), and your wagon itself seems well-loved. Good luck on the engine swap!, hope everything goes well for you!

[nikolaus.conrad]

Things could be going smoother, the engine hasn't been removed yet but that'll change today hopefully. I'm finding little hints here and there that suggest the engine was probably taken out at one point in time. The first thing I noticed was the little rubber door cover that gives you access to the bolts on the torque converter is missing. There are some bolts missing from the timing belt covers and in a few spots are broken. and the bolts to hold the header on are rock solid tight! Not to mention whoever slapped it on used a regular steel nut instead of a stainless nut so it rusted to the header and essentially became part of the header. I've been drilling out a nut I rounded off for about an hour now because my bits keep getting dull UGH. However, the replacement engine is almost 100% together, I replaced the waterpump as well as fixed a massive dent in the oil pan so now it holds oil, cleaned it up a bit, and I have all the timing sprockets and rollers on it. I just need a timing belt now which is in the mail on the way to my house I'm going to wait to put the engine in so I can put the timing belt on, much easier to do when it's out of the car! I'll update this here shortly with pics and shit

[nikolaus.conrad]

I got the 2.5 out today! It only took about an hour and 1/2 and some heavy drilling of stuck manifold bolts. My timing belt came in the mail today! So tomorrow I'm going to try and put it on and put the new motor in, if everything goes smoothly

Rhode Island here I come!

[GTDrifter]

You could always take the jdm machine that you brought to chads meet lol

[nikolaus.conrad]

HAHAHA might as well bring the Spitfire!

[xoSubieLegacyxo]

You could always take the jdm machine that you brought to chads meet lol

I thought VW was German?

[nikolaus.conrad]

I've got everything buttoned up on the new motor and it's ready to go in.



I paid a friend of mine to make me a track pipe, I wish I had some UELs to slap on with this



Fitting in the new engine, excited!



Sitting pretty 'n' stuff



I'm going to try and get everything hooked back up later today and see if I can get it to start! But for right now it's 5AM and the only reason why I'm up is because I took a shower at 3 and couldn't fall back asleep.