05 STI when OCD meets opportunity. pictures attached - Page 2
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This is a discussion on 05 STI when OCD meets opportunity. pictures attached within the Builds forums, part of the Tech & Modifying & General Repairs category; Originally Posted by 22B05STI While driving back from Indianapolis to Las Vegas the rear strut noise I had became worse ...

  1. #16
    Registered User 22B05STI's Avatar
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    Quote Originally Posted by 22B05STI View Post
    While driving back from Indianapolis to Las Vegas the rear strut noise I had became worse and I also started to get a bearing type noise that I thought was the right rear upright. I decided to take a look at everything and ended up stripping out the uprights and have them powder coated and also repainted the c.v joint housings and stripped and regreased the rear struts and fitted the STI strut mounts which are a harder rubber.
    I also have new plastic fender liners and all the misc plastic pieces have been replaced in the wheel wells. here are some of the pics of the project so far
    Attached Thumbnails Attached Thumbnails DSC00264.jpg  

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  3. #17
    Registered User 22B05STI's Avatar
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    Here are the inserts out of the housings, you can clearly see the marking in the hardchrome of the insert where the strut has been binding. I have regreased these struts and replaced the mounts with the STI hardened strut top mounts while I was at it.
    Attached Thumbnails Attached Thumbnails DSC00269.jpg  

  4. #18
    Registered User 22B05STI's Avatar
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    Quote Originally Posted by 22B05STI View Post
    I stripped all the driveshafts, cleaned and repainted the cv housings.
    I found this unsusual flat spot today on the rear tire, it is the only one and I never locked up the brakes to cause the flat spot on the tire. I am not sure what caused it to occour but I now believe this is what the noise is that I was hearing during my trip
    Attached Thumbnails Attached Thumbnails DSC00753.jpg  

  5. #19
    Admiral Ackbar the 1st mycologist's Avatar
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    Hmmm, tire might not have been round?

    Yeah, my car is very jealous of all the attention you give yours. Looks great & nice racecar project
    "From a little spark may burst a mighty flame." - Dante
    "The stitch is lost unless the thread is knotted." - Italian proverb

  6. #20
    Registered User wrx wagone's Avatar
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    My car is lucky to get half that attention.
    This message printed on 100% recycled electrons.

  7. #21
    Registered User 22B05STI's Avatar
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    today I put all the struts and rear seats back in, painted the wheel wells and fit all the plastic back onto the car . Here are a couple of pictures from the day
    Last edited by 22B05STI; 11-07-2010 at 03:36 PM.

  8. #22
    Registered User 22B05STI's Avatar
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    Quote Originally Posted by 22B05STI View Post
    today I put all the struts and rear seats back in, painted the wheel wells and fit all the plastic back onto the car . Here are a couple of pictures from the day
    Attached Thumbnails Attached Thumbnails DSC00268 (2).jpg  

  9. #23
    Registered User 22B05STI's Avatar
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    here is the tooling I made and the drawings to press all the bearings seals and hub into the rear upright
    Attached Thumbnails Attached Thumbnails DSC00504 (2).jpg  

  10. #24
    Registered User 22B05STI's Avatar
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    Quote Originally Posted by 22B05STI View Post
    here is the tooling I made and the drawings to press all the bearings seals and hub into the rear upright
    Attached Thumbnails Attached Thumbnails DSC00534 (2).jpg  

  11. #25
    Registered User 22B05STI's Avatar
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    rear wheel arch/strut installed
    Attached Thumbnails Attached Thumbnails DSC00535 (2).jpg  

  12. #26
    Registered User 22B05STI's Avatar
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    Quote Originally Posted by wrx wagone View Post
    My car is lucky to get half that attention.
    I have time to do it right now I was on contract at KV racing for the season on the Lotus car but now the season is over. With nearly 50,000 miles my Subaru needed some work and I discovered some things that I have fixed during this project, specially how bad the bearing bores were rusting, I have powder coated the uprights and the paint is much further into the bearing bore now, also noticed the cv joint grease is very fluid like and the grease was no longer on the joints so I have repacked all the cv joints. I also had a strut clunk in the rear and read a lot on forums about it and came up with my own solutions and amount of grease and what type based on what I read on forums. It is very obvious the inverted strut does bind on the strut housing and has caused the hard chroming to mark so I will let everyone know how it works out with what I have done as I had a very bad case with mine.I Also learnt that those struts were originally designed to have a heavier spring which might contribute to the problem. I was also given a little piece of advice while I was trying to figure out what the noise I had was and that is to run the GM limited slip additive to the diff, it apparantly fixes some of the diff related noises and that additive was given to me at the subaru dealership, and obviously used to help with chatter from the diff the guy at the dealership was very helpful and handed me the bottle and said here put this in your diff, it will help if there are any noises!

