What do I need for manual conversion (4LO transfer case) for my '92?

[DrieStone]

I might have the opportunity to pick what I want off a salvage 80s GL with manual/low range. I currently have a '92 Loyale auto. If I'm going to go through the trouble of a manual swap, I'll probably just do an EJ swap at the same time (but that's for another day). For now, I want to try to grab everything I may need off the GL. I probably won't even get to the actual swap for a year or more, but I'd hate to not grab something that I need.

I'm going to need:

• Master cylinder/clutch pedal
• Brake pedal (or can I cut the auto pedal down to fit?)
• Transmission
• Driveshaft (I assume)
• Rear Diff (not sure if the gearing is different, and maybe the diff on the donor is limited slip?)
• Interior trim/knob(s)

Can I continue to run my existing hubs and half-shafts?

If I don't care about the gauges, do I need to bother?

[el_freddo]

Flywheel and clutch pressure plate! Starter motor too.

Grab the pedal box with the brake pedal, clutch pedal and clutch cable. 

The instrument cluster could be a good idea for the correct lights when in 4wd etc. 

Gearbox cross member. 

Rear diff for sure. Unlikely to be an LSD, but you never know... more likely if from a turbo.

Grab the cv shafts front and rear for spares. Fronts will be different (and required) if factory turbo.

Centre console, 4wd lever etc. 

If it has rear discs grab them as well. 

That about it I think. Your list was pretty good. 

Cheers 

Bennie

[Numbchux]

ASSuming your donor is a non-turbo EA82, and your Loyale is already 4WD. If it's turbo, it won't be D/R unless it's an RX, which is it's own can of worms.

Trans and crossmember, starter, flywheel (you'll need a clutch kit, too, but get a new one), flywheel bolts.

Pedal box, clutch cable, shift linkage, center console (the GL has a much nicer center console, but it won't have space for the automatic shoulder belt retractors in the Loyale, I don't remember how that all works out, I think I'd already chucked the auto belts by the time I did the center console.

At least the front half of the driveshaft

Probably rear diff (EA82 D/R will use a 3.9, IIRC the 3AT uses a 3.7). 

 

The only way a non-turbo EA82 would have a rear LSD, is if it's been swapped in it.

 

Don't need the cluster, in fact, it's a pain to swap it, as the wiring is completely different.

Don't need the master cylinder unless you plan to retrofit the hill holder, and even still, you can just plug one of the ports on the master.

[DrieStone]

Thanks, good to know I'll need the flywheel (and starter). I figured I'd grab the rear diff either way since I kinda figured a different gearing. Good to hear that the cluster is a pain as well (I mean, not good, but goes along with my plan not to do anything with it). I didn't realize the clutch was cable activated, so I'll keep the eye out there.
 

I just wanted to make sure that I didn't have to screw around with axle shafts or hubs.

 

Thanks for the help!

[idosubaru]

 

23 hours ago, DrieStone said:

salvage 80s GL with manual/low range. 

An 80s GL can be EA81 or EA82, which is it?

Turbo or nonturbo?

Your loyal is 4WD right?

clutch is cable so there’s no cylinder to mess with. Cable is more reliable and less maintenance work anyway. Hydraulic clutches are a complete waste of my time for no gain. 

If the donor is an EA82 nonturbo your loyale axles slide right onto the trans. No axles or hubs needed.

all EA82 rear axles are interchangeable.

although if any of the axles are original Subaru with green cups they’d be worth saving.

[DrieStone]

51 minutes ago, idosubaru said:

 

An 80s GL can be EA81 or EA82, which is it?

Turbo or nonturbo?

Your loyal is 4WD right?

clutch is cable so there’s no cylinder to mess with. Cable is more reliable and less maintenance work anyway. Hydraulic clutches are a complete waste of my time for no gain. 

If the donor is an EA82 nonturbo your loyale axles slide right onto the trans. No axles or hubs needed.

all EA82 rear axles are interchangeable.

although if any of the axles are original Subaru with green cups they’d be worth saving.

I think it's a non-turbo (I think the turbo should say turbo on the intake right, and the gauge cluster looks the same as my '92). My Loyale is push button 4WD. I don't know much about the donor. I have a pic of the engine, but I don't know how to identify an EA81 vs EA82. My guess is that it might be an EA81, because I don't see a timing belt cover.

Are there non-interchangeable parts that I may have to worry about if it's an EA81?

[DrieStone]

On second thought, maybe it is an EA82. Looks like the EA81 cars had the battery on the passenger side? I don't think the EA81 came on the third gen Leone. So if the GL looks like the Loyale (it does), then it should be an EA82.

Edited December 11, 2020 by DrieStone

[Ionstorm66]

52 minutes ago, DrieStone said:

On second thought, maybe it is an EA82. Looks like the EA81 cars had the battery on the passenger side? I don't think the EA81 came on the third gen Leone. So if the GL looks like the Loyale (it does), then it should be an EA82.

That is a EA82

[el_freddo]

14 hours ago, Numbchux said:

Probably rear diff (EA82 D/R will use a 3.9, IIRC the 3AT uses a 3.7). 

Opposite applies for the Series 2 (‘87 was the crossover year). The series 1 had 3.9 ratio for the manual trans. I’m not 100% sure if this was across all manuals or just in the touring wagon (raised roof/roof bump model). 

That is definitely an EA82. 

Cheers 

Bennie

[Numbchux]

Yep, EA82. EA81s have the disty on the front. EA81 would be 4 speed, very different trans.

 

Being that it's carbed means I think it has to be '85-early '87, which likely means narrow trans tunnel, so the trans crossmember might not fit. But everything else should be good.