Levorg manual transmission conversion

[Peter S]

Hi gang,
I’m new here and thought I would kick straight off!
i Am shopping for a new wrx or Levorg. Want the Levorg but the Cvt is very much holding me back. My question is, has anyone:
- completed a Manual conversion (either the 6sp manual wrx box, or STI 6sp)
- is thinking about it or has investigated how?
- can it be done ? Costs? Parts needed?

noting subaru themselves made a 6 speed STI Levorg as a show car a couple of years ago -

many thanks all, love the Levorg !

 

[IANDLP]

Can it be done-yes. Is it worth doing-unsure. Getting it to talk to all the electronics is the challenge and not sure yet that the Eyesight can be programmed to work as it should without fault

 

[Oz B-Spec]

As IANDLP mentioned, yes it could be done and probably fairly easily too, as one would assume that the standard WRX gearbox would bolt up fairly easily to the FA20 in Vorg, considering its the same engine in the WRX. The STI however, maybe a little more difficult, as the STI box is mated to the EJ motor and so may not easily bolt up to the FA20 (unless of course, the bell housings between the WRX and STI are interchangeable?).
Mechanically, you'd need a modified driveshaft, clutch system (the standard WRX setup would be the first choice). With the WRX manual gearbox, you may be lucky to find out that the front CV's transfer over to the Vorg, however, if the track between the Vorg and WRX are different, then you'll either need to have new ones made or the WRX ones modified to suit. Also for consideration is working out how the factory dash will pick up the engine revs and speed. An aftermarket ECU may be needed to get it running right.

EyeSight will be a difficult one to get operating, if at all, as my understanding is that it heavily linked in with the 3 front cameras, braking system and CVT, so you may have to sacrifice cruise control and collision avoidance, but, who cares if you have a manual Vorg!

Cost-wise, it would be a pricey exercise unless you're doing most of the modifications yourself. I would estimate over 10K AUD to do it with very "rough" estimates below;
Gearbox - 1500-2000AUD
ECU - 2000AUD
Tuning - 1500AUD
CV's - 200-500AUD
Drive Shift - 500-1000AUD
Unknowns - 2000-3000AUD (switches, sensors, wiring, labor etc)

The exhaust may need to be modified if the manual box encroaches on it, although I would think not as I believe the CVT's are bigger than the manual gear anyway.

Oh and make sure that diff's in the WRX and Levorg share the same ratios otherwise you need to put a WRX diff in as well I would think.

See, simple to do

Hope this helps.

 

[IANDLP]

We have utilised a WRX gearbox and rear diff (non STI) but I have been advised (yet to confirm) that bolt pattern is shared. Tailshaft is a combination of the WRX front section before the centre bearing and Levorg rear section. Front driveshafts from the WRX are a straight fit as they share the same track and splines to the hub. We also linked the WRX ECU etc without issue. Almost everything works bar what’s mentioned below.

Issues so far evolve around the Eyesight and active cruise. Still trying to nut those out. Normal cruise control functions as it should. But without the Eyesight system being operational legality of the conversion is unobtainable.

 

[Peter S]

iandlp!
Sounds like you are getting close!
Would love to hear more about this. with such a conversion I wouldn’t have thought a state based engineering report is needed. E.g. Eyesight isn’t a compulsory roadworthy feature.
where are you based in au?

thanks all -

 

[IANDLP]

Engineers report is required as M/T was never an option on these vehicles. Although not compulsory, it is technically against the law to remove safety features fitted standard to a production vehicle eg pre tensioners, curtain airbags, eyesight etc.

Based in Sydney

 

[Peter S]

So it’s been a while so I thought I would just check in.
Iandlp - How is the manual project is going? Do you have a driving manual levorg? Any major challenges ? Who did the work in the end?
Cheers
Peter

 

[Sandman]

I am very interested to see how you get along, because when my CVT shits its bed, I will be looking at this. Not throwing 12-15K into a another boat anchor. What about the WRX eyesight? can we swap that over including the active cruise?

Very neat. Keep us posted, your a pioneer! In Japan they did have a manual levorg as their demo car. It can be done!

