Taza's Foz 2.0

Well I thought I better start again as it's like a new car since the last journal (here: https://www.offroadsubarus.com/showthread.php?t=2887 - RB).
Modifications have been severe! :lildevil: Damage has been extreme :surprised: Repairs have been expensive and tiresome :cry: After all she and I have been through over the past 3 years and 100+k km. You could say it's really been an adventure :lol: With many more to come :cool:

Stock in June 2010
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Now as of September 2013
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Mods

Suspension
  • KYB front SF shocks/struts
  • KYB rear SG(04 Forester N/A) shocks/struts
  • Heavy duty raised dobinson springs all round
  • GC8 WRX STIheavy duty rear swaybar(19mm)
  • Whiteline rear swaybar endlinks
  • Audi A3 light weight 15" cast alloy wheels(+38 offset, 5kg each)
  • Impreza 15" alloy wheels
  • 65mm rear strut top lift blocks(made by Stilson)
  • 50mm front strut top lift blocks
  • 50mm rear trailing arm spacers

Engine/Drivetrain
  • Fully reconditioned SF Forester gearbox(170,000km on foz from All Drive Subaroo in eastern states)
  • Fully reconditioned EJ25 N/A SOHC block from 2003 Outback
  • Custom made front CV shafts with lifted Toyota Hilux CV boots, heavy duty inner joints(cup, balls, grease, etc...)
  • 2004 Forester VLSD rear diff
  • Grimmspeed lightweight crank pulley
  • Grimmspeed Phenolic manifold spacer
  • Haltech Platinum Interceptor Piggyback ECU(wired in by myself - apprentice auto sparky) - Manages fuel and ignition timing for the new engine.

Interior
  • 2000watt worth of Stereo - Sony headdeck(wth bluetooth, USB, Auxilary), 2x amplifers, Pioneer 12" Sub, Alpine S-Type 6 1/2" speakers
  • Dynamat sounder deadener
  • Clarkrubber 10mm sound proofing(boot, tailgate, under passenger seat, rear doors
  • Repco plain black seat covers
  • Supercheap bucket heavy duty rubber mats, front and rear
  • Led interior light conversion
  • Tint-A-Car Octane 35% on front two windows(drivers and passengers), 20% from B-Pillar back - Darkest legal all round
  • Momo WRX steering wheel
  • Genuine Dash mat
  • 12v auxilary sockets in glovebox
  • Uniden UHF radio 80channel(mounted where ash tray goes)
  • Hard wired android Samsung phone charger on drivers side A-Pillar

Exterior
  • TJM bullbar(to Suit SF Forester - airbag compliant)
  • Subaru genuine reece-hitch towbar 40x40mm - rated at 1300kg
  • Rhino sportz roof racks
  • Lightforce 170's
  • Dual battery setup in boot with Redarc smart solenoid under bonnet(100amp alternator)
  • Subaxtreme sumpguard
  • Resprayed bonnet(faded)
  • 225/70R15 Dunlop Grandtrek AT3's(soon to change to Toyo Open Countrys's)
  • Uniden 7db aerial
  • ARB 2m side awning(stolen one night :()

Future Mods
  • Gearbox done - L-Series 1.59 low range, front STI 5 speed helical LSD, DCCD centre, taller 5th gear, shorter 1st gear, oil drip feed
  • Dyno tune for piggyback computer running EJ25
  • Subaxtreme rear bar
  • HID kit for Lightforce 170's
  • GCD(2004) WRX dash swap(SF dash looks very old fashion and makes car feel old and sad) - This is a major!
  • Safari Snorkel (NK Pajero)
  • Rear mounted winch
  • LED lightbar
  • 2 1/4" exhuast from catback with high flow cat and UEL headers for that awesome boxer rummble :cool:
  • OBDII Computer conversion/upgrade to replace stock ECU and piggyback computer

