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Old 03-20-2013, 11:19 AM   #51
robo_robb
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I registered just to reply here. Sorry for resurrecting an old thread, but I just want to thank you, subeman, for posting this. I just purchased an '01 Legacy GT 5 speed (absolutely love it!!) and will be doing an outrageous amount of highway driving with it in the next 4 years. I'll be commuting to grad school 160 miles a day. I think my car's stock 5th gear ratio is .85 - I'm at around 3.5k @ 75mph. The rpms are so high I feel like it's really stressing the engine. I'm going to try to ask my Subaru dealer if they are comfortable with changing my gear to the .738 from the WRX... the lower the better (there's nothing lower that fits, is there?).

Thanks again for the detailed post!
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Old 03-20-2013, 12:47 PM   #52
subeman90
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nope there is no lower.

I have a feeling that the dealer will say no way to doing that...or they are going to charge you out the a$$. Google map reinholds PA and see if it is a reasonable distance for you. You could go to the guy that did mine.

Glad to be of help.
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Old 03-20-2013, 01:36 PM   #53
robo_robb
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Reinholds isn't too far-- about 80 miles away. I might take you up on your suggestion! What do you think I should expect to pay for a job like this?
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Old 03-20-2013, 03:08 PM   #54
subeman90
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budget $400 in labor ((estimate)for the guy I went to) and parts you can call around to get a good price.

If you do go that route I'll hook you up with info and who to talk to, they will be very upfront with you on cost etc.
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Old 03-20-2013, 04:28 PM   #55
robo_robb
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Great! I'll go ahead and shop around for the parts. I'll circle back in a bit!
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Old 05-28-2014, 12:17 AM   #56
CRX7
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Note, in order to get this to work with phase 1 transmissions. You need to change out the synchro hub assembly as well, as the synchros are not compatible.

BTW, this can NOT be done on the car. Taking the end housing off requires a lot of manipulating movement which would not be possible in the tight transmission tunnel.
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Old 06-04-2014, 11:04 PM   #57
subeman90
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Quote:
Originally Posted by CRX7 View Post
Note, in order to get this to work with phase 1 transmissions. You need to change out the synchro hub assembly as well, as the synchros are not compatible.

BTW, this can NOT be done on the car. Taking the end housing off requires a lot of manipulating movement which would not be possible in the tight transmission tunnel.
well mine was in the car and we are talking about Baja's here not phase 1 transmissions.
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Old 06-06-2014, 05:29 PM   #58
ristiphx
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I do know an amateur mechanic who swapped a 2004 sti 6 speed into an 02 wrx with differential and all. I wonder if anyone has done this on a turbo?
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Old 10-14-2014, 02:10 AM   #59
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Quote:
Originally Posted by subeman90 View Post
well mine was in the car and we are talking about Baja's here not phase 1 transmissions.
So I actually did this, not a shop.
1) you need access to all the bolts on the exterior or the case, this would be difficult with it in the tunnel
2) To get the end casing off the shifter forks you need to tilt it at some funny angles, nevermind getting it back on with the forks in the right position. This would be next to impossible in the tunnel.
3) The 3 large nuts on the ends of the shafts need are locked and need to be unlocked with a chisel then you take an impact wrench to get them off.
4) The 50mm nut holding 5th gear is very difficult to take off and requires a special tool or two 50mm sockets welded together.
5) The 5th gear shift fork needs to be removed by hammering out the roll pin.
6) 5th gear had to be pressed/pulled off with a very fine toothed gear puller.
7) This all has to be put together nicely with everything clean as it is the inside of a transmission so that it seals well and does not leak. Good luck doing that in the transmission tunnel.

I'm not saying I don't believe you, but that mechanic you had do this has to be the most skilled mechanic I've every heard of. I do all my own work and this is not my first transmission to take apart, and this was a very technical and difficult job for me. I did it with a spare transmission and swapped them.

Maybe I'm off topic, but I gave the info for phase 1 transmissions, in case any one with a phase 1 tries to do this. There isn't much info on the net on doing this swap and I thought it would be helpful info. Swapping the synchro hub assembly is easy, you just need to source it.

BTW, I've got it in, it's working, and God it is beautiful. Car is so much nicer and quieter at speed, I'm passing everyone and wondering why they're going so slow, look at my speedo and realize I'm going too fast.

And power, I'm running a TD05 which spools a little later 3300 to 3500 rpms, and I've still got plenty of passing power in 5th with the .738 and 4.11 final drive. I don't recommend anything higher for a US Highway cruising gear.

Thanks for your write up and helpful information, it inspired me to do this swap, just adding to the info.

Last edited by CRX7; 10-14-2014 at 02:24 AM.
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Old 05-06-2015, 10:21 AM   #60
clint78z
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I have a question for CRX7. I am looking to do the 5th gear swap on JDM STI 5speed DCCD RA box. If you could elaborate on what tools you used to get the nuts off the shafts, did you use the special tool or modify a socket??. Will any of the 5th gears fit the phase 1 transmission. Just looking for a bit of clarification before I jump right in. Looking forward to this swap.
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Old 05-29-2015, 07:41 PM   #61
CRX7
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The main issue is the 50mm nut as it needs the special subaru tool or a very deep 50mm which doesn't exist. I took two 2" sockets from tractor supply, cut the end off one and welded them together. Otherwise the other socket you need is a 32mm I think.
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Old 05-29-2015, 07:45 PM   #62
CRX7
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You just need a phase 2 syncro hub, and I would assume any corresponding phase 2 5th would fit, but I only have experience with the 0.738
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Old 05-31-2015, 02:44 PM   #63
Baja_Gernaut
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Gee, this sounds so complicated
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Old 06-15-2015, 11:36 AM   #64
Mr.Chow
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I'm very interested in the 5th gear swap too as I have a 99 v.5 RA box coming this week. So as far as parts (and I think I'm going to have a transmission shop do the wrenching and inspect the trans) I'll need the following:
-phase 2 syncro hub
-phase 2 fifth gear .738

CRX7, would this be all I would need to provide the shop to do the swap?
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Old 11-27-2019, 05:03 AM   #65
mihael
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I am really glad to announce that I finished installing a .634 5th gearset (that I got from a 5MT diesel) into my 5MT on my Forester!

Thanks to everyone for everything that was posted here... it really helped and encouraged me to do the job.

I did it with the gearbox out of the car because I changed the whole case and the front differential as well. But, after putting everything together I realised I installed the hub for the 5th gear backwards and I solved that with the transmission on the car - more details and a picture for that here: https://forums.nasioc.com/forums/sho....php?t=2912115 - so, I guess you could do the 5th gearset change with the transmission on the car but you need the gearpuller and the 50mm extra deep impact socket... But there is space. I recommend getting the transmission out of the car though - this way you can inspect the clutch. Plus, putting back the extension case in the horizontal position was a real pain!
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Old 12-02-2019, 04:59 AM   #66
mihael
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After a long drive I can say that there is no noticeable improvement in fuel economy so, the greatest gain is the fact that I don't need to go over 3000 rpm on the highway anymore so the engine does not struggle anymore and it should not use that much oil as before when I was driving it at 3500 rpm.
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