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Old 08-18-2014, 06:24 PM   #1
That One Guy
Scooby Newbie
 
Member#: 307270
Join Date: Jan 2012
Chapter/Region: NWIC
Location: 29 Palms,CA
Vehicle:
2002 WRX
WRB

Default Step by step 6 speed/5x114 swap into an 02 WRX

If someone gets butthurt about this whatever, but I figure I should try to contribute to the community in whatever way I can. This isn't meant to be like cyclops' thread about what you need, its going to be more like a step by step walkthrough with pictures so people can just copy me and not have to ask any questions. In all my research into this topic, I've read some very helpful threads and stickies and gotten random bits of information from here and there on doing this swap, but the whole time, what I really wanted was a step by step w/ pictures and a comprehensive list of what I would need, INCLUDING all the little things you don't remember until you're halfway into it and have to go somewhere to get whatever it is. being that I live on base and the stealership is over an hour away, this part is important.
So here it is as I know it right now. I should be starting the swap on wednesday and will update this thread with pictures every night. I'll only probably have a couple hours a night I can work on this but I am hoping to have it done by friday.

Parts sitting in my storage unit
-JDM '03 STi 6 spd w/dccd &clutch fork
-6 spd xmember
-STi driveshaft
-r180
-all 4 axles
-all 4 06 STi knuckles/hubs
-Tein Super Street coilovers
-group n tranny mount
-kartboy tranny bushings
-exedy 6 spd lw flywheel
-exedy oem 6 spd replacement clutch
-rear brembo calipers (ive had front brembos for like a year)
-group n pitch stop
-goodridge ss brake lines
-goodridge ss clutch line
-5x114.3 rotors & pads
-6 speed shift linkage
-3 extra flywheel bolts (wrx uses 6, STi uses 9)
-all 4 bolts, nuts, washers for the driveshaft to diff flange
-ATE brake fluid

Other parts you should consider having on hand:
-exhaust gaskets from the turbo back
-the metal parts that hold the tranny bushings, I hear those get destroyed often during swaps

Obviously you don't need everything I have, but i figured I would replace mounts and bushings and such while I've got everything out

For 02-05 wrx's you DO NOT need the clutch slave cylinder, 06-07 wrx's DO need either STi or 02-05 wrx slave cyl

Also, don't worry about starters. wrx and STi use the same starter

I know there are things I'm forgetting but I will remember (and update accordingly) as I go along
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Old 08-19-2014, 10:59 PM   #2
wurkenman
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Member#: 300974
Join Date: Nov 2011
Location: Elk River, MN
Vehicle:
1992 Legacy
White

Default

I am getting ready to do about the same thing in my sons 03 WRX. We picked up a V7 6 speed non dccd.
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Old 08-22-2014, 03:49 PM   #3
That One Guy
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Member#: 307270
Join Date: Jan 2012
Chapter/Region: NWIC
Location: 29 Palms,CA
Vehicle:
2002 WRX
WRB

Default

Quote:
Originally Posted by wurkenman View Post
I am getting ready to do about the same thing in my sons 03 WRX. We picked up a V7 6 speed non dccd.
Good luck with that man, hope this can be of some help to you.

Haven't gotten a whole lot done. Both lower ball joints and 1 tie rod end stopped me in my tracks yesterday. Also, when I said step by step, it doesn't necessarily mean go in the order I did it in.

Anyway, here goes.

Get your wheels off


unbolt your abs sensors (12mm) and remove brake lines (12mm for the banjo bolts, 10mm for the other end) if you're replacing them. Otherwise, remove the banjo bolt at the calipers and tuck the hose up out of the way.



Remove calipers and after removing the top 3 nuts on the tophat and the two 19mm strut to hub bolts, remove struts. Make sure your abs sensors line is unclipped from the strut as well as the brake lines.



At this point, I installed my new goodridge brake lines front and rear, got all 4 rotors off, and got the impact out to remove the axle nuts. (make sure your car is in gear for this)





I then removed my catback, and after an hour of hammering and prying a pickle fork inbetween the lower ball joints and hubs to no avail, gave up because the shop was closing.

Heading back to continue as soon as I get off work.
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Old 08-22-2014, 04:00 PM   #4
IheartAWD
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Join Date: Aug 2012
Chapter/Region: BAIC
Location: Bay Area
Default

I dig this! Please keep up the good work and finish the DIY. More pictures = Better.

Also, those are some long studs you got there. Are they extended?
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Old 08-22-2014, 05:09 PM   #5
That One Guy
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Member#: 307270
Join Date: Jan 2012
Chapter/Region: NWIC
Location: 29 Palms,CA
Vehicle:
2002 WRX
WRB

Default

Quote:
Originally Posted by IheartAWD View Post
I dig this! Please keep up the good work and finish the DIY. More pictures = Better.

Also, those are some long studs you got there. Are they extended?
Thanks! Believe me I'm finishing this as soon as I can, this is my only car and I need to drive. And yes, ARP extended studs in the front so i could mount spacers to clear the front brembos that I've had on my car for about a year. Already put them in my new 5x114 hubs as well.
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Old 08-22-2014, 07:52 PM   #6
sys202
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Member#: 364064
Join Date: Aug 2013
Chapter/Region: RMIC
Location: N. Idaho
Vehicle:
2003 S202
Sonic Yellow

Default

I'm doing the exact same thing in my bugeye as well! short of 07' USDM transmission, full complete swap though. Making way for the 2.5L next year..

Subscribed!

Last edited by sys202; 08-26-2014 at 02:27 AM.
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Old 10-01-2014, 04:55 PM   #7
tt383lt1
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subsribed
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Old 10-01-2014, 09:36 PM   #8
sys202
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Member#: 364064
Join Date: Aug 2013
Chapter/Region: RMIC
Location: N. Idaho
Vehicle:
2003 S202
Sonic Yellow

Default

The part list looks pretty accurate. Just did the same 07' 6MT swap into my 03' as well.

The one and I mean one and only issue I had that didnt carry over is the stock rear brake lines. They're super tight if mounted to stock 05-07' STi struts(now this might be different with coilovers), but there is almost no flex to them when they're clipped to the struts so I had to leave them off because they probably would have ripped off once the car was on the ground.

Will be getting some SS brake lines now it looks like.
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Old 10-10-2014, 04:02 PM   #9
That One Guy
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Member#: 307270
Join Date: Jan 2012
Chapter/Region: NWIC
Location: 29 Palms,CA
Vehicle:
2002 WRX
WRB

Default

Sorry I haven't updated this. Took 9 weeks to complete due to insane amounts of rust and other unforeseen issues. That and my laptop took a dump on me. Another part to add to the list of **** you might need is a vss (make sure your tranny comes with one, from what I've read so far 5 and 6 speed vss are the same.) and you also need some sort of intermediate adaptor for the harness to connect to your vss. (My speedo doesn't work)


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