6 Speed swap into 08/09/10 WRX

[Bu11dogg2]

A friend recently asked me to help him swap a 6 speed into his 2008 WRX.


I'm starting to collect data and this thread will be updated as I find more info.


If you have anything to contribute please post :)


2008 5speed manual
1st 3.166
2nd 1.882
3rd 1.296
4th 0.972
5th 0.738
final 3.900

2008 STi 6 speed manual
1st 3.636
2nd 2.235
3rd 1.521
4th, 1.137
5th 0.097
6th 0.756
Front final gear ratio: 3.9
Rear final gear ratio: 3.545

2009 WRX 5 speed manual
1st 3.166
2nd 1.882
3rd 1.296
4th 0.972
5th 0.738
final 3.900

2009 STI 6 speed manual
1st 3.636
2nd 2.235
3rd 1.521
4th, 1.137
5th 0.097
6th 0.756
Front final gear ratio: 3.9
Rear final gear ratio: 3.545

2010 WRX 5 speed manual
1st 3.166
2nd 1.882
3rd 1.296
4th 0.972
5th 0.738
final 3.900

2010 STI 6 speed manual
1st 3.636
2nd 2.235
3rd 1.521
4th, 1.137
5th 0.971
6th 0.756
Front final gear ratio: 3.9
Rear final gear ratio: 3.545

Couple of issues:

1. The new STi transmission uses a different speed sensor so swapping an 04/05/06/07 STi tranny into a 08/09/10 requires creating something to give a speed reading to the 04-06 speed sensor. AFAIK nothing has been offered by any vendor.



2. The final drive in the 08/09/10 WRX is 3.9 so you will have to swap the Rear diff. Unless you get custom axles you will need the hubs also.



Swapping a 6 Speed into your 08/09/10 WRX

Option 1:

1. 2008-2010 STi Transmission
2. 2008-2010 STi Drive Shaft
3. 2008-2010 STi Transmission mounts
4. 2008-2010 STi linkage COMPLETE including reverse lockout
5. 2008-2010 STi R180
6. 2008-2010 STi Front/Rear Axles
7. 2008-2010 STi Front/Rear Hubs
8. 2008-2010 STi Clutch?????? (might be able to run stock?)
9. DCCD Controller
10. Brakes?

Option 2.

1. 2008-2010 STi Transmission
2. 2008-2010 STi Drive Shaft
3. 2008-2010 STi Transmission mounts
4. 2008-2010 STi linkage COMPLETE including reverse lockout
5. 2008-2010 STi R180
6. Custom Rear Axles
7. DCCD Controller
8. 2008-2010 STi Clutch?????? (might be able to run stock?)


Option 3: (not 100% positive on this)(need to confirm if front axles will line up)

1. 2006/07 sti tranny
2. Auto wrx/93-2001 auto drive shaft (need to confirm fitment with R160)
3. dccd controller
4. 6 speed Trans mounts
5. Complete linkage, frame work for the shift assembly, reverse lockout tidbits.
6. Your stock or aftermarket clutch
7. Something to make the speedo work? 08+ trans dont use a speed sensor
8. Front axle circlips??? Need confirmation


Option 4 (not 100% positive on this)
1. 2004/05sti tranny
2. 2004/05 sti drive shaft
3. dccd controller
4. 6 speed Trans mounts
5. Complete linkage, frame work for the shift assembly, reverse lockout tidbits.
6. STi clutch (complete)
7. Something to make the speedo work? 08+ trans dont use a speed sensor
8. Front axle circlips??? (Need confirmation)
9. R180
10. 04 wrx rear hubs (not sure if this work) or custom axles from driveshaftshop.com
11. 04/05 sti rear axles (if swapping hubs)

[2007st3]

OK you've peaked my interest.

[Bu11dogg2]

keep refreshing every 10 minutes or so... this is a work in progress

[etaks99rs]

wow, I thought the 06 and 07 6 speeds had more differences than just 4th gear.

Subscribed

[jwebsta32]

DCCDPRO is working on the VSS control......

[Bu11dogg2]

DCCDPRO is working on the VSS control......



