Possible Manual Transmission Problems

[krosbow]

Hi All,

I have a 2005 LGT 5MT, There has been an odd noise under my car for quite some time, It sounds like it is in the front right hand corner near my feet. It is a loud scraping/rotational noise when under load, its is kind of sounding similar to engine speed, but possibly not, it only lasts for about 1/4 of a second, when launching the car in 1st and sometimes second, when the car squats.

I had this investigated earlier this week, firstly I thought it may have been exhaust dragging, the local exhaust shop couldn't find anything, there was a mark on the tail-shaft, we painted this, went for a drive and it was not marked, so then I thought it may have been a suspension/body scraping noise, however Pedders came for a drive then completed a pretty through investigation under the car, a few small things need fixing, a front lower control arm bush, rear D bushes, oil filled diff mount bush, new pads and shocks (100k+, I'm going to purchase some Billies), none of which I'm told or think could make this noise, Because it seems to do this when the car 'squats', was the reason for the Pedders under body business.

Pedders then recommended that I proceed to see a transmission specialist, as the noise seems to be happening at a certain rev range when the vehicle is under load. The transmission shop was excellent, the owner came for a drive with me, I replicated the noise and he thinks the noise could be bearing related, possibly due to a warped transmission casing (apparently not uncommon??). The vehicle has had another transmission fitted just over a year ago, due to a loud whining noise in 2nd, this was done under statutory warranty, by a so called dealership in Melbourne, the transmission currently in the car still has noticeable noise in 2nd - compared to other forward gears.

I have a few questions, If anyone on the forum can assist with some answers it would be greatly appreciated, I have searched the forum and couldn't find an exact case like mine!

Has anybody else heard this noise in a MT GT? Or any Subaru?

Has anybody else had problems and noise with 2nd in a 5MT?

Does this sound like a transmission noise? (I can possibly upload a sound recording.)

If this is a transmission problem, what is recommended, repair or replace?

How much would a replacement (reco) likely cost, minus labor? I don't want to buy someone else busted/crashed transmission, I am suspecting this may be the case with the dealer replacement!

Does anybody know a good place to source transmissions from in Melb, the local guy is getting me a number, just putting the feelers out!

Thankyou all for your time...

Cheers.

[Robbks]

in 5 speeds, 2nd is usually the one that cops the punishment in the traffic light GP
does it do it when turning or straight ahead? or both?

soud clip may be useful

[krosbow]

in 5 speeds, 2nd is usually the one that cops the punishment in the traffic light GP
does it do it when turning or straight ahead? or both?

soud clip may be useful

Thanks for your reply, I do agree on the traffic light GP, however I've been pretty careful with this box!

I doesn't sound CV related (ie not clunking) when turning, however it does it in both straight line and when turning, I actually think it is more evident/lasts longer when turning, usually right from memory, I also remember that I need to get the clip on the outer end of the LHS CV boot replaced, very minor fluid mark on the cross member. I'll try get a sound clip this afternoon...

[Robbks]

see if you can replicate it in other gears, that should point it more towards diffs/ shafts/ bearings if you can
i know it can be hard to get the load right in the higher gears.

does the car need to be warm/ cold/ both?

[Dropz]

I'm going to throw an oddball in the mix, what's the condition of your turbo? Does it blow smoke, leak any oil or anything? Are all the heat shields secure around it etc?

Are all the pulleys and belts at the front of the engine ok, not hitting anything? Are the engine mounts/ gearbox mounts soft or cracked at all?

And lastly, check inside the wheels aren't scraping on anything that may be loose and the wheel weights aren't hitting anything.

A bit out there, yes, but when you've had it investigated so many times and so thoroughly already, it may be time to start thinking outside the box.

[krosbow]

Hey guys, thanks for your reply's, I can still only get the noise to happen in 1st and sometimes 2nd, I tried for about 30mins to replicate the sound in the other 3 cogs, with no luck. Usually the car does this more when cold, I cannot replicate the sound in 2nd easily when the car is warm. When cold it is very easy to do... I will do the sound clips when cold and warm.

Dropz, Cheers for the ideas, definitely a possible lead, that's where the problem is most likely to be, and honestly I am happy for any advice at all! I had a poke around the trubo today, everything seems to be in order, have not noticed any smoke or oil usage, however I may get a mate to follow me tomorrow, just to be sure. Ive had a good look under the car and engine bay for any fouling etc, I also strapped a cheap webcam under certain parts of the car and went for a drive, nothing found, but a pretty cool low res bumper cam - untill it fell off I will get my mechanic to check all mounts at the next service, which is about 200km overdue, Its going in once my Bilstien struts and springs arrive.

I seem to be able to replicate this problem better when turning - which may be a hint...

*** To Be Continued ***