motohead Posted July 4, 2012 Share Posted July 4, 2012 I will try to keep this as brief yet detailed as I can: Car: 2005 Legacy GT Automatic, 5EAT History: Swapping in long block from 2008 WRX manual. Did not use Subaru Tool to hold Torque Converter (TC) assembly (works by hooking onto ring gear and bolting to starter mount hole if you do not know what I am talking about). Motor was hard to separate from transmission but when it finally did, the TC stayed in the bellhousing (on the tranny side). During assembly, in my folly I assumed the TC was just fine where it was, did not realize that all that wiggling may have unseated TC. Made common error of trying to mate engine to transmission with an improperly seated TC (I see this is a common shadetree mechanic mistake in google searches). Done a few R&R of transmissions and engines, but never with automatic, and never with subaru. Took a lot of effort to get the motor even close but motor would not seat for the last 3/4 inch up to bell housing (of course). I know better, but due to 4 hours sleep, time crunch, stifling heat and short temper, I was not thinking straight, and decided to use bellhousing bolts to "help" seat the bellhousing. Went really slow, Gap closed a 1/4 inch, then heard pop sound coming from TC area. Stopped right away. 15 minutes and a lot of cursing later, motor was back out to assess the damage. Fished the oil pump tube out, luckily no damage to tube nor tabs that interlock with oil pump. Circlip slightly bent but bent it back and now it clips in fine Removed (and replaced with new) torque converter seal, while seal was out I shone a light down into the hole and looked that the area where the oil pump tube interfaces with oil pump, saw no damage but don't know if anything behind that area is damaged where I can't see. I hope my oil pump is not damaged... checked TC, tube flange that connects with oil pump tube has no damage on it. There are 2 things that worry me and this is where I need expert help: 1) inside the TC (looking down the hole) there are 2 sets of female splines. The deeper, smaller diameter one has no play as far as I can tell (hard to get my fingers down that far) BUT the shallower, wider diameter splines (for the stator I believe) had a lot of play, like 1/4" each way is my guess, and when I wiggle it around it makes a "thwock" sound as it hits something inside the TC. It is not so loose that it rattles if I shake it (mind you the TC is still full of fluid) just that I can move it around inside with my fingers. Google search shows one person also having this issue (which was never resolved on the forum) and another saying he bought another TC because of this, and the new TC was tight. Is my TC fubared? 2) The input shaft coming out of the tranny (central smaller diameter spined shaft that rides inside a larger diameter splined shaft) only protrudes out past the edge of the larger shaft by 42 mm. The FSM I have specs it at 50-55 mm. It still spins by hand (requiring decent force to twist, similar to turning an assembled RWD diff by hand) and I can't hear any noise or roughness when turning the shaft, but the 42 mm protrusion concerns me. Closest thing I could find by searching yielded a post where a person with a 4EAT had jammed his input shaft in, and a Subaru technitian said that shaft should be removable by hand and easily re-inserted. My input shaft DOES NOT come out when I pull my hardest on it. Did I fubar my tranny? I mounted the TC (with oil pump shaft) back on, and it seated really easy, almost too easy based on descriptions on the net. It just fell into place without the 3 steps that ppl usually describe. TC mounting flange was within spec distance to bellhousing face (under 8 mm is spec, was like 4 mm). Span TC around both ways and it span smoothly, no sounds, but no oil coming out of trans fluid cooling line like I thought there might be. I can confirm that oil pump tube was engaged because when I pulled the TC off, the tube tabs were lined up with the oil pump slots. Any help is appreciated, it's taken me many hours to get this far, it would be heartbreaking to find out I damaged something with my mistake, but I rather find out now with the motor out than find out the hard way later. Thanks in advance! Link to comment Share on other sites More sharing options...
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