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Old 07-05-2020, 04:51 PM   #251
KeithS05RS2.5
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Next up I wanted to adjust they way I have to coolant bottle, Im probably over thinking it but I didn't want it rubbing at all on the brake lines so I added some self adhesive foam to insulate it from rubbing





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Old 07-06-2020, 08:32 AM   #252
KeithS05RS2.5
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Next: Big project for this year .... 4/2 Pot conversion.
Went the cheaper route and got 06 WRX remans from Rockauto:


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Old 07-06-2020, 08:46 AM   #253
trueno92
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So far I have had good experiences with them and the price cannot be beat thats for sure.

one of my sets had this casting. Pretty neat seeing this in North America!

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Old 07-06-2020, 02:11 PM   #254
KeithS05RS2.5
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Post moved to another forum

Last edited by KeithS05RS2.5; 05-29-2021 at 03:03 PM.
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Old 08-20-2020, 10:13 PM   #255
KeithS05RS2.5
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Ok so got one project done with the WRX

The old battery in the trunk died. Which meant I could downsize since the old one was admittedly way too big.

So I went with a Odyssey PC925:



And went with their mount to go with it. I did the mount in wrinkle black



Then drilled new mounting holes. Used nutserts this time, and plugged the old holes with rubber grommets:



Then used some countersunk hardware to mount:




Then decided to cut the section of carpet that it sits on away this time instead of having the carpet bolted to the floor under the mount like last time:




Then added some rubber insulator to the bottom since my flush mount hardware stuck up above flush ever so slightly



Then hooked the battery up. Didnt like it. The mounts were to chunky and too large for the battery and I didnt have a place to mount the circuit breaker.






So I removed the SAE terminals and added these adapter posts



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Old 08-20-2020, 10:14 PM   #256
KeithS05RS2.5
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Then made a bracket and attached it to the top half of the mount:





Then added ring terminals to the end of the cables along with rubber boots, used nylon lock nuts to secure them and hooked everything back up:






Before and After

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Old 09-16-2020, 09:44 PM   #257
stiboost04
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nice build and great pics with detail. any pics of how u did the battery relocate as far as wiring?
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Old 09-17-2020, 05:29 PM   #258
KeithS05RS2.5
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Thank you!

Page 6, post 132 shows when I originally did the relocation.
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Old 04-07-2021, 09:50 AM   #259
KeithS05RS2.5
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Post moved to another forum

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Old 04-16-2021, 03:12 PM   #260
KeithS05RS2.5
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Post moved to another forum

Last edited by KeithS05RS2.5; 05-29-2021 at 03:03 PM.
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Old 04-29-2021, 06:29 PM   #261
KeithS05RS2.5
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Update time:

A lot of maintenance has been going into the Forester so I think Im going to stop posting stuff about it here and start a thread over on SubaruForester.org.

But I do have to mention it again to explain whats going on with the WRX.

OK, so the used transmission came in for the Forester and a family member picked it up from the transmission shop along with the taken apart old transmission and dropped it all off to me.
It wasn't until after business hours that I realized the transmission shop forgot to send the rear portion of the old transmission case ... and the salvage yard that pulled the used transmission removed the shifter bracket that happens to be on the tail portion of the transmission that was left at the shop.

Luckily the WRX uses the same bracket so I borrowed what I needed off the WRX. But I figured while im in there with everything taken apart I might as well let my OCD run wild and update that area of the car.

So I Broke down the transmission cradle, brushed off the rust and hit it with some rustoleum satin black.
Put it back together with some "Group N" STI bushings as well as picked up a Group N transmission mount. Also replacing the rusty hardware as I go.






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Old 05-03-2021, 10:06 AM   #262
KeithS05RS2.5
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Prices were decent so I picked up some OE parts to replace the rusty/crusty stuff:



Pulled the exhaust to get the drive shaft out. Couldn't believe how much moisture collected in the exhaust from sitting so long.



And everything out that needs to come out:

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Old 05-05-2021, 09:02 AM   #263
KeithS05RS2.5
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And got around to another project that ive been putting off since the downpipe was off anyway.
The power steering is getting air in from somewhere. There is no visible leak in terms of drips but there is a wetness around the adapter fittings.

