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06 CGM FXT- Full STi Swap
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57 Posts
Discussion Starter #1
Hey All -

Long time lurker. Finally building a dream car of mine. I'm not new to subarus and had built a JDM swapped bugeye that was unfortunately totaled by someone not paying attention last year.
A while ago I was looking at craigslist/nasioc for sale ads and this 06 manual xt popped up with a blown up motor. It was a really good deal and I thought i'd just toss a new longblock in and have a DD.
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Next thing I new I found an 05 STi with a 4500 mile old shortblock, heads rebuilt, new clutch & flywheel, fresh rotors and pads and a new VF48.
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Plan is to now do a full STi swap!
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Few things i'm trying to figure out:
  1. will the sti long block plug and play minus the secondary air? Would like to keep the bling factor of the red intake manifold.
  2. Has anyone pulled trans and motor together out of a suby? I've always done them separate. With the fresh clutch i see no reason to separate them and think it'd be easier to just pull the whole unit and stick it in the foz with sti cross members.
  3. Is anyone running 05 stock suspension on their wagons? Trying to figure out if/how many/what size saggy but spacers to run.
  4. Are those that have done this running the xt or sti ecu? I've heard of both but unsure of the better way to go.
Planning on getting the DCCD plug and play kit from iwire including the trans harness just to make it easier.
Also planning on doing the cluster swap but can't locate any of the DIYs where people talk about how to fit it.
Most likely going to pick up the jumper harness that is made by aaronsubieelectronics.


Hoping to get this essentially done by mid october to beat some of the rain in the PNW! Things seem to be pretty dead around here at this point unfortunately but hopefully anyone with knowledge will chime in!
 

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05 Forester xt 6speed
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10 Posts
Hi not too long ago i did a full swap from a 04sti to a 05 manual forester xt the main thing to remember is to transfer everything from the sti to your forester. You would remove the crossmember front spacers and use the sti bracket that holds the bolts because your forester one are too long now that the spacers are gone and your eng will move up the amount the height that the spacers were and you would need to trim your top radiator hose being your eng moved upwards.As far as removing your eng and trans as one unit can be done but at lot trickier due to space. now would be the time to swap over the brake booster ,master cylinder and clutch slave from the sti also like i said the universal joint for your steering needs to be swaped due to the forester being longer.i swapped out lower control arms to aluminum.
Everything just bolted right up including r180 ,driveshaft. Going into detail i kept my stock xt ecu and it runs fine .another thing i kept my stock abs sensor harness and plugged into sti hubs and they worked fine no abs issues. getting to the parking brake cables i swapped to sti but your gonna find out when you pull your handbrake its too long so you need to transfer the short piece of cable in your handbrake from the sti to your forester which is about 3/4 to an inch shorter but it makes all the difference to engage parking brake.
for the dccd controller highly recommend i wire spider plug and play kit make life a lot easier and i also purchased a v9 jdm sti cluster from aarons subie electronics had mileage corrected and converted to mph and temp to F. and purchased plug and play harness one thing to mention is that if you purchase a ddcd controller you might want to send the connector going to your dccd cluster to aarons so he can intergrate it into your harness more plug and play.
fyi i sent my sti bulkharness and eng mailed it to them for a discount on controller also same for cluster gave my usdm for a jdm cluster cause he said the abs light will be on but not for an 05 usdm cluster so you might be ok cause my cluster was an 04.
good luck on your build.Erik
 

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06 CGM FXT- Full STi Swap
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57 Posts
Discussion Starter #3
Hi not too long ago i did a full swap from a 04sti to a 05 manual forester xt the main thing to remember is to transfer everything from the sti to your forester. You would remove the crossmember front spacers and use the sti bracket that holds the bolts because your forester one are too long now that the spacers are gone and your eng will move up the amount the height that the spacers were and you would need to trim your top radiator hose being your eng moved upwards.As far as removing your eng and trans as one unit can be done but at lot trickier due to space. now would be the time to swap over the brake booster ,master cylinder and clutch slave from the sti also like i said the universal joint for your steering needs to be swaped due to the forester being longer.i swapped out lower control arms to aluminum.
Everything just bolted right up including r180 ,driveshaft. Going into detail i kept my stock xt ecu and it runs fine .another thing i kept my stock abs sensor harness and plugged into sti hubs and they worked fine no abs issues. getting to the parking brake cables i swapped to sti but your gonna find out when you pull your handbrake its too long so you need to transfer the short piece of cable in your handbrake from the sti to your forester which is about 3/4 to an inch shorter but it makes all the difference to engage parking brake.
for the dccd controller highly recommend i wire spider plug and play kit make life a lot easier and i also purchased a v9 jdm sti cluster from aarons subie electronics had mileage corrected and converted to mph and temp to F. and purchased plug and play harness one thing to mention is that if you purchase a ddcd controller you might want to send the connector going to your dccd cluster to aarons so he can intergrate it into your harness more plug and play.
fyi i sent my sti bulkharness and eng mailed it to them for a discount on controller also same for cluster gave my usdm for a jdm cluster cause he said the abs light will be on but not for an 05 usdm cluster so you might be ok cause my cluster was an 04.
good luck on your build.Erik
Thanks Erik!

