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Old 02-13-2007, 01:38 AM   #1
crashtke
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Default Master swap list for 04-07 Sti 6 speed into WRX

Ok, so I have read the FAQ's, read lots of threads and I would like to compile a list of what all is needed for the various years of Sti transmissions to be swapped into the 02-05 WRX. What I really have not been able to find is what is needed when you throw JDM transmissions into the mix. Here is what my understanding is so far. PLEASE feel free to jump in and add your knowledge.

I know there is a large number of swaps that have been done with all kinds of year and there are some differences with each. I just think with a superior design the Sti transmission is a great option for those needing something that can hold some more power. While it may not be indestructible, it is still a HUGE improvement over the WRX 5 speed glass box. Other upgrades include the RA gear set for mild power, M-Factory, MTR gears, Kaz gears and of course PPG gears. There are a fantastic selection of products not only for the WRX 5 speed but also for the Sti 6 speed available from a variety of companies. . So here goes:

04 USDM Sti 6 speed:
-transmission
-driveshaft from an automatic or from Sti with a yolk for a wrx
-3.90 R&P gear to replace the 3.54 in the WRX
OR
-R180 rear differential and Sti hubs, rotors, brakes and axles*
-6 speed shifter and assembly****
-front axles and hubs can be reused provided the transmission still has the axle stubs in it.
-DCCD controller optional but recommended**
-6-speed clutch fork and slave cylinder?
-5speed or 6 speed flywheel and clutch

1st - 3.636
2nd - 2.375
3rd - 1.761
4th - 1.346
5th - 0.971
6th - 0.756

04 JDM Sti 6 speed:
-transmission
-driveshaft again
-3.90 R&P gear to replace the 3.54 in the WRX
OR
-R180 rear differential and Sti hubs, rotors, brakes and axles*
-6 speed shifter and assembly****
-front axles can be reused if it has stubs in the transmission?
-some seem to be DCCD and others non-DCCD with Viscous LSD
-6-speed clutch fork and slave cylinder?
-5 speed or 6 speed clutch and flywheel

1st - 3.636
2nd - 2.375
3rd - 1.761
4th - 1.346
5th - 1.062
6th - 0.842
Final - 3.900

05 USDM Sti 6 speed:
-transmission
-driveshaft
-3.90 R&P gear to replace the 3.54 in the WRX
OR
-R180 rear differential and Sti hubs, rotors, brakes and axles*
-6 speed shifter and assembly****
-hubs or Stubs? Not clear on this one for the front but it seems there is extra that needs to be done with an 05***
-DCCD controller optional but recommended**
-6-speed clutch fork and slave cylinder?
-5 speed or 6 speed clutch and flywheel

1st - 3.636
2nd - 2.375
3rd - 1.761
4th - 1.346
5th - 0.971
6th - 0.756

05 JDM Sti 6 speed:
-transmission
-driveshaft
-3.90 R&P gear to replace the 3.54 in the WRX
OR
-R180 rear differential and Sti hubs, rotors, brakes and axles*
-6 speed shifter and assembly****
-hubs or Stubs? Possible using 03-04 stubs could work with the correct clip and seal like the 2006 tranny and then reuse wrx axles***
-Again not clear, but seems some come without DCCD**
-6-speed clutch fork and slave cylinder?
-5 speed or 6 speed clutch and flywheel

1st - 3.636
2nd - 2.375
3rd - 1.761
4th - 1.346
5th - 1.062
6th - 0.842
Final - 3.900

06 USDM Sti 6 speed:
-transmission
-driveshaft
-Stock R160 can be used without changing the gear ratio due to change in 06 that makes the ceneter diff a 1.1:1 vs the old 1.0:1
-stock rear axles can be used on rear due to no need to change the rear diff
-front...04 Sti Axle stubs can be ordered along with seals and clips that retains the WRX front Axles, hubs, etc? Special seals are needed. Axle Stub Part Number: 38415AA110
Circlip Part Number: 805329010 from Wrinkleboi's thread about this***
-6 speed shifter and assembly****
-DCCD controller optional**
-6-speed clutch fork and slave cylinder?
-5 speed and 6 speed clutch and flywheel

