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Old 06-09-2015, 10:26 PM   #1
JarHarms
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Default STI front cross member info

I had the three versions of GD STI front cross members around to compare. I always wanted to know the actual differences between them and compare in-person. Posting up to share the info in case can help anyone else. Really these are mostly all the same. The main points of interest are 1) steering rack mounts/clearance and 2) subframe mounts.
Note: USDM left hand drive GD parts is the reference point I would be using.

Post#2 2004 STI Cross member complete-front suspension (20101FE200)

Post#3 2005 STI Cross member complete-front suspension (20101FE500 sub -> 20101FE510)

Post#4 2006-07 STI Cross member complete-front suspension (20101SA040)

Post#5 Support arms and Jack plates

Post#13 2008-16 STI Cross member complete-front suspension (20101AG031) *only adding this due to 2015-16 13:1 steering rack conversions*

My intent was GD STI only, since it could go on forever adding in other versions. Maybe I will consider adding other cross members if I get enough satisfactory info collected up.

AKAs
"Cross member complete-front suspension" = cross member, Xmember, subframe (although incorrect)
"Frame assembly-front" = subframe
"LCA" = lower control arm (in this case the front LCAs)
"clamp-gear box pipe" = 2004-07 round clamp
"clamp-gear box pinion" = 2004 square clamp or 2005-07 u-bracket or 2008-16 u-bracket
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Last edited by JarHarms; 06-08-2016 at 09:46 PM.
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Old 06-09-2015, 10:27 PM   #2
JarHarms
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2004 STI Cross member complete-front suspension (20101FE200)
*2002-04 WRX is entirely different*

weight w/o support or jack plate: approx 24.0 lbs
uppipe clearance: yes
forward bolting locations for Frame assembly-front: yes
forward LCA bolting locations: yes
rearward LCA bolting locations for Frame assembly-front: yes
RHS steering rack saddle: square
RHS mounting: clamp-gear box pipe (34166FE060) and shorter bolts
LHS steering rack saddle: square
LHS mounting: clamp-gear box pinion (34120AA010) and shorter bolts
support/jack plate: uses Support arm, front (20107FE001) and Jack up plate, front (20510AA000)
*Can also use Support arm, front (20107FE010) as an alternative for other two.

ARB uses an angle plane clamp-stabilizer bushing (20416FE000)
ARB mounting bolt c-l RHS to LHS distance: 767mm
LCA bolt c-l RHS to LHS distance: (forward) 692mm, (rearward) 705mm, canted inwards to front
LCA bolt c-l to body plane: (forward) 188mm, (rearward) 183mm, canted downwards to front
LCA bushing saddle width: 59-60mm, varies
Rack mount bolt c-l RHS to LHS: 25.5mm
Engine mount bolt c-l RHS to LHS distance: 355mm, it's slotted but mount stud is at inner position which I'm calling c-l
Engine mount bolt c-l to body plane: 105mm
Cross Member mounting bolt c-l RHS to LHS: (forward) 861mm, (rearward) 841mm, canted inwards to rear
Cross Member mounting bolt c-l front to rear: 140mm
Cross Member mounting thickness: 6.0mm


Steering racks:
2004 STI racks obviously fit.
2005-07 STI racks easily fit using longer bolts and w/o the u-brace, just use fender washers over mounting ears.
2008-14 WRX / 2008-16 STI racks can be fitted but require modifications such as grinding clearance, mounting spacers, and inner tie rod solutions.



2004 STI Cross member photos













Red dim = 184mm. The yellow area is where axle contact occurs due to excessive ride height reduction or adding massive amounts of caster.
NOTE: This same reference can be applied to the MY2005 and 2006-07 versions described below. Yea, parallax is in play here.......

Last edited by JarHarms; 06-08-2016 at 09:58 PM.
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Old 06-09-2015, 10:27 PM   #3
JarHarms
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2005 STI Cross member complete-front suspension (20101FE500 sub -> 20101FE510)
still searching for the FE500 vs FE510 specs, I "suspect" they dropped the forward LCA subframe mounts and changed to the stamped support arm.
*2005 WRX is entirely different*
weight w/o support or jack plate: approx 24.5 lbs
uppipe clearance: yes
forward bolting locations for Frame assembly-front: yes
forward LCA bolting locations: yes
rearward LCA bolting locations for Frame assembly-front: yes
RHS steering rack saddle: round
RHS mounting: clamp-gear box pipe (34166FE060) and shorter bolts
LHS steering rack saddle: round
LHS mounting: housing mount ears and clamp-gear box pinion (34166FE050) with longer bolts
support/jack plate: uses Support arm, front (20107FE001) and Jack up plate, front (20510AA000)
can also use Support arm, front (20107FE010) as an alternative for other two

