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92 Lib wagon AWD.

Gears are clashing intermittently on changing into gear, mostly 3rd and 5th - like synchros? Clutch doesn't appear to be slipping.

Heard a couple of nasty noises when driving in 1st gear, stopped when clutch in, didn't happen again..

Clutch probably has 180,000km on it.

Clutch cable is what I'm leaning towards but not sure. Cable hasn't been adjusted since last replaced I think 2 years ago - hasn't needed it as yet...

When moving clutch fork on gearbox there is some noise / play.

Ideas please.

Quick.

SUBYDAZZ

SubyDazz,
Thought about the throw out bearing on the clutch? Does the clutch need adjusting? - if your having trouble selecting first from a standing start it could be just an adjustment to make it right.

If its syncros you should beable to change gears at low revs with no problems or noises, but when pulling high gears accelerating hard expect a "crunch" noise, this will tell you if the syncros are on the way out - you'll feel it through the gearstick as well.

Someone might know more that will help.

Cheers

Downshifts are the problem to third, but upshifts to 5th. Like I say not all the time.

Will do the smart thing and nip up the cable a tad first and see how it goes. I have ALL the parts for in there if the clutch lets go except the clutch and pressure plate Have ordered cable just in case.

Cheers.

OK, took a little slack out of cable. Seems to have made no difference. Slightly more pronounced noises now, definitely harsh on downshifting and gearstick seems to move a bit more than usual when backing off at med to high RPM. Can mounts be an issue or selector bushes?

Still seems like a synchro issue but I wouldn't have though they go all of a sudden. 3rd is worst but 2nd and 4th it is there too.

Something just doesn't seem right.

Work with me here, what else would cause the clutch to not completely disengage other than an internat gearbox fault?

I think it's Synchros in the gearbox.

does the g box habe the correct oil in it

if not i ave seen a gbox not select some gears at all with the wrong oil
just another thimg to look at

Definitely has the right oil in it (+ some of the nifty nulon stuff) has been in there for 2 years at least and no probs until now.

Am learning further towards clutch / clutch cover replacement now. I think it is lucky to have lasted this long so I will take a gamble and pull it out if the new clutch cable (still waiting) makes no difference.

Other than that I guess it's an internal job and then probably time for a newer Suby...

Any noises from the box when you aren't touching the clutch?

If there is noise then it could be the standard bearing wear prob that they all get with a bit of age. Worst thing is if it isn't fixed then the box will let go for no apparent reason at any time. Good thing is boxes are quite cheap for them now. No need to get rid of it if the box does happen to die.

Not usually a clutch issue if you haven't had any slipping.

If it is just notchy between gears then some times an oil change can help along with some treatment.

Which bearing? And I take it that it is a reasonably involved task?

Gear oil is due for replacement in 20000km but I may do that sooner rather than later now. Been doing it every 100k km.

I thought noise in the box was a standard accessory? Think it has same noises it has always had. Just took it for another drive and apart from the odd squeal I heard in 1st the other day there is no noticeable box noise. Does seem to get harder to downshift into 4th & 3rd after it has been driven for a while, when it is cold it seems to be better?

What causes the slop / play in the gear lever when backing off? Engine mounts? I had a look and they seem fine.

Think it's time to spend some $ replacing rubber parts...

could be bad gear linkages ie. not tight or worn out

and replacing gear oil every 100k is way to long imo. usually is recommended every 40k i thought

Re:gear oil.

But it doesn't do much hard work. Subaru says every 50,000km so maybe I will do it a little more often.

What would I look for in the worn gear linkages?

All the boxes we have pulled apart that have died have had the bearing in the centre collapsed or worn out. It is around about 3rd gear in the box.

Ain't the clutch cable... half-way through replacing clutch now...

i wouldve had to say that replacing the clutch to fix it is just a waste of money really..
definitely dont seem like the clutch from wt ive read seems like internals basically

Yes, am leaning this way now - how much metal should be coming out with the gearbox oil anyway?

Replaced the clutch as more of a preventative measure anyway - wasn't sure how much guts it had left. Now know it was plenty.

Who does recon'd boxes?

SUBYDAZZ wrote:how much metal should be coming out with the gearbox oil anyway?

As far as i know it should be none or close to it. The oil should be a dark brown if changed at the right times...

LOL, I know, I'd call it a "deep metallic brown with glitter fleck".

Sounds much like a bad 70's metallic brown

The changing probs definately sound like syncro issues but be very wary of the middle bearing in them they have a tendancy to split the outer race done the middle leaving 3 outer races and movement in the main shaft. As said before it aint an easy job and if you are careful with it you will get some time out of it but as Brett said it may happen anytime.