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Old 12-21-2007, 07:54 PM   #1
WRX-17
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Default FAQ: STi 6MT Swap into a WRX

FAQ: USDM STi 6MT Swap into a WRX

Well I thought I would finally try to give back to nasioc by sharing this with everyone in the hope that others would appreciate a simplified page about the swap.

Front Differentials:
02-07 WRX: open
04 STi: “SureTrac” LSD
05-07 STi: “Helical” LSD

Rear Differentials: R160, R180
These were originally used in the Datsun 510, 610 and other IRS Datsuns. The "R" stands for Fuji Heavy Industries. The R180 was used in the front axle of Datsun 4x4 trucks (720, etc). The number represents the ring gear size in millimeters.

R160 – 52lbs. WRX rear differential. It has a viscous LSD which is no better than an open differential since the unit is so tiny in this diff.
02-05 have a 3.54 gear ratio
06-07 have a 3.70 gear ratio
R160’s on 2.2L Legacy/Impreza’s have a 3.9 gear ratio

R180 – 64lbs. STi rear differential. It has a mechanical clutch type LSD.
04-05 R180’s have a 3.90 gear ratio
06-07 R180’s have a 3.54 gear ratio

Center Differentials:
02-07 WRX: Viscous coupling type
02-05 has a 1.1:1 gear ratio
06-07 has a 1:1 gear ratio
04-07 STi: DCCD (Driver Controlled Center Differential)
04-05 has a 1:1 gear ratio
06-07 has a 1.1:1 gear ratio

Do I need different front axles?
02-early 04 WRXs have female axles and need to use stubs that go inside the tranny. Late 04-07 WRXs use male ended axles that slide inside the front differential so there is no need for stubs. For the female axles, you need axle stubs, circlips, and seals to reuse the WRX axles (check out the seal differences link for part numbers). You can use the stubs from your 5MT. For the male ended axles, they just slide right into place with the correct seals and circlips. 04 STi front axles will work too.

Will my WRX clutch and flywheel work in a 6speed?
-Yes. The diameter of the WRX flywheel is smaller (230mm compared to 240mm) than the STi flywheel. The bell housing on the 5speed is also smaller. There is less surface area with the 5speed compared to the 6speed but is not a huge difference. There are no issues with running a 5MT clutch and flywheel in a 6MT. See post #24

Will my WRX starter motor work in the 6MT?
-Yes. WRX and STi starter motors are the same part number.

What if I don’t have/use a DCCD (Driver Controlled Center Differential) controller?
-The DCCD defaults to open mode which is a 35% front/65% rear power routing in 04-05 and 41/59 in 06-07. There isn’t anything “wrong” with this, but if you are running the R160 with the 3.90 Ring and Pinion the compromise is in an even shorter life of the differential since more power is being routed to the rear. This of course all depends on the driver as some have a knack for blowing parts out even at stock power levels. The options for a controller are: Spiider’s (DCCDPro.com), Neetronics.com, RocketRally.com…

Is there a strength difference between the WRX and STi drive shafts and axles?
Subaru’s use 2-piece drive shafts. The WRX drive shafts are 2.5” longer than the STi and they use a ball-joint whereas an STi driveshaft uses a universal joint which is stronger. The STi axles are stronger because of a larger diameter bar and beefier CV joints.

What are my options for doing a 6MT swap?
-There are really only 2 routes:

1) Thanks to Bayley for pioneering this route so a 6MT swap was actually feasible for most. This parts list includes:
• Tranny
• 6MT clutch fork
• Auto driveshaft or STi ds and enlarge the holes on the ds and yoke or switch the yoke on the R160 to the bigger R180 yoke if you can get one.
• Put 3.90 gears in your R160 Differential (if using an 06-07 tranny with an 02-05 R160 there is no need to change anything with the differential)
• Reuse your WRX axles
• STi shifter linkage
• 6MT tranny mount (5MT and 6MT mounts are different)
• DCCD controller (optional, but recommended)


2) Here’s the expensive but stronger way:
• Tranny
• 6MT clutch fork
• STi driveshaft
• R180 differential
• STi axles
• STi hubs
• STi knuckles
• STi Brembos (calipers, rotors, pads) technically you only need the rear
• STi strut assembly (05+ knuckles)
• STi shifter linkage
• 6MT tranny mount
• DCCD controller


All of these threads helped me out:
Swapping in a USDM STi 6-speed for under $3000 (my story – long)
2006 STi Transmission Differences
Master swap list for 04-07 Sti 6 speed into WRX
Master 6 Speed Transmission Decoder Ring
Axle seal differences in recent years
Trasnmission FAQ
For those wanting to make their own DCCD controller
WRX 6MT swap (part 1)
WRX 6MT swap (part 2)


I created this because the information I found was spread out over many threads. I did a lot of searching for this and aftering reading it you should have a pretty good idea of what is involved in a 6MT swap. I will do my best to keep this updated whenever I find any new info or if anyone needs more clarification on something let me know and I can add more detail. If there is an error please send me a PM with the facts.

