ChaksQ's 5-Speed swap [discussion/log/questions]

[chaksq]

I am tired of my automatic transmission and I have almost two months basically free this summer to do projects. A local member is parting out a 5-speed car so I can get all the parts I need from that car. I am creating this thread as a log of my progress and a discussion thread regarding my particular swap.

My car is a 98 BG Outback with the EJ25 and an automatic. The donor car is a 97 BD 2.5GT with a EJ25 that had the headgasket go and has a 5 speed.

For starters I have a few questions. Is there anything I should rebuild or replace when doing the swap? I need a number of parts from the donor car. What do I need that I do not have listed below, please be specific? Also what performance upgrades are worth doing while I am doing this swap. I'm thinking clutch/flywheel and short shifter. What clutches and shifters do you guys recommend? Are there any other parts worth upgrading/replacing while I have the transmission out? I will most likely be doing this swap in a garage that has no power, is this going to be a big issue? Also what tools should I have on hand for the swap? I am willing to buy some tools I don't have as long as I'll be able to use them for more than just a one time transmission swap and are not real expensive.

Parts list (Incomplete?):
-Transmission
-Rear Differential
-Drive shaft
-Shift Linkage
-Transmission Cross Member and Mounts
-ECU
-Full Pedal Assembly
-Clutch Master Cylinder
-Slave Cylinder
-Clutch Lines
-Flywheel/ clutch/ pilot bearing/ throwout bearing
Obviously I need more than this, please help me figure out everything I need.

Parts I have
-Shift boot

[jey]

Stage 1 Exedy is a great clutch, I have it and it even holds up to turbo power just fine.

[DarkPhoenix]

You may need the rear diff and the driveshaft.

[mike-tracy]

You may need the rear diff and the driveshaft.

You're exactly right - he's going from 4.44 to 4.11 FD.

[chaksq]

You may need the rear diff and the driveshaft.

You're exactly right - he's going from 4.44 to 4.11 FD.
That's good to know. Will the stock axles work or do I need those as well?

jey: I'll have to look into that Exedy clutch further, sounds like a good choice.

[mike-tracy]

Stock axles will work fine.

[StatGSR]

dont forget the tranny cross member and mounts. also you will need a new drive shaft. and the shift linkage

since you are going with a 2.5 manual (which is a hydraulic transmission) , u will need the full pedal assembly, the clutch master cylinder, slave cylinder, and the lines between the two.

Dont forget the flywheel/clutch/pilot bearing/throw out bearing either....

[chaksq]

dont forget the tranny cross member and mounts. also you will need a new drive shaft. and the shift linkage

since you are going with a 2.5 manual (which is a hydraulic transmission) , u will need the full pedal assembly, the clutch master cylinder, slave cylinder, and the lines between the two.

Dont forget the flywheel/clutch/pilot bearing/throw out bearing either....
Do I need a NEW drive shaft, I was under the impression I could use the one from the donor car if I use the rear differential on it as well?

I updated my parts list according the everyones advice. This is my first time doing any kind of swap on a car that involves part of the drivetrain.

Another question: What do I need as far as electrical, I believe I need the ECU but is there anything else? Do the transmissions have wiring harnesses and will I just be able to swap out the harnesses or will I need to splice anything? I'd like this to be as stock as possible from an electrical/wiring standpoint for right now (ie: no standalone or tuning).

[TbirdMan]

Why would you need the cross-member? is it different from auto to manual.

[peter]

I'll be following this pretty closely because I want to do the same swap for my 98 bd. Hopefully this isn't too hard to do, and Im wondering alot of the same things. My main concern is anything with the ecu and wiring

[StatGSR]

Why would you need the cross-member? is it different from auto to manual.

yes