I would say there are only minor changes in the wiring. All I noticed was at the headlights. That you may be able to work around. As long as all the wiring to the motor and tranny are good, you shouldn't have a problem. I've also heard that, like on eclipses, that you may not even have to change the harness, just plug up the new ecu, adapt the harness sensors to the tranny and just go about your business. You could try it that way.

 

Thanks for the info. How would I go about adapting the harness sensors to the tranny?

I think what I'm going to try is use the 03 harness (I can probably change the headlights) and if everything plugs in then I should be ok right?

 

Oh, and I also got the manual tranny out today! The pressure plate will need to be replaced, the throw out bearing and I'm going to need to get the flywheel resurfaced. Anyone have a good recommendation for a high performance pressure plate?

 

Well, the only wiring on a 5 speed is for the temperature and pressure I think. ON the auto tranny, of course it has more since it is controlled by the ecu. You may be able to use the sensors off of the auto, if not, you rewire the harness to the 5 speed sensors in place of the auto temp and pressure sensors. As for pressure plate, I think you get one from the clutch kit. They have some nice stage 1 clutchs on ebay. You should also go ahead and get a lightweight flywheel while your at it.

 

That sounds good. I'm going to check RRM because I'm pretty certain they have one and everything I've bought from them has been very good so far. Hopefully it isn't too crazy expensive. I will just have to check out the wiring when I get to it on Monday.

 

I got the wiring harness off today and it looks good. Everything should fit right in except maybe the headlights. I'm going to be tearing into my car on Monday and should be able to have the trans swapped by the end of the week for sure (hopefully by the end of Wednesday).

Also, does anybody else know of any other decent clutch kits. RRM sells a stage one kit for $379 and a stage two kit for $429 and I'm looking for something cheaper. Anyone know how much a stock kit is?

 

I ordered the stage 1 clutch kit from RRM for $425 (with shipping). I figured since I have the trans out I might as well do the performance upgrade instead of buying an OEM replacement that I would probably upgrade in 2-3 months anyway.

Anybody have any recommendations for any other upgrades while I have my engine/trans taken apart (not a flywheel, they are like $400 lol). Short shifter? Good shift knob?

 

Did the clutch kit come with a lightweight flywheel? If not, get one of those, some shifter cable bushins, shifter base bushings and a short shifter, also, get a ss clutch line.

 

^^ everything he said! Most def on that lightweight flywheel.

 

The clutch kit did not come with a lightweight flywheel. The clutch kit was $425 shipped and the lightweight flywheel would be $479 by itself. I just got the original flywheel resurfaced instead (couldn't afford the $479). I did get the brass shifter bushings, a short shifter but I didn't get a ss clutch line just yet.

Unfortunatley, the RRM clutch kit was backordered and it is going to ship out tomorrow (I ordered last Friday). I am dropping my transmission tomorrow and everything should go well.

I did weld in the plate from the 03 (where the clutch pedal mounts on) in my 05 today and it took much longer than I originally expected (I thought I could get it done by lunch, took me the whole day but I got it on perfect ). I haven't been able to take any pictures but if I get my trans out early tomorrow I'll take some then when I got the time.

 

I hope you are taking pics of all this stuff I found a donor car for $600 so this project may end up cheaper for me than I expected.

 

Yea if you have the $600, it won't get much better than that. There are a few little things that you should check before you buy it though. There is a short plug that connects into the clutch pedal and one that connects into the brake pedal (brake pedal for auto is 4 prong, 5 speed is two prong). You will def need the ecu/wiring harness. It will probably end up costing you more than just $600, new clutch disc, pressure plate, flywheel and anything else while you have the trans off. Let me know if you need help with anything.

 

Oh it's going to be a while, I haven't even finished my turbo install

 

haha, well good luck with your turbo

 

Alright, so the wiring harness was pretty ridiculous. I finally got it done late, late yesterday and placed it in my car today just to check the lengths and it fits well. The thing that had to change was the headlight wires. Apparentley this wouldn't have been a problem but the 05 OZ rally has it's own "special" wiring harness and nothing else will fit it except for another 05 OZ harness. The thing that is different is how the the blinker/headlight setup is.

Anyways, I haven't been able to take pictures of each step but most of it doesn't require a picture to understand what needs to happen. All I am waiting for now is the clutch kit from RRM (should be here by at the latest next Tuesday). I may yet write up a "How-to" but it will probably take me a month or so (I'm short on time) to get it all written up. I'll be as detailed as I can be but it won't be the EXACT same for any 02-06 Lancer (05 OZ has a few "unique" obstacles) but it should be very helpful for those of you who want to do it.