So between the first thread I created for a manual swap and the second thread I sort of hijacked on accident I figured it would be a good idea to round up all of the information that has been put together in one place for this project. Several ideas have been tossed around including stealing the drivetrain from another car which while great in theory adds a lot more headaches than are necessary. Let me get this out of the way now, yeah I could sell the Juke and another car that would be AWD and manual like an Evo or a Focus RS but that wouldn't be the same since it wouldn't be as unique and cool as the Juke in my mind.
What I ultimately settled on is to modify a FWD Juke Nismo RS 6 speed transmission to accept the AWD Juke CVT transfer case and then using the AWD rear end connected to an aftermarket AWD controller. The modifications to the 6 speed transmission will include modifying the case to allow the transfer case to bolt up, this includes the larger seat for the larger race bearing on the passenger side of the differential. Welding on the splined section from the differential in the AWD transmission to the 6spd LSD. The passenger size axle from the RS might be able to be adapted for the AWD system or worst case it will be custom axle bar. The differential controller is from DCCD Pro and functions as a standalone unit meaning I can run a manual ECU which simplifies a lot of things. At this point I will still need to manual swap the car but by comparison this will be a much more straight forward task as it has been done before.
As far as tools go I a decent TIG setup that will get the job done when it gets there but I will likely farm out the precision machine work since I don't presently have a mill or a lathe. The plan is to pick up a new welding table specifically for this project so I can build fixtures for mock up and don't have to move anything while I work on other projects at the same time.
The first step for this will be to acquire all of the needed parts which will be as listed below and are separated into two lists, AWD conversion and manual swap parts. I will be getting a second CVT transmission and transfer case which adds some expense but I would rather do that then pull my daily off the road for this. The first part I will be going after are anything specifically related to the RS transmission since they are harder to come by. I may buy a wrecked manual car if I come across one for the right price. I might also see if it is possible to have a deal reprogram the body computer and cluster I have when I get to that point.
RS 6spd transmission
RS 6spd Axles
DCCD Pro AWD controller
CVT AWD trasmission (hoping to find a dead one so I don't have to cut apart a good transmission)
AWD transfer case
RS 6spd shifter
RS 6spd shifter cables
Clutch master cylinder
Manual engine and dash harnesses
My first manual swap thread.
The most recent thread on the topic, there is a good amount of technical information in here. (page 4 is where I came in and accidentally jacked someone else's thread)