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The Six Speed Swap Thread

258K views 585 replies 93 participants last post by  sharpman993  
#1 · (Edited by Moderator)
I figured I'd start this thread to catalog the different six speed swaps and configurations available to the GC8. I'll list a few common configurations and parts lists.

To answer the usual newbie question: Any EJ motor (any Impreza motor) will bolt up to any EJ transmission, and the six speed is no exception.

1. Full STi driveline swap
STi 6 speed clutch
STi 6 speed flywheel
STi 6 speed pressure plate
STi 6 speed clutch slave cylinder
STi 6 speed transmission
STi 6 speed transmission mount
STi 6 speed shift linkage
STi 6 speed drive shaft
STi front axles
STi front hubs
STi R180 rear differential (final drive matching that of the transmission)
STi R180 rear axles
STi R180 rear hubs
STi front and rear Brembos
STi Brembo rotors front and rear
(If using '05-'07 hubs, custom coil overs are recommended to maintain proper suspension geometry to mate from the 5x114.3 bolt pattern to the GC top hat bolt patterns. These custom coil overs would be GC top hats with a '05-'07 STI bottom sleeve to mount to the hub)

2. Version 6 style driveline swap (maintains 5x100 bolt pattern, allows for use of 16" wheels over 4/2 pot brakes while keeping R180)
STi 6 speed clutch
STi 6 speed flywheel
STi 6 speed pressure plate
STi 6 speed clutch slave cylinder
STi 6 speed transmission*
STi 6 speed transmission mount
STi 6 speed shift linkage
STi 6 speed drive shaft
Stock GC front axles
Stock GC front hubs
STi R180 rear differential (final drive matching that of the transmission)
STi R180 rear axles
2004 STi R180 rear hubs
STi / WRX 4/2 pot brake calipers
WRX 4 pot front brake rotors
DBA Group N rear gravel rotors or later model JDM GC8 R180 2 pot brake rotors


3. STi/WRX hybrid driveline swap (cheaper than the previous two setups, many WRX drivers choose this because they already have the matching rear end)
STi 6 speed clutch
STi 6 speed flywheel
STi 6 speed pressure plate
STi 6 speed clutch slave cylinder
STi 6 speed transmission*
STi 6 speed transmission mount
STi 6 speed shift linkage
Impreza 4EAT automatic transmission drive shaft
Stock GC8 front axles
Stock GC8 front hubs
WRX R160 rear differential (final drive matching that of the transmission)
Stock GC R160 rear axles
Stock GC R160 rear hubs
Stock GC brake calipers
Stock GC front and rear brake rotors


4. STi/WRX hybrid axle swap (cheaper than the previous three setups, you get the stronger R180, but the weak link is the axles)
STi 6 speed clutch
STi 6 speed flywheel
STi 6 speed pressure plate
STi 6 speed clutch slave cylinder
STi 6 speed transmission*
STi 6 speed transmission mount
STi 6 speed shift linkage
STi 6 speed drive shaft
Stock GC front axles
Stock GC front hubs
STi R180 rear differential (final drive matching that of the transmission)
STi R180 rear axles
Stock GC R160 rear axles - Use the four rear axles and a custom race by suberdave of NASIOC to make a hybrid axle to use your stock hubs
Stock GC R160 rear hubs
Stock GC brake calipers
Stock GC front and rear brake rotors

*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. Additionally, it is possible to obtain an '04 STi transmission that has had these parts removed. 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

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.

Final Drives:
'02-'05 USDM WRX 5MT: 3.54
'04-'05 USDM STI 6MT: 3.90
'06-'07 USDM STI 6MT: 3.54
Based on these final drives, it is possible to use an '02-'05 WRX 3.54 final drive R160 rear differential with an '06-'07 STI 3.54 final drive 6MT transmission. Other combinations of trans and rear diff will require the ring and pinion on the rear differential to be swapped to the proper final drive.

Six speed transmission codes and details (this helps immensely when picking a transmission based on features):
Master 6 Speed Transmission Decoder Ring - NASIOC

'08+ STI 6 speed transmissions:
08+ STI transmissions are slightly different to swap into an older model (GD's included) because they don't have vehicle speed sensors for the older ECU's and speedometers, and the newer ECU's and speedometers instead rely on the CANBUS system to relay a speed signal from the ABS sensors. To remedy this, you can use one of the two solutions:
VSSPro: A device built to read the ABS ring sensors and convert that to a speedo signal found here.

