Welcome to the North American Subaru Impreza Owners Club Sunday July 13, 2014
Home Forums WikiNASIOC Products Store Modifications Upgrade Garage
NASIOC
Here you can view your subscribed threads, work with private messages and edit your profile and preferences Home Registration is free! Visit the NASIOC Store NASIOC Rules Search Find other members Frequently Asked Questions Calendar Archive NASIOC Upgrade Garage Logout
Go Back   NASIOC > NASIOC Technical > Subaru Conversions

Welcome to NASIOC - The world's largest online community for Subaru enthusiasts!
Welcome to the NASIOC.com Subaru forum.

You are currently viewing our forum as a guest, which gives you limited access to view most discussions and access our other features. By joining our community, free of charge, you will have access to post topics, communicate privately with other members (PM), respond to polls, upload content and access many other special features. Registration is free, fast and simple, so please join our community today!

If you have any problems with the registration process or your account login, please contact us.
* Registered users of the site do not see these ads.
Reply
 
Thread Tools Display Modes
Old 06-28-2004, 06:33 PM   #1
big_adventure
Scooby Specialist
 
Member#: 40501
Join Date: Jul 2003
Location: Paris, FR
Vehicle:
2005 Decathalon 21sp
One WheelSeanPower

Talking Full V7 STi drivetrain into 04 WRX wagon!

Saturday and Sunday my friends and I completed the installation of a full V7 STi driveline into my 04 WRX wagon. Well, almost a full STi driveline. Details to followÖ

First off, I want to thank everyone: Kingpin Performance, who set me up with the drivetrain, Wales Garage in Ft. Lauderdale, FL, Ben, Kyle, Gabe, Jose, Glenn, Orlando, Andrew and everyone else involved.

Second, if you will host the pictures for this adventure, Iíll put them up AND be eternally grateful.

On to our storyÖ

Two pallets (one regular, one double-sized) of goodies arrived at Wales Garage in Fort Lauderdale, FL on Thursday. On these pallets lived an STi 6-speed (with clutch-type center diff and suretrac mechanical front diff, R180 mechanical rear LSD, 4 axles, 4 hubs, 4 STi gold Brembos, 6MT shifter, STi prop shaft, and all of the other goodies.

As an aside, Wales is a great facility. Itís huge, one of the largest shops Iíve been in, and has top-notch tools, Hunter DSP400 alignment rack, many chassis lifts Ė basically everything. Compared to working in MY garage, there is no comparison. Wales Garage doesnít typically rent out the facility, but Ben Levy (Batscubie) runs the place, is a friend and a good man, and he cut me a pretty good deal for the rental.

FedEx freight had KILLED the pallets. Remarkably, the only thing with any damage at all was the shifter Ė the reverse-lockout ring has a chip out of it. Everything else was fine. Seeing the pallets, you would not have believed it. I didnít.

We started off Saturday morning around 8:00. The car was on the lift, wheels off.

I pulled off the exhaust behind the downpipe as one piece and set it aside (3 bolts).

We pulled the brakes, and tied the calipers to the strut to save us a fluid mess (4 bolts each total (caliper to caliper body and caliper body to hub). The rotors slipped off with just a few taps of the mallet.

We pulled the rear ABS sensors from the hubs and hung them out of the way (1 bolt each).

We dismantled the e-brakes to release the e-brake cables. If you donít want to do that, you can go inside the car and tear out the carpet to pull the stock e-brake cables and run the attached STi e-brake cables to the clip point, but thatís not how I chose to do it.

We pulled the propshaft cover (6 bolts).

We drained the fluid from the 5MT, and pulled the propshaft. (4 nuts on studs, it slides right out of the tranny.

We unbolted the hubs from my Tein coilovers (2 bolts each).

We put the tranny jack under the diff, then unbolted the rear subframe (4 bolts), unbolted the nuts from the rear diff support bolts (4), unbolted the trailing arm brackets (3 bolts each), disconnected the fuel tank heatshield (2 screws), and dropped the whole rear clip out of the car Ė hubs, axles, trailing arms, lateral links, R160 diff, subframe, everything. It comes out as a unit pretty easily.

