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#76 2007-12-08 21:27:53

hammyt
0_0
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From: Chicago, IL
Registered: 2005-07-18
User Number: 562
Posts: 14251

Re: 6 Speed swap

up up


2005 Saab 9-2x Aero 5MT | 275whp/250wtq | [email protected] | SOLD
2014 Focus ST 6MT | Tuxedo Black | SOLD
2012 Mazda 3 Hatch 2.0 AT | Shiny Blue

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#77 2007-12-08 21:44:52

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

Re: 6 Speed swap

This is an awesome write-up.  Thank you.

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#78 2007-12-09 18:50:04

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

Re: 6 Speed swap

I think I see the light at the end of the tunnel - still a ways to go though

Tme to get out the soldering gun. The STi trans has a six pin connector - 2 pins each for neutral, reverse and DCCD. The connector on the car has only 4 pins. So I spliced the 4 pin connector to the corresponding wires - I understand that in earlier cars this is a simple swapout, but the intermediate connectors are different on my car and the 05 STi trans. the colors are the same though - green and green/white for one and green and black for the other.

5 speed intermediate connectors.

http://i179.photobucket.com/albums/w303/06Saabaru/5spconnect.jpg

6 speed intermediare connectors.

http://i179.photobucket.com/albums/w303/06Saabaru/6spconnect.jpg

Spliced in 4 pin connector.

http://i179.photobucket.com/albums/w303/06Saabaru/4pin.jpg

For the other two wires I used the leftover connectors from the 4 pin to intermediate connector harness. One is male and the other female, but one is right handed and the other left handed. I just filed off the offending ridge:

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

And I have a free factory look waterproof connector.

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

Time to remove the clutch.

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

The stock components are on the bottom. OEM factory Subaru STi pressure plate, throwout bearing, clutch disc, flywheel bolts, clutch bolts and pilot bearing at the top with ACT street flywheel. Note that the stock "Saab" flywheel has "EXEDY" stamped on it. Note that the STi clutch is a pull style and the throwout bearing appears to be sunk into the pressure plate. When tightened to the flywheel, it moves out. Note that the pressure plate mounting surface on the flywheel is raised from the surface and there are 9 bolts instead of six. Weight fot the stock flywheel - 23.5 lbs, assembly - 36lbs. Weight of the ACT flywheel - 15 lbs, assembly - 31 lbs. The STi clutch is larger diameter and heavier.

http://i179.photobucket.com/albums/w303/06Saabaru/clutch-fly.jpg

There is a cross shaft that is supposed to be removed to allow later positioning of the clutch arm into the pull-style throwout bearing.

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

New flywheel in place. Note the old faithful VW flywheel lock at the lower right - kind of useless for the stock flywheel, but the STi unit has the raised bosses for the pressure plate - makes torquing to 53 ft-lbs easy (with a dab of locktight).

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

On wth the clutch - 140 inch-lbs

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

On to the trans jack - real men or those with friends don't need the hoist.

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

Up, up and away...

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

Comparison of 5 speed and STi crossmembers and mounts.

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

Installation is typical jack, wiggle, adjust, jack, wiggle, adjust......  I removed the pitch stop bracket at the top front of the tranaxle and the slave cylinder to gain extra clearance and I used to floor jack to raise the front of the engine. No issue with the turbo on install - the six speed seems to have a little more clearance in this area. So now the 6 speed is actually in the car. banana

http://i179.photobucket.com/albums/w303/06Saabaru/6.jpg

So much left to do...

And thank you to Spiider for answering Sunday morning E-mails - excellent customer service.

Last edited by LC (2007-12-10 12:39:54)


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

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#79 2007-12-09 21:33:27

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

Re: 6 Speed swap

http://www.euroteknik.com/forum/images/smilies/bowdown.gif


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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#80 2007-12-09 22:08:23

hammyt
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From: Chicago, IL
Registered: 2005-07-18
User Number: 562
Posts: 14251

Re: 6 Speed swap

eurospek wrote:

http://www.euroteknik.com/forum/images/smilies/bowdown.gif

QFT.