ARB uses an angle plane clamp-stabilizer bushing (20416FE000)
ARB mounting bolt c-l RHS to LHS distance: 767mm
LCA bolt c-l RHS to LHS distance: (forward) 692mm, (rearward) 705mm, canted inwards to front
LCA bolt c-l to body plane: (forward) 188mm, (rearward) 183mm, canted downwards to front
LCA bushing saddle width: 59-60mm, varies
Rack mount bolt c-l RHS to LHS: 25.5mm
Engine mount bolt c-l RHS to LHS distance: 355mm, it's slotted but mount stud is at inner position which I'm calling c-l
Engine mount bolt c-l to body plane: 105mm
Cross Member mounting bolt c-l RHS to LHS: (forward) 861mm, (rearward) 841mm, canted inwards to rear
Cross Member mounting bolt c-l front to rear: 140mm
Cross Member mounting thickness: 6.0mm


Steering racks:
2005-07 STI racks obviously fit.
2004 STI racks can be "forced in" using shorter bolts and the corresponding clamps but the hydraulic pipes interfere with the cross member.
2008-14 WRX / 2008-16 STI racks can be fitted but require modifications such as grinding clearance, mounting spacers, and inner tie rod solutions.



2005 STI Cross member photos
















There is a "slim" chance that this could be an RAR front cross member. Since I cannot confirm it...it remains a regular STI sample.

Last edited by JarHarms; 06-08-2016 at 09:56 PM.
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Old 06-09-2015, 10:27 PM   #4
JarHarms
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2006-07 STI Cross member complete-front suspension (20101SA040)
*also used on the 2006-07 WRX*
weight w/o support or jack plate: approx 24.0 lbs
uppipe clearance: yes
forward bolting locations for Frame assembly-front: yes
forward LCA bolting locations: none
rearward LCA bolting locations for Frame assembly-front: yes
RHS steering rack saddle: round
RHS mounting: clamp and shorter bolts
LHS steering rack saddle: round
LHS mounting: housing mount ears and clamp-gear box pinion (34166FE050) with longer bolts
support/jack plate: uses Support arm, front (20107FE010)
can also use Support arm, front (20107FE001) and Jack up plate, front (20510AA000) as an alternative to the other one

ARB uses an angle plane clamp-stabilizer bushing (20416FE000)
ARB mounting bolt c-l RHS to LHS distance: 767mm
LCA bolt c-l RHS to LHS distance: (forward) 692mm, (rearward) 705mm, canted inwards to front
LCA bolt c-l to body plane: (forward) 188mm, (rearward) 183mm, canted downwards to front
LCA bushing saddle width: 59-60mm, varies
Rack mount bolt c-l RHS to LHS: 25.5mm
Engine mount bolt c-l RHS to LHS distance: 355mm, it's slotted but mount stud is at inner position which I'm calling c-l
Engine mount bolt c-l to body plane: 105mm
Cross Member mounting bolt c-l RHS to LHS: (forward) 861mm, (rearward) 841mm, canted inwards to rear
Cross Member mounting bolt c-l front to rear: 140mm
Cross Member mounting thickness: 6.0mm


Steering racks:
2005-07 STI racks obviously fit.
2004 STI racks can be "forced in" using shorter bolts and the corresponding clamps but the hydraulic pipes interfere with the cross member.
2008-14 WRX / 2008-16 STI racks can be fitted but require modifications such as grinding clearance, mounting spacers, and inner tie rod solutions.



2006-07 STI Cross member photos














Last edited by JarHarms; 06-08-2016 at 09:57 PM.
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Old 06-09-2015, 10:28 PM   #5
JarHarms
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Support arms and Jack plates
2004-05 Support arm, front (20107FE001) - approx 1.5 lb, multi part fabricated steel, rubber end plugs


Jack up plate, front (20510AA000) - approx 0.5lb, single piece stamped steel, undertray bolts to this plate



2006-07 Support arm, front (20107FE010) - approx 1.0 lb, single piece stamped steel, serves as support arm and jack plate, undertray hooks and bolts to this plate
certainly a cost reduction effort by Subaru. I'm not convinced there is any functional advantage over the older version aside from less weight.



2008-16 STI (2008-? WRX) Support arm, front (20107AG000) - approx 2.0 lb, single piece stamped steel, serves as support arm and jack plate, undertray bolts to this plate. It's span is huge compared to the GD comparable parts and attached with ten separate 10mm x 1.25 bolts. It braces up the cross member pretty well.

Last edited by JarHarms; 06-06-2016 at 10:58 PM.
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Old 09-04-2015, 07:00 PM   #6
mrsaturn7085
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Surprised I missed this when posted - awesome work! Now get started on the rear crossmember and front subframe

Rear Crossmembers:

20150FE300 ('04) > 20150FE400 ('04-'05)
20150FE210 ('05-'06) > 20150FE430 ('06-'07)

I imagine bushing changes were the biggest factor here... though I'm not sure why there are 4 parts.

