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Old 05-27-2009, 01:31 PM   #1
DS1
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Default The end all 6 speed swap information thread

Due to the constant asking of the same questions about 6 speed swaps into different year car I've decided to put together a thread out lining the parts and misc info needed to complete a successful swap.

Basic 6 speed info:

JDM STi 2001-2006
Ratios= 3.636 / 2.375 / 1.761 / 1.346 / 1.061 / 0.842
3.90 final drive (front and rear) or 4.44 Front and rear /has both male and female front axles (check production date, changes mid MY03). LSD Front diff(except STi Forrester, some EDM and V7 Wagon)/DCCD Center (MY01-MY04 is 36F/64R Bias Open/ MY05+ is 41F/59R Bias Open)
Clutch = Pull


USDM STi

2004- Part# 32000AG880
Ratios= 3.636 / 2.375 / 1.761 / 1.346 / 0.971 / 0.756
3.90 final drive (front and rear)/has both male and female front axles (check production date, changes mid year). LSD Front diff/DCCD Center (36F/64R Bias Open)
Clutch = Pull

2005- Part# 32000AH150
Ratios= 3.636 / 2.375 / 1.761 / 1.346 / 0.971 / 0.756
3.90 final drive (front and rear)/ Male front axles. LSD Front diff/DCCD Center (36F/64R Bias Open)
Clutch = Pull

2006- Part# 32000AJ760
Ratios= 3.636 / 2.375 / 1.761 / 1.346 / 0.971 / 0.756
3.90 front final drive-3.54 rear final drive/ Male front axles. LSD Front diff/DCCD Center (41F/59R Bias Open)
Clutch = Pull

2007- Part #'s 32000AJ350 and 32000AJ100
Ratios= 3.636/ 2.375/ 1.521/ 1.137/ 0.971/ 0.756
3.90 front final drive-3.54 rear final drive/ Male front axles. LSD Front diff/DCCD Center (41F/59R Bias Open)
Clutch = Pull

USDM Legacy Spec B

2007- Part# 32000AJ390
Ratios= 3.636 / 2.235 / 1.521 / 1.137 / 0.891 / 0.707
3.90 front final drive-3.54 rear final drive/ Male front ales. Open front diff/ Viscous center diff
Clutch = Pull

Please note: I didn't list the 08' STi or Spec B because of the lack of the vehicle speed sensor on the front diff. The can work if you swap the bell housing from an older 6 speed but it is a lot of work.
--------------------------------------------------------------------------
Now that you've chosen your 6 speed here is the axle/ final drive specs for your USDM car:

1993-2001 Impreza:5mt / 4eat
Final drive: 3.90/4.11/4.44 Please look in your owners manual or consult a dealer to run your vin # and figure out which you have.
Front Axles = Female
Clutch = Push

2002-early 2004 WRX 5mt/4eat
Final drive: 5mt= 3.90 Front/3.54 Rear - 4eat 4.11 Front and rear
Front Axles = Female
Clutch = Pull

Late 2004-2005 WRX 5mt/4eat
Final Drive: 3.90 Front/3.54 Rear - 4eat 4.11 Front and rear
Front Axles = Male
Clutch = Pull

2006-2007 WRX 5mt/4eat
Final Drive: 3.70 Front and Rear - 4eat 4.11 Front and rear
Front Axles = Male
Clutch = Push

--------------------------------------------------------------------------

Driveshafts to use with 6mt:

1993-2001 Impreza: This generation 4eat shaft is the best choice as it has the correct center support bearing mount. If you have an R180 use this Subaru part# 38358AA000 (small bolt pattern) yoke to adapt the 4eat shaft.

2002-2007 WRX 4eat: Will bolt directly in with a R160 rear diff, will not bolt to USDM R180 without Subaru part# 38358AA000 (small bolt pattern)

2004-2007 STi: Will not bolt to a R160 unless you use flange Subaru part# 38358AA040 (large bolt pattern)

Both of these yokes are interchangeable between R160 and R180 to suit the drive shaft you have available.

--------------------------------------------------------------------------
Rear Diffs:

R160- Depending on your choice of 6mt, you may need to change the ratio in your R160 to coordinate to the final drive of the 6mt. (please compare the front and rear final drive ratios of your stock car vs. the 6mt in the charts above)

Subaru Part #'s

3.90 - 38104AA010
3.54 - 38104AA060

R180- There are 3 Subaru ratios available (3.54/3.90/4.44). Choose the one that coordinates with the 6mt you have choosen.

USDM 04'-05' STi = 3.90 (also all JDM STi's)
USDM 06'-07' STi = 3.54
USDM Spec B = 3.54
JDM 01'-02' Gravel Spec STi = 4.44

--------------------------------------------------------------------------

Front Axle:

Female Axles- Held in by a roll pin tht has to be tapped out to slide axle off of transmission stub.

