Topic: 6 speed swap, What youll need JDM and USDM

[02_hybrid]

First off i got full permission from the user that made this to use it on here, Thanks to Crashke on Nasioc.

Ok, so I have read the FAQ's, read lots of threads and I would like to compile a list of what all is needed for the various years of Sti transmissions to be swapped into the 02-05 WRX. What I really have not been able to find is what is needed when you throw JDM transmissions into the mix. Here is what my understanding is so far. PLEASE feel free to jump in and add your knowledge.

I know there is a large number of swaps that have been done with all kinds of year and there are some differences with each. I just think with a superior design the Sti transmission is a great option for those needing something that can hold some more power. While it may not be indestructible, it is still a HUGE improvement over the WRX 5 speed glass box. Other upgrades include the RA gear set for mild power, M-Factory, MTR gears, Kaz gears and of course PPG gears. There are a fantastic selection of products not only for the WRX 5 speed but also for the Sti 6 speed available from a variety of companies. . So here goes:

04 USDM Sti 6 speed:
-transmission
-driveshaft from an automatic or from Sti with a yolk for a wrx
-3.90 R&P gear to replace the 3.54 in the WRX
OR
-R180 rear differential and Sti hubs, rotors, brakes and axles*
-6 speed shifter and assembly****
-front axles and hubs can be reused provided the transmission still has the axle stubs in it.
-DCCD controller optional but recommended**
-6-speed clutch fork and slave cylinder?
-5speed or 6 speed flywheel and clutch

1st - 3.636
2nd - 2.375
3rd - 1.761
4th - 1.346
5th - 0.971
6th - 0.756

04 JDM Sti 6 speed:
-transmission
-driveshaft again
-3.90 R&P gear to replace the 3.54 in the WRX
OR
-R180 rear differential and Sti hubs, rotors, brakes and axles*
-6 speed shifter and assembly****
-front axles can be reused if it has stubs in the transmission?
-some seem to be DCCD and others non-DCCD with Viscous LSD
-6-speed clutch fork and slave cylinder?
-5 speed or 6 speed clutch and flywheel

1st - 3.636
2nd - 2.375
3rd - 1.761
4th - 1.346
5th - 1.062
6th - 0.842
Final - 3.900

05 USDM Sti 6 speed:
-transmission
-driveshaft
-3.90 R&P gear to replace the 3.54 in the WRX
OR
-R180 rear differential and Sti hubs, rotors, brakes and axles*
-6 speed shifter and assembly****
-hubs or Stubs? Not clear on this one for the front but it seems there is extra that needs to be done with an 05***
-DCCD controller optional but recommended**
-6-speed clutch fork and slave cylinder?
-5 speed or 6 speed clutch and flywheel

1st - 3.636
2nd - 2.375
3rd - 1.761
4th - 1.346
5th - 0.971
6th - 0.756

05 JDM Sti 6 speed:
-transmission
-driveshaft
-3.90 R&P gear to replace the 3.54 in the WRX
OR
-R180 rear differential and Sti hubs, rotors, brakes and axles*
-6 speed shifter and assembly****
-hubs or Stubs? Possible using 03-04 stubs could work with the correct clip and seal like the 2006 tranny and then reuse wrx axles***
-Again not clear, but seems some come without DCCD**
-6-speed clutch fork and slave cylinder?
-5 speed or 6 speed clutch and flywheel

1st - 3.636
2nd - 2.375
3rd - 1.761
4th - 1.346
5th - 1.062
6th - 0.842
Final - 3.900

06 USDM Sti 6 speed:
-transmission
-driveshaft
-Stock R160 can be used without changing the gear ratio due to change in 06 that makes the ceneter diff a 1.1:1 vs the old 1.0:1
-stock rear axles can be used on rear due to no need to change the rear diff
-front...04 Sti Axle stubs can be ordered along with seals and clips that retains the WRX front Axles, hubs, etc? Special seals are needed. Axle Stub Part Number: 38415AA110
Circlip Part Number: 805329010 from Wrinkleboi's thread about this***
-6 speed shifter and assembly****
-DCCD controller optional**
-6-speed clutch fork and slave cylinder?
-5 speed and 6 speed clutch and flywheel

1st - 3.636
2nd - 2.375
3rd - 1.761
4th - 1.346
5th - 0.971
6th - 0.756

06 JDM Sti 6 speed: into wrx
-transmission
-driveshaft
-6 speed shifter and assembly****
-6-speed clutch fork and slave cylinder for 2007 sti
R160 rear diff (02-05 wrx)
6 speed clutch and flywheel
Circlips from 2004 sti, oil seals and axle stubs

1st - 3.636
2nd - 2.375
3rd - 1.761
4th - 1.346
5th - 1.062
6th - 0.842
Final - 3.900

07 USDM Sti 6 speed: into wrx
-transmission
-driveshaft
-6 speed shifter and assembly****
-6-speed clutch fork and slave cylinder for 2007 sti
R160 rear diff (02-05 wrx)
6 speed clutch and flywheel
Circlips from 2004 sti, oil seals and axle stubs

1st: 3.636
2nd: 2.375
3rd: 1.521
4th:1.137
5th:0.971
6th: 0.756
reverse - 3.545
final drive ratio - 3.90

JDM 07 Sti 6 speed

-transmission
-driveshaft
-6 speed shifter and assembly****
-6-speed clutch fork and slave cylinder?
-no clue
-no clue
-no clue

unknown ratios.


*For those wanting to use the R180 but not switch out the hubs, Apparently driveshaftshop.com offers custom axles (pricey) that allow you to retain the wrx hubs while using the R180 rear end.

** DCCD controller options...seems a member on here Spider? is making one for around $150, others go up from there. Without going to an Sti ECU it does not appear to be able to be used as a fully automatic setting, but Spiider's and the Neetronic units seem to get close. Then there is the 100% lock up with a toggle switch. I am unsure as to how soon this could kill the DCCD, but who knows it could last forever! Some sites with controllers:
www.neetronics.com
www.gems.co.uk
www.rocketrally.com
www.motec.com
www.dccdpro.com

*** There may be a difference between the 05 axles and the 02-04 axles on the WRX. There may have been a change to the axle and some 05 wrx might be able to use their stock axles. I have not verified this, just read some threads suggesting it.

****The shifter boot is suggested, but not necessarily an absolute must. The old shift boot can be reused with some modification and work. Shift knob is the same, it can be reused if necessary, but not the best option. Thread about this located here see post #66.

Parts and numbers for some of the parts:

32000-AJ350 2007 STi transmission
805329010 Circlips need 2
38415AA110 stubs need 2
806730041 oil seal Left and right side are different
806730042 oil seal Left and right are different
C1010FE004 short shifter
35046FE010 -shifter joint
633046020-spring pin

Thanks to WJM for the part numbers