Subframes:

50515FE020 ('04) > 50515FE021 ('04-'05) > 50515FE022 ('05)
50515FE011 ('06-'07) > 50515FE012 ('06-'07)

This one is even worse... I know one difference was the additional 2 holes for the forward LCA mounting bolt. IIRC, the really early ones also had a different tie-down hook.

Last edited by mrsaturn7085; 09-04-2015 at 07:06 PM.
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Old 09-04-2015, 08:10 PM   #7
JarHarms
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Default STI front cross member info

Thanks
I do suspect you're on the right track for the subframe differences. Agreed that the rear cross member difference to mind is the solid vs rubber isolated mounting points. I have both rear types in hand I guess I could do the same for those.
At this point I'm not keen to invest in buying other parts until I unload some of these first. Honestly I'd rather sort out all of the trans cross member differences first. Although I would like to inspect a confirmed SpecC/RAR front in person. I know the 2008+ SpecC/RAR versions got additional plating. Not sure if the GD-era did though.

Last edited by JarHarms; 06-08-2016 at 09:46 PM.
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Old 09-05-2015, 01:57 PM   #8
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The Spec C/RA-R front crossmember was 20101FE500/510 - I've already looked that one up in a JDM parts database. The international FSM also clearly denotes that the Spec C (inc. RA-R) is the only one that had the additional 2 bolts fore of the transverse link mount. Basically, for the GD-series, the 500/510 p/n is *the* one to have.

The 2009+ Spec C front crossmember was plated.



Later model Spec C (GD) reinforcement was all done in the front strut towers and tube steel fender bracing ('06 Spec C got the tube braces, while all JDM '07 models got them, as did the USDM '07 limited, oddly enough). The rear chassis 'legs' were also different to accommodate the trunk bar.

The second picture below clearly shows the additional plating welded to the strut tower.




I spent a good day comparing structural part numbers between the USDM and JDM chassis; the main (welded in) differences, not already mentioned, were in the roof and front roof support, the transmission tunnel, and the seat mounts. This obviously doesn't cover all the bolt-in lightweight parts, and there were a TON of those.



The transmission cross member only had minor differences.

41310FE010 - earliest model with identical LH and RH bushings; bolt-in harmonic dampers
41310FE031 - mid-'02 upgrade to mismatched LH and RH bushings; bolt-in harmonic dampers
41310FE050 - '06 "upgrade" to welded in harmonic dampers

The lower bolted-in u-joint guard was different between Spec C and all other models; the Spec C part omitted the welded in damping weight on this plate. I've got it on my car - I think it was 2+ lbs less.
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Old 10-02-2015, 01:37 AM   #9
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Does anyone know the part number for the Front tower reinforcement for the 2005 spec C?

Quote:
Originally Posted by mrsaturn7085 View Post
The Spec C/RA-R front crossmember was 20101FE500/510 - I've already looked that one up in a JDM parts database. The international FSM also clearly denotes that the Spec C (inc. RA-R) is the only one that had the additional 2 bolts fore of the transverse link mount. Basically, for the GD-series, the 500/510 p/n is *the* one to have.

The 2009+ Spec C front crossmember was plated.



Later model Spec C (GD) reinforcement was all done in the front strut towers and tube steel fender bracing ('06 Spec C got the tube braces, while all JDM '07 models got them, as did the USDM '07 limited, oddly enough). The rear chassis 'legs' were also different to accommodate the trunk bar.

The second picture below clearly shows the additional plating welded to the strut tower.




I spent a good day comparing structural part numbers between the USDM and JDM chassis; the main (welded in) differences, not already mentioned, were in the roof and front roof support, the transmission tunnel, and the seat mounts. This obviously doesn't cover all the bolt-in lightweight parts, and there were a TON of those.



The transmission cross member only had minor differences.

41310FE010 - earliest model with identical LH and RH bushings; bolt-in harmonic dampers
41310FE031 - mid-'02 upgrade to mismatched LH and RH bushings; bolt-in harmonic dampers
41310FE050 - '06 "upgrade" to welded in harmonic dampers

The lower bolted-in u-joint guard was different between Spec C and all other models; the Spec C part omitted the welded in damping weight on this plate. I've got it on my car - I think it was 2+ lbs less.
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Old 10-02-2015, 10:29 AM   #10
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Quote:
Originally Posted by mrsaturn7085 View Post
The transmission cross member only had minor differences.