Last edited by WRX-17; 06-14-2008 at 03:50 PM.
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Old 12-21-2007, 09:04 PM   #2
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A few things to add:

06-07 WRX Rear Diff is 3.70
06-07 WRX Center diff is 1.0:1, not 1.1:1, according to the factory service manual

06-07 WRX STI tranny swappers have to swap out the ring and pinion or the entire R-160, as 3.70 will not match up to anything. An 02-05 WRX 3.54 R-160 is perfect for the 06-07 STI 6 speed.

For a full swap using 05+ STI drivetrain, you will also need the Strut assembly, due to the inverted strut design used. Lateral links are optional, as I believe you can keep your WRX links, WRX rear swap bar, and endlinks. Don't forget the Brembo rotors...

What about the STI rear subframe, since the R-180 and R-160 don't mount the same?
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Old 12-21-2007, 10:25 PM   #3
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Hey thanks a lot, I was just thinking about the necessity of the different struts and subframe and i missed that I didnt have that in there. I guess I wasnt familiar with 06-07 wrxs...thanks for the clarification!
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Old 01-19-2010, 12:51 PM   #4
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If I go with option #1 would I be able to re-use all 4 axles, as long as I keep the same diff in the car? I have an 02 wrx and was thinking of getting a 06-07 sti trans.
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Old 01-19-2010, 01:53 PM   #5
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Ok I have 2 options as I get ready for this swap.

Been reading and digesting several threads on the subject.

O3 wrx.

Option 1 2004 STI 6mt
-R160 Regeared
-6 speed shifter and assembly
-Crossmember and Mount
-DCCD controller
-6-speed clutch fork and slave cylinder?
-STI Driveshaft and Flange

Option 2 2005 STI 6mt
-R160 Regeared
-6 speed shifter and assembly
-Crossmember and Mount
-DCCD controller
-6-speed clutch fork and slave cylinder?
-STI Driveshaft and Flange
-2005 WRX front axles OR 2004 STI front axles OR re-use my current W/Stubs

This sound accurate?
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Old 01-19-2010, 02:33 PM   #6
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Quote:
Originally Posted by The Phenx View Post
Ok I have 2 options as I get ready for this swap.

Been reading and digesting several threads on the subject.

O3 wrx.

Option 1 2004 STI 6mt
-R160 Regeared
-6 speed shifter and assembly
-Crossmember and Mount
-DCCD controller
-6-speed clutch fork and slave cylinder?
-STI Driveshaft and Flange

Option 2 2005 STI 6mt
-R160 Regeared
-6 speed shifter and assembly
-Crossmember and Mount
-DCCD controller
-6-speed clutch fork and slave cylinder?
-STI Driveshaft and Flange
-2005 WRX front axles OR 2004 STI front axles OR re-use my current W/Stubs

This sound accurate?
- You'll have to use the 6MT's clutch fork
- Your WRX's slave cylinder can be re-used on the 6MT
- You can re-use your WRX's front axle but will need the stubs/oil seal/circlip IF the 6MT is "stubless".
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Old 01-19-2010, 04:09 PM   #7
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Quote:
Originally Posted by njk8010 View Post
- You'll have to use the 6MT's clutch fork
- Your WRX's slave cylinder can be re-used on the 6MT
- You can re-use your WRX's front axle but will need the stubs/oil seal/circlip IF the 6MT is "stubless".
Can't I just use the stubs from my 5mt?

And leave them attached to the axle via the roll pins?
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Old 12-21-2007, 11:25 PM   #8
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Quote:
Originally Posted by WRX-17 View Post
FAQ: STi 6MT Swap into a WRX


R180 – 64lbs. STi rear differential. It has a mechanical clutch type LSD. It is bigger, wider, heavier, and doesn’t directly bolt up to a WRX subframe. The front mounts line up, but the rears do not.

.........

