1998 Subaru Forester, 5-speed, 275K miles. ONLY does it it in 2nd Gear. Drives fine in 2nd Gear.

If it's not internal tranny noise, Is there anything that the linkage could be rubbing against? The shifter linkage and related parts were replaced at about 250K.

Transmission Noise

 

Thanks for feedback.

Edited January 9Jan 9 by wtdash

That’s an interesting one! 

A chipped tooth will make a rotational clicking noise that’s speed related and only when in the chipped gear. 

That noise sounds like something is grinding - and interesting that it’s only in one gear. 

Other thought is that it’s multiple teeth that are damaged - unlikely though as the gear would most likely strip as a result, but anything is possible. 

Hopefully it’s something simple. 

In second gear, when you clutch in does the noise go away?

@nvu

The noise does go away mostly, but I put it  UP on ramps engine running, trans in neutral and the noise is coming from the area 'between the axles'. 

Edited January 11Jan 11 by wtdash

Have you drained the gearbox oil and see what comes out with it? 

Also carefully feel around inside the gearbox through the drain hole for any other fragments that may be present. 

Noise will travel to different areas. You’d need to use a dowel/long screw driver/stethoscope to pinpoint where the noise is coming from more precisely.

Seems more likely that second gear is chipped, possibly both gears - if that’s the case you’d get an un-rhythmic sequence that will repeat after some time. This is because all gearsets have at least one gear that’s got an uneven number of teeth so they wear all teeth against each other for even wear across all the two gear cogs’ teeth.

 

Quote

 

Have you drained the gearbox oil and see what comes out with it? 

Not yet - next troubleshooting step. 

Thanks

1 hour ago, wtdash said:

I put it  UP on ramps engine running, trans in neutral and the noise is coming from the area 'between the axles'. 

That pretty much confirms it's inside the trans.  

Though, when I had 2nd let go on one, it broke off an entire tooth on the small gear only make a light clicking noise, and lodged the tooth in the center section.  Draining didn't find anything, only taking apart showed the issue.

Though with how old yours is, it might also be loose bearings causing enough slop to make that constant noise

Bearing issue *should* make similar noises if it’s a bearing issue. From memory there’s a bearing set between input shaft/front diff and 1st, 2nd and 3rd; 4th and 5th.

Better to change a manual than auto trans!

Changed the gear oil and sparklies were in the oil but no chunks...tried to feel in the drain hole and nothing there...The differential is 'part of' the transmission, correct - I may as well replace the whole trans vs. just the differential? 

yup, swap out the trans. you mentioned noise was only in 2nd gear. bad diff would make noise according to speed of the car regardless of gear

Whole gearbox swap = easier than repair. 

I find it easier to pull the gearbox out from under rather than pull the engine from above. 

The drive shafts can be left to slide off as you take the box out, no need to pull them off first. Once the gearbox is clear of the bellhousing of the engine, push it left, remove shaft then push it right and remove the other shaft. 

Lining it back up if stub axle is a little tricker but possible. I’ve done it several time now and it works a treat!