95 eagle talon tsi awd swap started!

[2slow4now]

Robbed awd parts clean up

I recently got a donor car and started the tear down and part clean up. So far I have the subframe, new OEM lsd diff, knuckles, driveshaft with a new OEM Ujoint (gonna go with the 3.5" DSS 2 piece design), hubs, Ebrake assemblies, aluminum poly filled dif bushings, energy suspension bushings (although I'm still looking for some for the rear control arms), sway bar, sway links, and some tubular upper and lower control arms off a 2001 galant (They are ready to be sand blasted and painted). The fuel tank is still on the donor so I've got some rolling around on the floor to do yet.

The AWD's former home.

The AWD's future home!

 

[gofer]

That's great, can't wait to see another GS-T spinning all four wheels.

 

[2slow4now]

Got my Shep tranny in and rebuilt my axles.

Some DSS sweetness!

These are some mounts I made for the front bolt location to make it more rigid but I still need to do some tweeking to get the FWD bolt to sit at the same height the AWD bolt would.

 

[buhay6]

nice man! I got a question for ya though, where you buy the axle rebuild kits/ parts?

 

[2slow4now]

The actual CV joints are used but all the boots are new. I stole some parts from some FWD axles I had.

 

[2slow4now]

I welded in my front location bolt mounts that use the fwd bolt that give some structural support and keep the fwd bolt at the same length as the awd bolt.

The subframe is in its new home! Looks like it was supposed to be there.

Shep rebuilt my Tcase and there she sits all sexy waiting for some action.

I cut out my second sending unit access panel and put some stock plastic anchors.

She's on here way! Now if work will stop calling me in. I worked 12 all last night with no sleep then today they called after I slept for about 3 hours and want me to work tomorrow. So much for vacation.

 

[DSM's 4 life]

looks good subed.

 

[2slow4now]

I got a few more baby steps in today.

The gas tank, cover, diff, rear driveshaft carrier bearing mount, carrier bearing, and rear driveshaft installed! I thought about putting on the DSS driveshaft on just to look at it. Calm down just a step at a time

 

['99GST]

Nice build! Cant wait to see the finished product

 

[2slow4now]

Thanks. I'm getting excited!

I got the suspension put back in the rear last night.

 

[2slow4now]

Its been awhile since I posted anything. Between work and the girl friend the crap rocket hasn't gotten much attention. Just little stuff here and there but nothing worth posting. I even got a text from her saying "Thanks for taking the time to go to the lake with me instead of working on the bi***."

Since I had the engine out I went ahead and did some refresh and O-ringed the block.

 

[2slow4now]

Finally got some more time to give her some attention.

Time for the power to dangle up in the air and nestle down in her home were she's supposed to be.

 

[simons3z]

great progress, looks clean as all hell.

 

[2slow4now]

I'm at a stand still. I have most everything wrapped up and this weekend I was putting the drive shaft in and "clunk". HHMm the yoke hits the Tcase and the rear of it isn't even close to slipping in. I never looked at the box when it came in but looks like I got a 1g drive shaft. I guess that serves me right for opening part boxes like a 10 yr old on Christmas morning knowing the whole time the Ipod is just waiting inside.

Sheps team has been real champs looking for a 2g shaft in stock for me and has helped arrange getting it shipped back to DSS to be shortened. good guys there.

BTW Thanks Twicks for grabbing up the last 3.5" hd DSS 2g shaft in the entire country! Just eat up all the desert and leave none for anyone else.

The stall has given me some time to mess with the stereo and subs.

 

[92AWDHX40]

Looks good.

 

[2slow4now]

Thanks.

I just got off the phone with Drive shaft shop and my drive shaft is on it's way! I may have her running again tomorrow! WWWHHHHHOOOOOOO!

 

[2slow4now]

I just took her for her first drive officially as an awd!
I have some minor things to work on. A few minor leaks, install the calan catch can (I've got my test crap can on now), Snow performance meth injection, and some tuning. She idles and drives down the road good.

Oh yeah i need to clean my garage up too. Hey look there's that wrench. I was wondering if the car ate it.

The test drive was without the hood. I kind of like how it looks without it. It's like looking down a gals blouse and seein the goods! "Thank you very much honey!"

 

[GoRiceGo]

that looks great i cant wait to conver me!

 

[2slow4now]

The hardest part is getting all the parts together. Some cutting, welding, and swapping things out. Well there is the waiting to get it done with nothing fun to drive. Buy another car first then swap.

 

[2slow4now]

Man oh man I have not updated this in a long time. I've got a list of stuff I need to get posted up. Well here is a start at least. Heck probably just need to change the title too!

I made the ole girl some evo sized center caps that have the Eagle emblem.

 

[2slow4now]

Not long after getting the first couple of drives in with the awd my PTE took a dump.

The thrust washer cracked and allowed the blades to contact the housing. Could hear it "dinging" like a wind chime.

Talked with justin and went with a Holset.

Polished the snail up.

Pretty!

 

[NWHTanK]

Nice job indeed!

 

[2slow4now]

Thanks.
Since the old girl was down I did what I always do.......... Delay the project by tearing into other need/want to do projects. Doing the "well since I have this apart"........

Took the headliner out because it was sagging. Went ahead and did a color change to a dark gray that matches fairly well with the rest of the interior. Yeah nothing fancy just boring old grey.

I always thought how all manufacturers just cut the cloth and leave that edge exposed was pretty lazy and just asking for it to get pulled down by the wind. Especially since my A/C will depend on speed I wanted to do something that would hold it up well. I got some heavy thread for upholstery and sewed the front edge to the liner so it will never be pulled down again. Trust glue? Nope. You can see some of the thread in the pic right up against the windshield but you can't see it when sitting in the car or when looking in from the outside.

 

[952g63t]

Its been awhile since I posted anything. Between work and the girl friend the crap rocket hasn't gotten much attention. Just little stuff here and there but nothing worth posting. I even got a text from her saying "Thanks for taking the time to go to the lake with me instead of working on the bi***."

Since I had the engine out I went ahead and did some refresh and O-ringed the block. View attachment 141853

That's exactly how my wife refers to my DSM!

 

[2slow4now]

Yeah she does like it but sometimes I spend quite a bit of time wrenchin especially when I'm getting close to getting something done or when I haven't messed with it for awhile. That's when she doesn't like it.

Well to play catch up on posts. I had gotten an ERL manifold because the other one didn't have enough clearance to the block for the new turbo.


HHmm plain rough cast.....leave it as is?

Well lets just pretty it up some. Hours later and yep this was one of those "I'm in the garage doing something."