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Old 06-19-2015, 01:00 AM   #1
clint78z
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Default Inside a 5 speed DCCD RA transmission

I bought a 5 speed DCCD transmission a while back. I am going to pull it apart and put the DCCD transfer case and helical LSD on my 2007 forester XT turbo transmission. Going to control it with a MapDCCD controller.





I pulled the transfer case off to inspect all bearings and replace seals. Next I opened up the DCCD unit to see how it works. Plenty of tiny roller bearings. Lots of stuff packed in a little unit. Tested the coil unit. I missed taking a picture of the center shaft in relation to the clutches. There are small oil holes. Does anyone know how these oil holes are clocked according to the holes in the clutches??



Here we see the planetary gears which gives 65% rear drive when the clutches aren't locked = 0% duty cycle to the DCCD coil.




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Old 06-19-2015, 01:40 PM   #2
mrsaturn7085
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Thank you for the contribution. There are very few easy-to-find images of a disassembled DCCD online. I will be rebuilding a 2006 STI DCCD in the next year or so, and plan to take step-by-step photos of the process, both for maintaining accuracy in the rebuild, as well as helping everyone else that would like to attempt this on their own.

I am unsure if the earlier JDM GC DCCD units differ from the 04-05 model, but they are clearly similar vs. the massive changes that were made for 06-07.

Last edited by mrsaturn7085; 06-19-2015 at 02:43 PM.
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Old 06-20-2015, 07:38 PM   #3
Bikelok
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Good for you to take this on.

Good luck and keep posting. Even if there is a failure lets us know. Failures add information too.

Again good luck.
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Old 06-21-2015, 12:18 AM   #4
clint78z
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I don't imagine the oil holes are critical for orientation. Just nice to put it back the same way it was factory.
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Old 06-21-2015, 02:03 AM   #5
mrsaturn7085
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They could be... are there 4? If I had to guess, I'd say the gaps on the friction discs ride on the oiling area so you have full tooth engagement on disc itself.
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Old 06-22-2015, 10:09 AM   #6
clint78z
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I did put the oil hole inline with the gap in the friction disc. That way oil would be distributed equally among the friction discs. Not sure if that is what they were intending??
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Old 06-22-2015, 12:52 PM   #7
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How many radial oil holes were there, per section, and total?

If the answer is 4 per section, 8 total, I'm 99% sure you did it properly.
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Old 06-22-2015, 03:32 PM   #8
Mr.Chow
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Interesting you just posted this, I'm about to install a v.5 dccd into my turbo baja...my two questions are:
1. Can you run a oem GD sti USDM dccd controller on this trans? (I DD mine and don't need to spend $400 on dccd pro or dccdmap)

2. I want to run a .738 5th gear and wanted to know if all I need is the gear or if I'll need the sychro hub as well? Phase 2 I believe.
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Old 06-23-2015, 02:59 AM   #9
ParadigmShift
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Question 5 Speed DCCD Plates

Fantastic timing,
These boxes are legend, with a replacement Group N ratio 3-4 cluster very competitive as a track car.
I am approaching the power handling (and wear) limits of my venerable MY99 STi Type RA 5 Speed and cannot find find any OEM or other options for DCCD overhaul.

I noticed some new parts in you pic. Are you aware of any place to get rebuild parts for these old DCCD units. Specifically the friction plates. Would you be able to post any detailed dimensions on the plates please. ID ,OD thickness etc. would very helpful.

I cannot find any references to 5 speed dccd overhaul parts and have been reduced consider custom build for the components.

Thanks Simon
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Old 06-24-2015, 10:45 AM   #10
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Quote:
Originally Posted by ParadigmShift View Post
I noticed some new parts in you pic. Are you aware of any place to get rebuild parts for these old DCCD units. Specifically the friction plates. Would you be able to post any detailed dimensions on the plates please. ID ,OD thickness etc. would very helpful.
I am just replacing all the seals in the transmission. From what I have been reading during my exhaustive search is not too much goes wrong with the transfer case side of the transmissions. The C clip on the DCCD unit sneaking out of it's groove is the only problem. Since the 5 speed can only take so much abuse the gears will probably shatter before you kill your friction discs in the DCCD. I think the only way you would do it is drive full lock on tarmac with sticky tires, or towed it with only 2 wheels in the air.