What are my options for doing a 6MT swap?
-There are really only 2 routes:

1) Thanks to Bayley for pioneering this route so a 6MT swap was actually feasible for most. This parts list includes:
• Tranny
• 6MT clutch fork
• Automatic tranny driveshaft or STi driveshaft and enlarge the holes on the coupler or switch the couplers.
• Put 3.90 gears in your R160 Differential (if using an 06-07 tranny with an 02-05 R160 there is no need to change anything with the differential)
• Reuse your WRX axles
• STi shifter linkage
• Tranny mount (5MT and 6MT mounts are different)
• DCCD controller (optional, but recommended)


2) Here’s the expensive but stronger way (I am personally not as familiar with all the details of this route...yet):
• Tranny
• 6MT clutch fork
• STi driveshaft
• R180 differential
• STi rear subframe (the front diff bolts line up but not the rears)
• STi axles
• STi hubs
• STi knuckles (e-brake assm. and cables)
• Brembo's (calipers, rotors, pads)
• Strut assm. (05+ knuckles)
• STi shifter linkage
• 6MT tranny mount
• DCCD controller
I have done a 6speed swap to my 02 using the second method. It would have been nice to have a thread like this before I started. I just have some constructive criticism and thought I would point out a few errors that you might want to fix. I underlined the areas that I wanted to point out.

First the R160 and R180 rear mounting points are spaced evenly and even use the same studs. I reused my rear sub frame and rear differential mount bracket. They worked fine.

Second you can't switch the rear yoke on the drive shaft from WRX to STi shafts the U joints on the STi shafts are much larger.

Third you can reuse the entire e-brake assembly including the cables from your WRX. The only difference between the two is that the STi e-brake handle has red stitching. You must, as you said, use the R180 hubs for this method.

Great post though I'm sure this will help out a lot of people.

I vote sticky


Ryan

Last edited by FourOnTheFloor65; 12-22-2007 at 01:31 PM.
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Old 12-23-2007, 02:32 AM   #9
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Quote:
Originally Posted by FourOnTheFloor65 View Post
First the R160 and R180 rear mounting points are spaced evenly and even use the same studs. I reused my rear sub frame and rear differential mount bracket. They worked fine.

Second you can't switch the rear yoke on the drive shaft from WRX to STi

I vote sticky
Good to know about the mounting points, even though I personally am not swapping R-180s

Thanks for reminding me about the driveshaft rear yoke, I sourced the Rear diff companion flange (what the driveshaft connects to) at about $80 shipped from a Subaru Parts place, so that would probably be cheaper and better than having the driveshaft cut, balance, redrilled, or whatever.

Second the sticky vote, or at least add the swap threads together.
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Old 12-23-2007, 06:43 PM   #10
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l'll add some info as well:

Here is a link to all the info you need to know regarding JDM Transmissions

http://translate.google.com/translat...%3Den%26sa%3DG

Here is a snapshot of the SPDA transmission chart (note it does not include transmissions after TY856WB6JA - 05 STi Spec C)

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Old 12-22-2007, 01:42 AM   #11
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Oh, awesome thanks for that help! I am researching that second method right now so that helped me out too. I made this exactly for that; to help out others. I sure hope it will and thanks for the sticky vote. Thanks again...anyone else, feel free to chime in too as I want to make this as complete as I can.

Last edited by WRX-17; 12-22-2007 at 01:52 AM.
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Old 12-22-2007, 03:25 AM   #12
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great write up, also 06-07 JDM STi R180's are 3.9, and all spec C R180's are plated

Front diffs in all spec C's are hellical regardless of year
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Old 12-22-2007, 01:29 PM   #13
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Quote:
Originally Posted by Ben v5 View Post
great write up, also 06-07 JDM STi R180's are 3.9, and all spec C R180's are plated

Front diffs in all spec C's are hellical regardless of year
Actually only 2005 and up Spec C front diffs are hellical 2001-2004 Spec C are Suretrac thats what mine is.

This is the best thread ever for transmission and diff identification....

http://forums.nasioc.com/forums/showthread.php?t=1225160

And when you get into JDM and European R180s there is all kinds of weird stuff. The one I have uses the smaller R160 driveshaft bolt pattern on the front yoke. Some don't have a rear diff temp sensor in the drain plulg location. A lot of them are clutch type, some are Suretrac and a few newer ones are Torsen type.
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Old 11-30-2009, 08:32 PM   #14
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Quote:
Originally Posted by FourOnTheFloor65 View Post
Actually only 2005 and up Spec C front diffs are hellical 2001-2004 Spec C are Suretrac thats what mine is.

