Crazy_Pilot's 6MT Swap (Lots-O-Pics!)
 

When I bought my car 5 years ago there were two main things I wanted to do with it: Restore the body and convert to a manual trans. A number of things have come up in the meantime, both mods and repairs. I replaced the engine last fall (Thanks Nate!), swapped in coilover suspension, replaced the original doors that were completely rotten, BBS wheels, custom exhaust, etc etc etc. (See my signiture mod list ;) )

This spring I finally had the opportunity to grab a 6MT with all the bits I need, and last weekend I finally started the swap.

Bring it all home:

https://fbcdn-sphotos-g-a.akamaihd.n...82064290_o.jpg

Last weekend I started the work, but had some other stuff to take care of on the car first. My parking brake had seized up a while ago, so new cables and rear brakes were the first order of business. I also picked up a set of front calipers, I've been doing impromptu rebuilds on mine since I bought the car and got a little bored with it. The calipers will end up black as well.

http://www.subaru-svx.net/photopost/...9969794511.jpg

Amusingly, the parts guy couldn't believe that the calipers were for a Subaru. Between the size and the dual pistons he was sure they belonged on a Chevy half-ton.

Today I got a bunch done. I'll let the pictures do the talking:

Not long for you my old friend...

http://www.subaru-svx.net/photopost/...9969680791.jpg

4EAT out and meeting it's replacement! Anyone want it? Trans jacks are the **** by the way.

http://www.subaru-svx.net/photopost/...7996932834.jpg

My sophisticated engine holding tool. Keeps it from falling forward without the transmission there. (It's one of the bellhousing bolts. Do not try this if you don't have a PWR rad!)

http://www.subaru-svx.net/photopost/...9969435611.jpg

Tomorrow is interior day. Get the shifter and stock pedals out, remove the TCU, all that fun stuff.

Re: Crazy_Pilot's 6MT Swap (Lots-O-Pics!)
 

Very cool. Welcome to the club. :)

Any issues/questions so far?

What are you doing with the pedals? That part may turn out to be trickier than you think.

Re: Crazy_Pilot's 6MT Swap (Lots-O-Pics!)
 

No issues so far. It's amazing how well built these cars are; 20 years old and the only bolts that are stuck are the tiny ones holding the parking brake cable to sheet metal brackets. All of the bolts for the subframe, rear diff, suspension and everything else come apart like they were assembled yesterday.

The transmission came with one of YT's conversion kits, so I've already got the pedals sitting and ready to go. I may build my own transmission cross member down the road some time just because this one is a little rusty and I'd like to have things looking show-room underneath.

Re: Crazy_Pilot's 6MT Swap (Lots-O-Pics!)
 

Nice pics! Good luck with the project, this is great motivation for me to get off my butt and start the 6 spd conversion!

Re: Crazy_Pilot's 6MT Swap (Lots-O-Pics!)
 

Can you please take pics of these things? I'd like to make a comprehensive m/t swap thread and those would really help. Also the shifter linkages. If you can, I will write it all up, and I'm sure it will help others in the future. Especially as the older members who have the experience become less active.

Re: Crazy_Pilot's 6MT Swap (Lots-O-Pics!)
 

Absolutely. I won't be back in town for two weeks, but I'll definitely do that for you. I'd been wondering about a few of the details myself before I got the kit and saw how it all goes together.

Re: Crazy_Pilot's 6MT Swap (Lots-O-Pics!)
 

Round 2: I'll be starting on the swap again tomorrow, but in the meantime I had a little bit of fun with some Brembos.

As YT found out a while back, the mounting lugs on the SVX knuckles are farther out than an Impreza's. The caliper mounts up, but with the added outward push my 17" STi rims don't clear them. Fortunately I just happen to have an 18" wheel lying around...

http://www.subaru-svx.net/photopost/...9969833041.jpg

The stock rotors don't work at all, so I just tossed the wheel on without one. It's a tight fit:

http://www.subaru-svx.net/photopost/...9969863541.jpg

Hard to tell in that picture, but there's about 2mm clearance from the wheel to the caliper. Obviously with a rotor installed that would be better.

