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Old 04-29-2009, 12:22 AM   #1
whatishe
Scooby Specialist
 
Member#: 65711
Join Date: Jul 2004
Chapter/Region: Tri-State
Location: NJ
Vehicle:
2004 WRB WRX Wagon
2.5 Hybrid STI Conversion

Default 5mt to 6mt USDM WRX Wagon Swap Help!

I also posted this in the transmission forum, I don't know which is more correct. I'm doing the 6mt swap into my 04 WRX wagon. I had gotten a rear diff off a turbo legacy (told it was 3.9) and then bought a supposed 4EAT driveshaft off ebay out of a totaled 04 wrx wagon. Axels didn't hook up to the rear diff so I had the guts swapped to the R160. Got this note tonight from my buddy at the shop:

"After setting up the WRX differential in the case with the 3.9 gear pinion, spending two hours getting the correct gear lash and bearing clearance.....then installing it. The driveshaft you provided does not fit, its most likely something wrong with the rear. The problem is the rear flange has holes in a rectangle with the dimensions of:

44mm x 53mm

The driveshaft has square dimensions of:

53mm x 53mm


The dimensions are approximate (+_ 0.3mm), center to center.

Unfortunately, it's not as easy as just changing the flange. With most cars there is a crush collar on the pinion side of the rear end that needs to be changed and setup when changing the flange or any bearing on the pinion side of the rear. This puts the proper amount of preload on the pinion bearing, too much and it vibrates apart, too little and it over heats and locks up.

So;
1) the driveshaft is wrong and we need a new one.
2) the rear is wrong and we need a new one. "

This of course is the last major obstacle in the build and makes me a super

Anyone know the quickest, most effective way (both in cost and quality) to remedy this problem? Answers would be great, part numbers too.

Parts List:
'04 USDM 6mt
'04 stock WRX wagon axles
'9x Turbo Legacy 3.9 Rear
'04 4EAT Driveshaft (what I was told is an auto driveshaft, has a square flange)
'04 Stock 5mt Driveshaft (don't know which flange)
1/2 of a random manual Driveshaft that came with the 6mt (square flange)
Aftermarket DCCD Controller

Thanks a lot everyone!
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Old 04-29-2009, 01:47 AM   #2
gordini69
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Member#: 119591
Join Date: Jul 2006
Default

If the flange from your old diff is the same bolt pattern use it. As far as pre-load on pinion bearings just replacing the flange will not affect this, unless you go crazy with the impact gun.
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Old 04-29-2009, 02:20 AM   #3
whatishe
Scooby Specialist
 
Member#: 65711
Join Date: Jul 2004
Chapter/Region: Tri-State
Location: NJ
Vehicle:
2004 WRB WRX Wagon
2.5 Hybrid STI Conversion

Default

I'll make sure to ask.
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Old 04-29-2009, 08:43 AM   #4
whatishe
Scooby Specialist
 
Member#: 65711
Join Date: Jul 2004
Chapter/Region: Tri-State
Location: NJ
Vehicle:
2004 WRB WRX Wagon
2.5 Hybrid STI Conversion

Default

bump for 2nd opinions?
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Old 04-29-2009, 12:05 PM   #5
whatishe
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Member#: 65711
Join Date: Jul 2004
Chapter/Region: Tri-State
Location: NJ
Vehicle:
2004 WRB WRX Wagon
2.5 Hybrid STI Conversion

Default

Bump for justice
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Old 04-30-2009, 12:49 AM   #6
whatishe
Scooby Specialist
 
Member#: 65711
Join Date: Jul 2004
Chapter/Region: Tri-State
Location: NJ
Vehicle:
2004 WRB WRX Wagon
2.5 Hybrid STI Conversion

Default

issue resolved. thanks to those who replied.
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