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Old 11-11-2010, 10:26 AM   #1
chudlo
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Member#: 15505
Join Date: Feb 2002
Chapter/Region: TXIC
Vehicle:
2002 JDMV8 STI Wagon

Default 05 Sti hub swap into 03 JDM STi tranny problems

Does anyone have detailed info on what axles fit in different 6 speed trannies?

Background:

I have an 03 JDM STi swap in my 02 buggeye wagon. The swap came with everything but wheels and tires. I have been trying, over the last few weeks , to complete a hub swap to the 05 STi hubs so that I can stop having wheel bearing issues. (I have been averaging a wheel bearing replacement per year since I got the car in Oct. 2001. )

Here is my problem:

After getting everything installed, finally, I went to get an alignment at the dealership. I returned home to re-tighten the suspension bolts and just make sure everything was tight. To my dismay I see gear oil under the tranny and find that the front 05 Sti axles are popped out of the transmission. After trying to play with the circlips and making sure I was ramming the axles home properly, I removed the new 05 sti axles and compared them to the original JDM axles.

The 03 JDM tranny that I have is a female type unit and the 05 axles will not stay "clipped in" to the tranny no matter what I do. As soon as any force is applied, like tightening the axle nut, they pop back out.

There are a few differences in the axles that you can see in these pictures: http://picasaweb.google.com/chudlojo...eat=directlink

For one, the JDM axles are both plug in type and have removable stubs. The 05 axles seem to flare out near the Green DOJ housing, whereas the JDM axles are a consistent diameter.

So, does anyone have any experience doing the 05 STi hub conversion into a JDM 6 speed that could tell me how to make this work?

Is there a difference in the oil seals that might account for the axles not being direct replacements?
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Old 11-11-2010, 12:24 PM   #2
Evil Imports
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Old 11-13-2010, 08:59 AM   #3
chudlo
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Member#: 15505
Join Date: Feb 2002
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Vehicle:
2002 JDMV8 STI Wagon

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Originally Posted by Evil Imports View Post
Thanks for that link! I had seen it but didn't look at it closely enough since I didn't think the seals could be the problem.

I wound up having the JDM and 05 STi axles hybridized so that the JDM bits would secure the axle to the tranny. I also wound up having to remove the lash adjusters and pop out the seals. It was a big pain in the butt-dyno, but it all seems to be holding together.
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