Soooo pretty...

http://www.subaru-svx.net/photopost/...7996989760.jpg

Re: Crazy_Pilot's 6MT Swap (Lots-O-Pics!)
 

Sunday (Canada Day for we Northerners!) Update:

Flex plate out, flywheel in, auto pedals out, TCU out, other misc stuff. The main thing today was pretty-ing up the transmission:

http://www.subaru-svx.net/photopost/...7996995972.jpg

http://www.subaru-svx.net/photopost/...7997002614.jpg

http://www.subaru-svx.net/photopost/...8/DSC00602.JPG

Don't mind the broken engine in the background. :rolleyes:The colour is Rustoleum Hammered Black, it's basically a very dark grey with a beaten/cast texture. Looks really nice. I spent most of yesterday afternoon cleaning the transmission with a combination of wire brushes, degreasers, and other means. (Turns out electric toothbrushes make excellent cleaning tools :lol:)

Tomorrow I'll hopefully get the pedals mounted (I'm honestly finding this to be the hardest part of the job), the clutch disc/pressure plate installed, and maybe swap the R180 into the back end.

Re: Crazy_Pilot's 6MT Swap (Lots-O-Pics!)
 

Having removed or put back the pedals at least 5 times, I can assure you that that is the hardest part. Without ever taking out any of the interior to do so. I am a skinny basterd so I can get away with stuff like that.

Try to make the hole for the clutch master cyl as small as you can. You'll appreciate it years later, I promise. Also, if you don't and you don't cover it up somehow either, your feet and the pedals will get hot on long drives.

MAKE SURE THAT NO PART OF THE CLUTCH PEDAL CUTS INTO THE WHITE PLASTIC THINGY that covers all the wires above the pedals.

That trans looks very nice. I wish I had had the forethought to paint mine. I have used that paint and it does look really good.

Re: Crazy_Pilot's 6MT Swap (Lots-O-Pics!)
 

Love the paint color!

Re: Crazy_Pilot's 6MT Swap (Lots-O-Pics!)
 

I am planning on doing a really comprehensive write-up on manual swaps, and since you're taking Lots-O-Pics anyway, can you make sure to take some pics of the following:

Auto and M/T pedals
Crossmember
Shifter linkages
Whatever you do in order to mount the lower shift linkage to the body
Whatever you do to seal the shifter area with the rubber seal or whatever
Master cylinder and especially the tubing going to the slave cyl
The wiring to the old auto harness (btw, making an adapter from the extra loom that plugs into the trans worked really good for me)
The wiring to next to the auto shifter (that 4-wire white plug you have to jumper 2 of the wires)

Re: Crazy_Pilot's 6MT Swap (Lots-O-Pics!)
 

Will do. I actually just took the shots of the pedal assembly to show what's modified, I'll grab the rest as I go.

:lol: I'm a skinny bastard too, but unfortunately I'm also 6'-1" with long arms and big hands. The contortions required to get in there are not the most pleasant.

Re: Crazy_Pilot's 6MT Swap (Lots-O-Pics!)
 

Thanks.

"Contortions" is the perfect word for that, lol. Yea, not an experience I'm looking to repeat.

What kind of 6-speed is it btw? Year/DCCD?

Re: Crazy_Pilot's 6MT Swap (Lots-O-Pics!)
 

Did you use longer bolts than the standard flexplate bolts?;)

Re: Crazy_Pilot's 6MT Swap (Lots-O-Pics!)
 

It's a 2007 long-geared USDM. It has DCCD, but I haven't decided if/how I'm going to employ it. Honestly this swap is enough work at the moment, I'll worry about that once the car is driving again.

