Well after having the clunk for a year or so on tight turns, I finally got under my wife's 2002 Legacy only to find massive carnage in the rear of the trans with the center diff.  The input and output gears are toast, and the rear bearing on the center diff side was fused to the outter case cover.  I'll post pics if anyone wants, but at work right now.  I could not even beleive the car could drive, but it did, with some nice noises!

 

Anyway, now I need to decide whether to rebuild the rear of the trans or put in a used JY trans.  The gear lube had a serious amount of metal in it, and no idea if any large chinks made it to the trans (trans shifts fine for now).  On the other hand a used trans presents the unknown history problem...

 

1.  Anyone have any experience with this?  

2.  Anyone have any parts for a rebuild?  

3.  Even in VT these manual trans are hard to come by, but I have some leads...what years will work in an 02 Legacy?  I know diff ratios must match the rear. 

 

Thanks in advance!

Final drive ratios vary depending on model: L typically uses 3.90. GT and Outback typically use 4.11.

 

The big chunks don't usually make their way to the front half of the case, but the small bits are the ones that float around and get into the bearings and ruin everything.

The major problems in these don't typically manifest themselves as shifting problems unless there is major wear. The mainshaft ball bearing is the most common failure, and tends to make a bit of racket on its way out. It can take several thousand miles for it to fail after starting to make noise. The thing is, you probably wouldn't be able to tell until you get the center diff and tailshaft replaced.

You can try to move the mainshaft (the upper shaft in the main housing) fore/aft to check for play, but there can be damage to the bearing races and still show no play.

I would just try to find a whole trans.

 

Check car-part.com for used trans near you.

Edited April 2, 201411 yr by Fairtax4me

Final drive ratios vary depending on model: L typically uses 3.90. GT and Outback typically use 4.11.

 

The big chunks don't usually make their way to the front half of the case, but the small bits are the ones that float around and get into the bearings and ruin everything.

The major problems in these don't typically manifest themselves as shifting problems unless there is major wear. The mainshaft ball bearing is the most common failure, and tends to make a bit of racket on its way out. It can take several thousand miles for it to fail after starting to make noise. The thing is, you probably wouldn't be able to tell until you get the center diff and tailshaft replaced.

You can try to move the mainshaft (the upper shaft in the main housing) fore/aft to check for play, but there can be damage to the bearing races and still show no play.

I would just try to find a whole trans.

 

Check car-part.com for used trans near you.

Car part has nothing local, JY I usually use can get one shipped to the tune of 1300 bucks.

 

Does the Forrester use a different bellhousing?  Did they come with 2.5s even?  There is a local 2002 Forrester, but not sure they can be used.

bucknarly,

 

Not sure if this helps, but check out the tranny listed at     JDMTigerJapanese.com. They have a 5 speed tranny

with 45 000 miles max for $399.

Forester used the same trans but has 4.11 final drive.