Good thoughts on the ebrake, cluster and DCCD stuff!
I'm still working through trying to figure out engine wiring.
Apparently the 04-05 xt are plug and play with 04-06 sti's but the 06 xt wiring is slightly different.
Wondering if i keep the xt engine accessories and am only trying to keep the red intake manifold if i could pull it off just by moving all the bits from the xt over to the sti block.
I've been reading too much conflicting info and definitely want to do the work while the motor(s) are out of the cars.
 

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06 CGM FXT- Full STi Swap
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57 Posts
Discussion Starter #4
Spent most of saturday ripping down the XT.
All thats left is:
-one hub with axle splines stuck (need a 3 jaw puller)
-Rear diff/carrier & assembly
-trans, motor & DS
-subframes/cross members

Those that have done this - did you swap the front subframe and cross members? Or just remove the spacers and swap to the sti x member?

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XT motor had a full on blowout. The rod cap bolt that is missing was melted into the DS fender liner somehow

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Lastly found this gem. Going to have to figure out how to repair this. Someone had a leaky battery... Unfortunately it's too soft to hold tie downs at this point. May need to weld an Al plate over the top with tie down holes in it. Or try to cut out/weld in the one from the STi...

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05 Forester xt 6speed
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10 Posts
Re-use front sub frame from forester two piece and use sti crossmember. For the wire harness your not reusing your old harness on the new engine for me i purchased a new harness because alot of the plugs we brittle and cracked.
 

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06 CGM FXT- Full STi Swap
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57 Posts
Discussion Starter #6
Thats what i thought - STi xmember/cradle and forester subframe/u brace/antisubmarine brace.
I heard you need some form of a spacer with this setup but i don't understand how quite yet.


For wiring since i'm putting an 05 sti motor in an 06 xt the wiring isnt plug and play.
I'll be moving the TGVs, topfeeds, and wiring harness from the XT over to the sti block and using the sti red intake manifold.
Going to add some 3mm phenolic spacers while i'm in there and inspect/replace vacuum/fuel lines.
I debated TGV deletes and decided against since i want to be mostly stock as this will be a DD with a mild tune and catless exhaust.
 

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05 Forester xt 6speed
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Im not sure how your car would run without tgv deletes but i live in a warm climate so no problem also i did an e tune and the tuner turned off ck eng light for tgv so i never had a problem.
connector is just tied to the side. for the sub frame spacers a lot of people remove them.
 

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06 CGM FXT- Full STi Swap
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57 Posts
Discussion Starter #8
Long overdue for an update.
I moved the rear end over as a full unit solo in a few hours. Was not easy but not hard. I wanted to avoid dismantling the whole rear if i didn't need to. Proved you can disconnect ebrake inside, then just drop the trailing arms, outrigger and subframe.
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Gave it a scrub and put it in the forester.
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I removed the rotors and calipers, but honestly didnt need to.
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Everything buttoned up & torqued with new stoptech stainless lines.
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06 CGM FXT- Full STi Swap
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57 Posts
Discussion Starter #9
Next I needed to do something about the battery tray metal.
The PO had no plastic tray or tie downs on the battery. Result was battery acid leaking all over and eating the tray.

wire wheel - primered (only color on hand) - wire wheeled again next day
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Made a replacement piece for what i cut out from small aluminum angle. JB welded the piss outta it.
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Not pretty but strong. If i had more time i was thinking of cutting this out and replacing with a billet tray.

Painted. The rustoleum grey auto stuff is pretty close to the engine bay color.
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Once everything is buttoned up i don't think you'll even notice it.
 

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06 CGM FXT- Full STi Swap
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57 Posts
Discussion Starter #10
Two nights ago i decided to go for the engine/trans move. Started at 5PM with sunset at 630. Great idea.
Also decided since the engine has 4000 miles on it with a fresh clutch, timing belt, sparks, etc there was no reason to separate it from the trans.
Long story short, it is doable with the engine xmember in place but the c. diff drain nub gets stuck on the cross member. you HAVE to remove the pitch stop from the chassis, and the clutch master & starter from the trans. after wrestling it, removing it and doing that it slid right in.
While it was out i put new group N motor and trans mounts on.
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Everyone said that the NSS from the 5 to 6 speed were reversed (open in gear vs closed).
I went to move the sensor over as everyone said you could. No way. Different plugs and the 5MT was too short.

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I dug through the FSMs and found that they actually have the same polarity.
5MT:
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6MT:
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Thinking i should be okay for the forester ECU to see correct values without changing sensors.
Someone correct me if i'm wrong please!
 

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06 CGM FXT- Full STi Swap
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57 Posts
Discussion Starter #11
And my favorite photo from the night i pulled the forester motor.
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06 CGM FXT- Full STi Swap
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Discussion Starter #12
Swapped the master cyl & lines over from the STi. I buggered the XT one when i put the motor and trans in. They look to be the same part anyway.

