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Old 05-10-2021, 10:43 AM   #1
Kavy43
Scooby Newbie
 
Member#: 524199
Join Date: May 2021
Default Help Help Help

I recently had help from a few friends as this is my first Subaru.
We took my transmission out as I bought the car knowing 3rd gear was gone.

This is kind of long I appreciate any insights.

We took apart a 02-04 5mt manual trans. Mine 2006 5 speed manual year was a push style clutch and the one we took apart was a pull style.
We Swapped the guts and the front diff gear ring to my diff, Then used 2006 casing and tail end center diff and output shaft.

Got all the guts in and the only issue we had was binding so we removed the Half moon or 3/4 moon spacer or shim we buttoned it back up and had free motion and could cycle all the gears freely.

The issue I am having now is the car will not go all the way into 4th gear it will start to grind on clutch release but will go to all other gears.

Next issue the car has an ACT heavy duty clutch.
Could this be causing an issue being I have previous year transmission?

The clutch from 1st gear take off will click and feels like an axle is bad.

Then intermittently almost control the car by itself for example I hope this makes sense.

On clutch engagement while giving throttle and release I get about 50 percent disengaged feels like axle is binding clicking clapping so on and the clutch will take control for itself depress and come back to my foot where I left it and drive somewhat smooth.

I guess what I’m asking is what did we miss or do we need to do differently.

Just to clarify my axles did not make any weird noises as I drove the car while 3rd gear was gone,

Could this be backlash measurement related?
Do I need the other years shifter linkage?
Or possibly the rear Differential?
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Old 05-10-2021, 12:26 PM   #2
cboggess
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Member#: 30804
Join Date: Dec 2002
Chapter/Region: SWIC
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87 Yugo
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That "moon" sets thrust. You gotta measure and use the right one.
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Old 05-10-2021, 04:56 PM   #3
Kavy43
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Member#: 524199
Join Date: May 2021
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thank you @cbogges!
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