xman

Make sure everything is clean, spray it down with brake cleaner. Then bed them in well. Here is a good bedding in process from StopTech. http://www.stoptech.com/tech_info/wp_bedinstock.shtml dissimilar material from the old pads embedded in the rotor can cause this kind of issue. I *assume* that you did not install new rotors, turn the rotors or scuff off the old pad material when you did the brakes?

Got the 5 speed d/r mated to the engine in the brat, some details left to button up on the driveline, axles, driveshaft, starter, shifter trim etc. Then need to turn my attention back to the carb rebuild to get it running. Steady progress

ast night I worked on the Brat. Installed 2 new front axles installed new crossmember and mounts to 5 speed dual range (thanks Jerry!!) installed clutch and pressure plate to flywheel looked at throw out bearing from 4 speed that is too small for 5 speed, went to PepBoys and was told they don't carry any TOBs retired early to finish the driveline reassembly another night.

Auto or manual? Many transmissions will "fit" depending on how much work you want to do. I am in the process of fitting a 5 speed dual range transmission into my '86 Brat. It required a new "kit" from Jerry (Bratsrus) a lengthened driveshaft and different clutch. I believe an EJ series transmission would require even more. How much work are you willing to put into it?

Just take off the timing belt and leave everything else as it is. No need to disassemble further. For the bolts use a 12 point metric socket that fits (I don't recall the size off hand), works perfectly.

awesome, thanks man.

Can someone please indulge me with a photo of the OEM frame and mounts? Mine is an '86 that did not come with the seats and I am trying to fab up a frame to put them in. A picture would make it a lot easier to get right on the first try. Google has not been fantastically helpful as this is a rather obscure request. Bonus points for seatbelt and head rest mounting also!! Thanks guys.

I wish I could help you, but I am interested in the same thing. If I don't come across an affordable OEM mount, I will design and fabricate one myself and share my results. Being easily removable is also important to me. That part of my project is still a few months down the road however.

Seals can be hard to get in, even the OEM ones. Patience and lining them up perfectly is required. I've mashed a couple myself. They are cheap, so I typically buy extras for such an occassion. That's not saying you got a size that was too large, but more than likely he is just not being patient enough.

It could also be the catalyst inside the cat converter. On my rally car the cat sometimes breaks loose from rock impacts and rattles like crazy inside the housing. Just happened to my 04 STi recce/ daily driver car also. Rattle goes away with rpms above idle. Something else to think about if you are SURE it's not a heat shield.

Right, EA81. It's more than "some" coolant. Turn the engine over and at least 2 tablespoons of coolant came out of the exhaust port. I did a compression test when it was running well and it came out pretty good, ~135psi for that cylinder.

My Gen 2 Brat is sitting with the exhaust manifold off while i am doing a 5 speed swap into it. While I was removing the clutch pressure plate the crank shaft turned and some coolant came out of the #2 exhaust port. I can see exactly where it came out. Since the engine has been sitting, is this likely a seeping gasket leak (headgasket or other)? I am doing things "properly" with this car, so should I do a full gasket set, a full gasket set AND a new head or just toss the EA82 for another that doesn't have any issues? Thanks

Ensure good grounds and proper coolant. I think this is pretty far down on my list of things to worry about, but I am glad someone is aware of it. In all my years of being around Subaru's this is the first time I have heard mention of it.

Think I found what I needed, on an atuozone website no less. Last place I would have looked. http://www.autozone.com/autozone/repairguides/Subaru-ff-1-1300-1400-1600-1800-Brat-1970-1984-Repair-Guide/Carbureted-Fuel-System/Carburetor/_/P-0900c15280065ae8

I tried searching this here and on google, not much luck at all. I'm working to get the float set properly on my hitachi EA81 carb. I've done the trial and error method with little success. I am really good at disassembling the top fo the carb and would rather set it one last time and be done with it. That being said, does anyone have the spec dimension for the float level? I tried 11mm which is the only spec I could find that was for an SVX. Probably not right since it stumbled and ran rich. I know the sight glass should help me, but I can't see the fuel through it, any tricks there? Thanks to anyone who can help me, if I get this set properly it will pass CA smog test

I got mine at Rock Auto.com $2.50 for the cap, $1something for the rotor and $3.59 for the wires. Some of the items were on closeout, but the regular prices are incredibly cheap for this stuff.

I never use anything on the head gaskets. Using a good quality gasket is all you should need as long as the heads and block are flat. I tend to go aftermarket, but I also build for rally or turbo applications, that might be overkill for you. As for the other bits & pieces, just follow the service manual suggestions. If you can't find a service manual for that engine you can use one for the turbo engine, the differences would be in torques and such, not in sealing materials. If you don't have a manual to give you the torque specs and sequences, you will need to get them, they are quite important to success. Keep a clean work area and take your time. It's not that hard and is very satisfied when it's a job well done.

Move to SoCal, visit the snow when you want, live with the beaches and bikinis every day

Hi welcome, sounds like a cool project.

Welcome, lots of Subie lovers here, I loves 'em all, old school and the new stuff, well not too new, the hatch back imprezas are fugly. Happy to be here myself.

Yep, 10 posts and you are ready to go. This post gets me closer too.

Very good stuff here, I am looking to do a 5-speed DR into my Gen2 brat. Please forgive my noobness, but how can I contact Jerry to buy one of his kits? sorry for the thread hijack brysawn, your project seems to be coming along, keep up the good work.

Yeah, I think I will really like it as a daily driver once I get it sorted out, and it is much more suited to recce than a lowered STi Plus it will be just damn cool to have it out at rallys.

thanks for posting Aaron!

Hi all, I picked up a very solid Gen 2 Brat to serve as my rally recce car and as a daily driver instead of my 04 STi. Know there is tons of info here to help me get the Brat back in tip top condition. Just wanted to say hi and note that I need to get my PMs working. Thanks in advance for the assistance on my project. Kevin