Author Topic: Chronicle of Jer's Subarus (Read 46005 times)

Attached is the matrix of parts for swapping an 05-07 STi trans into an 06 WRX. There are a few "gotchas" (like wiring) that I'll document later but otherwise it should cover all you need.

bigdl · « **Reply #32 on:** January 26, 2010, 09:10:52 am »

That is a nice looking wagon I like it a lot

jer · « **Reply #33 on:** January 26, 2010, 04:35:50 pm »

Ok, wiring:

You need this cable off the WRX trans(no hacking/soldering this one):

Next you have a cable that goes from here(click link to show where plug is):
http://flic.kr/p/7yEPny

to here (under the car - driver's side on trans):

When done you'll be left with these three pieces from the two merged wires(note that the 4 wires you need to solder are the same color/stripe):

And you'll have to tie up these two cables (unless or until you get a DCCD controller) - same location as 2 plugs above:

jer · « **Reply #34 on:** January 26, 2010, 04:37:30 pm »

Also, it during all this I discovered it's time to change the rear pads:

jer · « **Reply #35 on:** January 26, 2010, 04:38:09 pm »

The final parts for the project are promised to be here tomorrow, so I'll update when the whole thing is ready to roll! YAY!

GrantC · « **Reply #36 on:** February 01, 2010, 11:35:01 pm »

5x100 (ie. 01-04) STI rear hub on the left, 06/07 WRX on the right.

DBA rotor for 2-pot brakes (290x18mmx190mm) on the left, 06/07 rear rotor on the right (290x18x170mm)

Progress:

All the pics are here:
http://www.flickr.com/photos/grant_subaru/sets/72157623105922861/

silent · « **Reply #37 on:** February 02, 2010, 12:04:52 am »

Hey jer, are those the conversion rotors or just regular rotors for that MY?

jer · « **Reply #38 on:** February 02, 2010, 05:58:59 am »

The hub/knuckle/ebrake are from a JDM V7 STi with the (as Grant mentioned) DBA Group-N rotors.
I guess you could call them conversion rotors but I'm sure SOMEONE (coughgrantcough) would know.

Thanks for the help (GrantC, Ultimatt, Snackers) and the pictures (Ultimatt er, I mean GrantC)

GrantC · « **Reply #39 on:** February 02, 2010, 07:11:40 am »

Quote from: jer on February 02, 2010, 05:58:59 am

I guess you could call them conversion rotors but I'm sure SOMEONE (coughgrantcough) would know.

They're the size of the:
Group N 5x100 rotors
DBA Group N style rotors
01 STi rear rotors
04 STi Spec C Gravel rotors

Which are:
290x18x190mm

(Specifically they're the DBA 4000 Group-N sized rotors)

OEM 06/07 are:
290x18x170mm

(Same size as what's on there, except for the parking brake hat)

Brembo's are:
316x20x190mm

(Thus the larger diameter of that dust shield behind them.

)

Quote from: silent on February 02, 2010, 12:04:52 am

Hey jer, are those the conversion rotors or just regular rotors for that MY?

Really they're the inverse of the "conversion rotors" you usually see. They usually have the big Brembo diameter/thickness, with a small 170mm (WRX) e-brake hat. This is the small diameter rotor with the big e-brake.

silent · « **Reply #40 on:** February 02, 2010, 07:38:23 am »

Yeah, when I was originally planning the swap, DBA was starting to make a set of 'conversion' rotors to use a set of 06/07 wrx brakes that work with the STI hub/e-brake assembly. Pretty much the same thing, likely just a name change.

GrantC · « **Reply #41 on:** February 05, 2010, 12:17:43 am »

Once again, I'll let jer give the details... I'll just say this, "It drives!"

So, would you like to share with "the rest of the class" what you learned about pull-style vs. push-style flywheels?

ultimatt · « **Reply #42 on:** February 05, 2010, 12:37:24 am »

Quote from: GrantC on February 05, 2010, 12:17:43 am

Once again, I'll let jer give the details... I'll just say this, "It drives!"

So, would you like to share with "the rest of the class" what you learned about pull-style vs. push-style flywheels?

Haha. They are different, not interchangeable and as such bugger up a nearly finished project.

But who cares! It's done now and pulls like a astardbay!

jer · « **Reply #43 on:** February 05, 2010, 06:17:50 am »

Well, it's done (as Grant ruined for you. lol). After quite a few hours waiting, working, and a few shed tears (damn, Wally can be MEAN!) it's finally working correctly.

Pull Vs Push
02-05 WRX's (and 04-07 STi's) use a pull type clutch while the 06/07 WRX use a push style clutch. The slave cylinder, pressure plate, release bearing, clutch disc, and flywheel ARE NOT INTERCHANGEABLE! The pilot bearing is.

The push style flywheels have a "stepped" mating surface in that the mating surface is stepped or recessed down into the flywheel. I did not take a picture of the difference but I'm not sure it would have helped much since it was OEM vs lightweight flywheel.

