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Old 11-26-2007, 05:27 PM   #1
Xess
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Default did 1-4 ppg gearbox, now 5th gear is blown

hey forum gods... after falling victim to the 06 3rd gear issue in my protuned 2006 wrx limited wagon i followed the best course of action there was to be had. andrewtech rebuilt my 5mt with helical syncro ppg 1-4. done deal right....???

i wish....so cruise control is reaccel(ing) up to 75 mph when 5th gear just falls out of gear. 1-4 are rock solid 5th is non existent, no grinding nothing.

nursing it home i notice a subtle wheel speed dependent (clutch independent) click click...ect.... not loud, but its there...

call to andrewtech results in them telling me 5th gear is most likely in two halves and this is a very rare issue they have seen once or twice. lucky me!!!

the issue is this, i would rather not spend the time/money to r&r my broken tranny then ship it down to andrew.... i have rebuilt a 5mt in a previous obs without issue, so i know i am capable of doing work properly
and from what i remember, 5th gear can be accessed without actually dropping the whole case. what i dont know is can i actually replace 5th gear in this same fashion.?


any comments, suggestions, advice is greatly appreciated...
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Old 11-27-2007, 02:46 AM   #2
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Well, today is NOT the day to buy a lottery ticket. No advice for you other than an e-hug as what happened to you sucks and is rare and I feel for you for what that's worth.
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Old 11-27-2007, 08:42 AM   #3
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Hmm, and in the other thread I was given crap for thinking it would be nice for 5th to be replaced also

Just funny, because why would 5th be safe and not 4th? 5th actually would be seeing more torque being overdrive. But what the hell do I know?

5th can be replaced by just taking off the transfer case / center diff case. Really if you are going to go that far, it would be easier to just split the case and take the shafts out.
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Old 11-27-2007, 10:27 AM   #4
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At least its the last one on the stack and you don't have to go down any further on the shafts. That should be a quick and simple press job but sorry dude.......that stinks.
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Old 11-27-2007, 10:54 AM   #5
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that sucks... but thanks for the info... when i finally go PPG's i guess i will be gett'n all 5.
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Old 11-27-2007, 11:05 AM   #6
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damn...
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Old 11-27-2007, 12:47 PM   #7
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Thats Is Happening To Me To!!!!
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Old 11-27-2007, 01:55 PM   #8
Xess
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well....guess what.. ppg does not make a 5th gear..

ok, so i think i will do this on my own. i know i can get the rear part of the case off without dropping the whole tranny, but can anyone help me visualize how i am going to get 5th gear off/new one on without being able to get the shaft in a press....

i havnt touched this yet, but i'd like to start tonight, so any words of wisdom or insite as far as getting that back case off and swapping the gears with the tranny still mounted....well i welcome anything that could help....

btw....before 5th gear went all was working perfect with the ppg's and unless someone tells me different, i have to believe this is in no way related to the ppg 1-4 or andrewtech's work on the gearbox....
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Old 11-27-2007, 02:17 PM   #9
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doood wouldn't it just be easier to take your tranny out ???
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Old 11-27-2007, 05:13 PM   #10
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well... if i have to, i will.. but anyone who has pulled one of these trannys will know that if it is possible to do as i hope i can and just drop the driveshaft and the back of the case to replace 5th, then thats the esier of the two options
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Old 11-27-2007, 05:29 PM   #11
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I am guessing both gears are ruined and you will need these tools which are made from an old center diff. Never mind the arrows in the top pic.
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Old 11-27-2007, 05:41 PM   #12
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Quote:
Originally Posted by Rasmusson14 View Post
At least its the last one on the stack and you don't have to go down any further on the shafts. That should be a quick and simple press job but sorry dude.......that stinks.
True... hey it could be a lot worse... at least this way you don't have to drop the whole trans as 5th is quite accessable by just removing the center diff case.
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Old 11-27-2007, 05:42 PM   #13
Xess
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now were getting somewhere... i have a full lathe, milling machine, arc and mig welder setup and can make tools that will work if need be...i just need to know if i am gonna run into an issue where i need to press off the 5th gear pair and not be able to do it not having access to the whole shaft..

p.s.i have also been known to make use of the local fire depts hurst (read jaws of life) cutters and rams when need be...lol
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Old 11-27-2007, 05:44 PM   #14
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Seems like a good gear puller would do the trick for just 5th... or do you still need a big shop press for that? Jaws of life would definitely be overkill though!
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Old 11-27-2007, 05:50 PM   #15
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yea i know....but cutting through an a and b pillars and rolling the roof of an old junker (a la instant convertable) is just sooooooo fun...


back to reality though.... can anyone say with any certainty that i will/will not be able to Remove and replace 5th gear from a MOUNTED tranny.....(read will i need to press 5th off in a shop press, or can i use a gear puller)
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Old 11-27-2007, 09:26 PM   #16
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It can be done but you will have trouble.

The main shaft should be relatively easy. Once you get the nut unstaked and removed the 5th/R assembly falls off. An impact for removal should do the trick but you're going to have to put it in gear to keep the shaft from turning.

The driven shaft on the other hand will be a pain. 5th is very close to the bearing on that side and this ones a press fit. You're also going to need an extremely deep deepwell metric socket to remove the lock nut. I believe that one's a 50 mm. and btw, the torque spec on that nut is 195 ft. lbs. You may luck out with a specialized gear puller of some sort to fit between the gap in there.

I would check it out first. If the drive 5th(main shaft) is the one that's toasted you should inspect the other carefully and just replace the broken part. If it's the driven 5th(driven shaft) then I'd just finish dropping the tranny and split her open.

Your biggest pains will be:
1. getting the 50mm nut off.
2. removing the driven 5th.
3. reinstalling a new 5th.
4. torqueing to 195ft. lbs successfully.

Good luck.
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Old 11-28-2007, 06:06 PM   #17
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thanks tim...thats what i needed to hear.

Anyone else with any experiance...incite??? Pitty???

unabomber...thanks for the e-hug...lol... I need it.
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Old 11-28-2007, 06:35 PM   #18
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Did yo get a PPG 5th gear hub or use oem?
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Old 11-28-2007, 08:26 PM   #19
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A very clever idea!!!! I'll have to remember this one.
Quote:
Originally Posted by Crazykev View Post




I am guessing both gears are ruined and you will need these tools which are made from an old center diff. Never mind the arrows in the top pic.
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Old 11-28-2007, 08:41 PM   #20
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So rare to blow a 5th gear. good luck with that.
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Old 11-28-2007, 10:13 PM   #21
Xess
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as far as i know its a stock 5th as ppg does not make any 5th gear parts for the 5mt...
i'll post more info/pics when i get the rear case off...
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Old 11-28-2007, 10:28 PM   #22
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They make a 5th gear hub. My dogbox has one.
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Old 11-29-2007, 03:00 PM   #23
Xess
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learn some thing new every day...

school me... is this part something i should look into using, is it compatable with helical gears and syncros???
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Old 11-29-2007, 08:22 PM   #24
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http://forums.nasioc.com/forums/showthread.php?t=916239

First page....first post....about halfway down


Just call them for a straight forward answer.
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Old 12-02-2007, 10:34 AM   #25
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Quote:
Originally Posted by Crazykev View Post
Just funny, because why would 5th be safe and not 4th? 5th actually would be seeing more torque being overdrive. But what the hell do I know?
What makes you think that?

Does your car make more power in 5th than any other gear?
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