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Old 06-08-2014, 12:33 PM   #1
smhammen
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Default No 5th Gear Engagement

Hi, I'm looking for some help before I tear into this transmission too far. Quick background.... I'm building a kit car and using Subaru 2.5L and 5 speed manual gearbox. Gearbox was purchased used and I don't have any history to go with it, perfect right? I removed the rear differential and installed a splined coupling to convert the AWD into just 2WD, these parts came with the car kit but I don't think have any affect on my issue.

So 1-4 and Reverse work fine, it wasn't until I was on the highway and tried 5th that I realized it wasn't there. I can shift in but no power transmission and revs shoot up.
I now have the gearbox plate back off so I can see the back of the main and drive pinion shafts. When in 5th and I roll the vehicle I can see the 5th drive gear is rotating too, while the rest of the gear assembly is stationary. So it's obvious the 5th drive gear is not connected to the main gear assembly. Maybe a problem with the syncho hub or coupling sleeve? Any other thoughts why this would be happening?
I included pics of the gearbox and overall of the car.

Thanks!


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Last edited by smhammen; 03-15-2018 at 10:19 PM. Reason: I found some new information
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Old 06-12-2014, 07:56 AM   #2
smhammen
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Any suggestions?
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Old 03-08-2018, 01:57 PM   #3
smhammen
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Any new thoughts on this?
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Old 03-08-2018, 03:16 PM   #4
mrsaturn7085
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Without practice, it takes less than a full day to pull the transmission and open it up.

Why has it taken you three and a half years?
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Old 03-13-2018, 12:51 PM   #5
smhammen
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So let me get this straight...you're implying when someone has a transmission issue they should dedicate a full day to pull it out of the car and open it up?...regardless of one's transmission knowledge and experience? This post is not just for me but for anyone out there experiencing a similar issue, and so far it's not helping any of us.
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Old 03-15-2018, 11:17 AM   #6
Charlie-III
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Quote:
Originally Posted by mrsaturn7085 View Post
Without practice, it takes less than a full day to pull the transmission and open it up.

Why has it taken you three and a half years?
Quote:
Originally Posted by smhammen View Post
So let me get this straight...you're implying when someone has a transmission issue they should dedicate a full day to pull it out of the car and open it up?...regardless of one's transmission knowledge and experience? This post is not just for me but for anyone out there experiencing a similar issue, and so far it's not helping any of us.
OK, different thought line.........

Rule out the shifter linkage/stick is hitting something or is really loose preventing full engagement.
If it all looks good on the outside, then dropping and opening the trans is the only way to figure it out.
Really nothing on the outside to "adjust/fix" if it's an internal issue.
Thus, the comment on time to pull the trans.

Since 5th is a "corner" under a shift boot, the shifter rod mark be contacting something preventing full gear engagement.
Major slop in the shifter linkage, shifter mounts, etc. may also prevent full engagement.
Common example is someone goes to a SS, then has issues. We get them to pull the shifter boot and they find they need to trim the tunnel or boot surround so there is shifter clearance.
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Old 03-15-2018, 09:39 PM   #7
smhammen
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Thanks for the reply Charlie-III.
I'm changing gears directly at the gear selector shaft coming out the back of the trans....using a screw driver through the cross hole in the shaft. I get positive engagement in all gears including 5th...but 5th gear was just free wheeling when I rolled the car back and forth... in other words 5th gear is not locking up on the shaft it's mounted to... which is pointing me to the synchro components.
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Old 03-16-2018, 09:06 AM   #8
Charlie-III
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You won't know, until you open the case.
You may see pieces in the trans when you open the case up so repairs will be easier to diagnose.
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Old 02-07-2019, 11:05 PM   #9
smhammen
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Well I finally got to removing the tail section of my 5sp manual. After pulling a few parts off and removing 5th Gear I see the issue. 5th Gear and the 5th synchro Gear have become separated so this explains why when I shift into 5th and engage the 5th Gear synchro Gear that the driven 5th Gear just spins free.

