Starting 5spd conversion

[Earthworm]

As the title says.

Who can I call on here if I run into any problems?

Also what were some of the problems you ran into in your conversion? I want to be prepared for everything.

How long do you think it should take? I'm no mechanic but my dad's been working on cars his whole life. We don't have the SVX service manuals but could probably borrow ones from the former Subie dealership here if needed.

[elninoalex]

I did mine in about 40 hours. I didn't have a whole lot of 'mechanic' experience at the time. The most I did was pull the AT. It's not that difficult, just time consuming. Getting the pedals in was the biggest chore I experienced. I probably installed and removed them about 10 times until they were perfect. Modifying the crossmember could be an obstacle, if you don't Brian's templates. That made it very easy. The shifter was pretty easy. Swapping the rear diff was a snap. I probably spent 25 of the 40 hours working on the pedals. Have fun and pm me with any questions you may have.

Stephen

[Earthworm]

What's so hard about the pedals?

[elninoalex]

Lack of access.

[Subafreak]

Definitally beware the pedals!


I think if you just bolt a regular Legacy pedal assembly to the brake booster and then make an adapter to bolt the front of them to the steering colume mount it won't be that bad but I didn't do it that way and I still have a very heavy pedal.


BTW. You know there are alot of us to call on now just make a post if you have a problem and we'll come running.

[Earthworm]

Everything I bought came from the 2002 WRX donor.

I just remembered that the alarm system a previous owner installed is located in the pedal area. Maybe now would be a good time to get rid of it. (I don't like it)

[huck369]

You can PM me if I can be of any assistance...I don't keep up with the threads as regular anymore.....

[Ralph Gibbs]

Hi David, Sorry I have not replyed back to you on my engine problem but I'm short on cash at this time and waiting until spring.

About the 5 spd. I have some info. you are welcome to use or photocopy. It's not mutch but it may help. It's 1985-1996 repair manual w/ about 4 pages on SVX, Legacy 4 spd. electronic Tran. removal. I also have a diagram of the Tran. Where did you get the wRX parts from.
Bye for now..........Ralph

[Earthworm]

Ralph, the 2002 WRX tranny came from a member in BC.

Day one of Project 5 spd is complete.
Tasks completed:
- cleaned work space
- removed exhaust up to the manifolds
- drove car into work space (parents' basement)...LOUD!!
- removed driveshaft & axles
- removed driver's seat
- removed center console
- removed shifter assembly
- removed ECU & TCU
- removed throttle body to gain access to torque converter bolts
- removed transmission

Side tasks completed:
- reassembled lighter after the back nut fell off a few months ago
- working on wiring on aftermarket alarm for potential removal (alarm is also installed in pedal area)

***QUESTIONS***
- to confirm: The 2002 WRX tranny has a "pull" type clutch right?
- anyone know the EXACT difference in length between the auto & 5 spd? Is it exactly 2 inches? Does it have to be exact? I'm going to bolt an extension to the back of the driveshaft and relocate the carrier bearing since I cannot separate the driveshaft.
- what is the exact difference in length of the shifter linkages? Does that have to be exact or is that more of a preference?
- the rear engine seal is still good. Should I replace it anyway or don't mess with it? (I'm already using synthetic oils if that makes any difference)
- which color wires both on 5spd and SVX are for the neutral safety switch, reverse lights and cruise? (I'm working without service manuals right now)

That's enough for now...it's been a long day and it's time to sleep.

G'night

[Earthworm]

Oh yeah...needed parts list:

- starter solenoid for damaged 2002 WRX starter
- 2 exhaust gaskets for front of center cat & probably a couple nuts as well since I need a smaller socket each time I remove them.

Maybe parts list:
- rear engine seal
- exhaust manufold gaskets
- band for rear exhaust gasket (right before muffler)
- timing hole plug

[huck369]

2" on the driveshaft extension is exactly what I've used on mine...3 years and still fine.

The shifter length will vary depending on what car it came from.

I think I posted the wire colors for the NSS in my write up (in sig)
And the reverse ones are the 2 directly above the MSS one in the connector.

[Earthworm]

Day 2 is over.

I measured the difference in length between the auto and the 2002 WRX manual and found it to be 2 3/8". My dad will be getting a shim made to fit in front of the rear differential.

I removed most of my aftermarket stereo because I have 6 large RCA cables going through the pedal area and they were getting in the way.

I also decided to remove the aftermarket alarm system and was surprised that it wasn't all that difficult. All the wires were just spliced in to except for the ignition wire that obviously must be cut in order to properly disable.

Without the stereo cables & alarm I was able to remove the stock pedal assembly was removed and we're deciding how the WRX assembly is going to bolt in under the dash.

Tomorrow I'll be starting to put things back together. I have to pick up a solenoid for the starter, rear engine seal (may as well since we have it apart) and a few other clips & clamps.

Unfortunately a couple pieces are missing from this tranny. I noticed there's supposed to be a bracket mounted on the rear of the tranny to mount the lower shifter arm (anchor). Hopefully if Dan reads this he'll let me know if he still has it. Also missing but not as important was the bolt to mount the main shifter arm.

That's all for now. G'night.

[Earthworm]

Day 3 of project 5 spd:

Spent half the day looking for a solenoid for the WRX starter.

Picked up a solenoid and rear engine seal for CAD$60 after taxes.

In comparison the original Subaru solenoid would have cost me around CAD$300!!

Now for one of the problems: ***PEDALS***

The 2002 WRX pedals do not match at all to the SVX layout. What did everyone else use for pedals and how did you install them?

Another question: how do you completely remove the brake master cylinder? We can get the 4 bolts out of the firewall but can't remove the unit itself. There doesn't seem to be enough room.

Now my other problem: I seem to have caught a relatively bad cold sometime in the last few days. This is definately going to slow down the conversion progress. My vacation time runs out next tuesday and then I'm back at work.

Last question: To those who used hydraulic clutches what did you do about the mass of wires that come through the firewall at almost exactly the same place as you mount the clutch master cylinder?

That's all for me today...I need my sleep.

Please offer any suggestions that may help my progress and solve my conversion snags.

Thanks!

[huck369]

I didn't use a hydralic set-up, but I think eveybody that has done a 5-speed swap, ended up grafting the clutch and manual brake pedal to the SVX brackets, so they would bolt back up iunto the car.
On the brake booster, did you unhook the master cylinder?
And why do you need to remove it anyway, I left mine in place during the swap.
As for the cold, Laying on a cold concrete floor will do it every time, especially when it first turns cold.
Hope you get it all lined out soon.

[Tim]

Wow you really make it sound easy. I hope mine goes as smoothly as everyone elses when my time comes hopefully in the distant future. Good luck earthworm