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Old 09-03-2008, 05:05 PM   #1
N101PA
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Default GC8/EJ20 Swap questions (ie stock tranny)

I recently bought a 2007 Chevrolet Silverado because I tow a lot of stuff, which is not what a Subaru is for, and I have been bit (again) by the Suby bug but I don't have enough money to throw into another loan for a newer WRX or STi. I have been thinking a long time about doing a swap into a '95 Impreza L, I have decided that I am going to make it a long term project for the winter, with a budget of course.

Originally I wanted a complete STi swap, but even wrecked STi's at auction are selling for more than 10k. I've decided on an 02-05 WRX engine swap w/ some mods, 07 WRX Limited interior (seats, steering wheel, and gauge cluster), 99-01 RS front end conversion, and 04-07 STi suspension/brakes.

This forum has been great as a resource for my swap project, although I haven't found any clearcut answers to some of the questions I have. I am planning on a stock USDM EJ20 w/ these mods:

Cobb Short Ram Intake
Perrin Equal Length Header
Perrin Uppipe
Random Tech 3" Downpipe w/ Hi-flow Cat
Invidia N1 Cat-Back
IHI VF43 Turbo
STi "Pink" 5XXcc Injectors
STi Intercooler
EcuTeK ECU Reflash

Will a stock '95 Impreza AWD 5-speed Transmission, diff, and axles w/ 150xxx miles on it be able to handle roughly 300 hp to the wheels? Would a WRX Trans be a better option?

Will a WRX fuel pump be able to handle the fuel duties or will I need a larger pump?

Thanks,

- Josh W.
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Old 09-03-2008, 05:11 PM   #2
ciper
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I have a 2005 STI engine behind a stock 98 RS five speed with 120k miles. Its the exact same trans as your L but with different gears and final drive ratios.

I don't think the WRX pump will flow enough for your expected modification level. Walbro's are a dime a dozen so why not get that?
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Old 09-03-2008, 05:28 PM   #3
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Ciper, thanks for getting back so quick, just had been wondering for the past few days. A Walbro 255lph fuel pump kit for a '95 Impreza L is $99, whereas a HP 255lph pump kit is $114...is there a major difference between the HP and normal pumps?

Thanks,

- Josh W.
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Old 09-03-2008, 05:43 PM   #4
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I'm lazy read this - http://www.contour.org/ceg-vb/showthread.php?t=2788
gss-317 is the regular while gss-342 is the HP.

As far as the transmission it is my personal opinion that the 5 speed is fine for a daily driver. Any type of competition (even auto-x or canyon runs) might be too much stress for it unless you have excellent shifting technique.

As far as the swap I did its freaking awesome. The gear ratios and short final drive makes the car faster than a similarly specced car with a 6 speed.
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Old 09-03-2008, 05:53 PM   #5
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It will be mostly a "when I feel like being cool" car considering I already have my 07 Silverado that I'm paying a pretty penny for now. As for being daily driven, it might share time with the truck, but it will mostly see sunday drives and the fairly frequent trips to LA or Tahoe, so the driveline needs to be reliable for those longer hauls and strong enough for the occasional pull down the 1/4 against my friends Evo. Thanks for the insight ciper!

- Josh W.
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Old 09-03-2008, 05:54 PM   #6
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Looks like the standard 255lph pump will be just fine =)
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Old 09-03-2008, 06:00 PM   #7
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I see you have put some thought into your plan but I'm going to throw out another idea. If you are worried about the drivetrain components why not purchase an entire wrecked donor car and swap the tranny / drivetrain / engine into the Impreza? Then you would have basically an Impreza with all the same guts as a WRX underneath. It might save you some time and trouble finding specific parts and you can always part out the rest of the donor car to make some money back.
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Old 09-03-2008, 06:05 PM   #8
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Yeah I was thinking about that too, and a rolled WRX can probably be had for ~$5k or less, but the "storage" of the wrecked WRX becomes an issue as I only have enough consistent garage space for 1 car.
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Old 09-03-2008, 08:03 PM   #9
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A few more questions for you guys...

