montana tom

This job looks horrendous, but it is not that bad. I have done three of them; here are many pictures, but not much write up on the process. https://permies.com/t/197844/Black-Car Like most jobs, getting started can be the hardest part.

You are not giving us any information. I assume your having trouble filling the tank? If so, your Evap system has issues and must be evaluated. What codes is it throwing?

The heads must be 251's, be sure to use MLS factory turbo head gaskets. The PCV arrangement may need to be modified. Pistons should be ok although new rings and cleaning the drain back holes in the pistons is always a good idea.

I suspect the driveline as well. Best to disconnect it at the rear end and see how smooth the joints feel. CV 's can give a vibration on acceleration. Tire ballance is always worth checking. Enjoy your new outback, I consider the second generation to be the best ones made.

Rear driveline, usually at the u-joint directly behind the transmission. CV axels can do this as well.

Yes it will

Don't buy a cheap one or you'll be relacing it again soon. O.E. or denso

Yes it is.

I suspect the flywheel.

2004 cars issued to California had round port heads and drive by wire throttle. 2004 cars sold to the rest of the country are the same as 2003.

Down at the transmission shop getting a rebuilt tranny. In the case of the delay in drive engagement on late 90's and 2000 transmission's. Trans X works perfectly to temporarily fix slow engagement. Be sure to change fluid to synthetic and replace the factory filter .

Hi Bass; In Spokane try Hopkins automotive Address: 3018 N Nevada St, Spokane, WA 99207 Very good independent Subaru shop. (509) 483-3943

Under normal conditions that sprocket should slide off without a puller. As you already broke a tooth just use a screwdriver to move it off the crankshaft.

I agree, check the IAC valve. It is different between automatics and 5 speeds. For your 5 speed I would remove it and carefully clean inside with a q-tip and alcohol. I've had about a 50% success with that. New ones are not cheap.

Thanks Imdew! Same to you and yours!