Damage
  • Ripping front end of chassis off(tow point LHS)
  • Blown gearbox(chattered first gear)
  • Blown rear diff(stripped teeth off spider gears)
  • Snapped CV axle shafts
  • Dented drivers door due to a sand dune
  • Oil rings gone in Engine 1 (EJ20 N/A)
  • Oil rings gone in Engine 2(EJ20 N/A)
  • Snapped timing belt in Engine 2
  • Bent steel rim(15" stock LHF)
  • Bent rear struts
  • Snapped Dobinson heavy duty coil spring(2x on different occasions 6 months apart)
  • Broken spot lights(due to ramming a fence down)
  • Stereo amplifer catching fire(evening peak hour traffic)
  • CV boot ripping
  • Split radiator (while offroad, had to get towed home)
  • Clutch burnt out x2
  • Bent towbar
  • Ripped off front and rear bumpers
  • Ripped off trailer plug
  • Ripped off passenger side skirting
 
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^ I'm not keen on the obscenity of any kind of planned obsolescence, specially not of the compulsory kind ...

From my Batphone
 
crazydave said:
Good to hear it is all back together and working well - without major head damage.
What is the story with the trust bearing? Didn't you replace that when you did the motor/ clutch - it is a bit hard to keep up of what bits you have replaced and when. And 20k seems very early for a thrust bearing. I ask because my original thrust bearing seized solid :surprised: a couple of weeks ago with only 150k km on it. The 2nd question why use Exedy v OEM?
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Thanks mate, No I originally replaced my clutch at 145,000km when the car was stock as it was slipping. The bearing was done then and has remained the same one until I pulled the motor a week ago. When I changed to my 2.5l motor from 2.0l at 204,000km I only changed the clutch disk as it was worn right down. Having to ride it through sand due to the gutless 2.0l engine. The pressure plate, flywheel, thrust and spigot bearings were all fine.

I rechecked the clutch when I pulled it a week ago at 222,000km. All looks good, however the thrust bearing left clunky not smooth and was noisey.

Exedy is far superior to OEM as it comes in heavy duty form and is more suitable to offroad dusty and dirty conditions.

catchya said:
Kudos also for using Head Torque...Now that's customer service:quitar:
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Yep, I've been to other places around Perth but have never had experience like that. Was recommended to them by a mechanic mate and will use them again in the future.

I also find the 2.5 NA quite thirsty as well back in the day when I had the my04 liberty and from what I hear it is still the most common complaint. With the 2.5XT, I avg 1 litre / 10ks on e100 with my driving style to give you some comparison.
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I average 10.5l per 100km most of the time, sometimes better on the highway and generally worse offroad.
For the power of the engine I find it thirsty, especially if you compare it to a turbo equivalent engine. However it provides adequate, pokey performance and unbelievable torque offroad for such a small motor.
Next engine, if I don't upgrade the car will be a turbo engine. Probably EJ255 from an XT Foz.

Got to have a chat with you soon about your gearbox / diff upgrade. At the moment I can't get my head around all the possibilities of what fits and what doesn't. :raz:
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No worries, took me about a year to get my head around it all and work out exactly what I want. What suits my needs and will work well behind my engine.
Having stripped down a few boxes it's given me a huge insight to how it all kinda works.
 
Its a shame its cost you under $1k, but at least now you've got the good bits in there. Driven sensibly you should have many reliable years :biggrin:
 
Glad it's all sorted mate - now LOOK AFTER IT!!!

I know you did it in a short amount of time, but I reckon you still could've got a few items cheaper than what you've mentioned. I've replaced my O2 sensor but don't remember it costing $200! Little things like that can make a difference.

And in saying it cost you just under a grand you've done more than just a general head gasket swap - you've got a cam belt and other new bits in there too. Take these out and you're closer to being on par with what I paid to do my HGs over summer - except I didn't have the heads checked, I did this myself and was satisfied with what I saw.

Cheers

Bennie
 
Will do mate! Learnt the hard way, now with the EJ25 I don't have to rev the ring out of it to get it going :)
O2 sensors for N/A SF's are some of the most expensive for some odd reason. I'd rather spend then extra few $$ and get the heads pressure & vacuum tested and skimmed. I don't plan on doing them again on this motor.