 

[Parian]

See, simple to do

 

[Skijin]

Ok, I'm another watching this keenly and looking for an update.
In an alternative attempt to have a manual [go-fast] wagon, has anyone done or researched placing a Levorg body on a WRX drivetrain? This query also includes grafting a Levorg rear halfcut onto a rear-damgaged WRX.
I'd be interested to know of any certifying engineers in Australia to speak to about this option - perhaps some who know Subarus well. If you know of any, could you please let me know. Thanks.

 

[Guvna]

Ian you still around mate?
How's the conversion coming along??

 

[Downundersir]

Do manual WRX have eyesight? A Subaru wrecker in Revesby sold a complete wrx body wiring harness to a shop in Melbourne who did the swap. Maybe they can help?

 

[Scottyd]

You can only get the eyesight with the CVT transmission

 

[robo498]

True, it needs to control the speed.

 

[nicodache]

True, it needs to control the speed.

could do so with manual.
1. I'm in gear, I need to slow down or speed up ; remove/add fuel
2. I get too low/to high in revs ; put warning on dashboard, disable eyesight.
3. I'm not in gear, disable/refuse to engage eyesight
4. in emergency breaking situation ; cut engine, apply full breaking power.

you can get manual cars with cruise control for 20+years now; I really don't think a gearbox can technically prevent eyesight from being (at least partially) implemented. But happy to be corrected by a FHI engineer

 

[IANDLP]

Ian you still around mate?
How's the conversion coming along??

Very well.
We have now got the EyeSight to work with the MT and ECU successfully. The Active Cruise Control is harder than thought and expected. Still moving forward though.

VSCCS Engineer is happy so far and if we can get the Active Cruise sorted it will be signed off

 

[Guvna]

Very well.
We have now got the EyeSight to work with the MT and ECU successfully. The Active Cruise Control is harder than thought and expected. Still moving forward though.

VSCCS Engineer is happy so far and if we can get the Active Cruise sorted it will be signed off

Hey welcome back Ian. Good to hear mate. You must keep us posted. She's been a long road but well worth it to throw a six speed manual at this baby. What do you estimate the cost to be?

 

[IANDLP]

could do so with manual.
1. I'm in gear, I need to slow down or speed up ; remove/add fuel
2. I get too low/to high in revs ; put warning on dashboard, disable eyesight.
3. I'm not in gear, disable/refuse to engage eyesight
4. in emergency breaking situation ; cut engine, apply full breaking power.

you can get manual cars with cruise control for 20+years now; I really don't think a gearbox can technically prevent eyesight from being (at least partially) implemented. But happy to be corrected by a FHI engineer

If only it was that easy mate.
The adjustment of speed is also reflected by the chosen gear selected. So sudden deceleration would require a change of gear. ECU can’t do that with a MT.

Partially or fully disabling EyeSight while that happens means it can’t work as designed and is basically ineffective and illegal.

Cutting engine if full breaking is required won’t disengage the gearbox. Also meaning the Vacuum Assistance to the breaking system is removed. Not safe at all.

 

[IANDLP]

Hey welcome back Ian. Good to hear mate. You must keep us posted. She's been a long road but well worth it to throw a six speed manual at this baby. What do you estimate the cost to be?

Cost is difficult to determine at this point as we are still in the development stage. More hardware may be required, software changes along with component variations and associated pricing.

 

[nicodache]

Partially or fully disabling EyeSight while that happens means it can’t work as designed and is basically ineffective and illegal.

Cutting engine if full breaking is required won’t disengage the gearbox. Also meaning the Vacuum Assistance to the breaking system is removed. Not safe at all.

1. This assumes the Eyesight is presented as a base feature of the car, not an option. If it's an option, it could be disabled for <reasons> and not be considered a fault, given <circumstances>.
But I'm not certain which market do require automated emergency braking or lane keeping assist in new vehicles.

2. Indeed. But no fuel for the engine will have the engine help slow the car down through the gearbox. As for the vacuum assistance, I don't think ABS require vacuum to activate brake calipers (but I could be wrong).

Anyhow, keep us posted on your project