I recalled that when I put everything together I forgot to change the o-rings on the factory lines. So i went ahead and replaced them.
The wet looking ones are the old ones and you can see they are pretty deformed:






If air keeps getting into the system then Im going to assume that the adapter fittings don't seal properly and Ill probably replace the limes all the way back to the rack.

I also went ahead and changed the fittings on the reservoir return outlet, I hated how the old adapter looked.
This was the old setup: -10 female to female 90* fitting with -10 to -6 male to male adapter to the -6 return line:




I changed it to -10 female to -10 male 90* with a -10 female to -6 male adapter to the -6 return line:





Last edited by KeithS05RS2.5; 05-05-2021 at 09:08 AM.
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Old 05-07-2021, 05:26 PM   #264
KeithS05RS2.5
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Cleaned up some more of the rusty crusty stuff: Shift linkages and drive shaft cover:



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Old 05-08-2021, 07:07 AM   #265
KeithS05RS2.5
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Ok so got into the whole project that caused me to pull all this apart in the first place: The leaky shifter shaft seal.

I made up a little tool out of the old linkage bracket to easily pull the tail shaft cover off the trans with ease:




Cover off: You can see all the black on the aluminum where its been leaking all these years, Overall not bad, but like I said before, this is mainly practice for needing to do it on my Forester:





Went with the Lisle shaft seal puller for this job, I wish they used hardened steel for the shaft because this bends a little before the seal pops out, but you can just bend it back no problem:



This is as far as I got. Still need to run to Lowes to get a piece of 3/4 PVC tube to use to seat the new seal, so everything is covered up to keep it safe until I can get back at it
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Old 05-09-2021, 06:08 PM   #266
KeithS05RS2.5
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Ok so I got the new seal installed today:



And got the cover back on, sealed up with some RTV. Cleaned up some of the gunk on the cover too



And got the Group N transmission mount installed:



Next step is to get the shifter linkage installed. Im going to be replacing the OEM one with the Turn-In-Concepts update one, so ill be ordering that soon
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Old 05-10-2021, 08:50 AM   #267
bym
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So nice to update/upgrade stuff to modern standards
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Old 05-18-2021, 12:49 AM   #268
D-Rodman
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I’ve used this kit a couple of times with excellent results and super durable.
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Old 05-18-2021, 06:04 PM   #269
KeithS05RS2.5
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Quote:
Originally Posted by bym View Post
So nice to update/upgrade stuff to modern standards

I know!


Quote:
Originally Posted by D-Rodman View Post
I’ve used this kit a couple of times with excellent results and super durable.

Thanks for the heads up, I ended up going with the whole unit from TIC anyway though.
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Old 05-18-2021, 06:13 PM   #270
KeithS05RS2.5
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OK so I got the shift linkage update from TIC installed with a new roll pin. And got the linkage arms put back in as well as the bracket on the back of the trans. Also ordered new drive shaft bolts, Im told the newer round head ones are compatible and I like those better.







Next thing is to order the Kartboy shifter bushing set.

Also got the 4/2 pot calipers painted up.
Went with G2 gold, not sure how gold calipers with gold wheels is going to play out but the gold was much cheaper than the Porsche acid green I had planned on going with.

Not sure how I feel about the G2 system. The pain goes on very thin, coverage evened out after three coats but still seems like a thin coating, and I don't know how durable its going to be. Also it seems like the aluminum on the rears holds onto contaminates despite thorough cleaning ... the paint fish-eyed a lot on the aluminum rears which usually indicates that there are contaminates on the surface

Still was able to even everything out by the third coat. This is the best picture I have right now, they are still drying. Ill post up better pictures when I put the stickers on. Which BTW aren't easy to find. I did buy a set but are skeptical of whether they are the right size or not.


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Old 05-24-2021, 09:40 AM   #271
KeithS05RS2.5
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OK so heres a better picture of the calipers now that the paint is dry. Overall im not too blown away with the results, you can see a ton of brush strokes, although they did turn out super glossy. Either way, they look good and wont rust.