We carried the STi rear end over to the WRX rear and started trading parts. Because I have a wagon, I canít use the longer STi lateral links. The STi links are welded from tubular steel, unlike the puny WRX links which are made from stamped sheet metal. We pulled the toe eccentric bolts from each side, and the rest of the sub-frame to suspension bolts from both rear ends. We then put the WRX Wagon links onto the STi subframe. We only hand-tightened the rear suspension, to prevent damage to the bushings Ė you donít want to crank them down until you have the weight back on the car Ė the bushings can tear or bind, and kill your alignment.

As an aside, some of the STi parts are considerably more massive than the stock WRX stuff. The axles are awesome looking, the R180 diff is beefier, the tranny is huge and tough-looking. All in all, itís impressive gear.

Once the STi rear was assembled, we loaded it on the tranny jack, and dragged it over to the car. We had from 4 to 6 people holding that thing in place while we tried to get the 4 hanging diff bolts through the holes in the diff. We finally got them in and nutted them into place. We bolted the sub-frame back on, and re-attached the hubs to the coilovers.

Voila, a completed rear end, and it was only 10:25AM. I was seriously thinking we would be done by 3PM.

About now, Jose started re-surfacing the brake rotors Ė they were covered with shipping rust, and we discovered that they had some deposits in them. They came out perfect after taking off around 6/1000Ē.

I re-connected the ABS sensors and e-brake cables (dismantling the STi e-brakes to remove the old cables and connect the new).

I pulled the downpipe now (3 nuts, 2 bolts and nuts Ė my heatshield has 3 bolts as well), disconnecting my WbO2.

We moved slowly for a little while, and ate the pizzas Iíd ordered. The rotors finished up.

I moved to the front hubs, and got ready to pull them and the axles so we could yank the 5MT (and put in the STi front axles and hubs). I pulled the cotter pin off the steering tie-rod ball-joint castle nut on each side, and removed the castle nut. Damn, that bolt is ON THERE.

Around this time, one of the many, many participants was pulling the STi axles off of the 6MT on the pallet. One of the spring pins popped out immediately. The other? Not so immediately. Nope, not at all. I guess it had frozen in there in transit and Kingpin had removed the tranny and axles as a unit, because that thing just mushroomed right up.

First little issue, and Iím sure I caused it with that flip comment about being finished at 3:00. Anyway, it took us FOUR HOURS to get the pin out. During this time, we broke 6 tool-steel hammer punches and made some futile efforts with drills.

I took my turns with the hammer and the drill, and hammer and drill we did. Eventually, that damn thing popped out, but at a huge time-cost. Time waster #1.

Around this time, Gabe and his brother finished working on his Evolution RS. One member of our party took it for a test drive and managed to spend some time in the company of drunks and druggies in a metal room. The Evo got impounded. This, obviously took a little more time.

During this, I also bought the right puller for the tie-rod bolt Ė a shop that big and we just didnít have the right puller for that thing. We pulled the strut from the knuckle (2 bolts), and pulled the strut off of the ball joint (pull the clamp bolt on each hub). I then popped the axle pins from the transmission and pulled out the front axles, still attached to the hubs.

We brought the car down and removed the starter and disconnected the sensors. We pulled the shift-fork retainer cap with a 10mm allen key, inserted a 6mm bolt into the hole, screwed it into the shift-fork retainer, and worked that out. Wiggling the shift-fork helped. We removed the bolts from the top of the 5MT.

We pulled rest of the 5MT bolts, disconnected the ground, and pulled the clutch-slave cylinder from the 5MT, and lowered out the transmission. This isnít quite as easy as it sounds, but by throwing (literally) Gabe up into the engine compartment with a prybar, we got it moving with style.

We got the 6MT onto the transmission jack. A word about 6MTs: they donít fit onto tranny jacks very well! If you are not careful, the jack will hook the mount, and you will not have a chance in hell of getting the damn thing into the car. They are also BIG, compared to the 5MT. There is not much clearance around the case in the tunnel.

It took us almost 2 hours to get that 6MT into the compartment, onto the lower studs, onto the dowel pins and onto the input shaft. Gabe (I think he might still be in my engine compartmentÖ) was up there again, working his prybar to get the shaft lined up and getting everything set while I pushed and used three different jacks to lift the front of the motor and the back and front of the transmission. We secured the bolts, stuck the starter and clutch back on, put in the shifter, and called it a transmission.