This is the best thread ever for transmission and diff identification....

http://forums.nasioc.com/forums/showthread.php?t=1225160

And when you get into JDM and European R180s there is all kinds of weird stuff. The one I have uses the smaller R160 driveshaft bolt pattern on the front yoke. Some don't have a rear diff temp sensor in the drain plulg location. A lot of them are clutch type, some are Suretrac and a few newer ones are Torsen type.
whats the difference between hellical and suretrac?
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Old 12-01-2009, 04:55 PM   #15
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Quote:
Originally Posted by 25rsti View Post
whats the difference between hellical and suretrac?
The Suretrac is made by AP Racing. The same company that makes big brake kits, clutches, etc. It is a very strange design that uses 12 little free floating cams or nuggets that fit in groves in the diff case and recessed triangles in plates on the ends of the axles. The cam nuggets can slide left and right in the differential, and the cam profiles are designed in a way that torque from the engine forces the cams to hold both axles at the same rate of speed, but when there is a speed differential from one side to the other, like when turning, the cams slip within their groves and allow this speed differential. They can be a little noisy and slow to respond, but with more torque from the motor, the more lock force it has. This is not the case in a Helical. This site has some neat pics of a Suretrac toward the bottom of the page. It is not a Subaru one but the design is the same.

http://www.mycaterham.com/66828/117416.html

Here is a good description on it from Subaru.

http://wrx.grapon.com/techdocs/dccd/...%20Booklet.pdf

Helical diffs work a lot differently. The most common types of helical diffs are JTEKT's Torsen (like some STis use) and ones like Eaton's TrueTrac. They have two helical worm gears on the ends of the axles and then 3 pairs of long shaft like helical worm wheels bolted into the case that connect the two together. The gear teeth are designed specifically so that the worm wheel pairs cannot turn the worm gears on the axles but the worm gears on the axles can turn the worm wheels. This has to do with the friction between the gears, their size, tooth profile, orientation, and ratio. This is the same way winches work, like in cranes, so the load on being hoisted won't simply turn the motor and fall. When cornering, one axle, turning the worm gears, can rotate the worm wheels enough so that one wheel can spin faster than the other. But when torque is applied from the motor the worm wheels are locked and cannot rotate one axle at a different speed than the other. It really is an ingenious design. It responds immediately to torque from the motor but doesn't have a true lock force per say like the suretrack. Here is a cool video of how the Eaton one works.


And next is one of the Torsen. You can see that with the Eaton the worm wheels are meshed together, and on the Torsen they have spur gears on each end that mesh the worm wheel pairs together.


Here is a site that gives the history behind the Torsen and probably a better explanation of how it works.

http://members.rennlist.com/951_racerx/PS84Gleason.html

Last edited by FourOnTheFloor65; 12-01-2009 at 05:01 PM.
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Old 12-22-2007, 01:50 PM   #16
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i think that settles it...im going to keep my info based on USDM stuff cuz like u just pointed out...that gets confusing, too confusing for me

nice thread...im definitely putting a link to that in my post
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Old 12-23-2007, 09:15 PM   #17
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option #2 ftw
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Old 12-24-2007, 11:57 AM   #18
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Nice Faq! Lots of useful info for those doing a 6 speed swap, too bad my writeup didn't make the list for reference! great job!
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Old 12-27-2007, 12:33 PM   #19
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hey thanks a lot. i know i sure wish i had something like this when i did my swap, so i did my best to keep it simple. thanks for the additional help guys
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Old 01-01-2008, 08:02 PM   #20
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how much would option 2 theoretically cost?
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Old 01-01-2008, 08:40 PM   #21
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lookin from anywhere from 3500.00 to 5000.00
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Old 01-13-2008, 07:27 PM   #22
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Impreza WRX 5 spd list

Anyone have a list of 5spd swap parts needed. switching my wrx from auto to 5 spd. Need a list and procedures if possible.
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Old 01-13-2008, 07:59 PM   #23
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it's a really long list, just sell your car and get a 5 or 6 speed
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Old 01-13-2008, 08:24 PM   #24
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Just got the car and am willing to do the swap. Just need a list to make sure i can get everything before I start. It would be much appreciated.
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Old 01-13-2008, 10:04 PM   #25
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This is not the right thread for you. There is no information here that can help you so try a search. Good luck
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