Looking at the tranny from the front, on the left side of the plate theres a round head with one side cut off. Is this lined up so the plate misses it?

All the gears are pressed on the shaft, so I dont think they could slide forward. Was the seal replaced? It may not be seated all the way in.

Theres also a bearing a little further in. I dont know if this is easy or hard to pull. Have you tried giving the shaft a rap with a block of wood and hammer?

 

THANK YOU for replying. Yes, the reverse idler gear shaft is flush with the housing and the cut edge is lined up with the cover. The seal has not been replaced at all in input shaft. What happen was that he (the nosy neighbor) removed 3 bolts and tried to pull the cover off using two prybars it would not move anymore after past 3/4 of inch or so from the main case. So, he tried to put the cover back in and it stopped about 1/4 to 1/8 of gap to go. Then I took over at that point and could not persuade the cover to go back little further. I put 3 bolts in and tighten it a little at time and the input shaft binds up (it will not spin easy). A thought occured to me that maybe a bearing or something (perhaps a sychro ring?) inside or at the back the input shaft slipped and blocked the input shaft from going in little further so the cover can install. My mechanic experience lies mostly with Eaton Fuller transmission from 5 speed to 18 speeds.

 

I did tempt to use BFH on the cover but the cover looks too puny to handle that. So I just tap it in gently with mallet. No joy. I think worst case is that i may have to split the case apart to see whats going on. Yes, I turned the transmission front side up (holding it vertically) to see if the cover can go in. No joy either. I rotated the input shaft while tightening the 3 bolts a little a time and it binds up.

 

Now, the question is... can that cover be removed from case without tearing the case apart? I just dont have a "exploded" diagram of this transmission. ,

Yes, according to the manual you can. Thats why I'm confused at why its binding now. The bearing that further in on the shaft may not be seated now. I'll try and get a scan of the manual and post it for you.

Hope this helps.

That diagram is a big help.

 

The needle bearing (#4) - is it possible that it fell apart and preventing the input shaft from going seated properly against the main shaft?

 

Can the input shaft be able to remove with front cover or the oil tray (#38) blocks that movement?

 

I am going to try to pry the cover off again but tapping the input shaft back in while prying the cover at same time. Is that acceptable method?

I'll try and scan some more of the FSM and post it tomorrow. I'm fighting a cold right now(again) and the meds I took are putting me out.

Very sorry to hear that you're fighting the cold, buddy. Get well. I have 15 yr old kid fighting the cold as well - probably from his buddies at end of school party they went to.

Alright, a new development.

 

I got the cover back against the main case. The input shaft only spins a little to the left and a little to the right (total 1/2 inch of rotational movement). When backing the cover bolts off a bit and cover allowed to move out of the main case by 1/8 of inch, the input shaft spins free.

 

Now, how do I know if the front (item #50) and rear shifter is in neutral?

Alright,

 

I am going to have to tear it down. Question.. does the rear housing come off without disassembling???

Ya'all are useless.

 

I tore it down yes rear housing is torn down as requried and split the case. Found the spring that applies pressure to sychnoizer tabs broke and causing the input shaft side sychronizer to bind up and bent out of shape. That in turn causes the input shaft to bind up.

What is recommended dealer to buy the parts from? Rockauto.com does not have that sychro that I need (high/low range sychro).

If I was in your situation, I would source another tranny. Your in a location where there should be some available and for cheap. A low mileage tranny should go for no more than $150.

It might be cheaper and alot quicker.

And I think I would be hitting up my neighbor for a "donation".

In item #40 in the drawing, what is the part number for that? I checked AllDataPro and their drawing is not clear at all.

 

Now, the 5 speed transmission when torn down looked great shape. I am willing to pay for that part and reassemble back together. As for "donation" from the neighbor, I think I wont ask for it because it would be well spent keeping him away from my garage.

 

I have emailed Prestiage Subaru of Asheville. Is there another source I should consider??

 

By the way the front input shaft seal does not come out without splitting the case apart and removing the entire input shaft and bearing assembly because the bearing is retained by a snap ring to the front cover.

 

Thanks.