Oops, we forgot the shift fork retainer. Ah, well, out with the starter and I had that thing back on in 15 minutes. Gabe had to take off after dinner (thoughtfully picked up by Kyleís girlfriend and Ben). Ben, Drew and I kept working.

I popped in the STi front axles and hubs, and secured them with pins, the tie-rod castle bolt and the strut bolts. I left it off of the control arm ball-joint for now. We attached the prop shaft, and tried to turn it to attach the other two bolts. But we could not. Not at all. We thought that we might have e-brake issues, and I tried to pull the back rotors. Nope Ė not going to happen. They had gone on with finger pressure and now could not be removed. As I began to ďtapĒ them with a hammer, Ben wisely suggested that we call it a night and start again the next morning, as we were just too tired. Reluctantly, I agreed.

End of day one, at 12:30AM.

Start of day two, 7:30AM.

Ben and I started to work. I wisely jumped up on the car and released the F$%&ing e-brake, freeing the rotor like nothing. We mounted the other two prop-shaft studs and nuts.

I bolted on the downpipe. Orlando, who works at Wales, came by for the alignment. Heís a wrenching wizard. We did the four Brembos and the front hubs in no time flat, bled the brakes, and bolted the back wheels on. I then tried to bolt on one of the front wheels.

Nope. Not by a mile. My OZ Superleggeras donít come CLOSE to clearing the calipers. Itís really not even spacer-able. And itís a Sunday. Orlando was there to do the alignment, so he took off since the car wasnít rolling.

Ben and I wasted 3 hours looking for wheel places that would have anything worthwhile to fit an STi on a Sunday, but such creature simply is not to be found. He and I drove back to my house and picked up my stock rotors (I sold my front Carbotech Bobcat pads and front and rear Carbotech Panther slotted rotors on Saturday, to w0rXer). We drove to TWO places to find brake pads, and got the wrong ones anyway. Not to be denied, I used the grinder to MAKE them fit. I bolted them on, and the baby was back on wheels! Well, she would be soon. First, I had to put the exhaust back on, the turbo heatshield, the fuel tank heatshield and a few other parts.

We filled the transmission and the diff with Redline, and brought her down. Ben cranked her up and pulled her off the lift and onto the Hunter rack.

We took a little break for me to fire up the laptop to tune Benís car (an APS DR500 somehow found itself onto Benís car, who knew?), and aside from some compressor surge, it runs pretty well.

Orlando showed up again and around 10, and set to work. He aligned it, and tightened all the rear suspension bushings. The alignment came out ALMOST perfect, though I could use a little more adjustment range on a couple of things. At 11, I took the car for a drive around the block, getting the prop-shaft seated, and more importantly, the car warm.

We lifted it back up, tightened the prop-shaft nuts and bolted the prop-shaft protector back on. WooHoo! Finished!

Now that my 374hp at the wheel monster has a drivetrain that wonít break, I decided that I wanted to see just what an STi style 4 wheel burnout would feel like with an extra 140whp. I let it run and warm a little more, and when I left, I backed away a little bit to give Ben and Orlando a show.

I revved to 6K and feathered the throttle. On the upswing, I popped the clutch and flattened the gas. SCREEEEEEEEEEEEEEEECH! 40 feet of four-tire stripe. Let me just say, I know exactly how STiís lay down such amazing 60-foot times.

Driving Impressions:

Well, Iíve got around 50 miles on the setup so far. The shifter action is flawless. Itís as short as anything Iíve ever felt, always positive, and you can select the gear you want when you want without bothering to double-clutch. Try that with an 5MT!

Revs are definitely higher with this setup. In 6th, my car does 75mph at 3500rpm. With the 5MT, it did 75 at around 3100 in 5th. But the benefits make it worth it! When 6th is at 3500, 5th is at 4500, and 4th is at 5500. Thatís just indescribably beautiful, especially with a big turbo (like my GT30R-11). You ALWAYS have a gear in the powerband, but with plenty of revs to go.

I love it. Stay tuned for the story of the engine swap (the RA Spec-C is on the way!!!!!).

Again, if someone has the space and the time to host the pictures, Iíll gladly post them!