Male Axles- Held in by retainer clip on the diff side of the axle. They have to be "popped" out of the front diff for removal.


If you choose a male axle 6mt and you have a female front axle car you will need these:

806730042 Oil Seal LH x1
806730041 Oil Seal RH x1
38415AA110 Axle Stub x2
805329010 C-Clip x2

If you have a Female 6mt and a male front axle car you will need the following:

806735230 Oil Seal x1
806735240 Oil Seal x1

--------------------------------------------------------------------------

Clutches:

Pull Style- The release bearing is snapped into the pressure plate. It requires the release fork pivot rod to be removed to separate the transmission from the engine. The slave cylinder actuates forward (pointed away from the firewall).

Push Style- The release bearing and fork stay with the transmission when separating it from the engine. The slave cylinder actuates rearward (pointed to the firewall).

Flywheels:

02'-05' WRX all use the same clutch and flywheel (except very early 02's). The 5mt clutch can be used with the 6mt but is a smaller diameter than the 6mt unit. The WRX slave cylinder can be reused on all 6mt's.

06'-07' WRX will have to switch to either the 02'-05' WRX clutch or a 04'+ STi clutch and slave cylinder.

Misc. Part numbers that may be helpful:

Clutch fork shaft (long part the clutch fork pivots on) - 30532AA020
Clutch fork shaft plug (threaded cap that holds the fork shaft in) - 30550AA000 (all pull style 5mt from 93'-05')
Output Shaft Oil Seal (oil seal for the driveshaft interface) - 806735210
Clutch fork spring (spring that connects clutch fork to bell housing) - 30546AA060



This is a preliminary post, if you see something I missed or mis-information please let me know.

-Dylan @ DS1
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Last edited by DS1; 06-25-2009 at 02:20 PM.
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Old 05-27-2009, 01:39 PM   #2
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Well damn! im ready for the swap next month! and a 30r! lets see how long my engine last!
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Old 05-27-2009, 02:08 PM   #3
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this is VERY helpful. Thanks Dylan! YOU ROCK!
-Gaddis
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Old 05-27-2009, 03:09 PM   #4
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Good write up Dylan.
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Old 05-27-2009, 03:17 PM   #5
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nice write up on the difference in transmissions
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Old 05-27-2009, 05:21 PM   #6
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yes, this information is helpful, but there are other threads detailing 6 speed swaps - why not just make one comprehensive swap thread, lock and sticky it???
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Old 05-27-2009, 05:31 PM   #7
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Default

That was the idea, to try and get all the 6mt's and all the year cars in one thread.

-Dylan @ DS1
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Old 05-27-2009, 07:01 PM   #8
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I'm not aware of Subaru offering a 4.44 final with the 6 speed (OEM). My Ver 6, Type-R 5 speed has 4.44 final though . To the best of my knowledge, all 6 speeds had a 3.90 front diff and the rear varied between 3.54 or 3.90. 3.54 cars had a 1.1:1 dropdown in the transfer case to match the F&R gearing (3.90 actual). Here's a link to Rallispec's Subaru transmission chart:

http://spda-online.ca/modules/tinyco...ite/tc_28.html


Ryan
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Old 05-27-2009, 07:23 PM   #9
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I think your oil seal numbers are incorrect for the female 6MT transmission; you have the same number twice and I thought the right and left were different.

806735230
&
806735240

Awesome write up! I'm doing this myself right now (swap) and this would have been easier than all the searching. Thanks

Quote:
Originally Posted by DS1 Motorsports View Post

If you have a Female 6mt and a male front axle car you will need the following:



806735230 Oil Seal x1

806735230 Oil Seal x1



--------------------------------------------------------------------------

Last edited by kpluiten; 05-27-2009 at 07:34 PM. Reason: female not male... opps
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Old 05-27-2009, 07:27 PM   #10
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Quote:
Originally Posted by kpluiten View Post
I think your oil seal numbers are incorrect for the male 6MT transmission; you have the same number twice and I thought the right and left were different.

806735230
&
806735240

Awesome write up! I'm doing this myself right now and this would have been easier than all the searching. Thanks
for the male tranny with stubs sticking out.

Early 2004 Axle Seal Part Numbers:
Left: 806730041
Right: 806730042


http://forums.nasioc.com/forums/show...seals+stubs+06
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Old 05-27-2009, 07:32 PM   #11
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Quote:
Originally Posted by penusai View Post
for the male tranny with stubs sticking out.