2005 Saab 9-2x Aero 5MT | 275whp/250wtq | [email protected] | SOLD
2014 Focus ST 6MT | Tuxedo Black | SOLD
2012 Mazda 3 Hatch 2.0 AT | Shiny Blue

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#81 2007-12-10 19:33:32

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

Re: 6 Speed swap

Time to finish bolting things up. Tightend up the shift linkage bolts - note the washers under the one bolt - this bolt was missing from the parts I received so I used one of the bolts from the pitch stop bracket on the 5 speed. Bolted up the Kartboy rear shifter bushing to the body - 156 inch-lbs. Then started torquing the crossmember; 102 ft-lbs on the 2 17mm bolts and 52 ft-lbs on the 4 14mm bolts. Then 35 ft-lbs on the trans mount bushings. Then to the crossmember bushings (the pink ones fron TIC) - 52-ft-lbs - then on the last one, one of the nuts on the front - it spins before reaching torque spec - and it won't back off  mad I have to remove the crossmember now - at least I have a spare on the original crossmember. I also opened the drain plug while I was underneath and some nice clean fluid drained out drained out - I will let it drain overnight.

It sure is a tight fit compared to the 5-speed.

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


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

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#82 2007-12-10 19:35:52

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

Re: 6 Speed swap

damn! holy sh*t! thats going to be sweet as hell!  *will this be the FIRST 6-spd aero?
and... its given but... up up up up up banana


05 9-2X Aero, Loaded, IxizHood

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#83 2007-12-14 07:01:51

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

Re: 6 Speed swap

Bad news - started it up - loud grinding/metallic vibration noise - flywheel/clutch? - the transaxle is coming back out so I can find what is rubbing. Does the STi use a spacer between the flywheel & crank? At least it will go much faster the second time.


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

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#84 2007-12-14 17:51:02

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

Re: 6 Speed swap

this happened to a friend of mine when he did a clutch in his older wrx. his problem was that he forgot to put in the little "dowels?" <-sp? for the flywheel. im sure you did put those in but just thought i might let you know? good luck troubleshooting!


05 9-2X Aero, Loaded, IxizHood

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#85 2007-12-14 18:02:28

Keirik
Member
From: Long Island, NY
Registered: 2007-11-11
User Number: 2378
Posts: 229

Re: 6 Speed swap

im getting excited.....too ba when i get back to my car though it won't be the 6 speed! end of excitement, lol...

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#86 2007-12-18 13:00:17

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

Re: 6 Speed swap

I have been out of town for the past four days. I have two suspicions. One: The spring preloading the clutch arm is stretched very tight. If there was a missing spacer between the crank and flywheel it could account for this, and the flywheel would be rubbing on the engine - but I did not feel or hear any rubbing of the flywheel when I was installing it, but then again, I did not rotate it after it was torqued. Two: I may have dropped a nut and possibly a socket into the starter hole while disconnecting the pitch stop bracket from the transaxle. I did this with the transaxle halfway in, late at night. I am missing one of my two 14mm 3/8' drive sockets.

Research necessary for the first. Clean up the garage for the second. Then take the transaxle out.

I was really trying hard to complete things by last Friday - I had to drive my no-heat pickup to Tennessee this past weekend - it was 24 degrees when I left Pigeon Forge on Monday morning.

Yes, I put the dowels in - you can see them in the clutch/flywheel comparison picture. The other dowels on the engine never came out - I had to remove the ones from the 6-speed.


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

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#87 2007-12-18 13:02:47

hammyt
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From: Chicago, IL
Registered: 2005-07-18
User Number: 562
Posts: 14251

Re: 6 Speed swap

GL I really hope this turns out well for you.


2005 Saab 9-2x Aero 5MT | 275whp/250wtq | [email protected] | SOLD
2014 Focus ST 6MT | Tuxedo Black | SOLD
2012 Mazda 3 Hatch 2.0 AT | Shiny Blue

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#88 2008-01-16 13:01:42

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

Re: 6 Speed swap

Update ; I have not touched the car in about a month - I have had a respiratory infection. Hope to get back to this in the next week or so. I have found no mention in the literature of a flywheel spacer on the STi so I am hoping to find a socket in the bellhousing with my magnet.