OMGWTFBBQSAUCE there are longer bolts?! ;) :D

Re: Crazy_Pilot's 6MT Swap (Lots-O-Pics!)
 

Or you can use the shorter bolts, just double the torque spec to compensate :eek: :D

Re: Crazy_Pilot's 6MT Swap (Lots-O-Pics!)
 

WOW!
You kids sure talk funny!:eek:

Re: Crazy_Pilot's 6MT Swap (Lots-O-Pics!)
 

Normally, Dave, I pull the crankshaft and pesky rear main seal so that I can use both bolts, AND nuts.
Naturally this takes a little longer, but at $50.00 an hour, what do I care.:D

Re: Crazy_Pilot's 6MT Swap (Lots-O-Pics!)
 

More progress! Shiny transmission. Less shiny crossmember.

http://www.subaru-svx.net/photopost/...8/Trans_in.JPG

Shifter part way into it's new home:

http://www.subaru-svx.net/photopost/...48/Shifter.JPG

I think I can now say my car is more manual than automatic. :banana:

On Friday I also picked up a set of quarter panels and fenders for the car. So nice to have a beautiful set of factory sheetmetal. One thing I did note is that on one of the fenders there is a bracket which is spot welded in place. However, only one fender has those welds. On the other one it's not welded and bounces around. Anyone else ever seen this before?

http://www.subaru-svx.net/photopost/...0/Q-Panels.JPG

http://www.subaru-svx.net/photopost/...00/Fenders.JPG

Re: Crazy_Pilot's 6MT Swap (Lots-O-Pics!)
 

i really like this style of wheel :cool:

Re: Crazy_Pilot's 6MT Swap (Lots-O-Pics!)
 

Chris,
Where did you get the quarter panels? :cool: I'm definitely in need of a pair for Racer X :eek:
The fender bracket is on the passenger's side fender then it's probably for the air intake that feeds up into the airbox.

Bill

Re: Crazy_Pilot's 6MT Swap (Lots-O-Pics!)
 

I agree, they fit the SVX really well. I'm not a fan of wheels with 5 skinny spokes, the SVX is better suited to a chunkier design. My wheel is a Rota Grid in 18x9.5" size. The "authentic" version is the Volk/Rays Engineering TE37, but an entire set of Rotas costs roughly the same as a single TE37.

Hey Bill,

I bought them from Nomad, who was parting out his car and selling his spare bits. I don't know what the availability currently is from Subaru. subaruparts.com showed them as backorder last time I checked.

Re: Crazy_Pilot's 6MT Swap (Lots-O-Pics!)
 

Chris,

Mind me asking how much you paid for them?

Thanks.

Bill

Re: Crazy_Pilot's 6MT Swap (Lots-O-Pics!)
 

yeah ive been watching a set on ebay for aud$999 but ive been too busy buying stuff for the brake kits im making

Re: Crazy_Pilot's 6MT Swap (Lots-O-Pics!)
 

i want the 19s though :cool:

Re: Crazy_Pilot's 6MT Swap (Lots-O-Pics!)
 

whats the offset on yours

Re: Crazy_Pilot's 6MT Swap (Lots-O-Pics!)
 

+38 on those wheels.

Re: Crazy_Pilot's 6MT Swap (Lots-O-Pics!)
 

thanks mate

Re: Crazy_Pilot's 6MT Swap (Lots-O-Pics!)
 

A bit more progress this weekend:

Block-off plate I made for the transmission harness hole. The clutch M/C requires a 1.25" hole, and the bolt holes are 3/8". It's painted Rustoleum Hammered Black, like the transmission.

http://www.subaru-svx.net/photopost/..._off_plate.JPG

http://www.subaru-svx.net/photopost/...m/P1010241.JPG

With the clutch M/C installed:

http://www.subaru-svx.net/photopost/...m/P1010242.JPG

Got the R180 and STi axles in:

http://www.subaru-svx.net/photopost/...m/P1010245.JPG

http://www.subaru-svx.net/photopost/...m/P1010247.JPG

You can see the slot that has to be cut into the support bracket. The exhaust hanger from the subframe is also in the way. My advice for anyone doing this job: Lift the diff up and slide the studs into the rear bushings, then use a jack to support the front. A 19mm box wrench is prefect to sliding onto the exhaust hanger and bending it. Lift the diff up and bend as required until the bolts go in.