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Got everything for the front in and torqued down. Tried on the limited wheels i have off the STi. Look better than i thought they would.
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06 CGM FXT- Full STi Swap
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Discussion Starter #13
Decided i wanted to clean the old flaking paint off the shifter trim.
Steel wool + polishing compound + Testors enamel red.
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06 CGM FXT- Full STi Swap
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Discussion Starter #14
Wanted to use the STi airbag but not the wheel since the STi wheel i have from the donor was pretty buggered.
Didn't think i'd be able to since the 06 xt is 2 stage vs the 05 sti is 1.
Realized reading posts here i could just swap the charge over.
It sits a bit leaned left for some reason on the xt wheel even though they're the same shape.
Also swapped the nicer STi leather into the forester trim for the e brake handle.
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Don't mind the mess. Zip ties were used to keep the wheel from spinning when there was no steering rack. Didn't want to wreck the clock spring.

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06 CGM FXT- Full STi Swap
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Discussion Starter #15
Also picked up a set of 07 limited STi seats. The black leather matches well and they're heated as is.
I didn't realize how bad of a nightmare the 06 xt was in regards to the SRS system.
Copy of my post looking for help from the ultimate seat thread:

Looking for some help with 07 Limited STi Seats into an 06 limited XT.
For some reason i can't wrap my head around this and most of the photos are gone or the members who have done this don't post anymore. (yes i read all 30 pages and links like @2.5x_sleeper seat swap). Just totally lost here.
The driver side my plan is to just swap the entire harness off the XT seat onto the STi seat. Since they're both heated and have airbags the only difference is that the XT is a power seat. The plugs for the heater are in the large black connector that operates the motors. Seems easiest to just move it all over and have a few plugs not going to the motors on the sti seat. Thoughts?

The passenger seat is the doom i can't figure out and @Team Scream struggled with.
-Is my only option to use the XT base?
-Has anyone used the hole on the B pillar instead of the seat frame mount point the 06 Xt used?
-Is it worth it to attempt to move the occupancy bladder from the 06 xt seat onto the 07 sti seat?

I just did a full sti swap into the forester yet the seats are confusing the hell out of me.
Any help is appreciated from those who have swapped 06-07 wrx/sti seats into an 06 limited XT. If anyone is in the Seattle area who has done this, i'll gladly buy the beer and pizza for your help.
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Passenger seat bases. L is 07 sti, R is 06 forester XT
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Driver seat bases: L is 06 forester XT Limited R is 07 STi limited
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I'm either freaking out over something that is actually simple, or these are going on craigslist so I don't have to deal with it.
 

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06 CGM FXT- Full STi Swap
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Discussion Starter #16
Yesterday i finally had a break from the rain and swapped the trans pan out for a new one.
The PO had mangled the drain plug to the point where it wasn't worth it to even try and get the plug out.
A new pan assembly (pan + drain plug) was only $30. It's also a good idea to pull the pan on the 6 speeds occasionally to clean off the large magnet hidden behind.

Mangled plug:
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Pan off - dirty and oily
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Cleaned up and mating surfaces wiped down with acetone for good bond of gasket maker
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New pan on. Bolts finger tight until the gasket maker sets up. They call for a very low torque.
Used toyota FIPG since i had it on hand. Stuff seems to be the best i've used.
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Still looking for advice on the seats! People are reading this but all i hear is crickets!
 

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06 CGM FXT- Full STi Swap
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Discussion Starter #17
Been a while since i've updated this.
-the car is fully together and running.
-Threw two CELs on startup. Emissions (left charcoal cannister unplugged accidentally from sway install)
and P0182 Fuel temp sensor. Turns out I somehow spun the sensor in its housing and it was grounding out to the fuel pump bracket. Couldn't find much info from others but i think that was all that was causing it.
I'm getting a dyno tune saturday at Surgeline. Will update with tune numbers.
Some photos:
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.
Slightly nervous about exhaust clearance. May take it and have it rotated/extended a few inches. Don't want to melt my bumper or catch it on fire.
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2005 Forester XT 5spd
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Great build! I might be starting a similar swap here soon so I know where to go for questions (especially since you're in Seattle as well, haha).
 

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06 CGM FXT- Full STi Swap
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Discussion Starter #19
Great build! I might be starting a similar swap here soon so I know where to go for questions (especially since you're in Seattle as well, haha).
Absolutely feel free to reach out. I got frustrated starting this swap since so many threads have dead photos/members that don't post anymore.
Figured i'd just go for it since i knew it was possible.
Lots of odds and ends i figured out that i'd be happy to share depending what path you take.

Also have the full 5 speed drivetrain for sale locally if you know anyone looking to swap!
 

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2005 Forester XT 5spd
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Absolutely feel free to reach out. I got frustrated starting this swap since so many threads have dead photos/members that don't post anymore.
I feel ya - I've been neck deep in searching threads for the past two weeks and feel like none of my questions have been answered fully. Almost too much info and a lot of dead/old threads. I think I came to the conclusion though that the easiest swap would be using a 5spd FXT.

You note that with the '05 STi engine in your '06 FXT you had to swap the engine harness over to the STi. What is the compatibility there? Would it be more plug and play with a different year FXT? Also, did you end up just reusing the FXT ECU or did you swap over the STi one?
 
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