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Old 06-02-2009, 12:18 PM   #51
DS1
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If you grind the case you will weaken it severely.

-Dylan @ DS1
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Old 10-05-2009, 07:42 PM   #52
inthenameofweez
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Does anyone else have opinions on this subject? I've got an STi clutch and flywheel at my disposal. Very cheap. Low miles.

Going into a 2004 wrx.
Would it be easier to just buy the Exedy Stage 1? Are the power capabilities about the same?
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Old 10-06-2009, 07:36 AM   #53
AndrewtechAutomotive
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I probably wouldn't waste my time for an OEM 6-speed clutch. An ACT Stage 1 would be sufficient for 99% of the people on the road.

If you HAVE to have a 6-speed clutch, just bolt the clutch to the flywheel, slide the clutch onto the input shaft, mark where it hits, and grind away! I think saying you'll "weaken [the case] severely" is overstated at best. You'll weaken it, but to no extent that your average person would notice. You'll break gears before you twist the bellhousing off the case.

Phil
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Old 03-15-2010, 01:22 AM   #54
biggreen96
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Bump. I'm curious about using a stock 6mt clutch disk with 5mt flywheel and 5mt PP. Going into a 5mt case. It looks like it will fit and work to me... just here for a confirm yes/no.
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Old 03-15-2010, 10:11 PM   #55
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Way to bump an ancient thread...
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Old 07-21-2010, 08:20 AM   #56
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Quote:
Originally Posted by biggreen96 View Post
Bump. I'm curious about using a stock 6mt clutch disk with 5mt flywheel and 5mt PP. Going into a 5mt case. It looks like it will fit and work to me... just here for a confirm yes/no.
It won't work as they don't have the same diameter. 230mm for the WRX disc and 240 mm for he STI disc.

Tou have to use complete STI kit (flywheel, disc, PP...).

That's what I'm intending to do: mount a 6 speed STI clutch in my 5 speed GC8 gear (with a KAAZ kit inside).

I've read this post with a lot of interest but I've been unable to see any picture of what to be ground in the bell house.
Thanks for pics!!!

Last edited by jm747200; 08-01-2010 at 05:34 PM.
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Old 09-12-2011, 12:42 AM   #57
rdrz14
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bumping an old thread.. anyone have any tips on where to grind the bellhousing?
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Old 12-11-2011, 06:21 PM   #58
sdmideas
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Installed an act xt sti clutch today in my 2003 wrx. It was mentioned in this thread that aftermarket flywheel pp combos do not work. That information is not correct. It does work, it takes a little more grinding than per the oem clutch but it is manageable. Used the whole act/flywheel clutch kit, the feel is great! All the torque holding capability I need(I hope) and a much better pedal feel than the previous wrx clutch assembly.
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Old 06-19-2012, 10:14 AM   #59
maxouni
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Bump an old thread.
I have installed 6spd clutch assembly on my 04 WRX. There is no problem to grind bell housing if tarany is detached, but as 03GLHWRX mentioned - the top of the fork is too far forward. I made custom rod between cylinder and fork but it does not helps. When clutch pedal is fully depressed, TOB contacts transmission case, but PP remains slightly depressed and transmission were unshiftable.
Does anyone know how to resolve this problem?
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Old 09-25-2012, 04:12 PM   #60
salvi
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I was thinking of using an STI oem clutch/pp/fw, can anyone confirm that this works and why are other people having issues with the fork?
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Old 09-25-2012, 10:01 PM   #61
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I've had no issue with my 2003 5sp ground out to fit the act sti clutch...I love it
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Old 10-25-2012, 10:27 PM   #62
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Im having some issues with the amount to grind also. cant get the Competition PP to clear ahhh!! Can someone please post some damn pictures that work lol but seriously
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Old 01-10-2013, 07:53 AM   #63
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I'm doing a hybrid swap on my 04 WRX wagon. I have a bunch of STi parts laying around, including a good clutch and flywheel. I decided to fit a clutch in there this week while I'm waiting for the heads to come back. It took a few tries, but I think I have it here:



I basically kept taking off a little, then grinding it down. I haven't bolted it all together yet, but I will definitely spin the motor by hand before re-connecting everything to be 100% sure it's ok. The tricky part is the depth required around the starter. It doesn't come close anywhere except where you can see the bright spots. This took a total of 20 minutes with a flapper wheel. Most of the time was spent R&R the clutch.

Edit: Fitment was for an Exedy stage 1 clutch for a 2005 STi using a stock STi flywheel
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Old 01-10-2013, 10:01 AM   #64
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If you use clay like from the kids section of Wal-Mart or any art clay, just place it on the bell housing ribs and you'll know
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Old 01-10-2013, 11:42 AM   #65
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Play Doh.
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Old 01-10-2013, 01:09 PM   #66
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I did use clay, but the tolerance is loose enough between the pilot bearing and the shaft that you can tilt the assembly a couple degrees, which translates to a little more than 1/4" at the perimeter. It's not possible to know the final location without having the flywheel bolted to the engine. I think I'm pretty close using the flywheel/clutch combo lined up with the pilot bearing to guess.
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Old 01-10-2013, 01:49 PM   #67
Dave D.
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So that's the reason my JDM 6-speed feels so much smoother on engagement from a stop than my 5MT did. I'll vouch for that heavier flywheel right now!
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Old 01-24-2013, 08:03 AM   #68
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Update: I put the motor in last night and spun it by hand, only to find that it was rubbing here:



40 minute R&R with some grinding, and it went back together with no problems. The clutch seems to be working properly.
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Old 05-03-2013, 08:18 AM   #69
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Doing this is more a pain in the a$$ Than anything.. Takes away from your housing of the five speed. Those fines are there for a reason in the bell housing its for heat transfer. If you just go with an upgraded 5 speed clutch and flywheel you wont have any issues!!
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Old 08-01-2014, 11:12 AM   #70
beatyab
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Im about to jump into this with my 5spd trans. Any updates EE06STI?
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Old 03-01-2015, 11:42 AM   #71
2.5rsti_rolling
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I've successfully done this about 4 times with different wrx transmissions. Spray paint the inner bellhousing after a decent grind and slap it all together (loosely) spin by hand and remove the transmission to search for score marks in the paint...when found, these areas will be where needs more grinding (Rinse,lather, repeat lol)
I'm currently working on a simple "how to" but I won't be back from Brazil for a few weeks.
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