For the record: you can use the 02-05 WRX clutch(including flywheel) on the 6spd but if you want to use the STi clutch setup on the 5spd you need to grind down part of the transmission bellhousing to get the flywheel to fit.

Initial Impressions
Um, is "whee" good enough? It's pretty insane at the moment. The low-end torque of the TD04 makes it rather easy to "move the tail end". The initial drive did feel like the TD04 setup will work but after the commute this morning's drive to work I found it will need a bigger turbo. I hate to say this but, especially on winter roads with winter tires, it might be too much low-end torque. Blasphemy!

Issues
I've not really read of this anywhere, but it seems that you NEED to upgrade the rear subframe bushings. It does clunk quite a bit. Although it could be the struts as I switched to my winter suspension while the car was up on jack stands. I have a couple paranoia noises and a boost leak to track down but on a scale of 1-10 for giddy I probably rate at 92.

Accolades
I'd like to profusely thank the following people
Wingless (Shane)
GrantC (Grant)
Snackers (Cam)
Ultimatt (Matt)
Mars636 (Stu)
Wally (Wally)
Tabibito (John)

I'd also like to thank the following:
Jackal (Duane)
Zuffy (Robin)
teg_09 (sorry I forget your name)
ScubaruSteve (Steve)
Pearl Boxer (Shaun)

I'm sure I've forgotten a name or two but I'm quite thankful to everyone that showed up over the last few weeks. I owe a few of these names quite a bit more than I can mention

Next Steps
- upgraded rear subframe bushings
- DCCDPro controller
- STi shift boot

jer · « **Reply #44 on:** February 05, 2010, 06:24:23 am »

Quote from: jer on August 25, 2009, 07:17:39 am

en route:
~~Clutch and lightened flywheel~~ installed and now removed. Gah.

Need to install:
Stainless braided brake lines

Need to do:
HPS+ front pads
DCCDpro controller (manual)
Rear subframe bushings

Wishlist:
Koni inserts for the WRX Wagon strut bodies
Engine/tranny mounts
pitch stop mount
27mm FSB + RSB
endlinks
shifter bushings
steering rack bushing
subframe bushings
STi rear lateral links
whiteline tophats (camber/castor adjustment)
STi TMIC
Fender flares (like goldrush: http://www.westernsubaruclub.com/smf/index.php?topic=7430.0)
Enkei RPF1 17"x8" wheels in silver
Header
~~STi 6spd + rear diff + DCCD~~ - complete! yay!
19T, HTA68, or 16G
DBA 4000 6x6 slotted front rotors
Fender braces

Thought I'd update this list

Funny how the biggest thing on the wishlist was the one thing I've done.

silent · « **Reply #45 on:** February 05, 2010, 06:58:29 am »

You'll want the dual mode controller, trust me. Glad to hear it's finally up and driving though, I had a feeling the TD04 would be too small. The "too much low end torque" thing will be fixed when you get your dccd controller, the car is much more tail happy when the dccd was set to open and my default ratios were 45f/55r. I can't imagine how "happy" the 35/65 split would be.

jer · « **Reply #46 on:** February 05, 2010, 07:04:46 am »

Quote from: silent on February 05, 2010, 06:58:29 am

You'll want the dual mode controller, trust me. Glad to hear it's finally up and driving though, I had a feeling the TD04 would be too small.

I understand what you're trying to tell me but I don't really see the value in the automatic mode. I don't need, nor do I want, a "computer" correcting my bad driving. If it's grip I sacrifice then I need to change my driving habits. I may get the auto for peace of mind while the missus drives the car but for me I feel it's useless.

It is a bit small but it'll be intensely fun for the auto-x courses this year

silent · « **Reply #47 on:** February 05, 2010, 07:27:13 am »

That's the thing though, you can't just set the controller and get an "ideal" setting. There are diffetent settings in different situations. If you leave it in full lock, your rear diff will bind when you turn. If you leave it full open, it'll handle like itshay. If you leave it halfway between both, it'll function but isn't ideal in most situations. It's not a computer that corrects bad driving, it's a computer that gives you the most possible traction at all times. I wonder if any of the faster STI guys down at Race City shut off their DCCD? (Serious question)

You still have control when it's in auto mode: wheel up means more calculations/second meaning faster response and quicker changes to conditions. Wheel down is less calcs/s therefore slower response to changes - it's if you want to play fast and loose without sacrificing too much traction.

GrantC · « **Reply #48 on:** February 05, 2010, 08:34:33 am »

Quote from: ultimatt on February 05, 2010, 12:37:24 am

It's done now and pulls like a astardbay!

+1

Munky · « **Reply #49 on:** February 05, 2010, 12:24:41 pm »

Yay! Success! Ready for when I am in town....I mean can I take it for a ride when I am in town? Or will it kill me?

Great to see it's done now.

PS. Your welcome for using my engine hoist. Think you may have used it morn then I have.