Gearbox Conversion

Automatic to Manual Gearbox conversion

When I bought my Legacy I could not find a manual version and so had to buy an Automatic, 2 ½ years and 50,000 miles later I had a problem with the gearbox so I decided to convert it to manual
The problem was caused by binding - in effect driving with a permanently locked centre diff. I bought all the parts from Grade A Subaru, in Derbyshire. Most of the parts were of a UK Impreza Turbo, this was to give higher gearing more suited to a UK GTB. The propshaft, starter motor were of a wrecked GTB

Parts Needed Manual Gearbox and mounts
Gear linkage
Flywheel
Clutch Pressure and Drive Plates
Clutch Pedal Assembly
Brake Pedal
Clutch Master and slave cylinders and piping
Propshaft
Rear diff to match front diff in gearbox
Starter motor
The correct speed sensor
Gearlever gaiter, knob and surround
Dash Blanking panel
Remove Brake Pedal, this will obvbiously be replaced by a smaller brake pedal and clutch assembly
Before Starting, remove the battery.
Install Clutch Pedal, the hole is already there for the conversion, the pedal bracket bolts through the hole to the master cylinder
Remove Intercooler, this is to allow access to the gearbox, starter motor, clutch assembly etc
Remove Centre Console, this is held by screws at the front, on the lower gearlever surround and two bolts at the back behind the handbrake
Remove Gear linkage
Remove Exhaust; these are the downpipes, the left side with cat is for the primary (low speed) turbo - it is best to remove the whole exhaust system
(I replaced mine with a Scoobysport system at the same time !)
Remove Propshaft, as can be seen the manual propshaft is shorter than the automatic prop, to do this unbolt from the rear diff and then remove centre bearing and pull off the gearbox.
Remove Front Drive shafts, these are held by a pin that needs to be romved at the inner end, and the the hub needs to be split from the wishbone at the outer end. Unbolt the suspension at the suspension turret, unbolt (and plug) the brake lines and remove the entire corner, this gives far more room to work
Remove Rear Drive shafts and rear diff, unbolt the diff, lower and then pull the driveshafts out of the diff (empty diff first)
Remove starter motor, this is a completely different Starter to Impreza, UK Legacies and Auto GTs. The bolts are not easy to get to but are much easier with the driveshaft and exhaust removed
Unbolt Torque Converter, there is a small access panel to the left of the upper engine mount, this needs to be removed and then the engine turned over to give access to each of the torque convert bolts (on the outer rim of the converter) these need to be removed as part of the torque converter comes off with the gearbox and part stays on the engine (Flywheel!)
Lift engine at front, remove the rear upper mount and jack the front of the engine up, this tilts the engine so that the gearbox can be removed
Disconnect wiring
Remove Autobox
Remove torque converter
Install Flywheel
Install clutch
Install Gearbox
Install Rear Diff
Install drive shafts
Install Propshaft
Install exhaust
Fill clutch fluid and bleed
Wiring
Install intercooler and battery
Drive!!!

Parts Needed	Manual Gearbox and mounts Gear linkage Flywheel Clutch Pressure and Drive Plates Clutch Pedal Assembly Brake Pedal Clutch Master and slave cylinders and piping Propshaft Rear diff to match front diff in gearbox Starter motor The correct speed sensor Gearlever gaiter, knob and surround Dash Blanking panel
Remove Brake Pedal, this will obvbiously be replaced by a smaller brake pedal and clutch assembly
Before Starting, remove the battery. Install Clutch Pedal, the hole is already there for the conversion, the pedal bracket bolts through the hole to the master cylinder
Remove Intercooler, this is to allow access to the gearbox, starter motor, clutch assembly etc
Remove Centre Console, this is held by screws at the front, on the lower gearlever surround and two bolts at the back behind the handbrake
Remove Gear linkage
Remove Exhaust; these are the downpipes, the left side with cat is for the primary (low speed) turbo - it is best to remove the whole exhaust system (I replaced mine with a Scoobysport system at the same time !)
Remove Propshaft, as can be seen the manual propshaft is shorter than the automatic prop, to do this unbolt from the rear diff and then remove centre bearing and pull off the gearbox.
Remove Front Drive shafts, these are held by a pin that needs to be romved at the inner end, and the the hub needs to be split from the wishbone at the outer end. Unbolt the suspension at the suspension turret, unbolt (and plug) the brake lines and remove the entire corner, this gives far more room to work
Remove Rear Drive shafts and rear diff, unbolt the diff, lower and then pull the driveshafts out of the diff (empty diff first)
Remove starter motor, this is a completely different Starter to Impreza, UK Legacies and Auto GTs. The bolts are not easy to get to but are much easier with the driveshaft and exhaust removed
Unbolt Torque Converter, there is a small access panel to the left of the upper engine mount, this needs to be removed and then the engine turned over to give access to each of the torque convert bolts (on the outer rim of the converter) these need to be removed as part of the torque converter comes off with the gearbox and part stays on the engine (Flywheel!)
Lift engine at front, remove the rear upper mount and jack the front of the engine up, this tilts the engine so that the gearbox can be removed
Disconnect wiring
Remove Autobox
Remove torque converter
Install Flywheel
Install clutch
Install Gearbox
Install Rear Diff
Install drive shafts
Install Propshaft
Install exhaust
Fill clutch fluid and bleed
Wiring
Install intercooler and battery
Drive!!!