STI dropping out of gear

[Guest]

Occasionally my STI drops out of 5th gear when there is no load on the engine. I've noticed there is also a bit of movement in my gearstick when going on and off the gas ( only in 5th gear).

I've been told it is likely the 5th gear cog in my gearbox is getting burred and will need attention sometime soon.

So I'm just wanting to check this info is correct, and its not a simple adjustment fix ?

Thanks

[Guest]

No one ?

Gearbox code is HC TY754VBAAA - if anyone has a good condition gearbox for sale I might be interested.

Or alternativley, you could buy my V5 NZ New STI hatch for cheap :'( :'(

[Guest keltik]

broken/worn transmission mounts or pitch stopper?

With no load on the trans it doesnt take a lot of movement to fall out of gear.

[Jammasta]

I ahd this exact thing on mine,

It was the nut on something comes loose over time (input shaft maybe, i'm no mechanic so can't really remember), i got my gearbox checked over at the same time it was out and it cost me around 800 all up. This included replacing the syncros as well.

It is apparently pretty common, how manyK's you done?

[Guest]

Lots of kms !! 200k - but apart from the 5th gear issue - car is going strong.

Thanks for the suggestions.

[Jammasta]

Mine happened at about 135 i think it was, and has been strong ever since.

If your based in Auckland, i'd suggest PS automotive in Puke, they fixed mine real quick.

[scooby-wrx]

I have the same problem and would love to know the cause... ???

I had my gearbox completely re-built because it was jumping out of 4th, it cost my 2k and is still jumping out! I replaced all synchro's selectors, hubs etc etc etc.... (basically everything other than the actual gears and shafts - which were in perfect condition). My car is back at the mechanics trying to sort this issue out!

[Jammasta]

Dammit, i wish i could remember the actual thing that was wrong, i suspect ICHI should know, and a guy called Crazy-MF diagnosed mine as well for me (correctly when i gave the same details).

Its something like the nut on selecter/input or something shaft comming loose overtime.

[funkytown]

 TURTLE said:

Dammit, i wish i could remember the actual thing that was wrong, i suspect ICHI should know, and a guy called Crazy-MF diagnosed mine as well for me (correctly when i gave the same details).

Its something like the nut on selecter/input or something shaft comming loose overtime.

yer i remember this, Im sure thats about right, its simply a nut that comes off, just where/what is the question. Where is Rick when you need him.

[Guest]

All sounds very interesting - so possibly may not need a $$$$ rebuild - lets hope.

[WRXER]

I had the exact same issue, wasn't a major fix. I'll try and find the receipt on what Tony at RDL performance but no it won't be an expensive rebuild. Especially as it occurs in 5th gear so no need to remove the other gearsets.

[Swindog]

 scooby-wrx said:

I have the same problem and would love to know the cause... ???

I had my gearbox completely re-built because it was jumping out of 4th, it cost my 2k and is still jumping out! I replaced all synchro's selectors, hubs etc etc etc.... (basically everything other than the actual gears and shafts - which were in perfect condition). My car is back at the mechanics trying to sort this issue out! H & N Auto (Tauranga).

Failed selector fork? Sounds odd if everything else has been replaced.

[scooby-wrx]

 Swindog']

[quote name='scooby-wrx said:

I have the same problem and would love to know the cause... ???

I had my gearbox completely re-built because it was jumping out of 4th, it cost my 2k and is still jumping out! I replaced all synchro's selectors, hubs etc etc etc.... (basically everything other than the actual gears and shafts - which were in perfect condition). My car is back at the mechanics trying to sort this issue out! H & N Auto (Tauranga).

/quote]

Failed selector fork? Sounds odd if everything else has been replaced.

Thanks mate, I'll go past the garage after work today and suggest the mechanic checks the selector fork.

Here's a pic of what it looked like once the casing was removed.

[rockr]

generally if a selector fork fails its broken!!! sometimes the smll plastuc inserts can wear but doubt that would cause it, need to check that it is not favouring 3rd and not fully engaging into 4th. fork should be in the middle of the 2 when in nutral

[crazymf]

Yip, certainly sounds like the nut on the end of the input shaft has come loose. And if its popping out of gear when on decel, it'll be the gear moving backwards thats doing it. So depending on how long its been going for there might'n be any damage except a loose nut. But make sure you check the fork cos it may be ground away and may need replacing too.

[Guest]

Had many 5spd MT jumping out of gear due to the nut on the rear of the input shaft coming loose

This fault can cause issues with other gears also jumping out of gear too (2nd and 4th on accel) and the others on decel

End float MUST be checked and reset if needed during rebuild.

[scooby-wrx]

philwalter - sorry about all my question etc... on your thread! Have you fixed your problem yet? ???

My car is still down at H & N Automotive (been there a month tomorrow!) I'm beginning to think its a waste of time and that I should try another gearbox specialist, because its getting a bit ridiculous now! Hamish (the mechanic) is now saying I need to replace 4th gear, but I don't want to fork out on this if its not the problem! I think I should rather buy another Type R or RA gearbox with low km's off trademe. I considered a 6 speed, but I love my ratio's and would not want to change them because this is what makes an RA quick!

[Guest]

4th is sold as 3rd and 4th gear assemblies inc driven "H" gear, cost new is bout $1200 (from memory)

Send me a PM and I might be able to sort your gearbox out

[cpt kernow]

 scooby-wrx said:

philwalter - sorry about all my question etc... on your thread! Have you fixed your problem yet? ???

My car is still down at H & N Automotive (been there a month tomorrow!) I'm beginning to think its a waste of time and that I should try another gearbox specialist, because its getting a bit ridiculous now! Hamish (the mechanic) is now saying I need to replace 4th gear, but I don't want to fork out on this if its not the problem! I think I should rather buy another Type R or RA gearbox with low km's off trademe. I considered a 6 speed, but I love my ratio's and would not want to change them because this is what makes an RA quick!

He got it back last week. All nice and tight now.

[scooby-wrx]

cpt kernow - Thanks for update.

Ichi Ban - Thanks for the offer mate. Just wanted my mechanic to try sort it out first as I have a year warranty and would loose this is someone else worked on it.

I finally picked my car up yesterday. The problem was a little more extensive than we initially thought... All these problems keep coming up (from the previous owner...!) My mechanic showed me silicone between the casing sections and told me the box had been apart before (which I thought nothing of...) Somewhere along the line the previous owner must have has a similar problem. When we removed the 4th gear assembly shaft we notice the hub was badly bent (so I replaced that). Then on closer inspection I noticed the inside of the casing had been a bit ripped up (see picture below)! We spoke to a rally mechanic and he has heard of people bending the hub to allow the shaft (4th) to be tightened further into the casing - this may not have been enough so the casing was hammered / deformed!

To cut a long story short, the gearbox had a shim / 4th thrust washer which was too long causing the shafts not lining up correctly and 4th not engaging properly (see the exploded view picture below - washer is colored in red). I have had to replace everything other than the gears and the shafts. Luckily Hamish at H & N is a good guy and he gave me a new casing and did all the work (cost free!) which I really appreciate. I have to say Hamish has been very helpful and did a great job finding the problem in the end.

A picture of some of the casing damage. Look in the top left of the picture at the cylindrical part.

Pictures of my DCCD (centre diff).

Exploded view.

[Swindog]

Good information well done. Glad you have it sorted mate.