I've had this Legacy for a couple years now, and I've put 36,000 miles on it in that time. I've replaced the shifter bushings once with Subaru parts and just three weeks ago I replaced the clutch. I pulled the engine to do it and replaced the rear main oil seal and the oil seperator plate while it was out. Everything went back in fine, but now the tranny pops out of fourth gear, and only fourth. It happens when I let off the throttle. I can see the shifter moving forward and back in every gear when I get on or come off of the throttle so I guess the tranny/engine is moving? I pulled the shifter linkage out and this time I used steel sleeve bushings and 3/8" bolts instead of plastic bushings. There's no play in the shifter linkage now. I double checked the pitch stopper and I did put it right back into the same position but I can see that the bushings are soft. I tried moving it forward and back in different positions to see if it changed anything but nope. I just think it's odd that this would happen only after replacing the clutch so I have to suspect that it's just a matter of getting everything into the correct position. What do you think could be the problem? Worn engine/tranny mounts? Worn tranny internals? Anyone have this happen before?

 

1996 Legacy 317,700 miles

Some movement of the engine and trans is normal, but it shouldn't cause it to pop out of gear.

I'm thinking something with the shift linkage isn't quite right.

 

The other cause for popping out of gear is a worn mainshaft ball bearing. Did you check the input shaft for play when you had the engine and trans apart?

Yes I did, and there was a minimal amount of play, I didn't properly measure it but it didn't move enough for me to think there was a problem.

 

It's just odd that it didn't do this until the first drive after the clutch replacement.

There's not a whole lot of room around the u joint on the shift rod. Take a close look at that and make sure the bolts you put in it are not hitting the stay rod or getting hung on the centering spring. Also check for good clearance between the joint and the dust shield around the driveshaft.