Then got ahead of myself and started pulling the brakes off the wrx. Ended up pulling the front dust plates and giving them a coating of paint since they had almost no rust on them.
I wish the rears unbolted like the fronts, I would have bought new ones due to the level of rust but Im not going to pull the hubs just because of some rust no one will see. So I settled for masking the area and giving them a lick of paint still on the car.






Then I got on to a project I wasn't looking forward to.
I while back I realized there was coolant slowly dripping onto the header.
Initially I thought it was from the thermostat gasket since the thermo elbow was covered in coolant,
But then I realized there was coolant above the thermostat and a little bit coming from under the timing cover.
So I pulled the timing cover, and yea, it looks like its the water pump gasket.




So even though I didn't want to start on this project yet, I noticed the all-japan parts timing belt kit ive looked at in the past was on sale for almost $200 off, I pulled the trigger and ordered that even if I don't get to it right away, it was a decent savings.
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Old 05-28-2021, 12:03 PM   #272
KeithS05RS2.5
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Ok so got some fresh parking brake shoes and hardware on the rear, and placed the front dust shields in place for now, waiting on new hardware.



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Old 05-29-2021, 02:55 PM   #273
KeithS05RS2.5
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So I was back at it today. As I was falling asleep last night, I realized I made a mistake installing the parking brake shoes:

I ran into a problem where the bottom retention spring was rubbing against the abs tone ring. I looked it up an found out it is relatively common. Rust gets in between the layers that make up the backing plate and pushed out the "pads" that the shoes rest on. The solution is to massage some clearance.

Not wanting to take anything apart I tapped the shoes themselves with a block of wood and hammer to push them inwards. But I realized that this created a groove in the "pad" that the shoe sat in, which would undoubtedly prevent them from adjusting outwards.

So I pulled all the parking brake stuff and hit all 6 "pads" with a wire wheel. Just the bottom two were damaged. I think filling them with some JB-weld and grinding it smooth should be fine. Replacing would suck: new backing plates are $100-$250 depending on aftermarket or OEM, and new wheel bearing kits are about 150 per side. Id like to avoid having to do that.




Now onto the interesting stuff. Got the Torque Solutions rear caliper adapter brackets in the mail today:
I have to say I am not too impressed as these require some work to fit and are definitely not "plug-and-play".
The OEM mounting bracket needs some clearance-ing as well as the caliper itself. I also had to slightly enlarge the mounting holes on the drivers side bracket as it seems as though they were milled too close together (Not sure if this is an issue with the bracket or a variance in the spacing of the holes in the caliper) -- I hope it doesn't throw off the alignment to the rotor at all.


Caliper adjustments:



Mount grinding along the lip:



Mount grinding again



Installed:



Caliper test fitted:



Also got some Torque Solutions carrier bearing bushings and new bolts for when the drive shaft goes back in.



With all of the rusty stuff I am encountering, I think this car may have seen more winters than I originally thought when I bought it.
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Old 06-05-2021, 03:51 PM   #274
KeithS05RS2.5
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OK so I got my "all-JDM'' timing belt and water pump kit in from FastWRX:



And got some decals in for the calipers. Had to order all the way from Turkey to find any in black:



And got the shifter bushing set installed. Went Whiteline over Kartboy only because they were on sale at the time.
Rear Bushing:




Front bushing:



Which meant I could get everything else under the car back together.
Transmission cradle back in with new hardware:




Driveshaft in with the Torque Solution carrier bearing bushings:



Lastly, the rear driveshaft cover with new hardware:

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Old 06-12-2021, 10:58 AM   #275
KeithS05RS2.5
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Ok so the repairs to the rear backing plates is done:
JB weld applied and ground back smooth:




Coat of paint to cover everything up:



... and parking brake hardware installed for the second time:



Looks like this ought to work. Driver side spring seems a little close to the tone ring, but it doesn't touch so that's all I can ask for.

And finally finished up a project that I procrastinated so badly its take literally years to finish up .... neon yellow wheels are now gold:


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