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Old 11-17-2012, 08:13 PM   #1
mj213
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Member#: 252218
Join Date: Jul 2010
Chapter/Region: SWIC
Location: Prescott
Vehicle:
2002 Forester
Paint colored!

Default Problems while diagnosing trans problems

Over the last few months I heard the pilot bearing making noises - I also noticed some clutch slippage (note that the VSS had also just stopped working). I ordered an Exedy kit with everything included. Last weekend I pulled the transmission and installed it. Everything appeared to be fine. Over the next day or so I began hearing the same noises as before - a mix of a metal on metal sound and a squeaking sound. Then I noticed increase resistance when taking off from a stop. THEN I noticed that the car wouldn't drive in reverse for more than a few feet before lurching to a stop (like an AT dumped into PARK). The transmission began making a lot of noise as well. It was making less noise when the clutch pedal was depressed but the noises were still there. When I try to shift into gear from a stop it's very difficult. It seemed to go into reverse without a problem (other than mentioned earlier), but I really had to work to get it into gear. The rear shifter bushing is installed correctly, the fluid isn't low, and nothing is loose. The car will drive forward but it does make noise.

I pulled the transmission back out hoping to find something in the bellhousing to be corrected, but it was perfect. Something was keeping the transmission from freely moving (even in neutral). So, I drained the fluid out of the transmission/diff/transfer case. Immediately noticeable was some rolled up and broken pieces of 'something'. Turns out to be plastic material. I thought it might be from the VSS gear getting bound up and shredded, but it's in the transfer case. Here's pictures of what I found. I'm not sure what to think of the gouges in the gear pictured, and I do not know what the arrow points to in the 3rd picture that is burned. I really hope that someone can be of help here.






Last edited by mj213; 11-18-2012 at 10:48 AM.
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Old 11-18-2012, 01:16 PM   #2
drewmob
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2003 WRX
WRB

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Is the circlip still intact on the fat end of the center diff?
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Old 11-18-2012, 06:50 PM   #3
mj213
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2002 Forester
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Default

Yep - I checked that out earlier today. I can't seem to get the internals to move - is that normal?
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Old 11-18-2012, 07:13 PM   #4
drewmob
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WRB

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Yes, the internals shouldn't move.
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Old 11-18-2012, 07:20 PM   #5
drewmob
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Btw, that's not a gouge in your gear. Several of the gears have a low spot in them. Not sure why but i've heard for oiling? Hardened steel doesn't dent, it shatters...

What sticks out to me the most is the severe damage to your gear selector arm in the right-hand side of the 3rd pic. That thing has HEAVY rubbing damage. That's gotta tie into your problem somehow.
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Old 11-18-2012, 08:24 PM   #6
mj213
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2002 Forester
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Ok - thanks for the info. Are you referring to the shaft or the part where it connects at the "T"? I wasn't sure if that was normal.

So the center diff may actually be alright. I guess it's break the transmission open time.
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Old 11-24-2012, 08:59 PM   #7
drewmob
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2003 WRX
WRB

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The very end of the shaft where the metal is all rubbed to hell. What's the progress?
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Old 11-26-2012, 10:27 AM   #8
mj213
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2002 Forester
Paint colored!

Default

I was looking at both selector/shift arms (from the forester and wrx transmission) and they seem to be relatively worn about the same. I called subaru - part is $76 for a replacement.

I've got everything back together with the exception of the rear diff. It's going in today. The shifter assembly won't move so I need to check tightness on the bolts and make sure nothing's backwards. I installed a clevis pin in lieu of the roll pins that were installed originally. I had a feeling I'd be removing this assembly, glad I made the switch. Will check back with updates.
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