Front diff failure/4.44 sanity check
 

So after noticing the dreaded 'baseball card in the spokes' sound from my 92 AWD the other day I dropped it off at the local Subaru specialist for verification that the front diff was the culprit. Not surprisingly it is.

So now I'm looking at options and would like some feedback here. My transmission, minus some minor slippage when cold, is in good shape.

Should I just have the diff replaced and call it a day?

The tech at the shop mentioned upgrading to a diff/trans from late 90s model outback. After looking around here I'm guessing that would be what equates to the 4.44 swap. Am I correct in that assumption? If that's the case can someone tell me what all is involved in that swap so I can have a sanity check on what they tell me? Does that include the entire front trans/diff assembly and the rear diff? Just a portion of that, or all that plus something more?

Ideally I'd like to have manual swap done, but I simply don't have the funds for that at the moment. How much does a manual swap usually run in cost vs a 4.44 swap?

Thanks.

Re: Front diff failure/4.44 sanity check
 

The 4.44 should be cheaper but the 5spd is funner.. ask me how I know! But you can get a used 4.44 cheaper than what sourcing a 5spd and all the parts would be. Unless you are up to making the shift linkage and modifying the drive shaft. Also the peddles but its worth it.

But I paid 1500 for trans and parts (pretty much a once in a lifetime deal) and another 1500 or so in Labor.

Re: Front diff failure/4.44 sanity check
 

The front diff/trans is swapped as a unit. You use the limited slip parts of the SVX diff with the gears/case of the Outback, minor grinding of case modification needed. You also swap the speed sensor from the SVX trans (3 wire) to the Outback trans (2 wire).

Re: Front diff failure/4.44 sanity check
 

Check out the link in my signature.:)

Re: Front diff failure/4.44 sanity check
 

I've got signatures turned off. Let me go through my settings and figure out how to make them viewable again.

Edit: Found it. Thanks! I wonder what else I've been missing by not viewing sigs?

Re: Front diff failure/4.44 sanity check
 

The 444 swap file from svxfiles is dead on! No guess work involved, get the parts, get going and before you know it your 4.44ing around in an svx444=fun! I did it and its very cool, its strange having 2 svx's one stock and one 4.44, stock ones are more relaxing, while 4.44s are eager to go? Good day to all......................G

Re: Front diff failure/4.44 sanity check
 

The write up does seem to be pretty detailed and makes this thing seem a lot more feasible.
Next question: Does someone have a complete parts list for this swap? With a write up like this I may attempt this myself.

Re: Front diff failure/4.44 sanity check
 

There is no parts list. You need the tranny and rear diff from the donor car thats it. Everything else to do is in the write-up.

Re: Front diff failure/4.44 sanity check
 

You think that's interesting, how about a stock geared, 4.44 geared, and a stock fwd... each one feels very different from each other.:p

As blacky said, there is not parts list, get a trans and rear diff from a 96-98.5 outback or other legacy models equipped with the 2.5. Then its just swapping a couple things from the stock trans and rear diff and some modification, its all in the write up and is very straight forward.:)

Re: Front diff failure/4.44 sanity check
 

if you wanna stick with stock gearing send me a pm i have a complete front diff ready to go.

Re: Front diff failure/4.44 sanity check
 

How about going from stock, to 4.44 to 3.90 MT, all in the same car? :eek:

Re: Front diff failure/4.44 sanity check
 

Sending you a PM now just to keep my options open.

It may be small parts list, but that's what I needed to know. Just trans and rear diff. No other sneaky parts I might miss.

And that's part two; specifically which year and model donors. A first gen outback should be pretty easy to come across.

Re: Front diff failure/4.44 sanity check
 

Yep, the only thing to make sure on the 98 models is that it does not have a spin on filter on the trans. That makes it a phase 2 4eat and therefore not compatible.:)

Re: Front diff failure/4.44 sanity check
 

So before I start calling around to salvage yards and searching craigslist, is there ANY way to determine the quality of these kind of used parts aside from taking a previous owners word, or just a shot in dark as far as pulling it from a yard? Any quick tests that can be preformed if they're in a non-running car, or already pulled?

Re: Front diff failure/4.44 sanity check
 

If there is fluid still in the tranny, check the colour (bright clear red, not dark) and see if it smells burnt. Check the diff fluid, even drain it and check the magnetic plug for metal filings.
Mileage would be an indicator also. Having said that the tranny I put in my Claret came from sisters old Outback and had over 160,000 miles but was well maintained.
Outback trannys are pretty tough compared to the SVX trannys.