Now where to find a replacement 5th Gear. Transmission has TY752VB1AA on it.
Can anyone point me in the right direction for a part # or even better a replacement part?

Thanks!


Last edited by smhammen; 02-07-2019 at 11:13 PM. Reason: Trying to link a picture
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Old 02-08-2019, 10:01 AM   #10
JarHarms
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TY752VB1AA was built with a 0.825 5th ratio, so I expect that is what you have there. I am not aware of any USDM 5MTs that came with a 0.825 5th gear set...only 0.738 5th gear set. NEW You would have to order a non-USDM part to get 0.825 gears, a US dealer is probably not going to work. Your looking at some place that imports those parts. Also the 5th gear set comes as a pair. Gearing would be different and you would add a ratio jump in there but "maybe" you could install the 0.728 5th as long as the hub/tab/etc specs match up. USED maybe someone is parting out a JDM 5MT and you could get the 5th gear set from it...
*How does the 5th bearings/races look, debris damage?

Last edited by JarHarms; 02-08-2019 at 10:07 AM.
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Old 02-08-2019, 04:58 PM   #11
smhammen
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The gear race has some light surface damage on the outboard side 1/4" in and the rollers also have light surface scuffing in the same area, main shaft race looks good. No debris or other damage. I spent a few hours today searching for this gear with no luck. I think the part number is 32315-AA130 but it's not available. It crossed my mind to weld these gears together but I don't like how much wear the syncho gear teeth have.... I'll look a bit more before I bring this idea up again.


Last edited by smhammen; 02-08-2019 at 06:07 PM. Reason: added some info
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Old 02-08-2019, 10:47 PM   #12
smhammen
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Thanks JarHarms and yeah it appears you are correct on the 5th gear ratio of .825. This car rarely sees the highway so I’m fine changing the gear ratio if I could swap in an available gear set. So now the question, is there a 5th gear set that would “drop in” to replace what I have?
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Old 02-09-2019, 10:43 AM   #13
JarHarms
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32315aa420 is the 5th gear set with 0.738 ratio (32t / 42t) which "should" directly replace those gears and can be ordered through US dealers/parts suppliers. Mind you I have not personally done this so I am 85% certain of the compatibility.

You will have to replace both gears, which means splitting the main case and using press. In addition you should replace that baulk ring, the needle bearing, possibly the bearing race, maybe the shaft end nuts (stake those better then factory did), and clean the entire shaft oil pathway of any debris. Also check the input shaft rear bearing, front bearing, and new front oil seal.

I have a feeling you are thinking inversely about that gear change. 0.738 is more so a highway gear than the 0.825 used in the JDM boxes. Going to 0.738 will change road speed -vs- rpm (lower). If you use 5th gear for track use (or whatever you are using that kit car for) it will alter the experience. If it was mine....I would use a gearing calculator with your tire size, etc input and compare the before after.

If that change is too much you might want to opt for souring the same JDM ratio 5th set instead. You could "probably" get away with just swapping the input shaft 5th gear (although pairs sets is best) and could do so without getting into the main case. It sort of depends on how far you want to go with it.
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Old 02-09-2019, 06:17 PM   #14
carnz-pj-410
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2009 Outback 5MT has a .825 5th gear ratio

the part number is 32315AA390, it's currently on backorder but is listed as orderable
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Old 02-23-2019, 09:18 PM   #15
smhammen
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I received my new 5th gear set, 32315AA390 and although it’s the same .825 ratio the gears are not interchangeable. The diameter of the machined surface where the brass baulk ring makes contact is quite a bit larger... like 57mm vs the old one at 52.6mm (measured at the largest part of this angled surface). The number of baulk ring teeth of the old gear is 30 while the new ring is 33.

Last edited by smhammen; 02-24-2019 at 12:16 PM. Reason: New information
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