1st - 3.636
2nd - 2.375
3rd - 1.761
4th - 1.346
5th - 0.971
6th - 0.756

06 JDM Sti 6 speed: into wrx
-transmission
-driveshaft
-6 speed shifter and assembly****
-6-speed clutch fork and slave cylinder for 2007 sti
R160 rear diff (02-05 wrx)
6 speed clutch and flywheel
Circlips from 2004 sti, oil seals and axle stubs

1st - 3.636
2nd - 2.375
3rd - 1.761
4th - 1.346
5th - 1.062
6th - 0.842
Final - 3.900

07 USDM Sti 6 speed: into wrx
-transmission
-driveshaft
-6 speed shifter and assembly****
-6-speed clutch fork and slave cylinder for 2007 sti
R160 rear diff (02-05 wrx)
6 speed clutch and flywheel
Circlips from 2004 sti, oil seals and axle stubs

1st: 3.636
2nd: 2.375
3rd: 1.521
4th:1.137
5th:0.971
6th: 0.756
reverse - 3.545
final drive ratio - 3.90

JDM 07 Sti 6 speed

-transmission
-driveshaft
-6 speed shifter and assembly****
-6-speed clutch fork and slave cylinder?
-no clue
-no clue
-no clue

unknown ratios.


*For those wanting to use the R180 but not switch out the hubs, Apparently driveshaftshop.com offers custom axles (pricey) that allow you to retain the wrx hubs while using the R180 rear end.

** DCCD controller options...seems a member on here Spider? is making one for around $150, others go up from there. Without going to an Sti ECU it does not appear to be able to be used as a fully automatic setting, but Spiider's and the Neetronic units seem to get close. Then there is the 100% lock up with a toggle switch. I am unsure as to how soon this could kill the DCCD, but who knows it could last forever! Some sites with controllers:
www.neetronics.com
www.gems.co.uk
www.rocketrally.com
www.motec.com
www.dccdpro.com

*** There may be a difference between the 05 axles and the 02-04 axles on the WRX. There may have been a change to the axle and some 05 wrx might be able to use their stock axles. I have not verified this, just read some threads suggesting it.

****The shifter boot is suggested, but not necessarily an absolute must. The old shift boot can be reused with some modification and work. Shift knob is the same, it can be reused if necessary, but not the best option. Thread about this located here see post #66.

Parts and numbers for some of the parts:

32000-AJ350 2007 STi transmission
805329010 Circlips need 2
38415AA110 stubs need 2
806730041 oil seal Left and right side are different
806730042 oil seal Left and right are different
C1010FE004 short shifter
35046FE010 -shifter joint
633046020-spring pin

Thanks to WJM for the part numbers
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Last edited by crashtke; 02-18-2011 at 06:51 PM. Reason: Added in some additional information
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Old 02-13-2007, 02:02 AM   #2
crashtke
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Last edited by crashtke; 02-18-2011 at 07:10 PM.
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Old 02-13-2007, 07:40 AM   #3
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Nice post and please keep searching and updating for others, once this gets more complete, I'll put it in the Transmission FAQ. Something to research:

driveshaftshop.com axles to allow the R160 to be used instead of the R180. While I think that option sucks, it is an option that allows someone to avoid the R180/STI rear end/bigger wheels process.

5MT clutch/flywheel can be used in the 6MT, though not the perfect solution, it can be done for more savings for those that have new or expensive 5MT clutch/flywheel already.

Substitute 6MT shift knob, 6MT shifter linkage, and 6MT shift boot for shifter assembly to make sure people know exactly what you mean by assembly.