Earlier 6MT bell housing swap:
You need the following parts to swap to a pre-08 6MT bell housing that includes a VSS (thanks to seangfy).
32001AA210 GASKET & SEAL KIT-MANUAL TRANSMISSION FIG-111 3232001 1

30400AA040 HOUSING ASSEMBLY-CLUTCH FIG-112 3030400 1

32024AA011 GAUGE ASSEMBLY-OIL LEVEL FIG-112 3232024 1

806912140 O RING FIG-112 G9G9121 1

031512000 SNAP RING-OUTER FIG-117 1

32714AA360 GEAR-SPEEDOMETER DRIVEN FIG-117 3232714 1

32713AA050 SHAFT-SPEEDOMETER FIG-117 3232713 1

803012060 WASHER FIG-117 D0D0120 1

805012020 SNAP RING-OUTER FIG-117 F0F0120 1

806712100 OIL SEAL FIG-117 G7G7121 1

32715AA050 GEAR-SPEEDOMETER DRIVE FIG-190 3232715 1

38415AA110 SHAFT-AXLE DRIVE FIG-190 3838415 2

805329010 CIRCLIP-INNER FIG-190 F3F3290 2

806730042 OIL SEAL FIG-190 G7G7300 1

806730041 OIL SEAL FIG-190 G7G7300 1

I believe that's about it, I'll add information I as I deem it to be necessary.
 
Discussion starter · #13 ·
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.
 
Discussion starter · #15 ·
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.
 
Discussion starter · #17 ·
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.
 
Discussion starter · #19 ·
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 :)
 
Discussion starter · #22 ·
Axle stubs will work.

The big difference between the '08+ transmissions is the lack of a vehicle speed sensor. The newer cars rely on CANBUS to get speed info from the ABS system. This can be remedied with VSSPro (VSSPro [DCCD_Vss] - $150.00 : DCCDPro, Active Center Diff Control!). I'm not sure if there are any competing products.
 
Discussion starter · #26 ·
Honestly, I'm not completely sure. Hopefully someone else can chime in, but I would see not working at all unless you converted to an electronic speedometer.

The reason '08+ transmissions are killer deals is that they're harder to get working in the older Imprezas.
 
Discussion starter · #28 ·
That depends on the situation. Verify that the final drives are the same. If they are, you only need to swap the trans, and worst case, the axle stubs if you need them.

Another way to do it would be to swap center diffs. You could swap the DCCD for the open diff.
 
Discussion starter · #31 ·
Thanks.
I checked The SPDA - Transmission Chart, and the final drives are the same.
Good deal! I'm not exactly sure when the JDM transmissions switched from male stubs to female, but that's easy enough to swap.

I did some more research and talked to a friend that works for subaru in order to use the early speedo cable on an 08 and up transmission you have to switch over the bell housing to that from a 06 or 07 part number 30400AA40 about $350 from online dealers and you have to buy the speedo gear and have it all installed. So it is do able with a little effort.
Let me know if you get this to work, and I'll add it to the sticky. I haven't heard of it before, and would prefer to have someone be able to have done it before telling others it can be done.
 
Discussion starter · #35 ·
hey guys I'm a little confused. I plan on doing a six speed swap hopefully within the next year or so to my 98 rs as I'm at a point where I dont really have a choice ( 2011 ej257 hybrid putting out more than 300awhp and close to 400wtq). but like I said I'm confused, I know the ver8 sti six speeds are all 5x100 bolt pattern as well as the usdm 04 sti's. I see that everyone uses the rear cross member from the sti's. any reason for that? wouldnt the r180 just bolt up to the rs rear member this way you can still use the rear lateral link and not worry about camber. I already have adjustable links for the rear ( would those just go into the sti rear memebr). then everyone says you would need hubs. Are the splines different on the sti axles and not fit into the rs hubs. I mean i know the r180 itself is different and thus is the reason for not using the r160 axles but if the axle set up is for a 5x100 bolt pattern hub shouldnt they just slide in? the other thing is like i said everyone says hubs. when people say hubs I think of "hubs" not knuckles. so is it the hubs that are needed? would i be able to press in the hubs from the 05 sti into the 98 knuckle thus allowing me to keep the oe parking brake set up and just buying a set of 07 wrx 4pots and use the 98 coilovers that i have or do I actually need the knuckles from an sti and crossmember for the rear then having to switch the switch over to a set of coilovers for a gd with rear top hats for a gc? please explain. i want to have everything figured out bf i start buying things. I love the car and this is the third motor in it including the original 2.5. so my wife is starting to wear thin with it lol so i would like to keep cost low and not rack up another 7gs like i did with the hybrid. thanks i greatly appreciate any help and sorry for the paragraph.
See below about axle descriptions. The knuckles are also different between R180 and R160 to fit the appropriate hubs.

Take a read through the sticky again, it sounds like what you want to do is basically outlined in option 2. If you want to use an R180 while not going with Brembos, outside of custom axles this is really your only option. It will allow you to retain your 98 coilovers. Look at suspension by bolt pattern: your 98 coilovers will bolt to 5x100 hubs/knuckles, be they your 98 hub/knuckle assemblies or off a Ver. 8 or '04 USDM STI assembly.

