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#51 2007-07-19 06:11:10

Spiider
Member
Registered: 2007-07-17
User Number: 2162
Posts: 6

Re: 6 Speed swap

Hey LC,

Yes, I can use the OEM DCCD thumbwheel if you'd like. I've done this many times for customers who prefer the look of the OEM control. (Both my control knob and the OEM thumbwheel are just potentiometers.) 

Unfortunately the OEM knob has a lot less rotation so it makes it harder to find the exact setting you need. This was more of a pain with the older manual controller as you had to adjust it all the time as conditions changed so having a control knob with more adjustment resolution was definitely better. 

The new controller operates totally differently. With the auto controller you are not directly adjusting the lockup, you are adjusting the "aggressiveness" of the programs running in firmware.

You can get the OEM thumbwheel from the dealership and I can set up your controller so that it is adjusted for the OEM thumbwheel. Once you have it installed you just solder on 3 wires onto the correct pins of the thumbwheel.

-Jeff

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#52 2007-07-19 06:16:10

Spiider
Member
Registered: 2007-07-17
User Number: 2162
Posts: 6

Re: 6 Speed swap

If you are going with the R180 rear, and normal rear brakes/suspension/knuckles you can get hybrid axles from the "driveshaftshop.com" but they are/were very expensive last time I checked. I think they used to be $800 for the pair.

Their website is down right now so I can't check....

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#53 2007-07-19 18:51:36

LC
Member
From: Cocoa, FL
Registered: 2006-05-12
User Number: 1131
Posts: 232

Re: 6 Speed swap

Spiider wrote:

Hey LC,

Yes, I can use the OEM DCCD thumbwheel if you'd like. I've done this many times for customers who prefer the look of the OEM control. (Both my control knob and the OEM thumbwheel are just potentiometers.) 

Unfortunately the OEM knob has a lot less rotation so it makes it harder to find the exact setting you need. This was more of a pain with the older manual controller as you had to adjust it all the time as conditions changed so having a control knob with more adjustment resolution was definitely better. 

The new controller operates totally differently. With the auto controller you are not directly adjusting the lockup, you are adjusting the "aggressiveness" of the programs running in firmware.

You can get the OEM thumbwheel from the dealership and I can set up your controller so that it is adjusted for the OEM thumbwheel. Once you have it installed you just solder on 3 wires onto the correct pins of the thumbwheel.

-Jeff

You just sold a controller.

Today's new info. Rear axle adapters that use parts of my original axles and the STi axles are $650 (Bolt-in completelty assembled adapter axles are $1200). One pair of complete used 04 STi rear hubs, carriers, e-brakes, rotors and calipers are $500. All prices are plus shipping. Does anyone know if 04 STi rear axles/hubs have 27 splines? If so, I think I see some Brembos in my future.


2006 Saab 92x Aero, Brilliant Red, 6 speed MT, Sport Package, Sunroof.

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#54 2007-07-20 19:32:55

Spiider
Member
Registered: 2007-07-17
User Number: 2162
Posts: 6

Re: 6 Speed swap

Lol, I only have one left until end of August when I get back from vacation and can build more.....

BTW, don't forget if you go to full STi rear suspension, brakes etc. that your wheels more than likely won't fit over the brembo's unless you have 18" rims.

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#55 2007-07-20 19:38:13

LC
Member
From: Cocoa, FL
Registered: 2006-05-12
User Number: 1131
Posts: 232

Re: 6 Speed swap

http://i179.photobucket.com/albums/w303/06Saabaru/DSC_00135.jpg

18X8


2006 Saab 92x Aero, Brilliant Red, 6 speed MT, Sport Package, Sunroof.

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#56 2007-07-20 21:06:15

Spiider
Member
Registered: 2007-07-17
User Number: 2162
Posts: 6

Re: 6 Speed swap

Looks like you are good to go!!! Tons of room for good brakes there.

Most people are put off by the rear end swap because of the issues you already know about.
ie. If you don't change the knuckles and brakes you need expensive hybrid axles, if you change it all you need a new set of wheels.