You forgot the 6MT clutch fork.
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Old 02-13-2007, 11:47 AM   #4
crashtke
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Ok updated with info about driveshaft.com, clutch fork, and clutch and flywheel. As for the shift knob and boot, I have seen people use the wrx shift knob and boot after words...not saying it is the best idea, but it is definitely possible...still have to have the whole 6 speed shifter assembly though. For now I will just leave it at assembly. Thanks for some things I forgot. Just a lot of information in this whole process.
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Old 02-13-2007, 12:46 PM   #5
crashtke
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OK next question...some say to use the Sti clutch slave cylinder. I have updated this as necessary equipment. It seems to be required from what I have found. I am not sure if you need the same year clutch cylinder as the tranny or not. Are they all the same?

Last edited by crashtke; 02-13-2007 at 03:29 PM.
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Old 02-13-2007, 06:01 PM   #6
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don't forget axle seals. there are different diameter seals for early 04, and late 04 and up. this depends on the style of the front axles of the 6MT youre swapping and the 5MT you already own.
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Old 02-13-2007, 06:25 PM   #7
03GLHWRX
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This thread is an excellent addition to the community. Thanks. Suggestion: Add gear ratio info.
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Old 02-13-2007, 10:15 PM   #8
crashtke
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Added another note about axle seals. I have no clue whatsoever what the JDM ratios are. As for the USDM they are the same from 04-06 right?
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Old 02-14-2007, 09:10 AM   #9
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The JDM ratios are the same as the USDM 6 speeds with the exception of 5th and 6th gear. I think those ratios are in the FAQ somewhere as I remember reading them.
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Old 02-14-2007, 09:50 AM   #10
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Updated with ratios
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Old 02-14-2007, 02:17 PM   #11
crashtke
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Does anyone have any problems with any of the information that has been posted thus far? Again, I really don't want to be posting any mis-information. This is just what I have been able to scrape up from here and a couple other sources.
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Old 02-14-2007, 02:59 PM   #12
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about the axle seals, I can personally vouch for this. if you have male style front axles (where the axles extend into the transmission), you have larger diameter axle seals. If you have stubs seaparate from the axles, you have smaller diameter axle seals.

example, my 03 WRX had female axles with male stubs in my 5MT. the 6MT I bought had no axle stubs, just the male axles with LARGER diameter seals. I used the larger diameter seals with the smaller diameter axle stubs, and had a LOT of fluid leakage until I replace the seals with the correct size.
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Old 02-14-2007, 06:22 PM   #13
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Quote:
Originally Posted by crashtke View Post
Does anyone have any problems with any of the information that has been posted thus far? Again, I really don't want to be posting any mis-information. This is just what I have been able to scrape up from here and a couple other sources.
You are doing a fabulous job so far and I personally love you for it! If you need more help, please PM some drivetrain Vendors like Rallispec, IA Performance, Gruppe-S, Andrewtech Automotive, etc. to get their 2 cents.
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Old 02-14-2007, 06:30 PM   #14
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Suggestion for **

www.neetronics.com
www.gems.co.uk
www.rocketrally.com
www.motec.com

This is 100% of the DCCD controllers on the market. I've heard from many though that Pat's (rocketrally.com) solution is the "best" though.
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Old 02-14-2007, 09:38 PM   #15
crashtke
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Quote:
Originally Posted by nicad View Post
about the axle seals, I can personally vouch for this. if you have male style front axles (where the axles extend into the transmission), you have larger diameter axle seals. If you have stubs seaparate from the axles, you have smaller diameter axle seals.

example, my 03 WRX had female axles with male stubs in my 5MT. the 6MT I bought had no axle stubs, just the male axles with LARGER diameter seals. I used the larger diameter seals with the smaller diameter axle stubs, and had a LOT of fluid leakage until I replace the seals with the correct size.
Ok to confirm, you can take the smaller stubs that the 02-04 wrx had and place them in the later models though, but you just have to use the correct seal right? That allows you to use your existing axles right? Can the stubs be removed from the WRX 5 speed transmission and used in the Sti 6 speed transmission or do you have to buy 04 Sti 6 speed stubs?

