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New on the forum but I've been reading a lot of your stuff for a while now.

 

I bought a Subaru Legacy 2003 sedan, 2.5L automatic transmission, no turbo. I was losing oil and started to stall so I eliminated the obvious then suspected the head gasket. On my way to my friend's garage I blew through over two litres of oil, limped to his place/garage and when we dismounted it we found piston number four was missing a chunk, right on the lower edge, with no visible damage anywhere else (ÔÔ never even heard of this before). Needless to say I went looking for a motor.

 

I found a Legacy 2003 2.5: Automatic transmission, no turbo but station wagon with a good motor and worn differential bearings (50,00 fewer kilometers). The serial numbers were compatible and It was in better shape overall so my friend and I pulled out my transmission and installed it in the new car. All went well, despite the inevitable skin and blood donations ... lol. We changed the differential, engine and transmission oil, radiator coolant, etc and started it up for a test drive. The initial grinding noise was traced to the heat shield which ended up requiring some adjustment (done). Following that, we found the torque converter needed topping up. Needless to say, I drove a loaner home and left the car there. The last grinding noise/vibration/rubbing has us baffled (and he knows a great deal more about mechanics and cars than I do, I just provide the body, a sounding board and some minor analytical thinking with occasional spurts of imagination)

 

From a dead stop in reverse, all is fine. From a dead stop (under load) there is a grinding/rubbing noise with a vibration starting from the transmission and travelling backwards. We already swapped the new brakes over from the old Subaru so it's not that. The heat shield is good, the bearings as well,  the driveshaft is clear and so are the wheels. It's been put into front wheel drive so it isn't the AWD. In first under load, the vibration and noise are prominent. In second if the gas is pressed heavily it's noticeable as well up to about 40 km/h. On the highway it comes back if kickdown is engaged. I'm having difficulty uploading the recordings I made with my phone so I had to convert the format to mp3 Voice_002.mp3

Since the sound seems to have improved, I'm wondering if air could have gotten in to the transmission. If so, searches suggest that transmissions are self-bleeding, so I'm also wondering if i should floor it until it stops or take it ease (or maybe even play with the gears stopped, with a foot on the brakes). My problem with this is that it doesn't happen in reverse; is that possible?

If not, I'm hoping someone here has an idea of what else to check

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A second sound recording, stopped with a foot on the brake and the gas pressed is available but I don't see an option to upload it on this window and the other window only accepts one file. The other two files are too large for the 2 MB limit (about 3.5 MB each)

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