About my Subaru:

1996 Legacy/Outback. AWD, EJ2.5L engine w/DOHC, 4EAT trans. 164,000 miles.

 

Backstory: Headgasket blew, as per the norm. Pulled the engine and took care of it. When we got it all together, it was making a funny noise but we couldn't figure out why, so I drove it for a couple days (about 200 miles). Then realized that the trans pan had been bent up and the noise was the pump cavitating. So we fixed the pan, changed the ATF and filter. The noise went away, but now I have NO SECOND GEAR.

 

Details: I can drive my car. I have to rev it up to about 4500rpm in 1st, then it shifts right into 3rd. If I use the shift lever to downshift into 2nd, it is almost like being in neutral. There is just a tiny bit of thrust, and it is jumpy.

 

So I guess my options are either rebuild or replace the trans.

 

Questions: What could be causing this (and don't say driving it for two days without fluid--I already know that)?

 

Does anybody have any experience rebuilding these? If so, where do I get the parts and about what do they cost?

 

I can get a salvage trans for $650, or a Japanese 30k for $950. The Japanese one has a different gear ratio (purported to improve freeway gas mileage) and comes with a matching rear diff. Can someone explain the gear ratio thing to me?

 

Any help anyone can offer me would be much appreciated. But please use small words, I'm pretty dumb mechanically. I do have three Army mechanics helping me, though, one of which is ASE Master Tech certified. Thanks.

Then realized that the trans pan had been bent up

 

there was a bent pan post last year in which the car had torque bind. the wire to the duty c solenoid had been pinched by the bent pan and damaged. it caused the duty c to fail in the 4wd locked condition causing binding.

 

it is possible that you have damaged either a wire or a solenoid which commands the shift to second. i wouldn't assume at this point that the trans is bad. it maybe but maybe not.

 

does the 'AT Temp' light on the dash flash 16 times at start up??

does the 'AT Temp' light on the dash flash 16 times at start up??

Yes, we need to know if the warning light is flashing.

Also, is the trans operating normally in 4th?

No, there is no light flashing at startup. 3rd and 4th gear run fine. 3000 rpm=75 mph on the freeway.

Could you verify that the warning light at least comes on briefly as you start the car? If the lamp is operational, yet doesn't flash at start-up, then the TCU (transmission control unit) isn't detecting an electrically-related diagnostic fault.

 

Here's a link to general info on the phase-1 4EAT: http://endwrench.com/images/pdfs/4EAT.pdf

Yes, the ATF light does come on when I turn on the ignition, with all the other warning lights. But it doesn't flash abnormally. Sorry, I should have specified before.

Yes, the ATF light does come on when I turn on the ignition, with all the other warning lights. But it doesn't flash abnormally. Sorry, I should have specified before.

 

i don't say this often, but this may be a time to have the dealer diagnose the problem. for a fee you can learn what's wrong, it maybe a 300$ solenoid or it maybe a 3000$ new trans. then you can decide if , when, and where you want to have the repair or replacement done. usually it's cheaper to have a used trans swapped in if you need a rebuild or a replacement.

 

first step, ask the dealer how much to diagnose