I added the DCCD controller information Ron. Thanks for the references. I just want this to be fairly complete and not be one of those guys just throwing around information that they have "heard" from some random source. I want correct information where future people considering the swap will know exactly what they are getting into BEFORE shelling out the cash and then later realizing they need to spend an extra $1k on other misc parts. Not that people will probably read this as FAQ's are often ignored but for those that take the time, the information will all be there rather than scattered over 500 different threads.
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Old 02-15-2007, 03:07 AM   #16
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add how the hell to get sti 6 speed in 06 wrx with different clutch engagement set up.....purty plz
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Old 02-15-2007, 01:16 PM   #17
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Quote:
Originally Posted by crashtke View Post
Ok to confirm, you can take the smaller stubs that the 02-04 wrx had and place them in the later models though, but you just have to use the correct seal right? That allows you to use your existing axles right? Can the stubs be removed from the WRX 5 speed transmission and used in the Sti 6 speed transmission or do you have to buy 04 Sti 6 speed stubs?
the 02-04 WRX axle stubs that are in the transmission can't be removed without disassembling the transmission. they are held in by C-clips on the inside of the front diff assembly. That being said, you can use your existing axles (Im doing it right now), but you must use the 6MT axle stubs.

I should make some kind of flowchart for it, because it seems a pain to describe
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Old 02-15-2007, 06:26 PM   #18
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Gotcha! Thanks for the update. As for the 06+ wrx I have no clue and there does not seem to be a lot of data out there right now. This is for the 02-05 That can be done at a future date. Anyone know if stubs can be used in the 2005 Sti 6 speed? Anyone have any information about the various years of JDM trannies?
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Old 02-15-2007, 06:49 PM   #19
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Quote:
Originally Posted by crashtke View Post
Gotcha! Thanks for the update. As for the 06+ wrx I have no clue and there does not seem to be a lot of data out there right now. This is for the 02-05 That can be done at a future date. Anyone know if stubs can be used in the 2005 Sti 6 speed? Anyone have any information about the various years of JDM trannies?
Correct me if I'm wrong, but I think the 05 and up Stis have axles with male ends as opposed to the female ends used in the 04 6 speed and the JDM v7 6 speed.
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Old 02-15-2007, 07:07 PM   #20
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Yeah, thanks for updating this and making it nicer as you go along so that n00bs will skip over it. You might have already seen it, but http://forums.nasioc.com/forums/show....php?t=1182979 is pretty sweet for content. I'm getting underway for a week, so I'm stickying this in hopes of more help.
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Old 02-16-2007, 03:47 PM   #21
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EXCELLENT POST AND INFO...thanks man
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Old 02-17-2007, 06:09 AM   #22
crashtke
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Quote:
Originally Posted by jdmboostfed View Post
Correct me if I'm wrong, but I think the 05 and up Stis have axles with male ends as opposed to the female ends used in the 04 6 speed and the JDM v7 6 speed.
Right, but just like the 06 I THINK you can use the stubs out of an 04 sti along with the proper seals. I could be wrong on that for the 05 6 speed. Can anyone comment?
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Old 02-17-2007, 06:10 AM   #23
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BTW I appologize in advance, but I am going to be out of it for a while. I am having some serious issues at home. I will be off and on with my posts for a while.
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Old 02-17-2007, 08:41 AM   #24
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Quote:
Originally Posted by crashtke View Post
Right, but just like the 06 I THINK you can use the stubs out of an 04 sti along with the proper seals. I could be wrong on that for the 05 6 speed. Can anyone comment?
the 6MT stubs are all the same.

yes the late 04, 05+ use male axles, which corresponds to the LARGER axle seals.
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Old 02-26-2007, 02:48 PM   #25
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Found this out today and I don't know if it is relevant or not.

The STi shifter boot has different part numbers between 04 and 05-06. It seems one has the clip and the other doesn't around the top of the boot.

Last edited by VipersEatLotus; 02-27-2007 at 12:51 PM.
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