Shifter fully mounted:

http://www.subaru-svx.net/photopost/...m/P1010249.JPG

And this little pest:

http://www.subaru-svx.net/photopost/...m/P1010254.JPG

To run SVX front axles the seals in the transmission need to be replaced with those from an early production '04 STi. Only the first 3 months production have the right part. Unfortunately, that part number is discontinued and unavailable to Subaru dealers. My transmission already had the seals changed, but one was damaged. In the end what I did was write down the NOK part number that was on the seal and have NAPA cross-reference it. About an hour and several phone calls later they tracked down a compatible seal across the country. A few days later it arrived in Ottawa. It's slightly thicker than the original seal, but overall seems to fit well.

I also picked up some black Gorilla lug nuts. Better suited to the car's theme than the chrome ones I had previously. They're also aluminum and weigh ****-all. No impact guns!!!

http://www.subaru-svx.net/photopost/...m/P1010251.JPG

Finally, my method for pushing the car into the garage. I wonder what the tow rating is on an Elantra... Also, RIP to the poor blue Forester... My brother rolled it at ~90 kph last year. Idiot.

http://www.subaru-svx.net/photopost/...8/P1010248.JPG

Re: Crazy_Pilot's 6MT Swap (Lots-O-Pics!)
 

I know it's a bit late to mention it, but the part numbers for the correct seals are here on the site. That is, unless your transmission is different from any other 6 speed. I got the seals for mine direct from Subaru.

Re: Crazy_Pilot's 6MT Swap (Lots-O-Pics!)
 

These ones?

Left: 806730041
Right: 806730042

That's what I tried to get from Subaru and was unable to.

Re: Crazy_Pilot's 6MT Swap (Lots-O-Pics!)
 

Your dealer sucks then. Those are the same ones I used, and just ordered for an '07 wrx transmission into my roommates SVX.

Re: Crazy_Pilot's 6MT Swap (Lots-O-Pics!)
 

Canadian dealer fail. I tried two different places, both couldn't help me. :mad:

Re: Crazy_Pilot's 6MT Swap (Lots-O-Pics!)
 

Small bit of progress this weekend. Got the drieshaft and heat shields back in (side note: Install the fuel tank heat shield before the rear diff. Doesn't really work the other way around. Ask me how I know this. :lol:) Also, I'm going to have to sort out my driveshaft. I have two of them, and both have stiff spots in the u-joints. I installed the better of the two, so I'll either have the second one rebuilt or suck it up and see what Subaru wants for a new one.

I also refurbished my spare set of exhaust manifolds. When I swapped my engine last year I snapped all four studs off removing the exhaust. Unfortunately the studs on the replacement engine's manifolds were also pretty aweful, the threads had almost completely rusted away. I didn't have time to fix it properly then, so I loaded it with high temp silicone and wrapped it all with coat hanger. Worked well enough :D

Either way, I managed to get three of the broken studs out. The fourth snapped off flush, so I simply drilled it and tapped for a smaller bolt. Ghetto helicoil FTW.

http://www.subaru-svx.net/photopost/...m/P1010257.JPG

A trick I learned from one of the local Subaru club guys: If you need a tap to chase threads, simply grab a bolt that fits and grind a slot into it. In this case, one of the cylinder head exhaust studs with a seized nut.

http://www.subaru-svx.net/photopost/...m/P1010258.JPG

The more eagle-eyed will notice a couple things. One, my EGR tube is sliced off and sealed. I disabled my EGR a while ago, and this makes installation of things many times easier. Two, the studs I've installed in the manifold aren't the correct ones. The dealer couldn't get me the parts in time (ordered them several weeks ago, no luck), so I stole those from my blown engine's cylinder head. Same thread, and seem to be made of some miracle metal that doesn't stick to things. Good enough for me!