Either way is not a cheap proposition, but you already can go wither way. Personally you are doing it right by going with the brembo's and r180. The stock r160 is a little weak unless you go with a replacement cusco tarmac diff.

With my JDM STi ver7 swap I could smoke all four tires off the line with the DCCD controller cranked up.
With the DCCD controller turned off I could smoke the rears for basically as long as I wanted.
(It would literally spin the rear tires when accelerating past 100km/hr even with the small twin scroll turbo.)

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#57 2007-07-20 21:44:43

robertob
Member
From: Los Angeles, CA
Registered: 2007-04-24
User Number: 1986
Posts: 349
Website

Re: 6 Speed swap

Man, for $500 I'd just go with the STi parts in the rear... but of course that means you need Brembos up front.

How much are used STis going for these days?

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#58 2007-07-21 12:40:54

LC
Member
From: Cocoa, FL
Registered: 2006-05-12
User Number: 1131
Posts: 232

Re: 6 Speed swap

robertob wrote:

Man, for $500 I'd just go with the STi parts in the rear... but of course that means you need Brembos up front.

Yeah, I would really like to do the whole Brembo / stronger bearing setup, but I just found out that the stock Saabaru front axles are supposed to fit directly into the 6 speed. If I had an 05 Aero, all I would need for the swap was the 05 6 speed & shifter, transmission mount, driveshaft and controller - the front axles fit, the 05 R160 rear end has the correct 3.9 ratio and the 05 clutch is a pull type (of course I wouldn't have 308 wtq either). I am sort of leaning toward the axle adapters at this point - I wouldn't have to get involved in the brakes & hubs at this time & I could always do the brakes/hubs later.

So:

$3562 - 2005 STi 6 speed, shifter, clutch, trans mount, driveshaft, R180 rear end, rear axles, Fla sales tax, shipping included
$ 325 - ACT streetlight STi flywheel, shipping included, I think I also need more cluch cover bolts
$ 250 - Spiider auto DCCD Controller, shipping included
$   55 - OEM DCCD thumbwheel + shipping
$   84 - OEM shift knob + shipping
$ 650 - axle adapters + shipping
$4926 + shipping

Less than PPGs; especially if I sell the 5-speed.

Now if I can just stay away from all those TiC & Kartboy bushings & the Momo shift knob...

Last edited by LC (2007-07-21 12:47:04)


2006 Saab 92x Aero, Brilliant Red, 6 speed MT, Sport Package, Sunroof.

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#59 2007-07-21 21:44:12

eurospek
#6458
Supporter
From: Hampshire, IL
Registered: 2005-06-08
User Number: 181
Posts: 27757

Re: 6 Speed swap

Nice wheels!!! Now I know who you are, I remember seeing a cruising pic of your car on nasioc.  roxor


2016 VW GTI S 2-door Reflex Silver 6-spd

2014 VW Passat S 1.8 TSI
2005 SAAB 9-2X AERO Arctic Silver 4eat | COBB Stage 2 Protuned

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#60 2007-07-24 17:46:32

LC
Member
From: Cocoa, FL
Registered: 2006-05-12
User Number: 1131
Posts: 232

Re: 6 Speed swap

eurospek wrote:

Nice wheels!!! Now I know who you are, I remember seeing a cruising pic of your car on nasioc.  roxor

Thanks - I like the wheels also, they weigh only 16 lbs each - one of the main reasons that I want to keep the 5x100 pattern.

Progress:

I'm going with the adapters - can't find out if the 05 STi rear axles fit the 04 STi rear hubs. 

I found an 07 STi knob with less tham 1000 miles of use for $25.

Flywheel arrived today.

"As long as I have it apart" disease relapse - ordered every Kartboy and TiC shfter bushing available, along with the street versions of the rear subframe bushings and urethane trans crossmember bushings.

Bought a hydraulic trans jack - I went to the Harbor Freight store to get the cheap scissor trans jack but they had the hydraulic version with knob adjustable tilt and rotation on sale for only $20 extra.