Got a rear strut brace for the foz, yet to put it in. Should help when combine with my current Whiteline 22mm rear swaybar, front Cusco swaybar and HD springs.

Did a good deal and scored some Maxxis Trepador muddies for the foz too... wonder how they will perform in the sand.??
 
taza said:
Did a good deal and scored some Maxxis Trepador muddies for the foz too... wonder how they will perform in the sand.??
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I've always been told muddies aren't so good for sand as they tend to dig holes. Road tyres or tyres with a slightly aggressive tread that bag out well are the best for sand.

With your Trepadors you'll have to go find some decent mud :lildevil:
 
Sourced an 05 SG gearbox for a good price, minus the centre diff.

Going to fit that with the standard 4.11 diff ratio, 6 speed sti front torsion lsd, All Drive Subaroo's 1.61 low range and a 20kg centre diff.
not going over board with the box as I plan to uograde the car in 2 years time. For now this should do the job :P
 
Taza, you might be waiting awhile for Alldrive's custom 1.61 low range gearset as it is not in stock until the end of August. I got the feeling that it may be longer.

The 20kg centre diff on road behaviours for everyday driving might get the better of you and most probably make the car harder to sell when the time comes. For offroad applications it will shine
 
Well I got it so may aswell try it out. If its too harsh ill swap it out for something else. I have a few spare 4kg's but ill see when/ if the time comes.
Its a 2hour job to change the centre diff and the gearbox doesn't have to come out so that's a bonus.

Im in no rush for the low range as it'll all get done once I'm back from Hawaii in September... otherwise I have a spare 1.47 low range which ill use but I'd rather 1.61 while the box is a part.
 
taza said:
Going to fit that with the standard 4.11 diff ratio, 6 speed sti front torsion lsd, All Drive Subaroo's 1.61 low range and a 20kg centre diff.
not going over board with the box as I plan to uograde the car in 2 years time. For now this should do the job :P
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Let me know if you're getting this as I want to arrange a group buy. There will be 2 LRs available, a HD for ~$1300 & a lighter duty for less. They will know more about prices when they get their shipment & he was keen to negotiate on a group buy :biggrin:
 
Good to hear NL. Looks as if we could have 3-4+ people keen on a group buy.
Id definitely go for the heavy duty option as I may see this box going behind a turbo in a few years time.

Catchya and myself are keen.
 
Hey Taza,

Where did you get your CV shafts? The ones I got cause vibrations, just after a reputable source. Looking at using ones from Outer Control in Myaree.
 
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Our usual mechanic, Ross Hallett, has used re-co shafts on both our Impreza and Camry in the past. The price was good - less than $250 a shaft, fitted; and there were never any problems of any description with them.

His comments were along the lines of: "We can't even remove, strip, clean, re-assemble and refit one joint with a new boot for the price of a complete re-co shaft that is done in a factory that specialises in them, fits over-size balls and cages if required, re-machines the grooves, etc". He makes a valid point IMO.

It's a lot cheaper if one is stripping, cleaning and re-greasing one joint and putting a new boot on it for yourself. This is OK if you notice a torn boot before the grooves in the inner and outer races or the cage are damaged.

Mostly, the first indication we have that the boot has been damaged is when we hear the fateful clicking noise on turning. By then it's too late to do this - at this stage one or all of the inner and outer races and ball cage have been damaged, so it's a waste of time and effort to try to clean and re-grease the joint.
 
Planning for the major overhall later this year... organised DCCD for my gearbox build to replace the 20kg centre I was planning to install.
Bought a heap of bushes for my tied suspension... diff, control arm, lateral arm, swaybars, etc..

Sourced a light weight flywheel whicj will be matched to an exedy suited ej25 single mass heavy duty kit.

When I'm bavk from overseas I'll stripp both my SF and SG wiring so I can semd it off to AM autos for the splicing.

Starting to get excited now!
 
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