Thanks for staying with me,

-Sean
* Registered users of the site do not see these ads.
big_adventure is offline   Reply With Quote
Old 06-28-2004, 06:50 PM   #2
dropmech
Scooby Specialist
 
Member#: 41477
Join Date: Aug 2003
Chapter/Region: South East
Location: Jacksonville
Vehicle:
2006 Tahoe that
will pull your bumper off

Default

Daym. Can't wait to take a ride!
dropmech is offline   Reply With Quote
Old 06-28-2004, 09:06 PM   #3
WRX8XB
Scooby Guru
 
Member#: 45323
Join Date: Oct 2003
Chapter/Region: MWSOC
Location: Iowa
Vehicle:
MY05 Impreza WRX STi
Pastelito Racing & SFSOC

Default

i would give you 10 bucks or a pizza for a ride....

Drew

Nice Write up by the way, very accurate about Gabe jumpin around.
WRX8XB is offline   Reply With Quote
Old 06-28-2004, 09:53 PM   #4
gabewrx
Scooby Newbie
 
Member#: 14688
Join Date: Jan 2002
Location: florida
Vehicle:
04 EVO!!!!
white i think!

Default

me i was jumping!! nahh i didn`t even get a ride YET!


i see how things are... use me abuse me and "NO RIDE"

and .....AND!!!! i only got one slice of pizza....

lol guys my car sounds like a jet bike..... on drugs.!
gabewrx is offline   Reply With Quote
Old 06-28-2004, 10:05 PM   #5
gabewrx
Scooby Newbie
 
Member#: 14688
Join Date: Jan 2002
Location: florida
Vehicle:
04 EVO!!!!
white i think!

Default

Quote:
Around this time, one of the many, many participants was pulling the STi axles off of the 6MT on the pallet. One of the spring pins popped out immediately. The other? Not so immediately. Nope, not at all. I guess it had frozen in there in transit and Kingpin had removed the tranny and axles as a unit, because that thing just mushroomed right up.

First little issue, and Iím sure I caused it with that flip comment about being finished at 3:00. Anyway, it took us FOUR HOURS to get the pin out. During this time, we broke 6 tool-steel hammer punches and made some futile efforts with drills.

I took my turns with the hammer and the drill, and hammer and drill we did. Eventually, that damn thing popped out, but at a huge time-cost. Time waster #1.


do you see that... i did that.. i made it happend!!! i got it out!

Last edited by gabewrx; 06-28-2004 at 10:11 PM.
gabewrx is offline   Reply With Quote
Old 06-28-2004, 10:08 PM   #6
WRX8XB
Scooby Guru
 
Member#: 45323
Join Date: Oct 2003
Chapter/Region: MWSOC
Location: Iowa
Vehicle:
MY05 Impreza WRX STi
Pastelito Racing & SFSOC

Default

you also managed to break two punches....but we wont mention that.
SHE BANGS, SHE BANGS
Drew
WRX8XB is offline   Reply With Quote
Old 06-28-2004, 10:12 PM   #7
gabewrx
Scooby Newbie
 
Member#: 14688
Join Date: Jan 2002
Location: florida
Vehicle:
04 EVO!!!!
white i think!

Default

....and she moves she moves...
gabewrx is offline   Reply With Quote
Old 06-28-2004, 10:15 PM   #8
big_adventure
Scooby Specialist
 
Member#: 40501
Join Date: Jul 2003
Location: Paris, FR
Vehicle:
2005 Decathalon 21sp
One WheelSeanPower

Default

Quote:
Originally posted by gabewrx
do you see that... i did that.. i made it happend!!! i got it out!
back atcha. No doubt, Gabe was the man. Gabe pounded and pounded on that damn pin until it popped, finally, out.

Gabe, you get a ride anytime. We're thinking of taking a little trip up to Moroso Wednesday for a TnT. Should be fun.

-Sean
big_adventure is offline   Reply With Quote
Old 06-29-2004, 12:54 PM   #9
AZScoobie
Scooby Guru
 
Member#: 8785
Join Date: Jul 2001
Chapter/Region: SWIC
Vehicle:
02 c_turner@ix.
netcom.com

Default

Glad you got it done Sean. Sounds like you had some good help and a nice garage.

