Front Differential: Advice

[svxcentric]

Hey SVXers,

I read through the forums and I think I found the symptoms to my issue. I have a really bad clicking noise (jackhammer) even after axles were replaced. From what I read it sounds like it could be serious issues with the gears in the front differential.

Assuming that's the case, what is the best way to handle this? Should I have the front differential rebuilt? Should I look for a remanufactured or junkyard replacement?

Now this 4.4 swap business...I don't have a garage so I can't do this myself. If I wanted to do that does anyone know anyone in NJ who can do the job won't look at me like I'm a space alien because I don't want to do a stock replacement? Am I going to have to find a hot rod shop that likes Subies?

Finally, what's this gonna cost? $$$$

Thanks,

Jim

[longassname]

You could take it to Tom in West Virginia. His name here is svxfiles and his website is http://www.svxfiles.com

[svxcentric]

I've spoken with Tom before - he's a good guy and very knowledgeable. Unfortunately that's a 14 hr round trip plus however many days to do the work and this is my daily driver. I really need a local solution but I won't rule it out. Of course that assumes that Tom would want to or even have the time to do such a project.

[longassname]

Rebuilding any differential properly is in the wheelhouse of maybe 1% of mechanics. Rebuilding a Subaru front differential properly takes a few specialized Subaru tools that only a Subaru Specialist will have. You'll probably be hard pressed to find a place with both. You might call the Subaru dealerships closest to you to see if any of them are willing to do it and what their estimate is. If you look in the mod forums I recently made a thread showing how to set up a front differential. You might read it so you understand what is involved in what you are getting a quote for.

I don't know what's available to you locally but I know Tom trailers cars. Even with the time and paying him to come pick it up and take it back to you it might be easier and less expensive than taking it to a local shop. He is able to find and procure 4.44 transmissions and differentials. I've sourced several through him myself as cores for performance rebuilds. They were all nice transmissions. I know it's hard when facing a major expense like this but I would suggest you communicate wanting it done well and fast rather than pressing on the price so that he knows he has the tools to get the right parts from the right place right now.

[svxcentric]

@long

I've come to that same conclusion. I've got bids from car transporters so I know I can get the car moved at a reasonable price. I left an email and voicemail for Tom during the week. I'm ready to make it happen. I can get the car delivered to his doorstep next week but I haven't heard back from him.

I just need to know he's willing to take the job, then I can get on with booking the car transport. If anyone knows him and can give him a nudge in my direction, I'd appreciate it. I don't want to be a nuisance, but I'd like to get this sorted as soon as I can.

Jim

[svxcentric]

Woo Hoo! Got in touch with Tom and he can do the job. What a relief.

[svxcentric]

*Update*
A huge thank you to Tom (svxfiles). I've been driving my new 4.44 swap expertly installed by Tom. He's a really cool guy and an excellent mechanic. My car as been transformed by the swap. If I had known how much the performance would be improved I would have broken my front diff a long time ago. Seriously though, if anyone out there is hesitating to do the 4.44 swap, I assure you it's worth it. And if you have Tom install it you can be assured of a quality job. Respect, Tom.

[Blacky]

I love a happy ending.

My '92 Claret has a 4:44. Sadly I didn't get to drive it much before I had to take it off the road due to severe frame rust. At least it's there if I need it.

[longassname]

I'm glad it worked out for you.