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Old 04-07-2013, 10:36 PM   #1
brett192
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Member#: 274252
Join Date: Feb 2011
Chapter/Region: W. Canada
Location: Vancouver Island, BC
Vehicle:
2002 WRX Sedan PSM
Stage 2 w/ 6 speed

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Hey everyone, today I took a right corner by my house and heard kind of a pop sound, and now the transmission or somewhere in the driveline will make a knocking sound when no load is applied. If I am accelerating or decelerating at all it will be silent. Also will make the sound when I am in neutral or in gear with clutch pushed in. Knocking sound starts around 20 km/h and changes according to my speed.

2002 wrx with stock 5 speed, 138k kms

I changed the fluid last February I believe and I found a full tooth on the magnet, I am going to do a fluid change and see what I find...

I might be forgetting some info, car drives and feels fine except for this knocking sound, can only hear it when all windows are up and stereo is down. Thanks
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Last edited by brett192; 04-07-2013 at 10:46 PM.
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Old 04-07-2013, 11:06 PM   #2
Drakar
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Chapter/Region: VIC
Location: Coquitlam, BC, Canada
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Camellia Red Pearl

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Ill have an 02 trans in a few months if you need a replacement. Cant help with diagnosis otherwise.
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Old 04-08-2013, 12:34 AM   #3
brett192
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Join Date: Feb 2011
Chapter/Region: W. Canada
Location: Vancouver Island, BC
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2002 WRX Sedan PSM
Stage 2 w/ 6 speed

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Haha thanks man, hopefully it won't come to that though.. I'd like to go 6 speed if a tranny swap is necessary

The sound is more of a clicking, I will try to get a video of it on my iphone and gopro tomorrow. It is very loud when coasting at 60+ kms.

All gears sound good when you punch it and I can't tell where the tooth I found last Febuary came from. Such a mystery
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Old 04-08-2013, 02:03 AM   #4
AgentJ17
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Join Date: Jan 2012
Chapter/Region: VIC
Location: Duncan, BC
Vehicle:
1995 STi RA
3-cyl conversion...

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In case you haven't seen my FS ad, I have an early 04 STi trans for sale. Although I'm slightly tempted to keep it for a build now.

But it sounds similar to what happened to my 5mt. Either way, a broken tooth is never a good thing.
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Old 04-08-2013, 03:57 AM   #5
alcoolaid
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'07 SWP STi
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Quote:
Originally Posted by brett192 View Post
Hey everyone, today I took a right corner by my house and heard kind of a pop sound, and now the transmission or somewhere in the driveline will make a knocking sound when no load is applied. If I am accelerating or decelerating at all it will be silent. Also will make the sound when I am in neutral or in gear with clutch pushed in. Knocking sound starts around 20 km/h and changes according to my speed.

2002 wrx with stock 5 speed, 138k kms

I changed the fluid last February I believe and I found a full tooth on the magnet, I am going to do a fluid change and see what I find...

I might be forgetting some info, car drives and feels fine except for this knocking sound, can only hear it when all windows are up and stereo is down. Thanks
I think you're going to need to pull the tranny then lol
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Old 04-08-2013, 12:48 PM   #6
brett192
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Join Date: Feb 2011
Chapter/Region: W. Canada
Location: Vancouver Island, BC
Vehicle:
2002 WRX Sedan PSM
Stage 2 w/ 6 speed

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Going to lordco now to buy more fluid then draining the tranny... wish me luck

Car has like 37k kms on this trans fluid, is this too long of intervals?
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Old 04-08-2013, 01:39 PM   #7
Zefy
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Location: Coquitlam, BC, Canada
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1979 BRAT / 01 RSTI
99 2.5TS (DEAD) / 87 GL

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Quote:
Originally Posted by brett192 View Post
Going to lordco now to buy more fluid then draining the tranny... wish me luck

Car has like 37k kms on this trans fluid, is this too long of intervals?
37k is totally fine but if a tooth is missing changing your fluid more regularly won't do anything beneficial except drain out all the other teeth that are breaking off...

If you found a broken tooth in the transmission, it's original location should not be a mystery... it came from a gear, inside the transmission.

It is on borrowed time now. Start sourcing your swap before total destruction. All you're doing now is wasting time.
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Old 04-08-2013, 02:44 PM   #8
brett192
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2002 WRX Sedan PSM
Stage 2 w/ 6 speed

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Thanks, I know I should have changed the fluid again after I found that tooth but just kindof forgot about it Lame excuse I know

I just drained my fluid and found a suprisingly small amount of metal on the magnet.. I could have sworn I heard chunks rattling around on my way home from lordco, is there any non magnetic parts in the trans? Is there any way this could be sound from the driveshaft or u joint?


Last edited by brett192; 04-08-2013 at 02:50 PM.
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Old 04-08-2013, 04:16 PM   #9
brett192
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Join Date: Feb 2011
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2002 WRX Sedan PSM
Stage 2 w/ 6 speed

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No wonder it seemed like there wasn't much metal, the other chunks were too big to fit through the drain hole!!