Clark
AZScoobie is offline   Reply With Quote
Old 06-29-2004, 01:43 PM   #10
Kingpin
Vendor
 
Member#: 41252
Join Date: Aug 2003
Chapter/Region: SWIC
Location: 602-795-3036
Vehicle:
Twin 2005 600WHP
FormulaD/TimeAttack Sti's

Default

Hey Sean,

Gald to hear it is going well. Happy to host the pics if you like. Shoot them over to me. Thanks agian.

M
Kingpin is offline   Reply With Quote
Old 06-29-2004, 01:49 PM   #11
big_adventure
Scooby Specialist
 
Member#: 40501
Join Date: Jul 2003
Location: Paris, FR
Vehicle:
2005 Decathalon 21sp
One WheelSeanPower

Default

Thanks man, it was fun but hard work. Lots of distractions and a few problems, but she's worked out now.

Now I just need my new engine!

-S
big_adventure is offline   Reply With Quote
Old 06-29-2004, 01:50 PM   #12
big_adventure
Scooby Specialist
 
Member#: 40501
Join Date: Jul 2003
Location: Paris, FR
Vehicle:
2005 Decathalon 21sp
One WheelSeanPower

Default

Thanks Mike, I'll get on that tonight (after I pull them off my camera...).

-Sean
big_adventure is offline   Reply With Quote
Old 06-30-2004, 09:39 AM   #13
big_adventure
Scooby Specialist
 
Member#: 40501
Join Date: Jul 2003
Location: Paris, FR
Vehicle:
2005 Decathalon 21sp
One WheelSeanPower

Default

Pics...

Pallet shots - killed courtesy of Fedex Freight!





#1 Helper: The Destroyer...


Just pulling in...


Coming apart...

Last edited by big_adventure; 06-30-2004 at 10:03 AM.
big_adventure is offline   Reply With Quote
Old 06-30-2004, 10:04 AM   #14
big_adventure
Scooby Specialist
 
Member#: 40501
Join Date: Jul 2003
Location: Paris, FR
Vehicle:
2005 Decathalon 21sp
One WheelSeanPower

Default

No more e-brake, brakes or ABS...


How will I ever get these back together?


About to pull this trailing link...


WRX rear versus STi rear...


She looks naked to me...
big_adventure is offline   Reply With Quote
Old 06-30-2004, 10:04 AM   #15
big_adventure
Scooby Specialist
 
Member#: 40501
Join Date: Jul 2003
Location: Paris, FR
Vehicle:
2005 Decathalon 21sp
One WheelSeanPower

Default

Pre-resurfacing...


Resurfacing!


STi rear bolts right in...


The 10-second pin and the 4-hour pin...


Shift-fork rod:


Gabe likes to be on top...
big_adventure is offline   Reply With Quote
Old 06-30-2004, 10:05 AM   #16
big_adventure
Scooby Specialist
 
Member#: 40501
Join Date: Jul 2003
Location: Paris, FR
Vehicle:
2005 Decathalon 21sp
One WheelSeanPower

Default

6MT and STi axles are IN!


6MT shifter...


Rear brakes good...


...Front brakes BAD!


Creative exhaust bolting:


Lonely Front Brembos...


On the Hunter DSP400 - we be finished!


Thanks,

Sean

Last edited by big_adventure; 06-30-2004 at 10:17 AM.
big_adventure is offline   Reply With Quote
Old 06-30-2004, 11:05 AM   #17
WRX8XB
Scooby Guru
 
Member#: 45323
Join Date: Oct 2003
Chapter/Region: MWSOC
Location: Iowa
Vehicle:
MY05 Impreza WRX STi
Pastelito Racing & SFSOC

Default

those rear brakes look awesome, can't wait for the matching fronts to be installed on the new wheels. Keep us posted

Drew
WRX8XB is offline   Reply With Quote
Old 06-30-2004, 11:22 AM   #18
big_adventure
Scooby Specialist
 
Member#: 40501
Join Date: Jul 2003
Location: Paris, FR
Vehicle:
2005 Decathalon 21sp
One WheelSeanPower

Default

Drew - PM'd you...
big_adventure is offline   Reply With Quote
Old 06-30-2004, 02:07 PM   #19
Zephyr
Scooby Specialist
 
Member#: 3362
Join Date: Dec 2000
Location: On the Podium w/ a trophy girl
Vehicle:
1985 I've wired a
Few cars in my day

Default

I would avoid driving the car as much as possible with the current brake setup. The bias is so off that if you have to do any sort of agressive braking you will lock up the rears and crash the car. Please DO NOT drive your car like this unless it's an emergency.