2006 Saab 92x Aero, Brilliant Red, 6 speed MT, Sport Package, Sunroof.

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#61 2007-08-01 17:46:06

LC
Member
From: Cocoa, FL
Registered: 2006-05-12
User Number: 1131
Posts: 232

Re: 6 Speed swap

No luck getting axle adapters banghead. Gave in and ordered the axles from the Drive Shaft Shop - they may not be cheap, but it should be a painless install.

I got the Spiider DCCD controller and OEM DCCD thumbwheel today. Clutch pressure plate bolts (actually, to be technically correct, they are machine screws) are the last remaining item. I went to the dealer and they needed a VIN # from an 05 STi before they can look them up. Another 40 mile trip during lunch tomorrow....


2006 Saab 92x Aero, Brilliant Red, 6 speed MT, Sport Package, Sunroof.

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#62 2007-08-01 22:19:15

keaniegenie
92x fanatic
Supporter
From: Seattle
Registered: 2006-01-21
User Number: 979
Posts: 795

Re: 6 Speed swap

while its all apart, why not a cf driveshaft?


Element 92X

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#63 2007-08-02 20:00:00

LC
Member
From: Cocoa, FL
Registered: 2006-05-12
User Number: 1131
Posts: 232

Re: 6 Speed swap

keaniegenie wrote:

while its all apart, why not a cf driveshaft?

What does cf mean?


2006 Saab 92x Aero, Brilliant Red, 6 speed MT, Sport Package, Sunroof.

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#64 2007-08-02 20:01:51

Ryan
Anti-JDM
Supporter
From: San Francisco
Registered: 2007-04-05
User Number: 1941
Posts: 6090

Re: 6 Speed swap

Carbon Fiber


'05 Aero MT (BBS RK, Stage 2, Cobb suspension)
'06 Aero 4EAT (BBS CH, STi interior, Brembo GT, Epic suspension)
'12 GTI Autobahn/DSG/4D (BBS CK, Koni coilovers, APR tuned)

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#65 2007-08-02 22:33:35

LC
Member
From: Cocoa, FL
Registered: 2006-05-12
User Number: 1131
Posts: 232

Re: 6 Speed swap

Not at this point. I may replace the STi clutch parts though (with OEM) - I would hate to get it together and find out that the used parts are no good.


2006 Saab 92x Aero, Brilliant Red, 6 speed MT, Sport Package, Sunroof.

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#66 2007-11-19 12:45:44

LC
Member
From: Cocoa, FL
Registered: 2006-05-12
User Number: 1131
Posts: 232

Re: 6 Speed swap

The weather finally got cool enough and I am in the middle of this swap right now. I will be posting photos in a week or so. I am also installing the aluminum control arms, Whiteline roll center kit, underbody aero panels, rear underbody diffuser (with existing hitch). So far, I have the rear end in with the conversion axles and Karboy and TiC bushings and am installing the diffuser brackets.

http://i179.photobucket.com/albums/w303/06Saabaru/rears.jpg


2006 Saab 92x Aero, Brilliant Red, 6 speed MT, Sport Package, Sunroof.

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#67 2007-11-19 13:02:43

bump909
High Executioner to the King of England
Supporter
From: Lynn, MA
Registered: 2007-01-16
User Number: 1772
Posts: 6135
Website

Re: 6 Speed swap

nice, thanks for the updates.  cool

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#68 2007-11-19 14:03:41

nstelemark
The other Morgan
Supporter
From: Halifax, NS
Registered: 2007-04-15
User Number: 1964
Posts: 2561
Website

Re: 6 Speed swap

arrow-up +1


2015 WRX CVT Base Cobb-ProTune | Dunlop/Nokian | STi | Rally Armor | Phillips
2014 Forester XT Limited Cobb-S1 | Toyo/Nokian
2013 Impreza -> gone 2005 9-2X Aero 4EAT Cobb-S2 | Perrin | Toyo/Nokian | Whiteline | FHI | JDM STi | Rally Armor | IxizConcept | Paranoid Fabs | prodrive | Tokico
1999 JDM Legacy GT STi

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#69 2007-11-25 17:15:14

LC
Member
From: Cocoa, FL
Registered: 2006-05-12
User Number: 1131
Posts: 232

Re: 6 Speed swap

This is taking more time than I figured. First I had to make some space in the garage.