Update: Apparently “beating my brains out” over most of last weekend paid off…I’ve fixed all the remaining issues with the firmware!
The results on my electronics testbench are so promising that I will be forwarding the RC1 (release candidate #1) to our faithful tester in Michigan for final in car testing.
At the same time, since the hardware isn’t going to change prior to release I am ordering the Version 3 motherboards today. (Version 1 & 2 were prototypes)
I’m moving ahead towards production and sale in my webstore. Expect to see something in the next couple of days.
Thanks for waiting all this time, I know it has been a long time coming for some of you that have stuck with this since the beginning.
-Jeff Reid
DCCDPro.com

[Seraphinwolf]

08+ car MUST use the 08'+ 6 speed. Most other stuff transfers over and the ussually axle tricks to use 5x100 hubs still work if I remember.

[Bu11dogg2]

Hi
the 09 cars have different lenght axles, we dont make a complete one yet but if you were to send me
both axles we could cut the head off the R160 housings and weld the R180 heads to them (about 300.00)

Driveshaftshop.com


If you have a spare set or the available down time this sounds like a great deal :)

[Bu11dogg2]

VSSPro Version 3 initial product release Oct 22nd!
I’ve added the VSSPro product to my webstore for pre-release. Right now it is available pre-order for the official release Oct 22nd but you can go ahead and order if you have been waiting for this to be released and it will ship when ready.
Orders will be first come first served!
Thanks for your patience in waiting for this to finally come about.
Kind regards,
-Jeff Reid
DCCDPro.com


Time to get yer swaps on!!!!

[Bu11dogg2]

The VSSPro - Vehicle Speed Sensor Signal is really gonna Be vood for the pre 2008 folks :)

[Bu11dogg2]

did some research into the spec b 6speed tranny...

6 spd manual, spec.B only
1st 3.636
2nd 2.235
3rd 1.521
4th 1.137
5th 0.891
6th 0.707
final 3.900


Since it doesn't have the same center diff as the STi trans it should work fine with 08+ applications without swapping the rear diff.

It does not use DCCD and it has the same style speed sensor.

The only question is drive shaft....

[2007st3]

did some research into the spec b 6speed tranny...

6 spd manual, spec.B only
1st 3.636
2nd 2.235
3rd 1.521
4th 1.137
5th 0.891
6th 0.707
final 3.900


Since it doesn't have the same center diff as the STi trans it should work fine with 08+ applications without swapping the rear diff.

It does not use DCCD and it has the same style speed sensor.

The only question is drive shaft....


Is it as strong as the STI version though?

I don't mind my 5speed. Is there a way to build a tougher one?
Not sure I'll ever need to, but if my turbo decides to come out another would have to go in.

[KaizenTuning]

I don't mind my 5speed. Is there a way to build a tougher one?
Not sure I'll ever need to, but if my turbo decides to come out another would have to go in.

You could always get a PPG gearset and rebuild the transmission with the stronger hardware. That's what all the "built" 5sp wrx transmissions end up as. We use the PPG 1st or 1-2 combo's in some GTR trannys.

This thread makes me want to find a spec-b tranny and try swapping it in my WRX now :)

[Bu11dogg2]

Is it as strong as the STI version though?

I don't mind my 5speed. Is there a way to build a tougher one?
Not sure I'll ever need to, but if my turbo decides to come out another would have to go in.

From what I hear no.

But i've never seen one apart so I really don't know

Maybe Eric can answer what style of gears they use?

A PPG'd 5speed will hold power. all said and done (unless you swap the gears yourself) it will cost as much as a used STi tranny.

You could always get a PPG gearset and rebuild the transmission with the stronger hardware. That's what all the "built" 5sp wrx transmissions end up as. We use the PPG 1st or 1-2 combo's in some GTR trannys.

This thread makes me want to find a spec-b tranny and try swapping it in my WRX now :)

Let us know what drive shaft lines up :lol:

[jwebsta32]

Getting a PPG 5 speed doesn't get rid of the case flex problem.....

[Bu11dogg2]

case flex is a myth

[Berge56]

Based on my research its fact since the teeth flex apart under load (thanks to the case flexing) and run on the ends of the gear teeth. Aftermarket gears like PPG or Mfactory hold up to this abuse better but still fail.

[Bu11dogg2]

the two of you need to digest this

http://forums.nasioc.com/forums/showthread.php?t=665334

[Bu11dogg2]

What is the biggest transmission misconception? That when you shift gears, you are physically engaging the teeth of the transmission. As seen in the picture above, the teeth of your transmission are always engaged, meshed, and moving. When you shift gears, what you are doing for both dog and synchro engagement is engaging the sliding mechanism inside the gears to apply power to the selected gear. When this occurs, a load is generated in that gear and forward motion occurs.