The flat crests on the two biggest chunks are different widths and I beleive they are helixed opposite directions, so that means they are off different gears.. the largest chunk is clearly from the front diff ring gear..



I noticed the clearance between the drain plug magnet and the ring gear is very small, so I think a peice of metal got stuck to the magnet, then when I took the right hand corner, it flopped over and got wedged between trans case and ring gear and theres the pop sound I heard.

LAME
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Old 04-09-2013, 12:52 AM   #10
brett192
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Vehicle:
2002 WRX Sedan PSM
Stage 2 w/ 6 speed

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I got all the peices of metal out that I could, then filled with Castrol Hypoy C and Pennzoil Synchromesh, the sound is way worse now. It's really bad when in gear with clutch out, and goes away once you push the clutch in. Backwards from before the fluid change! Gets a lot louder the more gas you give.

Last fluid change I used those two oils as well as Red Line lightweight shockproof. Do you think this missing ingredient is to blame for increase in noise or is it just that much more effed?
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Old 04-09-2013, 01:29 AM   #11
originalozzyo
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WRB

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My brother had this exact same problem. Ended up just getting his whole transmission rebuilt, I think his was a stripped gear that just sent metal everywhere. Sounded worse the faster he went.
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Old 04-09-2013, 03:03 AM   #12
Zefy
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Location: Coquitlam, BC, Canada
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1979 BRAT / 01 RSTI
99 2.5TS (DEAD) / 87 GL

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Quote:
Originally Posted by brett192 View Post
I got all the peices of metal out that I could, then filled with Castrol Hypoy C and Pennzoil Synchromesh, the sound is way worse now. It's really bad when in gear with clutch out, and goes away once you push the clutch in. Backwards from before the fluid change! Gets a lot louder the more gas you give.

Last fluid change I used those two oils as well as Red Line lightweight shockproof. Do you think this missing ingredient is to blame for increase in noise or is it just that much more effed?
why are you even wasting your time thinking about different fluids. the transmission is BROKEN.

No amount of magical fluid will replace the MISSING GEAR TEETH.

It's like you've pooped yourself and you're curious about the skid marks in your undies. No matter how many times you put on clean undies, you're still gonna leave skid marks until you wipe your ass.
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Old 04-09-2013, 06:37 AM   #13
tryallzee
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97' Integra

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Old 04-09-2013, 10:21 AM   #14
brett192
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Location: Vancouver Island, BC
Vehicle:
2002 WRX Sedan PSM
Stage 2 w/ 6 speed

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Haha good analogy!


I am currently well under way sourcing parts for a 6 speed swap. Just thought I could limp my car around for another couple days... But since it's so much louder now, I think she'll stay parked.
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Old 04-09-2013, 05:55 PM   #15
tryallzee
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97' Integra

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Oh and don't be using ****ty coctails in the new tranny !!
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Old 04-09-2013, 10:48 PM   #16
Drakar
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Camellia Red Pearl

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Quote:
Originally Posted by tryallzee View Post
Oh and don't be using ****ty coctails in the new tranny !!
Lol so true. Cocktails for for the trannys having a slow death.
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Old 04-09-2013, 11:24 PM   #17
brett192
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Join Date: Feb 2011
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Location: Vancouver Island, BC
Vehicle:
2002 WRX Sedan PSM
Stage 2 w/ 6 speed

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I never had trouble with the tranny grinding or anything, I just read that the cocktail was the 'secret' for these terrible 5 speeds, I didn't know it was a bandaid. I found it interesting that even Uncle Scotty doesn't use the uncle scotty transmission cocktail.

The 6 speeds aren't so picky about fluids, are they? I think the guy said it was filled with fresh Motul, although I will be changing the fluid after the swap.

Does anyone have experience with WRX clutch/flywheel mated to STI tranny? Specifically 2002 WRX clutch and 2004 STI trans. Some people say I need an STI sized clutch..

Thanks
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Old 04-10-2013, 01:46 AM   #18
Drakar
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Join Date: Aug 2004
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Location: Coquitlam, BC, Canada
Vehicle:
2009 Forester XT
Camellia Red Pearl

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Extra-s and call it a day.
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Old 04-10-2013, 02:09 AM   #19
AgentJ17
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Location: Duncan, BC
Vehicle:
1995 STi RA
3-cyl conversion...

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You can most certainly use your wrx flywheel and clutch.

Seriously though, the oil isn't contaminated or anything and has only seen about 1000kms or so. The only thing is that this stuff makes the trans a little stiff/notchy until it gets up to operating temps.
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Old 04-10-2013, 04:47 AM   #20
tryallzee
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Vehicle:
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97' Integra

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I got rid of scottys a long time ago and switched to extraS . I run eneos now to try it and I like it a lot ,tranny is just as smooth as before !
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