http://i179.photobucket.com/albums/w303/06Saabaru/Before.jpg

Up on to the stands.

http://i179.photobucket.com/albums/w303/06Saabaru/Stands.jpg

http://i179.photobucket.com/albums/w303/06Saabaru/Stands2.jpg

The rear end before:

http://i179.photobucket.com/albums/w303/06Saabaru/R160.jpg

I removed the exhaust sysetm and drive shaft. The rear end is a pretty straight forward swap of parts. the biggest problem I had was getting the new adapter axles to snap into the rear end. I played with it for a day  banghead before I discoverd the secret - PB Blaster. I had been using grease to lubricate the new axle ends and they just would not snap into place. Then I tried PB Blaster and they just snapped right in. I figure that the grease just stayed where I put it it, but the PB Blaster penetrating oil traveled to where it was needed. I also installed Kartboy rear subframe outrigger bushings (comfort) and TiC rear diff mount bushings (comfort) while I was there. Then came the STi underbody rear diffuser. I have a hitch so I did not use the rearmost mount - I drilled the (17/64") and tapped (8mm-1.25) the hitch. I did a lot of cutting, sawing and filing on the diffuser itself to clear various parts of the hitch.

http://i179.photobucket.com/albums/w303/06Saabaru/Diffuser.jpg

Then came the forward mounts - this took an insane amount of time. Lots of taping, checking, moving, taping........ and finally drilling and pop riveting.

http://i179.photobucket.com/albums/w303/06Saabaru/Brackets1.jpg

I am pretty pleased with the result.

http://i179.photobucket.com/albums/w303/06Saabaru/HitchDiffuser.jpg

Now it is tme for the transaxle itself. So far all I have done is drain the 5-speed with my new T-70 Torx bit (aren't special tools wonderful roll) and removed the intercooler. Next weekend will be interesting.


2006 Saab 92x Aero, Brilliant Red, 6 speed MT, Sport Package, Sunroof.

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#70 2007-11-25 20:51:59

iamchris
Former Site Owner
Supporter
Registered: 2006-02-22
User Number: 1032
Posts: 25070

Re: 6 Speed swap

Awesome, thanks for posting!  I was interested to see how the rear diffuser fit with the trailer hitch (I have the same one), and now once I get myself financially comfortable, I will have to do the same thing.  Looks like it came out very well!  Thanks again smile

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#71 2007-11-26 19:23:50

nstelemark
The other Morgan
Supporter
From: Halifax, NS
Registered: 2007-04-15
User Number: 1964
Posts: 2561
Website

Re: 6 Speed swap

Very cool - thanks for the update!


2015 WRX CVT Base Cobb-ProTune | Dunlop/Nokian | STi | Rally Armor | Phillips
2014 Forester XT Limited Cobb-S1 | Toyo/Nokian
2013 Impreza -> gone 2005 9-2X Aero 4EAT Cobb-S2 | Perrin | Toyo/Nokian | Whiteline | FHI | JDM STi | Rally Armor | IxizConcept | Paranoid Fabs | prodrive | Tokico
1999 JDM Legacy GT STi

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#72 2007-12-01 20:41:57

LC
Member
From: Cocoa, FL
Registered: 2006-05-12
User Number: 1131
Posts: 232

Re: 6 Speed swap

Progress today:

Filled the rear end with Amsoil Severe Gear 75W-90.

Changed the engine oil & filter - Amsoil 5w-30.

Popped the front axles out of the their clips in the transaxle. Just pried between the inner joint and the bolt head just below and to the front of the joint.

Removed the front subframe/brace. 1 12mm, 3 17mm, and 2 14mm bolts per side.