Will a WRX Gauge cluster fit into the stock L Dash? If so, would I keep the Gauge Cluster wiring of the WRX Harness or just modify the L's wiring for the new cluster?

Will WRX Limited Seats bolt into the stock locations of the L?
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Old 09-03-2008, 09:03 PM   #10
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Quote:
Originally Posted by N101PA View Post
A few more questions for you guys...

Will a WRX Gauge cluster fit into the stock L Dash? If so, would I keep the Gauge Cluster wiring of the WRX Harness or just modify the L's wiring for the new cluster?

Will WRX Limited Seats bolt into the stock locations of the L?
I'm pretty sure the WRX cluster will not fit into the stock dash, but if you're considering picking up a wrecked WRX, why not swap the dash? I'm pretty sure the seats will bolt up. I have ver 3 STi seats in mine.

As for your drive train question. I'm swapping in my spare '04 STi motor into a 98L. While the '98 trans is fine, I have an '02 tranny, rear diff and axles that are going in. The 2.5L motor will be basically stock (looking for ~225-250hp to the wheels) with the 720cc inj. that came out of my STi (I know, way too big, but they're paid for), 255lph walbro and a VF43 turbo and will run open source tuning on the '04 ECU. FWIW, I'm sticking with the stock L dash (this is a build project on a tight budget) and will have ECS take care of the wire merger.
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Old 09-03-2008, 09:12 PM   #11
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The WRX trans is basically the same as your L. It would have an advantage since its newer (synchros that aren't dead) but don't assume its rated for significantly more power because its behind a turbo
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Old 09-03-2008, 09:14 PM   #12
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I know there will be some modification to fit a WRX dash, but how much, would I be able to cut and weld what is necissary in my garage or will it need major rework to fit?
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Old 09-03-2008, 09:16 PM   #13
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Im thinking it might be a good idea, instead of finding a WRX tranny, to rebuild the tranny I have...would it make much of a difference in the long run?
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Old 09-03-2008, 09:24 PM   #14
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There are alternate gearsets available for the 5 speed which can withstand high power levels. You should check out the transmission forum because its a common topic.
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Old 09-03-2008, 10:00 PM   #15
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Thanks for all the help guys, I'll check out the Transmission forum, I appreciate all the advice! =)
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Old 09-03-2008, 11:18 PM   #16
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Here is how I am planning my build:


1995 Subaru Impreza L Coupe 5 spd - $1500


2002 - 2005 USDM EJ20 2.0L - $2000
Walbro 255lph Fuel Pump - $100
WRX 2.0L MT ECU - $200
WRX 2.0L MT Wiring Harness - $300
90-94 Legacy Turbo Crossmember - $100
TOTAL - $2700


Stage 1
Cobb Short Ram Intake - $150
Exhaust Gasket Kit - $70
Perrin Uppipe - $200
Random Technologies Catted Downpipe - $700
Blitz Nur Spec S Catback - $450
EcuTeK Engine Management - $600
TOTAL - $2170


Stage 2
IHI VF43 Turbo (07 STi) - $750
STi Pink Injectors - $480
STi Top-Mount Intercooler - $350
TOTAL - $1580


Stage 3
Perrin Equal Length Header - $700
STi Oil Pan - $100 (needed for clearance for ELH)
TOTAL - $800


Interior Stuff
WRX Limited Seats (F&R) - $600
TOTAL - $600


RS Exterior Stuff
RS Hood - $200
RS Front Bumper Assy (w/ Bumper Bar and Fog Lights) - $400
RS Headlights - $200
RS Grille - $75
RS Spoiler - $200
TOTAL - $1075

SUBTOTAL - $10,425.00
7.25% tax - $755.81
PARTS TOTAL - $11,180.81


LABOR
3x Tunes @ $500 - $1500
Car Repaint - $1500
TOTAL - $3000

Incidentals - $1000 (nuts, bolts, wheels, other misc parts)

GRAND TOTAL - $15,180.81 (Or about what a decent used WRX is going for...but I get a unique car I built myself, 250+ whp doesn't hurt either =)

Last edited by N101PA; 09-03-2008 at 11:38 PM.
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Old 09-04-2008, 12:33 AM   #17
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You can use pretty much any pre 2001 turbo cross member and it will bolt right in.

