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2010 Outback 2.5i 6MT "Green Bean"
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6 Posts
Discussion Starter #1
I picked up this 2.5 OB 6-speed with 112k on it. Soon after doing its 120k service the throwout bearing failed catastrophically with no warning other than a very subtle whirring when the clutch was depressed. Not knowing at the time what had failed I limped it across town to a transmission specialist and had them do the clutch and throwout bearing. Since then, 3rd and 4th gears grind. The grinding is sometimes avoidable with delicate shifting habits but almost completely unavoidable when downshifting into 3rd or 4th. This happened last summer and as things cooled down the grinding seemed easier to avoid, but now I'm concerned about causing some real damage as it warms back up. The shop thinks synchro damage, which makes sense to me, but I'm open to hearing other diagnoses.

I'm at I think 127 or 128k now and trying to decide on next steps. I had it back at the trans shop for a road test and they gave me 3 options:
  1. Deal with it, be careful, and hopefully don't cause too much damage to the gears.
  2. Rebuild the transmission for $3400 - 3900 (up $500-1000 from the quote they gave me last year for the same job)
  3. Try a "high-end" synthetic fluid (BG Ultra-guard) that they thought might help the damaged synchros run smoother.
I ended up buying the BG oil but haven't done the drain and fill yet. Has anyone tried this fix for similar problems? Any other possible diagnosis for the grinding?
Should I just bite the bullet and do the rebuild? I am hoping to drive this wagon into the ground.
 

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Outback 2011 3.6R Premium
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1,431 Posts
If the grinding of the gears was not happening before the clutch replacement but WAS happening immediately after the clutch replacement, then I am thinking the clutch replacement is the probable cause of the problem.

I suppose it is remotely possible that a catastrophic failure of a throw out bearing could result in synchro damage BUT I am highly doubtful that this would actually happen.

Seagrass
 

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2010 Outback 2.5i 6MT "Green Bean"
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6 Posts
Discussion Starter #3
While doing the clutch service, the shop found metal shavings in the trans fluid that I did not see when I did a drain/fill a few weeks earlier. I’m thinking I caused the transmission damage by limping it around town with a clutch that may not have been fully disengaging.

I’m not sure how a clutch replacement could cause synchro damage, could you elaborate? This shop has been nothing but helpful so far and I don’t want to accuse them of bungling the job without evidence.
Thanks!
 

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2000 Outback Limited, Dual Range 5 Speed
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904 Posts
Did they change/assess the spigot bearing, as a sticky bearing can cause the input shaft to continue to turn, and can cause these symptoms.
 

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2010 Outback 2.5i 6MT "Green Bean"
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6 Posts
Discussion Starter #5
That’s a great question, I’ll have to check the invoice or ask them.
 

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2010 2.5 CVT Limited
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1,311 Posts
Since it is only happening in 3-4, I would look for something in the shifter and cables.
I am unfamiliar with the OB shifter but other cars with cable operated shifters have two control cables. One that translates the fore-aft movement of the shifter and one that translates the left-right movement. I would examine the latter cable. For some reason it may not be installed or adjusted correctly following the clutch replacement and maybe causing the gears to bind.

If it were happening in all gears, I would think the clutch is not fully releasing when the pedal is depressed.
 
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