What is the second biggest transmission misconception? Case flex occurs within Subaru transmissions. Here is how the Subaru 5MT transmission case appears removed from the vehicle:

Top view
http://www.wallpaperinstaller.com/scooby/top.jpg

Side view
http://www.wallpaperinstaller.com/scooby/side.jpg

The front transmission section houses the gears and is opened by removing the left and right half shells to expose the gears. These shells are bolted to each other as well as held in place by being bolted to the engine block and the rear transmission section which is another solid piece. Looking at the construction, it is impossible for the housing to flex.

Even if flex occurred, the gears sit on top of each other, so if flexing to any degree occurred, the gears would actually come together firmer due to gravity than apart as some contend. The premise of case flex when looked at from a construction aspect is a moot point and aside from the evidence listed here, there are any number of other reasons in the internal construction that any transmission professional can go over in further detail.

[Evoeater]

Looking at the construction, it is impossible for the housing to flex.

Even if flex occurred, the gears sit on top of each other, so if flexing to any degree occurred, the gears would actually come together firmer due to gravity than apart as some contend.

It is not impossible for this case to flex..In reading this I feel as if he is looking at the transmission on a visual basis not incorporation basic sums of physics.

1. He does not look at torsional stresses involving the case and both output and input shafts.

2. His statement with gravity has nothing to do with the gears or case and how they perform unless he ment through centrical force with I dont see any affect that would have towards a failure.

3. The gears would actual push themselves apart as the torsional stresses become greater. So this could actually relate some failure to the input and output shafts bending under torsional loads from the gears pushing apart since 3rd gear is in between the two shaft bearings.

4. I do however agree with 90% of everything else mentioned like shock load and how many teeth or how wide the gears are effecting strength.


How many people break stock STi 6 speeds? And how many break fully built PPG straight cut transmission wether dogbox or syncromesh. I know of one failure that one of my friends had leading to an RA gearset(3 transmissions later) it lasted him two years before it broke. The only thing that wasnt upgraded was input shaft..So I believe there is a reason for the wrx transmissions failing built or not. I think bending of the input/output shafts come into play just as much as case flexing if not more.

[Bu11dogg2]

The cut, design and material used to make the gears themselves play into strengh and longevity.

Case flex is a myth, i'll take that to my grave.

[jwebsta32]

the ends of my third sheared off....I has pictures to prove it....all im saying

[Bu11dogg2]

of course it will shear at the weakeast point silly

[yaya]

What is the biggest transmission misconception? That when you shift gears, you are physically engaging the teeth of the transmission. As seen in the picture above, the teeth of your transmission are always engaged, meshed, and moving. When you shift gears, what you are doing for both dog and synchro engagement is engaging the sliding mechanism inside the gears to apply power to the selected gear. When this occurs, a load is generated in that gear and forward motion occurs.

What is the second biggest transmission misconception? Case flex occurs within Subaru transmissions. Here is how the Subaru 5MT transmission case appears removed from the vehicle:

Top view
http://www.wallpaperinstaller.com/scooby/top.jpg

Side view
http://www.wallpaperinstaller.com/scooby/side.jpg

The front transmission section houses the gears and is opened by removing the left and right half shells to expose the gears. These shells are bolted to each other as well as held in place by being bolted to the engine block and the rear transmission section which is another solid piece. Looking at the construction, it is impossible for the housing to flex.

Even if flex occurred, the gears sit on top of each other, so if flexing to any degree occurred, the gears would actually come together firmer due to gravity than apart as some contend. The premise of case flex when looked at from a construction aspect is a moot point and aside from the evidence listed here, there are any number of other reasons in the internal construction that any transmission professional can go over in further detail.


You can't take everything this guy says as gospel...

Here's an interesting thread on 5MT case reinforcement: thread (http://forums.nasioc.com/forums/showthread.php?t=1602159)

[Bu11dogg2]

I know that.

there's a reason that thread has been going for 2 years and nothing has come of it yet.

[KaizenTuning]

I don't think the case itself flexes anywhere, it's cast aluminum and this can be measured with a deflection gauge, if it was an issue they would be drilling 1/2" studs through the transmission and bolting it together to make it stiffer.

The older GTR transmission internals started bending around 700whp, and even with Nismo reinforced gearsets started splitting the tranny cases or the castings in half one way or the other. While the gears help, it may be internally moving around as an assembly?

Overall, don't the 09+'s seem to be holding up better than early units? Are there any concrete identified changes that were made?