Removed the front control arms. I used PB Blaster on the ball joints last night and they just popped right out today after removing the 14mm bolts. I understand this can be a real pain if the joints have rusted in but mine were no trouble. Unbolted the sway bar end links (12mm) and then the front bushings(17mm) then came the rear bushings. This took a cheater bar (the old faithfull Matco floor jack handle) on a breaker bar on the 19mm socket. I tried the impact wrench but all it did was make noise. Removing the arms is not necessary to pull the axles out of the transaxle, only popping the ball joints loose - but I am installing aluminum GC8 control arms with Whiteline roll center adjusting ball joints.

http://i179.photobucket.com/albums/w303/06Saabaru/ControlArms-1.jpg

http://i179.photobucket.com/albums/w303/06Saabaru/BallJoints.jpg


2006 Saab 92x Aero, Brilliant Red, 6 speed MT, Sport Package, Sunroof.

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#73 2007-12-02 00:01:22

92XLOVER
Supporter
Supporter
From: Andrews AFB, MD
Registered: 2007-02-26
User Number: 1856
Posts: 495

Re: 6 Speed swap

awesome progress!  up


05 9-2X Aero, Loaded, IxizHood

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#74 2007-12-02 18:02:22

LC
Member
From: Cocoa, FL
Registered: 2006-05-12
User Number: 1131
Posts: 232

Re: 6 Speed swap

Today's Progress;

Installed control arms. The front bushngs are slightly shorter than the stockers so I needed a couple of washers to take up the slack. I installed the washers at the rear of the bushing so as to move the arm as far forward as possible thus maximizing caster. My car is already slightly caster challenged due to the front being lowered more than the rear. The front bushing bolts get torqued to 92 ft-lbs and the rears 184. I dont have a torque wrench that goes to 184 so I just tightened them with the impact, then a little more with the cheater bar. I did not connect them to the struts yet.

http://i179.photobucket.com/albums/w303/06Saabaru/Washers.jpg

I reinstalled the front subframe/brace but did not tighten it down. I wanted the extra slop in case I needed to push the control arms down later. I then installed the Whiteline bump steer correcting tie rod ends. First I measured from the inner boot on the tie rod to a casting ridge on the steering knuckle so that I could reproduce the length with the new tie rod ends. The tie rod end ball joint sits lower with the new ends so the installed length was going to be different than original. I figure this method would be the most accurate for getting the car to the alignment shop.

http://i179.photobucket.com/albums/w303/06Saabaru/TieRodEnd.jpg

I pushed the control arms down and pulled the struts out as far as I could until the axles pulled free of the transaxle. I then dropped the car down a little so I could work back on top. Removed the downpipe. Removed the pitch stop - note that it is identical to the used STi pitch stop I have. Removed the starter - it is easier if you remove the top bolt first - note that the top bolt also secures a bracket. Disconnected all the wires I could find. Disconnected the clutch flex hose from the clutch slave cylinder and plugged the banjo fitting.

http://i179.photobucket.com/albums/w303/06Saabaru/Almost.jpg

All I have to do now is the shifter and the crossmember then it will be time to unbolt it from the engine and remove it, but it is dark outside and I have had enough for today. So close...


2006 Saab 92x Aero, Brilliant Red, 6 speed MT, Sport Package, Sunroof.

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#75 2007-12-08 20:32:29

LC
Member
From: Cocoa, FL
Registered: 2006-05-12
User Number: 1131
Posts: 232

Re: 6 Speed swap

Getting the trans out was more trouble than I thought. Mostly it was getting the trans to clear the turbo - I dont know if the VF39 is slightly thicker at the downpipe flange but it took a lot of wiggling and cursing to get it out but the deed is done.

Note the push type clutch arm on the 06 5-speed and the pull type clutch arm on the 6-speed.

http://i179.photobucket.com/albums/w303/06Saabaru/compare2.jpg

The 6-speed is definitely bigger and beefier. reverse lockout on the 6-speed uses a cable. The 6 speed has a couple of extra bolt holes near the dowels that will not be used. The dowels stayed in the 06 engine so I will need to remove them from the 6-speed.

http://i179.photobucket.com/albums/w303/06Saabaru/compare.jpg

Time to remove the old clutch and flywheel.

http://i179.photobucket.com/albums/w303/06Saabaru/oldclutch.jpg

Last edited by LC (2007-12-08 20:39:51)


2006 Saab 92x Aero, Brilliant Red, 6 speed MT, Sport Package, Sunroof.

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