Trial installation of my front exhaust to make sure it clears things. Custom crossmember + custom exhaust built by two different people is a recipe for clashing parts.

http://www.subaru-svx.net/photopost/...m/P1010259.JPG

Fortunately, everything clears. Just.

http://www.subaru-svx.net/photopost/...m/P1010261.JPG

Clutch flex line installed:

http://www.subaru-svx.net/photopost/...m/P1010265.JPG

The bracket is actually half of the one used in the STi, bolted to the support for the A/C line that would normally be there. My condensor blew up and I never really cared too much, so I just removed everything. Cars with A/C installed my still be able to do this, I can't remember what it looks like there.

http://www.subaru-svx.net/photopost/...m/P1010263.JPG

Things are actually getting pretty close. Next week is fluids, starter, and wiring and then it should be ready to start. Just some buttoning up after that. :cool:

Re: Crazy_Pilot's 6MT Swap (Lots-O-Pics!)
 

So that's what the clutch lines are supposed to look like. Mine just kind of dangle and loop around. You're definitely doing things right with this swap, I'm very impressed, and making a list of things I'm going to need to go back and do right when I get the chance.

Re: Crazy_Pilot's 6MT Swap (Lots-O-Pics!)
 

Yep. I'm actually close-ish to the OEM STi setup, just fipped aroound:

http://t1.gstatic.com/images?q=tbn:A...WOVv-0CYn71fW_

Re: Crazy_Pilot's 6MT Swap (Lots-O-Pics!)
 

Nice. Looks very legit, man.

Re: Crazy_Pilot's 6MT Swap (Lots-O-Pics!)
 

Thanks! I think I need to clean up that A/C bracket now though. Nice painted part on a rusty old part... Does not work. Ah well, more small things :D

Re: Crazy_Pilot's 6MT Swap (Lots-O-Pics!)
 

She's alive!!!! MWAHAHAHAHAHA!!!! :banana::banana::banana::banana:

I've got a few small things to button up, but the job is 95% done. Here are some pictures for your viewing pleasure:

Clutch line installation: (and the throttle cable grommet I still have to poke into place. Annoying little guy that one.)

http://www.subaru-svx.net/photopost/...7997103909.jpg

Pedals installed and dashboard put back together. I have heard rumours, or perhaps you could say legends, of people who can install the pedals without taking the kick panel and steering column out. All I can say is that you people must be some kind of sorcerers, because there wasn't a snowball's hope in hell of me getting it done with everything still there.

http://www.subaru-svx.net/photopost/...7997107399.jpg

New calipers painted black and installed. One is going to have to get replaced though. When I tried to bleed it nothing would come through. I pulled the line back off and fluid came pouring out, so something was causing a blockage in the caliper. I jammed my pick tool (which is magnetic) into the bottom of the bleed port and broke through something, which turned out to be a pile of the metal bead shot they use to clean the calipers when they're reman'd. It bled fine after that, but I have a feeling that over time those beads will chew up the seals.

http://www.subaru-svx.net/photopost/...7997127597.jpg

Interior reassembled, minus the center console. I need to fab up the plate to clamp down that rubber shifter seal thing and finish trimming the shifter surround to fit properly.

http://www.subaru-svx.net/photopost/...7997132892.jpg

Work remaining is to drop the pre-cats and seal them properly (they were installed temporarily to let me test drive it), finish the console, and bed the brakes in properly, then go get an alignment. I still haven't done that since installing the coilovers.

Re: Crazy_Pilot's 6MT Swap (Lots-O-Pics!)
 

I have done this not once, but 3 times. :P