Also, you don't need the STI rear subframe/crossmember. I'm not using one on my swap, an R180 will bolt up to either.

the 05+sti has different splines than the 5x100 hubs. You won't be able to use the 05 sti hubs in the 98 knuckle since they won't fit. Only way to use the r180 with 5x100 is with custom axles.

I don't know if the r180 can bolt into a rear crossmember designed for an r160.
The '05+ STI axles are the same as the '04 STI axles. The way to look at axles is by R180 vs. R160 rather than by bolt pattern. I'm running '07 STI rear axles into my 5x100 bolt pattern setup.

I'm also using an RS rear subframe, which does hold the R180 just fine.
 
Discussion starter · #39 ·
Thanks for the clarification!
No prob!

ok i understand that now. but that brings another question, if I were to use either a ver8 rear knuckle and hub or 04 usdm would I be able to the oe calipar from the rs? I know the 04 usdm have bigger parking brake shoes for the bigger hats. would I be able to swap everything over from the rs to that knuckle? I'm going to go back and reread prob as you read this. my ultimate goal is to have the six speed with the dccd and matching r180 with the 07 4 pots up front and oe rs calipers in the rear.
The rear FHI 2 pot caliper is the smallest caliper you can go in the rear. Nothing smaller will bolt up to the R180 knuckle.
As a side note, the Kartboy adapter brackets for the rear 2 pots actually mount the 2 pot caliper farther out from the stock RS knuckle. The stock RS rear brakes really are that small.
 
Discussion starter · #41 ·
I should clarify. The 2 pot brakes are bigger, hence the Kartboy brackets spacing them farther out from the center of the stock RS knuckle. That's why the RS brakes won't fit on the R180 knuckles, as the smallest caliper that will bolt to the R180 knuckles are the 2 pots.

If you get WRX 2 pot rears and R180 knuckles/hubs, you will not need any adapter brackets. It will bolt right up. This is the same configuration that the Version 5/6 GC STi ran.

And no problem on the questions, that's what RS25 is for. It's better to ask now then have a pile of parts you need to make work :)
 
Discussion starter · #44 ·
The option 2 I listed uses 4/2 pot brakes instead of the STi Brembos. Is that what you're doing?

Since you have a 1998, I'd recommend finding a Ver. 4 STi DCCD cluster. Running a Ver. 5/6 cluster would take a lot more repinning than the Ver. 4 would. You can find them in the RS25 classifieds on occasion.
 
Discussion starter · #48 ·
just wanted to update got my 08 sti 6 speed back today with the 07 bellhousing and speedo gear installed every thing worked perfect. So if you can get a 08 and up 6 speed you need about 700 in parts and some one to install them for you. It is do able if you get the transmission cheap enough.

ps I have the parts list I used if any one is interested might post it up.
Thanks for the update! I'd be glad to include a parts list and section for the '08+ STI transmissions. That would probably help a lot of people out.

ummm....i believe he means Version 7 (2001) STI swap in the first post, not version 6 (2000) both have DCCD (optional on ver.6) but the version 6 is ej207 with Type RA gears and 5 speed.....unless ive had a sixth gear for the last 4 months and didnt know...
No, I actually mean Version 6 style as I typed. The reason I refer to it that way is the swap uses the R180 and 4/2 pots as the Version 6 does. If you were to swap your V6 to a 6 speed, all you would need for everything to bolt up is the clutch/flywheel, trans, 6 speed diff, R180, and maybe the axle stubs. You wouldn't have to touch your axles or hubs.
 
Discussion starter · #51 ·
Are you saying that rear GC R180 axles are compatible with a GD R180?
Not sure on the axles but I believe they do, but what chuck is saying is that you can use either GC version 6 R180 rear hubs or 5x100 sti rear hubs with 06/07 2pots with either Version 6 rotors(r180) or gravel sport make a rally spec rotor that will clear r180 ebrakes
I'm saying both, actually. The GC R180 axles are compatible. Ideally, I'd be running GC R180 rear axles because I'm still running the GC track width, but since GC R180 rears are harder to find and cost $Texas compared to GD axles, I'm running those.
 
Discussion starter · #53 ·
The GD axles are in fact longer, so that would put the CV joints at a slightly increased angle which could theoretically create increased wear and shorter life. I don't know how measurable that is, though.

As far as the DCCD: Making the STI 6 speed DCCD work with a non-native car is generally not recommended because of the wiring work involved. People who have full cars tend to opt for an aftermarket controller instead. The 5MT controller is probably capable of wiring up to the DCCD, but I don't believe that controller really has an auto mode, one of the huge benefits of an aftermarket controller.