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Hawk296's Old Green L
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Old 01-21-2018, 02:25 PM   #41
Hawk296
2.0L
 
Car: 1995 L
Join Date: Jan 2004
Location: Waterford, MI
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Iíll just have to find and open spot with enough meat on it to drill/tap when the time comes. Nothing happens quick with this car

With temperatures in the 40ís I did venture out to do alittle work to the car, but nothing performance oriented. Turns out the body shop partially cut the antenna wire and as a result the radio reception has been poor. Also it was cracked really bad. So I took an hour and put a new one on. Itís a small detail but looks and works much better.



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Old 04-16-2018, 08:32 PM   #42
Hawk296
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Car: 1995 L
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Well itís been sitting quietly all winter. Still snow in the forecast and 30 degree temps mean I donít want to be in the cold garage. The few reasonable days this year were spent fixing the Baja and putting the GT350 bits on the Mustang. I couldnít wait any longer and toughed it out today and started to wrap up where I left off last year. Remote mounted the oil press sender as it wouldnít fit under the alternator, connected the lines for the boost gauge and ran all the wires through the firewall and into the gauges. The oil temp sensor is still waiting for the oil change which will happen soon hopefully.

The last of the parts should arrive tomorrow to rebuild the JDM axles and if everything goes according to plan, the RA trans and LSD R160 will get installed this weekend!

Until then, glamour shots from a happier, warmer time... last summer.
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Old 04-16-2018, 09:05 PM   #43
The Yellow Monster
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What tires are those?

nice looking car.
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Old 04-16-2018, 09:20 PM   #44
Hawk296
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Car: 1995 L
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Thanks! They are Falken Azeni RT615K
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Old 04-20-2018, 06:52 AM   #45
Hawk296
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Car: 1995 L
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Lots of little stuff done in the last few days. Had a small leak at the line for the oil pressure sensor so I had to redo that. Changed the oil and added the temperature probe to the drain plug and ran the wires to the gauge inside.

Then I went to finish up this stupid rear diff. If I could do it all over again I would throw it in the trash and just spend the money on a new, modern, better rear LSD. I was trying to save money since I already had the early JDM R160 LSD sitting in storage with both special axles. That was a dumb move

The rear diff has been sitting assembled since Nov/Dec. I pulled the axles out recently to get them ready and when I unwrapped them (they were wrapped in shrink wrap) one has a ripped boot and and some spline damage.

I bought some aftermarket boot kits and after fighting with them for 45 minutes and being unhappy with the results I ordered the OEM ones from the dealer. Since I had them apart anyway and was waiting for the correct boots, I decided to refurbish them the best I could. I found the super hard to find dual spline DOJ on Amazon for $28 and installed that.




Then I checked the spline damage on the short side. It was pretty bad and wouldnt engage with the Diff. The splines at the tip were twisted and half missing.


Of course the internet is full of misinformation and there were a ton of old threads claiming the USDM 2.5rs axle fits in the short side so I went and bought one. Although very similar, the USDM axle has an extra bit of taper at the end of the shaft (the USDM diff is not tapered) to help engage the diff. Also the USDM axle doesnt have a very deep circlip groove because the clip stays in the diff.

The JDM axle has no extended tapered part to the shaft as the diff has the taper. Also the groove is deeper as the axle holds the circlip not the diff. The USDM axle fully engages until the opposites shaft is inserted, then it interferes. It also will obviously not stay in place without a proper circlip.

I could remove the damaged section of splines from the JDM axle and run only 2/3 the normal spline engagement or modilfy the USDM axle so I chose to modify the USDM axle. My cousin is a machinist for and OEM supplier so he helped me machine the axle to the correct dimesnsions to mimick the JDM one.

Before and after machining is below.




The worst part is, this is one that I bought back in the mid 2000ís from someone who said it was a ďmechanical LSDĒ Which everyone thought the same thing back then. I think it was proven to actually be an early Viscous unit. All this headache for a VLSD..... But at this point, itís all ready to go and Iím just going to install it and drive the crap out of the car. I can always swap in something better down the road. This was genuinely a bad decision trying and save a few bucks instead of just spending the money on a proper rear diff.
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Old 04-22-2018, 06:14 PM   #46
Hawk296
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Car: 1995 L
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Well, itís done. It took ALL day yesterday but the RA trans is in along with a new rear end. Went over to a buddies garage and he let me use his lift and helped me out. Got it done in a single day with very little snags. And itís now very, very, awesome!




Had some extra bolts and lateral links on hand in case the right side wanted to be as difficult as the left side was this past fall. They were actually easier to remove. Replaced the bolt and links anyway since we were there. Just need to get the proper swaybar to fit with the new links now.



This trip back and forth put 2 more hours on the car. Found a few more issues I have to address. The oil temp gauge works fine while stationary. Once I start moving over the course of about a minute it slowly drops to zero. Then when I stop it slowly comes back up to where I would expect. Wiring checks out so Iíll have to figure that out pressure is good the whole time. Temp probe is in the drain plug in the pan.

Super glad to have this giant hurdle behind me and start really enjoying the car.
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Old 04-24-2018, 08:43 PM   #47
Hawk296
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Car: 1995 L
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Weather was amazing yesterday so I finally got the opportunity to wash this filthy thing.



Took it out for dinner with my wife for some more shake down. The parking lot at Qdoba isnít in the best shape so I was taking it really slow. Encountered some uneven pavement followed by a small scrape noise and then things got really loud.



Stupid parking lot grabbed onto the exhaust clamp bolt and ripped it right off along with the tang it grabs onto! A new one should be here tomorrow or the next day. At least itís a cheap and easy fix!
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Old 05-04-2018, 01:46 PM   #48
Hawk296
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Car: 1995 L
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New exhaust clamp came earlier this week, so that is repaired.

Because the old adjustable swaybar isnít compatible with the new lateral links/endlinks, I went OEM. Pulled off all the aftermarket mounts and bars and links and put new OEM in itís place. Going to go back to a 20mm bar for now for an 02-03 WRX sedan. Maybe Iíll kick it up again in a year or so if I redo the struts/springs but itís nice to have new stuff on there. I am surprised I got the swaybar mount bolts out of the chassis without catastrophe!





Now I can focus on cleaning stuff up and prepare to swap to the Link G4+ and start the tuning process (still trying to find someone local to do it for me).
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Old 05-07-2018, 08:00 AM   #49
Flat4awd
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Nice updates, I'd like to see another proper photoshoot like you did on the first post. I had that image of it on the snow as my background for a while.
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Old 05-07-2018, 08:18 AM   #50
Stew3223
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Looking Good man!
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