  13. #27
    Registered User 22B05STI's Avatar
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    Quote Originally Posted by 22B05STI View Post
    I have time to do it right now I was on contract at KV racing for the season on the Lotus car but now the season is over. With nearly 50,000 miles my Subaru needed some work and I discovered some things that I have fixed during this project, specially how bad the bearing bores were rusting, I have powder coated the uprights and the paint is much further into the bearing bore now, also noticed the cv joint grease is very fluid like and the grease was no longer on the joints so I have repacked all the cv joints. I also had a strut clunk in the rear and read a lot on forums about it and came up with my own solutions and amount of grease and what type based on what I read on forums. It is very obvious the inverted strut does bind on the strut housing and has caused the hard chroming to mark so I will let everyone know how it works out with what I have done as I had a very bad case with mine.I Also learnt that those struts were originally designed to have a heavier spring which might contribute to the problem. I was also given a little piece of advice while I was trying to figure out what the noise I had was and that is to run the GM limited slip additive to the diff, it apparantly fixes some of the diff related noises and that additive was given to me at the subaru dealership, and obviously used to help with chatter from the diff the guy at the dealership was very helpful and handed me the bottle and said here put this in your diff, it will help if there are any noises!
    Attached Thumbnails Attached Thumbnails DSC00519.jpg  

  14. #28
    The Default One SeattleJeremy's Avatar
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    Great pictures and information!

    Thank you for sharing. I'm looking forward to seeing it completed

  15. #29
    Registered User 22B05STI's Avatar
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    Quote Originally Posted by SeattleJeremy View Post
    Great pictures and information!

    Thank you for sharing. I'm looking forward to seeing it completed
    you are welcome, I really hope that I can share some interesting things. Here are a couple of other things I found out, the caliper bolts often sieze and break off in the caliper, the bolt is not so good ( the bolts are a little undersize) as well as going in without any lube they are prone to breaking off in the caliper and it happened to me during this project. The Torque spec for the front caliper with Brembo brakes is 80 ftlbs not 114.3 ftlbs which is common in the factory Subaru Manuals ( I even checked an 02 03 japan STI manual which said the same thing) my bolt broke while removing it and I found this out while looking into what the bolts were torqed to. The strut clunk is very common to 04 to 07 STI's and it is easily mistaken for a problem with the differential it normally happens at very low speed and often pulling into driveways etc, it sounds like the diff and having pulled the struts apart the problem was very obvious. Torque spec on the bolt holding the insert in is 30 ftlbs! I will let you know what I figure out about the unusual flat spot that developed on the rear tire, it occoured on my trip from Indy to Vegas and sounded just like a bad wheel bearing,I am not sure at all what caused this as I had the wheels balanced and rotated from front to rear the day before the trip and there were no vibrations during the trip it just developed the noise in the last five hours!
    Last edited by 22B05STI; 11-04-2010 at 09:55 PM.

  16. #30
    Registered User 22B05STI's Avatar
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    Quote Originally Posted by SeattleJeremy View Post
    Great pictures and information!

    Thank you for sharing. I'm looking forward to seeing it completed
    I have big plans in the future for this car, I am going to change all the rear lateral links and the trailing arms to the spec c rar parts and add the chassis braces ( that were developed with yamaha) that the s204 has as well as the tuned by Arai strut and spring set up with group N strut mounts the struts are adjustable and I also plan on changing the front and rear rollbars to the same that the spec c and s204 have. I also found a sti differential cover that I would like to fit. I am thinking about the floating rotor setup that the spec c type rar has, I would really like to have those on this car. I basically want to have a car that has the spec c rar and S204 suspension and brakes although probably not going to change the caliper. I will post pictures of it when I get into that project, for now I am working on getting the car fixed up and cleaned up for that project.

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