Other than that the swap looks awsome

Z
Zephyr is offline   Reply With Quote
Old 06-30-2004, 02:32 PM   #20
big_adventure
Scooby Specialist
 
Member#: 40501
Join Date: Jul 2003
Location: Paris, FR
Vehicle:
2005 Decathalon 21sp
One WheelSeanPower

Default

It's not really as bad as that. I've actually bedded the pads a little with a few HARD 60-5 brakings, just before ABS pickup. Hard enough to send a bottle of Motul sitting in the wagon bed into the front seat, in fact, with no negative effects. The proprotioning valve will keep TOO much power from hitting the rears, it will just put that much more heat stress on the fronts. Also, I'm still on my 04 ECU, and it has EBD which may well help with the bias problem.

Anyway, I'm driving it, because not going to work would be an emergency. I'm staying off the speed though, and avoiding high-liability situations more than I perhaps usually would.

Thanks,

Sean
big_adventure is offline   Reply With Quote
Old 06-30-2004, 03:05 PM   #21
WRX8XB
Scooby Guru
 
Member#: 45323
Join Date: Oct 2003
Chapter/Region: MWSOC
Location: Iowa
Vehicle:
MY05 Impreza WRX STi
Pastelito Racing & SFSOC

Default

is moroso a high-liability situation?

Drew
WRX8XB is offline   Reply With Quote
Old 06-30-2004, 03:19 PM   #22
big_adventure
Scooby Specialist
 
Member#: 40501
Join Date: Jul 2003
Location: Paris, FR
Vehicle:
2005 Decathalon 21sp
One WheelSeanPower

Default

Not unless someone is coming down the strip the wrong way. Who uses brakes on a dragstrip?

-Sean
big_adventure is offline   Reply With Quote
Old 07-01-2004, 11:00 AM   #23
WRX8XB
Scooby Guru
 
Member#: 45323
Join Date: Oct 2003
Chapter/Region: MWSOC
Location: Iowa
Vehicle:
MY05 Impreza WRX STi
Pastelito Racing & SFSOC

Default

I USE BRAKES ON THE DRAGSTRIP
WRX8XB is offline   Reply With Quote
Old 07-01-2004, 11:55 AM   #24
big_adventure
Scooby Specialist
 
Member#: 40501
Join Date: Jul 2003
Location: Paris, FR
Vehicle:
2005 Decathalon 21sp
One WheelSeanPower

Default

I no longer have much clutch FROM the dragstrip

-Sean
big_adventure is offline   Reply With Quote
Old 07-04-2004, 03:08 PM   #25
big_adventure
Scooby Specialist
 
Member#: 40501
Join Date: Jul 2003
Location: Paris, FR
Vehicle:
2005 Decathalon 21sp
One WheelSeanPower

Default

One little wheel-swap later and we have:

Front BREMBOS!!!!!

(the wheels are 17x8 Rota Torque in Steel Grey)



big_adventure is offline   Reply With Quote
Reply

Thread Tools
Display Modes

Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off
Forum Jump

Similar Threads
Thread Thread Starter Forum Replies Last Post
05 STI swap into 04 WRX Wagon. HELP! pismobeachrider25 Built Motor Discussion 6 04-12-2010 09:58 AM
Full USDM STi Drivetrain into MY06 2.5i Boosted WRX STi Subaru Conversions 12 05-02-2008 09:15 PM
OEM 04 STI suspension into 05 WRX wagon javi-sti Newbies & FAQs 3 11-05-2007 01:17 PM
STi drivetrain into 07 WRX St3fan Newbies & FAQs 10 02-12-2007 11:58 PM
sti tranny into 04 wrx wagon? sakebomb Subaru Conversions 1 07-08-2004 02:34 PM


All times are GMT -4. The time now is 06:39 AM.


Powered by vBulletin® Version 3.7.0
Copyright ©2000 - 2014, Jelsoft Enterprises Ltd.
Powered by Searchlight © 2014 Axivo Inc.
Copyright ©1999 - 2014, North American Subaru Impreza Owners Club, Inc.