I could measure the plates, not sure how useful it would be. In order to reproduce the parts a machinist would have to accurately, measure and apply tolerances to the parts. Selection of material would be key to it holding up. Custom machined plates would probably add up pretty fast for a one off job. These guys reproduce carbon clutches for the 6 speed DCCD, perhaps you could get them to do 5 speed DCCD clutches?? eng.kaps-transmissions.com/products-carbon-dccd-kit.htm

Quote:
Originally Posted by ParadigmShift View Post
I cannot find any references to 5 speed dccd overhaul parts and have been reduced consider custom build for the components.

Thanks Simon
I think Rallispec can set you up with rebuild parts. I would suspect as soon as you opened it up you wouldn't need new clutches. http://www.rallispec.com/Transmissio...ice%20List.pdf

Could you do a function test on the car?? Saw a youtube video of a person putting the car on jack stands testing the DCCD somehow?? Can't find it again. Not sure how safe this was to do.
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Old 06-24-2015, 05:00 PM   #11
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Quote:
Originally Posted by clint78z View Post
I could measure the plates, not sure how useful it would be. In order to reproduce the parts a machinist would have to accurately, measure and apply tolerances to the parts. Selection of material would be key to it holding up. Custom machined plates would probably add up pretty fast for a one off job. These guys reproduce carbon clutches for the 6 speed DCCD, perhaps you could get them to do 5 speed DCCD clutches?? eng.kaps-transmissions.com/products-carbon-dccd-kit.htm
Your disassembled DCCD looks nearly identical to the 2005 models I've seen taken apart. I could be mistaken, but I do know the GC8 models were all 35:65, just like the '04-'05. They look similar externally, as well.

If you'd like to compare the internals to the rebuild kit instructions (for the '04-'05 DCCD), here you go:

http://www.sti.jp/en/competitor/n_pa...04S010List.pdf

Last edited by mrsaturn7085; 06-24-2015 at 05:17 PM.
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Old 06-25-2015, 10:09 AM   #12
clint78z
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Quote:
Originally Posted by mrsaturn7085 View Post
Your disassembled DCCD looks nearly identical to the 2005 models I've seen taken apart. I could be mistaken, but I do know the GC8 models were all 35:65, just like the '04-'05. They look similar externally, as well.

If you'd like to compare the internals to the rebuild kit instructions (for the '04-'05 DCCD), here you go:

http://www.sti.jp/en/competitor/n_pa...04S010List.pdf
That's great information. I looked through the PDF file it looks pretty close. A little hard to tell all information with a cross section drawing. Just a quick question about the shaft that fits in the friction discs. Do you know how the oil holes were clocked in relation to the gaps in the friction discs??
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Old 06-25-2015, 12:46 PM   #13
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I've been commenting on that since you asked initially - I'm not sure, but if there are 4 radial holes (8 total) then I would expect the holes to align with the gaps in the discs.
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Old 06-25-2015, 07:55 PM   #14
clint78z
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Quote:
Originally Posted by mrsaturn7085 View Post
I've been commenting on that since you asked initially - I'm not sure, but if there are 4 radial holes (8 total) then I would expect the holes to align with the gaps in the discs.
For sure, just wanted to verify with some one who has taken a similar one apart before.
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Old 07-11-2015, 02:49 PM   #15
clint78z
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Got around to splitting the transmission, and taking a peak inside the front helical LSD. Everything looks tip top in there. Should be a nice upgrade to the open diff in the snow.






Last edited by clint78z; 07-31-2015 at 02:46 PM.
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Old 10-29-2015, 02:08 PM   #16
drboogaloo
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Any new updates on this? Very interested. I have been trying to figure out the best option as far as transmissions go. So many choices. I also have a forester xt (05) and I really enjoy having a 4:44 final drive but there aren't many options as far as upgrade paths with that final drive ratio.
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Old 01-18-2016, 10:25 PM   #17
machineica
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Did you have to use a puller to remove the dccd coil?
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