5MT tranny / axle

[chuckthefuk]

97' BD GT Sedan EJ25D w/ 5MT

Hello SL-i,

This all happened overnight, I woke up to go to work turned my BD on left it in neutral to warm up. Around 750rpm's I decided to throw it in to 1st and head out. What happened at this point was:

Grinding noise and no power to the tranny. I can take my foot off the clutch and the car wont stall. No matter what gear I am in even reverse it wont stall, although the RPM's do drop the higher the gear. [Currently my BD is sitting at my buddies home and will be torn apart in the next 48 hours :-( ]

0) Clutch has never slipped since I have owned the car
1) Tranny will engage all 5 gears + reverse with no problem
2) Clutch still has good pedal pressure
3) With the car turned off I can go into any gear without the use of the clutch
4) There is no oil leaks nothing is abnormal under the car.
5) The shifter and synchros seem fine, no stiffness, no grinding, no issues

I just don't understand how this can go over night, everything was fine the night before.
.....

*update*

Spun my Passenger front axel :-( Teeth are ground to a smooth finish... Clips let go :-(

Since I don't have an LSD all the power went to the spun axel which did not let the tranny stop = no stalling.

Anyways I am rebuilding the axel and should be up in a day or two.

Thanks SL-i

- Chuck

[decke48]

well if you can engage in any gear and still have the same problem that rules out broken teeth/syncros. cant be the master/slave because the clutch would always be engaged so you couldnt shift into gears without stalling. i would suspect the clutch has worn down past the rivets and one side of the clutch material has worn of the metal part of the disc. or somehow you broke the input shaft to the tranny

[rougeben83]

Check the clutch fork. I've heard break before on other Subaru's...

It's that metal bar the slave cylinder pushes against when you press the pedal.

[AussieDan]

If the clutch fork was broken the clutch would be permanently engaged.

If you heard a grinding noise then most likely something mechanical is broken, as for finding out what the only thing I can suggest is to pull it apart and take a look. You could have a friend pump the clutch and verify that the clutch fork is moving, which will at least rule out the hydraulics.

You can use any 5MT with a 4.11 FD ratio & hydraulic clutch, so anything on your list will work. A later year transmission (99+) will have a different (stronger) case and better synchros so go for that if you can, you may need the matching starter for the 99+ trans, I'm not 100% sure on that. Stay away from Outback transmissions, as they have a lower 5th gear (because of bigger tires).

I actually have a spare 99 RS trans and a 97 trans with bad syncros (you could probably use it for parts to fix yours) pm me if you're interested in either one.