Custom CVs for ej/my conversion

TW83 · Post by **TW83** » Sun Jun 25, 2006 6:27 pm

Hi

Currently undergoing an ej22 conversion to my MY touring wagon.
We are installing an ej AWD 5 speed manual but having trouble with the front drive shafts. Read other posts the state custom inner CV's are needed by using my bearings in ej cups. Can't see how this can work as the my inner bearings are too large to fit the ej cup.

Any help appreciated, thanks.

tim_81coupe · Post by **tim_81coupe** » Sun Jun 25, 2006 7:27 pm

MY 4WD inner bearings will not fit. You need 2WD inner bearings, and unfortunately you need the 2WD axles as well.

There might be another way though, perhaps the MPFI L series 25 spline inner joints can be installed onto 4WD MY shafts? Only way I've done it myself is on 2WD shafts though.

legacytt · Post by **legacytt** » Sun Jun 25, 2006 8:44 pm

Just another thought here, I know you can swap the smaller L series output shafts into the EJ box. If the MY ones are the same setup they should also go in. Means you need to split both boxes but isn't a hard job and you can retain the joints you have now.

BaronVonChickenPants · Post by **BaronVonChickenPants** » Sun Jun 25, 2006 9:11 pm

Running with that idea it doesn't matter, the small L output shafts are the same as MY ones, if you know L ones work go with them.

Jordan.

TW83 · Post by **TW83** » Sun Jun 25, 2006 10:09 pm

damn, didn't see that one coming. Will try to swap the output shafts as sourcing the FWD shafts will most likely delay the project too long.
Thanks for the help.

tim_81coupe · Post by **tim_81coupe** » Mon Jun 26, 2006 12:40 am

Actually I wouldn't mind learning a bit more about swapping the output shafts, my EJ16 project would be much better off running stock CV joints in my opinion..

LegacyTT, have you done this swap? Is it applicable only to AWD EJ boxes? I take it the EJ carrier bearings stay in place, do you take the stub housing caps across?

legacytt · Post by **legacytt** » Mon Jun 26, 2006 9:12 pm

I have put Lib stubs into an L series box so I could use Lib driveshafts, so there is no reason why you can't go the other way. No need to change bearings or seals as you just remove the stub from the diff. It is held in by a circlip and slides in on splines. Similar to rear diffs but instead of the internal bolt holding it there it has the circlip. Unfortunately it isn't a spring clip so you need to split the box and take the diff out to get at them. From memory I needed needle nosed circlip pliers, the ones that expand when you compress the handle.

I also thought this would be an easier option with this MY coupe I am about to put an EJ in, at least untill I go the full Lib hub conversion.

It should work on both AWD and FWD boxes as the setup is the same.

TW83 · Post by **TW83** » Tue Jun 27, 2006 5:37 pm

Christ, splitting the ea81 box is no fun. Just found an old post so will have another crack, literally. Hope the ej isnt as bad.

TW83 · Post by **TW83** » Tue Jun 27, 2006 7:37 pm

Finally retrieved the output shafts, ended up pulling the casing apart with a tree, chains and a landcruiser. A sledge hammer assisted.
After destroying the box we found a pin at the top and back of the inspection cover when the cover is removed. I think if we had pulled it out with pliers it would have released the extension housing. Info on gearbox splitting in previous topics didnt seem applicable to our box.
Some additional info on the driveshaft configuration in the initial post on ej conversions by Baron would be very helpful as sourcing hybrid CVs not easy.

tim_81coupe · Post by **tim_81coupe** » Tue Jun 27, 2006 7:45 pm

The EJ conversion sticky was written by me. It's an overview of the conversion - not a guide. I did say that the inner CV cups are 'custom', and for brevity I didn't go any further into it. Basically it was made to answer most questions people had about the conversion before they got into it.

I am working on a longer explanation, although with the various facets of the conversion and many variants of engines, drivetrains and vehicles it will be a long read. Being such a convoluted topic too, it doesn't easily lend itself to be explained in a forum format.

For now, keep asking questions and we'll keep answering

.

legacytt · Post by **legacytt** » Tue Jun 27, 2006 8:04 pm

The EJ box is the easiest of them to pull apart as you just need to take off the inspection plate, loosen the reverse spring bolt(10mm) which allows the shifter to be released from the selectors. The extension then comes straight off once the bolts are removed.

TW83 · Post by **TW83** » Tue Jun 27, 2006 9:11 pm

I gathered thats what the article was for, just that i couldn't find many related posts and thought everyone would be sick of answering conversion questions again and again. Thanks for the help you guys have been giving me, definitely been the most useful ive come across.

Ps. Tim, the tip you gave about using the Liberty double jointed steering link was spot on, found one yesterday for free and it fitted perfectly.

steptoe · Post by **steptoe** » Wed Jun 28, 2006 10:23 am

WATCH THIS SPACE

for "Tims how to EJ anything subaru tips"

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downloadable version only available thru PayPal

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Gosh , I am chuckling hard here when reading, I wish I had chains and a landcruiser when pulling apart an EA81 4sp d/r 4WD box. I was under the tree though, it did not help.

It has got me how you are supposed to undo the big nut 22 or so mm when an appropriate socket does not fit thru the not round hole above it.

I ended up getting at it with a jigsaw, and I think I bent the casing with the blockbuster, the scrap metal man did not mind , $23.
I NEVER WANT TO HAVE TO REPAIR THE EA81 BOXES, EVER !!

legacytt · Post by **legacytt** » Thu Jun 29, 2006 9:34 am

I think you missed something fundamental as they are very easy to pull apart. Don't know what 22mm nut you are talking about, unless it is the one on the end of the gearset. Either way if that was what you had to take off to get it apart you were barking up the wrong tree. Maybe the one you were sitting under. LOL.

TW83 · Post by **TW83** » Thu Jun 29, 2006 5:54 pm

Swapping the output shafts doesnt seem like it will work as the liberty shafts still have a 25 splines where it inserts into diff, while the my's are still the smaller 23. Any ideas? Is swapping gears etc also nescesary?

tim_81coupe · Post by **tim_81coupe** » Thu Jun 29, 2006 6:55 pm

The output shafts are the ones sticking out the side of the diff. Swapping them with L series ones would mean you would have 23 spline stubs on the gearbox...

TW83 · Post by **TW83** » Thu Jun 29, 2006 7:11 pm

So they connect the inner CV to the diff, got that. Are you saying that the L series output shafts will fit but the my's won't. I am guessing that means the l series have 25 splines and a larger diameter inside the gearbox but a smaller diameter with 23 splines where it connects to the CV.

TW83 · Post by **TW83** » Thu Jun 29, 2006 8:43 pm

Going to put the ej box back together and bolt the engine and gearbox in so i can continue the rest of the conversion . In the mean time I'll have to call around the wreckers in Perth to try and find some genuine 2wd driveshatfts, another option is getting some custom axles made up with 25 splines on one end for ej inner CVs and 23 splines the other for my outer CVs. Might be pricey

tim_81coupe · Post by **tim_81coupe** » Thu Jun 29, 2006 9:01 pm

I'll have a look in my garage and figure out if I've got any spare 2WD axles for you too....

legacytt · Post by **legacytt** » Fri Jun 30, 2006 9:23 am

You should be able to get L series output shafts easily enough. You are right, they are larger where they go into the diff then scale down for the CV cup. Just make sure you get L series NA ones as the Turbo ones are the same as the EJ ones.

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