41310FE010 - earliest model with identical LH and RH bushings; bolt-in harmonic dampers
41310FE031 - mid-'02 upgrade to mismatched LH and RH bushings; bolt-in harmonic dampers
41310FE050 - '06 "upgrade" to welded in harmonic dampers

The lower bolted-in u-joint guard was different between Spec C and all other models; the Spec C part omitted the welded in damping weight on this plate. I've got it on my car - I think it was 2+ lbs less.
Got pics?
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Old 10-02-2015, 11:32 AM   #11
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USDM:


Spec C:


1.25 lb difference
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Old 10-12-2015, 04:25 PM   #12
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Quote:
Originally Posted by Kaptainballistik View Post
Does anyone know the part number for the Front tower reinforcement for the 2005 spec C?
The reinforcement is not a bolt on part, the entire strut tower welded member has a different part number on the Spec C. I have the p/n if you're curious, but the install would involve cutting out the old member and re-welding the new one, all the while trying to get the dimensions to stay correct.
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Old 06-08-2016, 09:44 PM   #13
JarHarms
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2008-16 STI Cross member complete-front suspension (20101AG031)
*also used on the 2008-14 WRX* 2015+ WRX went to electric steering, not sure if same cross member is used or not
weight w/o jack plate: approx 27.0 lbs
uppipe clearance: yes
*GD thing* forward bolting locations for Frame assembly-front: none
*GD thing* forward LCA bolting locations: none
*GD thing* rearward LCA bolting locations for Frame assembly-front: none
RHS steering rack saddle: round
RHS mounting: clamp-gear box pipe (34166AG050) and shorter bolts (901250077)
LHS steering rack saddle: round
LHS mounting: housing mount ears and clamp-gear box pinion (34166AG030) with longer bolts (901000181)
support/jack plate: uses Support arm, front (20107AG000)
None of the GD jack plates will work on this cross member.

ARB uses a flat plane clamp-stabilizer bushing (20416AG000)
ARB mounting bolt c-l RHS to LHS distance: 767mm
LCA bolt c-l RHS to LHS distance: (forward) 702mm, (rearward) 711mm, canted inwards to front
LCA bolt c-l to body plane: (forward) 182mm, (rearward) 178mm, canted downwards to front
LCA bushing saddle width: 57-58mm, varies
Rack mount bolt c-l RHS to LHS: 25.5mm
Engine mount bolt c-l RHS to LHS distance: 355mm, it's slotted but mount stud is at inner position which I'm calling c-l
Engine mount bolt c-l to body plane: 111mm
Cross Member mounting bolt c-l RHS to LHS: (forward) 865mm, (rearward) 841mm, canted inwards to rear
Cross Member mounting bolt c-l front to rear: 144mm
Cross Member mounting thickness: 34mm

Notes: from some "very" rough observations: 2005 STI -vs- 2008 STI
Subframe mounts - There aren't any, none at the front or near the LCA mounts. So there is no place to bolt your GD OEM U-brace or aftermarket subframe to. Maybe not a huge loss since the 2008 cross member is pretty beefy. I'm sure a GD fitment H-brace is out of the question as well.
ARB mounts- The mount pads are the same RHS/LHS span. They use different D-clamps specific to each cross member. GD angled and GR strait plane. I believe an aftermarket ARB (with strait center profile bar) will fit w/o contact to the cross member. It looks like an OEM ARB (has more bends in the center) could make contact, but I have no physical confirmation yet.
LCA mounts - The bushing saddle width is close. Since it's sheet metal there is some measured variance but it should be able to accommodate a GC 55mm bushing or a GD 61mm bushing. The RHS to LHS span is different, 2008 is certainly wider span than GD. The vertical location (relative the chassis mating plane) is higher than the GD position. These could be problematic.
Chassis mounts - These aren't exact matches but there is enough slop that they should bolt up fine. The 2008 is boxed in so you will need longer U-bolts to engage the threads. Pretty sure the existing GD U-bolts are too short. I think this can be worked around easily by using the longer Forester application u-bolts.
Engine mounts - They are the same span. Also very close in vertical distance (relative the chassis mating plane).
Undertray mounting - There are no threaded holes on the 2008 that match up to the rear bolting location of the GD undertray (plastic). I bet you can modify something to work though.

Steering racks:
2008-14 style racks obviously fit.
2015-16 STI 13:1 racks obviously fit.
2004 STI racks I can't see why you would even try this combo. These will not drop-in due to hydraulic pipe interfere with the cross member RHS, hydraulic pipe interfere LHS around quill, offset mounting ear planes which spacers will not fix, rack body direct contact with LHS saddle, etc.
2005-07 STI racks basically the same issues as the 2004 racks.


2008+ STI Cross member photos













Last edited by JarHarms; 06-08-2016 at 09:55 PM.
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Old 06-09-2016, 07:50 AM   #14
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great info! thanks for posting
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Old 08-16-2016, 04:46 PM   #15
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Subscribed.. Thanks for the info
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