You forgot to add the swaybar, turbo units are different IIRC
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Old 09-04-2008, 12:40 AM   #18
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will a 02-05 WRX Sway bar fit? If not, what will?
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Old 09-04-2008, 01:11 AM   #19
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Yes the WRX sway bar will fit an older turbo cross member. You may need new "bushing retainers" if you use a newer (say 98) turbo sway bar. Wagon bars are narrower than the sedan bars in case you go that route.
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Old 09-04-2008, 10:03 AM   #20
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FWIW, STI pinks should run you more like $250 not $480 and you may just want to buy a large eBay TMIC.
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Old 09-04-2008, 10:35 AM   #21
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Hello,
I am not seeing a clutch and pressure plate on that list of needed swap parts. You will also probably want a fresh flywheel as well.

To answer your question about the 5spd, it will be plenty strong for what you are doing. You sound like an adult. Adult drivers rarely break them. Rebuilding is never a bad idea.

To make it last as long as possible stick to a stage II clutch kit. Do NOT under any circumstances get a pucked clutch. This is the mistake that so many people make. That transfers all that load and shock to your gears and sliders. Keep a full clutch disc in there that has some slip left in it. Avoid kevlar and avoid pucked and your tranny will live.

Don't bother with STi pinks. Just send your stocker WRX injectors to DW.

The dash installation requires you to cut and reweld the cross bar. It's not major but if you don't have a welder, you may want to avoid it. The flipside is that the dash install lets you use the complete WRX harness with a bare minimum of cutting and splicing. You end up doing most of your changes to the headlight wiring. So, there's a tradeoff there, plus the WRX dash is much much nicer.

Here's another thought. Have you considered a JDM swap? You could even do it RHD and not cut a single waire. Just something to think about though CA emissions can be a hassle. Got any buddies up in Reno that will register the car in NV for you?
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Old 09-04-2008, 12:23 PM   #22
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Yeah the Clutch and Flywheel totally skipped my mind until last night, even though I have been asking about the reliability of the transmission under higher torque loads. Thanks for the advice on the clutch type I should use too. For my application, an ACT Performance Street Disc, ACT Heavy Duty Pressure Plate, and a Fidanza or ACT Aluminum Flywheel. This setup should be good for ~310lb/ft.

I want to swap in a USDM WRX motor because there won't many (if any) headaches on keeping this car CA smog legal, I'm trying to find a wrecked WRX with a CA Salvage Title so I can prove that its a CA engine.

As for the dash, I know some folks with metal/machine shops that can do the cuts/welds. Does anyone know what needs to be moved in order to fit the dash? I'm assuming I need everything out of the WRX from the firewall back.

During the swap, would it be worth it to rebuild the engine and/or transmission? Even just to inspect, clean, and regasket?

Last edited by N101PA; 09-04-2008 at 12:34 PM.
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Old 09-04-2008, 12:49 PM   #23
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you might also consider open source em and trim $600 off your budget
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Old 09-04-2008, 01:07 PM   #24
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With that budget you could probably buy a wrecked STI and sell whatever you don't end up using. You'll be at about the same power levels, maybe a bit less, but you'll have a 6 speed and brembos.
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Old 09-04-2008, 01:09 PM   #25
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That's another way to go, so far these are the decisions I have to make...

1) Buy a WRX engine, ECU, and Harness or buy a complete WRX and swap as much as I want/can (buying a complete WRX is cheaper but I don't have much space in my garage to keep the parts or the car...but I can leave the L outside while Im tearing apart the WRX)

2) Do all of the upgrades myself in stages or get a Stage 3 power pack +tuning for ~$4000 from one of the many fine performance shops in CA. (not really sure which is better)

3) Do the wiring myself or send out the Wiring Harness (difference is I can do wiring, but it might be worth the $1000 to make sure its done right)
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