I have a lead on a cheap 03' Baja in screaming bright yellow, but it has the N/A automatic drivetrain. The owner says the rear diff is noisy as well, so I'm thinking about a 5spd swap. From there, what are my options? I would assume a legacy/outback with a stick is the easiest option, but what about better gear ratios? Are the foot pedals legacy/outback only? What about the ECU?
Same goes for suspension - what other cars can I swap parts from to build something that handles?
Wait, I'll grab the popcorn and meet you in the build thread section.
I'd guess it would be easiest to grab everything mechanical from a BE/BH (3rd gen legacy sedan/wagon) for the 5 speed swap although transmission and rear diff you could likely get from something else as long as both differentials are the same ratio. I've read that some/all? Baja's use the newer CAN Bus which the rest of the BE/BH don't, this may only be true for the later ones though (05-06). It may just be easier tricking the stock ECU into thinking it still has an automatic in it rather than swapping a different ECU in and getting it to play nice with the rest of the car, the H6 guys have to deal with this when they swap to a manual so that's where I'd start my research.
Suspension should be the same as a BE/BH, I went with JDM take-off Bilstein's and springs that came from an importer and have been very happy, stock ride height in my legacy wagon but a bit firmer and planted. I added in a 17 mm stock rear sway bar from a Baja Turbo (bit of rubbing in a wagon but shouldn't be a problem going onto another Baja) to make the car more neutral. There are coil-over and H&R spring options as well. The car is great through the corners and fun to slide around in the snow or an open lapping day at the local track. You could likely make the shocks/struts work from the 4th Gen legacy as well but you'll need to research that.
I'm guessing the Baja already has the slightly larger (1/2") front rotors that the Outback and Legacy GT of that generation got, if it doesn't the calipers are the same, you just need the carriers and larger front rotors to upgrade. Stainless braided lines, new fluid and aggressive pads firm up the pedal nicely and get the car to stop. The ABS really sucks in these, I pull the fuse for the winter. There are plenty of other brake options that should bolt up but could require larger wheels.
Somewhere out there there is a Baja Turbo with a 5 speed that would be a great sleeper.
Hope this helps,
Adam
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