Great work!

 

wow, here I thought the two pot would be bigger than the sliding caliper that came on the 98 rs. So i wonder if the rs caliper would bolt up to that... never mind. you said nothing smaller. So the 4pot and 2 pot from an 07 wrx would be necessary. I think you just sold some calipers for someone without the intention of doing so. I think I saw some wrx 2 pots for sale on nasioc with front and rear brackets for sale and I know someone who will be selling their fronts in the near future. Thanks and sorry for being a pain in the ass. I'm a technician but when it comes to swaps I'm still learning.

 

Are 4/2 pot brakes a plug and play install on 5x100 6-speed transmissions?

 

Transmissions aren't ever 5x100, the hubs are. You can mix and match hubs with transmissions. Take a look through the second and third options to use a six speed, those two can make use of 4/2 pot brakes.

 

No, the front sway bar is dependent on the cross member, the end links are dependent on the control arms and lateral links, so if those aren't changing, you're fine with what you already have. Just keep in mind the weird suspension you get into if you go 5x114, what with needing custom coil overs or an equivalent solution.

 

As said by everyone else, well researched! A few things I'd note:
You will need a new pedal box, your cable clutch pedal box is different from the 98-01 Impreza 2.5 RS hydraulic pedal box.

I wouldn't worry about the master cylinder right away. Having the smaller non-ABS master cylinder will give a bit more pedal travel, but the Brembo brakes will still function and have bite. If you want a firmer pedal later, look into the master cylinder upgrade specified above.

However, I would make sure that you find a non-ABS rear disc brake proportioning valve. This will prevent your rear brakes from locking up before the fronts and give you a correct brake bias. Another option would be to replace your stock proportioning valve with a manually adjustable one.

As for control arms and lateral links: If you plan to go turbo eventually, swap the front subframe as well. You will not be able to run the GD STi control arms without this. As for which track width to use, it's up to you. The wider track width requires rear GD lateral links, a front GD subframe, and front GD control arms. If you're going to run STi sway bars, I'd recommend this route. Otherwise, you can run the front GD subframe, front GC control arms with shims, rear GC lateral links, and GC aftermarket sway bars.

Axle wise, I am running GD STi axles with the GC track width in the rear, and the axles are compressed a bit, but do function properly. It may generate a bit of rear end noise, but it's hard to tell, as I have Whiteline diff bushings and the subframe lockdown kit installed as well. GD track front and rear will free them up, but I would not run a GD track in one end with a GC track in the other.

Regarding subframes, they do not appreciably alter your track width, that is done by the lateral links in the rear and the control arms in front. Choose them based on condition in the rear (rusty vs. newer, etc) and your choice of control arm and motor (turbo yes or no) in the front.

The fuel tank is up to preference, although from what I understand the STi tank has better baffling and the pump arm is better suited for high speed cornering. While I've not performed the swap on any of my cars, if I had the opportunity to do so I would.

 

I don't know if they're identical, but they're at least very similar. Either one would be better than the SG arms.

 

Thanks !

 

I should have one in the shed too for the swap, I need to clean up

 

great to know.

 

Thanks! You need the 6MT drive shaft for the first list, it's listed below the shift linkage.

 

Fuuuuu read it 3 times too and still missed it! Don't mind me then!

Can you also use the 4EAT GC driveshaft? I thought they were the same length?

 

You can use a 4eat gc shaft if you are using an r160 (option 3).

 

^^ True story, that's what I'm running =)

 

And that's what I plan on running. It will probably end up being sooner rather then later. Haha

Nice write up!

 

*Note: Depending on the transmission you are swapping in, you may need to purchase axle stubs, seals, and circlips to mate your female axles to your female transmission. This essentially converts your '05-'07 female transmission to a male transmission that will mate to GC female front axles. The following part numbers are here:
Early 2004 Axle Seal Part Numbers (to be used with axle stubs / female axles):
Left: 806730041
Right: 806730042
Circlips (You need two of these): 805329010
Axle Stubs (You need two of these): 38415AA110

Since the axle stubs are removeable, it is possible to purchase an 04 STi transmission and have the axle stubs missing as was my case.

 

Ouch, that's a bummer... I'll add a note to that. Thanks.

 

THANK YOU!!! Awesome source of good info. I've been reading stuff scattered around various threads for a few days now. PLEASE, make this sticky.


I don't suppose you could add the info for the "custom" coil-over setup for using 05-07 hubs?

 

No problem. Updated with final drives and a little more organization and detail.

 

VERY Well put!!
I'm doing the 3rd Option - STi/WRX Hybrid driveline swap

So here's my dilemma; I have an 05 STi transmission (female) and since those axles (male) don't work in my stock RS hubs, I want to go with my stock RS axles (female). East Coast Swappers was one of the places that told me to purchase the axle stubs, seals, and circlips. Like I mentioned in my post, I just tried swapping the STi stubs to the RS stubs. no such luck.

I got the impression that these stubs would go on to the female axles themselves. But it seems like your write up here is implying to add them to the transmission side. Am I reading that correctly?

 

Yes, the axle stubs, seals, and circlips actually go into the transmission to allow you to use the female axles. They replace the existing axle seals that are in the female transmission.

 

Gotcha! Ok I understand. I tried calling a couple subie dealerships this morning. Both had the seals, but would have to order the circlips and stubs. Stubs being around $50 each (woah).

This morning I also pulled apart my old front LSD and put the stubs on my female RS axles, but the circlip position/thickness is a lot different than the STi stub (yet another fail).

I found a local guy who is willing to sell me his '06 WRX Axles (male). Question to you is, would they fit my RS?

It looks like they would, but I'm a little nervous since nothing else I've done is working.

Here is a comparison I found of an '06 WRX Axle (top) and I'm assuming '06 STi axle (bottom). Can you verify if it'll work or if they are too big/too long for my RS hubs?

Thanks!!

 

Do these stubs normally come with the transmission? If not where can I acquire some i'm looking to do the same thing!

 

The stubs only come standard with the '04 STI trans. For a different year, you'll have to order the provided part numbers from a Subaru dealer.

 

The 5MT axle stubs are different from the 6MT stubs.

As far as the axles go, the WRX axles will likely fit, but I can't say for certain. However,the sedan WRX axles are longer than the GC axles, and might wear faster due to the CV joints being constantly at harder angles. I would recommend going the route of the stubs.

 

Clutch/Flywheel/Pressure Plate/Slave cylinder notes:
It is possible to use an '02-05 WRX pull style slave cylinder, clutch, flywheel, and pressure plate with a six speed swap, but since the RS is a push style system, you would have to source these parts anyway, as none of it could be reused.

So basically if you're switching from a jdm 5spd all you need is the trans/mount/linkage, 4eat shaft, matching diff ratio, and maybe stubs?

This would be too easy for me to pass on. Thanks for the awesome writeup, sticky for sure. Here are all the six speed codes;

Master 6 Speed Transmission Decoder Ring - NASIOC

 

Provided your JDM 5 speed trans is a pull type clutch, you're correct. And thanks for the trans code link, I added that to the post

 

Subbed for a later date!