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

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#89 2008-01-16 13:21:40

Xaul Zan
sa4baru
Supporter
From: State College, PA
Registered: 2006-06-23
User Number: 1181
Posts: 2824

Re: 6 Speed swap

eurospek wrote:

http://www.euroteknik.com/forum/images/smilies/bowdown.gif

holy crap, that is a huuuuuge project.

good luck on the finishing touches  up


2005 Black Linear, 5MT     EQ Tuned w/ DeltaCams

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#90 2008-07-01 15:15:51

gonzocycle
Supporter
Supporter
From: Lakewood, CO
Registered: 2007-10-01
User Number: 2301
Posts: 2917

Re: 6 Speed swap

What ever happened to this project?  sad  I want update!


#5197  sold

now I drive a prius

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#91 2008-07-02 12:34:52

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

Re: 6 Speed swap

Mostly it has been sitting, I have been very busy at work (I was in India a few weeks ago) and I have another car, a truck and a motorcycle for transportation. I have taken the intercooler back off and removed the clutch slave cylinder and throwout bearing arm boot, but there is no space to get a magnet in. Next I will remove the starter and throwout bearing arm shaft and see if that gets me room to put the magnet in. If not, then I need to pull the transaxle back a couple of inches from the engine to see if the missing socket falls out.


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

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#92 2008-07-02 13:24:21

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

Re: 6 Speed swap

arrow-up

bummer on this - good luck finding the socket!


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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#93 2008-07-02 16:51:54

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

Re: 6 Speed swap

can I have the socket?   biggrin

This is history in the making guys!
good luck with that man. keep us posted


05 9-2X Aero, Loaded, IxizHood

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#94 2008-07-02 22:19:17

eqlized_aero
Forum User #2
Supporter
From: H-Town, Michigan
Registered: 2005-05-10
User Number: 3
Posts: 5856

Re: 6 Speed swap

I would just pull the trans again.

Are you sure you didn't install the clutch backwards? I had a friend do that in his wrx wagon.


JDM V9 Spec C Type RA swapped 92x - Smooth as silk EJ207
Factory Five 818S - Rough as sandpaper EJ255

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#95 2008-07-02 22:31:06

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

Re: 6 Speed swap

arrow-up Believe it or not, that happens more often than not. Sometimes they aren't marked clear.


05 9-2X Aero, Loaded, IxizHood

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#96 2008-07-07 12:43:02

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

Re: 6 Speed swap

I am pretty sure I got the clutch in correctly, but if there is no socket in the bellhousing, that would be a place to check. As I recall, the side of the clutch disc cushioning springs hit the flywheel on the STi style clutch if you put the disc in backwards.


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

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#97 2008-09-07 20:11:21

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

Re: 6 Speed swap

Finally back to the project. I have everything disconnected and removed except the front axles and the last bolt on the shifter linkage (& the transaxle itself). I took the front seats out this time also - makes working on the top side of the shifter & console much easier. It will also allow better access to the computer to hook up the diff controller.


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

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#98 2008-09-07 20:21:32

boston_errol
Supporter
Supporter
Registered: 2008-04-27
User Number: 2726
Posts: 3168

Re: 6 Speed swap

i am... so.. jealous!!! great work.


2005 Legacy GT Wagon Ltd 5 speed ABP

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#99 2019-12-07 13:28:30

le_Ruta
Member
Registered: 2019-11-29
User Number: 46709
Posts: 1

Re: 6 Speed swap

All These threads have died  facepalm

Cant even see the photos anymore!

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#100 2019-12-07 14:47:18

itsnotmeitsyou
Potato, Patreason...
Supporter
From: San Antonio, Texas
Registered: 2011-07-31
User Number: 5779
Posts: 2595

Re: 6 Speed swap

Pics are working for me... They are photobucket so try installing the firefox plugin that fixes the bullshit blocking photobucket turned on.  And what did you want out of this thread?  Should the OP have continued to post updates on how well the 6MT was working 11 years after installing it?!
If your first post is to bitch about the site then maybe Nasioc's offtopic subforum is more your speed?


2005 Saab 9-2x Aero:  More than you've had done to your car.
2015 Forester XT 'TS' clone

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