Early 2004 Axle Seal Part Numbers:
Left: 806730041
Right: 806730042


http://forums.nasioc.com/forums/show...seals+stubs+06
Sorry, typo, I meant female transmission oil seal part numbers. And I just verified them on SGP.com The numbers I posted are correct.
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Old 05-27-2009, 07:38 PM   #12
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DS1 Motorsports: Great start! I would like you to make this less Impreza centric as they aren't the only Subarus getting 6 speeds. For example driveshaft length differences between the Legacy and Impreza might be a hangup for swaps. Include information about many 4eat with a 2.5 liter being 4.44 final (Outbacks and RS for example). Include the Legacy turbo as having a pull clutch with 3.9 final and LSD. Talk about how the early rear differentials have female axles while later units have male axles and that swapping the carrier is an easy way to change the type of axle needed. (ill think of more with time)
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Old 05-27-2009, 10:46 PM   #13
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Okay, so I've been reading and researching for the past few weeks about doing a 07 6mt into my 07 WRX. From EVERYTHING that I've read, I'm needing a 02-05 R160 rear diff to mate to the 3.54 rear end on the 07 6mt. So, I call P&L the other day to make sure the list I have includes everything I need. They tell me I can use my stock 2007 R160 3.70 rear diff with the 2007 6mt and that they prefer using it over the 3.54 R160...this through off my whole groove.
So I've spent the past few hours searching threads on here to tell me if I can use my stock diff. I've found no sign that I can.

So, my question to you: Can I use my stock 2007 WRX R160 3.70 rear diff with the 2007 STi 6mt?
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Old 05-27-2009, 10:52 PM   #14
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You have to have 3.54 rear gears for 07 sti transmissions - you have 3.70's..

You have 3 choices... Pick up a stock 02-05 wrx R160 - Have a 3.54 ring gear put in your R160 or Buy rear hubs and 3.54 R180.

You must have 3.54's with 07 Sti Transmissions..
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Old 05-27-2009, 10:57 PM   #15
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Which is what everything I've read has said...but idk why P&L would say this and say that they do it frequently with success.
I bought the "proper" rear diff a few days ago, but was taken back when I spoke to Paul.
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Old 05-27-2009, 11:00 PM   #16
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There was obviously a mis comunication... You MUST use a 3.54 R&P with an 07 trans - you don't have that...

A Late version (02+) R160 is an R160 - Not sure on LSD type but they are the same...
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Old 05-28-2009, 02:01 AM   #17
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This isnt stickied yet?
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Old 05-28-2009, 03:45 AM   #18
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Instead of starting a new thread, I thought I'd ask this question here. It's my understanding that the 08+ WRX, like the 08+ STi, doesn't have the VSS on the front differential. If this is the case, am I correct in assuming that a transmission swap wouldn't require the bell housing to be changed? Basically the same as pre 08 swaps?
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Old 05-28-2009, 04:48 AM   #19
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Quote:
Originally Posted by Ryan23 View Post
I'm not aware of Subaru offering a 4.44 final with the 6 speed (OEM). My Ver 6, Type-R 5 speed has 4.44 final though . To the best of my knowledge, all 6 speeds had a 3.90 front diff and the rear varied between 3.54 or 3.90. 3.54 cars had a 1.1:1 dropdown in the transfer case to match the F&R gearing (3.90 actual). Here's a link to Rallispec's Subaru transmission chart:

http://spda-online.ca/modules/tinyco...ite/tc_28.html


Ryan
Chart also doesn't have 07 STi 6MT's with 3.54's...

Quote:
Originally Posted by JSarv View Post
You have to have 3.54 rear gears for 07 sti transmissions - you have 3.70's..

You have 3 choices... Pick up a stock 02-05 wrx R160 - Have a 3.54 ring gear put in your R160 or Buy rear hubs and 3.54 R180.

You must have 3.54's with 07 Sti Transmissions..
Most people don't realize that.
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Old 05-28-2009, 02:46 PM   #20
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Seal part numbers are fixed, thanks guys.

I didn't tackle the Legacy or Forester to try and keep it simple. I may sit down here in the next few days and try and cover them in this post.

The different generations of R160 and R180 are something I would like to cover but it would need a thread of it's own.

ThreeEleven- You are the second guy they have told this to. It is wrong, if you have an 06' or 07' 6mt you will need a 3.54 rear end. Your stock is 3.70 and will not work.

-Dylan @ DS1
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Old 05-28-2009, 04:46 PM   #21
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sticky!
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Old 05-28-2009, 06:13 PM   #22
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Quote:
Originally Posted by DS1 Motorsports View Post
ThreeEleven- You are the second guy they have told this to. It is wrong, if you have an 06' or 07' 6mt you will need a 3.54 rear end. Your stock is 3.70 and will not work.

-Dylan @ DS1
Seems like that could cause big issues with the DCCD unit. Probably a fatal mistake. I hope they haven't sent anyone off with that setup.
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Old 05-28-2009, 06:50 PM   #23
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Dylan - I found some stuff -

V7-8 Non Dccd 6 speeds may or may not come with LSD front diff...

Is that typical or is that in the forrester and wagon?
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Old 05-28-2009, 07:50 PM   #24
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^^ yep, wagon and forester only from what my info shows.

-Dylan @ DS1
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Old 05-29-2009, 02:25 PM   #25
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Another vote for a sticky.
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