Transfer case problems

[falco]

Hi - my father has a problem with his 2000 TS-R. It makes a weird noise from the transfer case, a strange buzz that changes with road speed. I've been under it with a stethoscope, I'm 99% sure it's coming from inside the transfer case (not the gearbox itself or the driveshaft). The car still seems to drive OK. So here's a few questions:

Is this a common failure? Anyone had this happen before? Any ideas what's gone wrong?

I have a transfer case off a 1990 Legacy RS. Will that be a bolt-on replacement?

Is it possible to remove the transfer case with the gearbox in the car, by removing the rear gearbox mounts and engine steady, and dropping the box down at the back?

And lastly, an unrelated question. My old PC died, so I didn't log on here for ages. Now, it looks like my account vanished, I had to remake it! Do accounts get deleted after a while of inactivity?

Thanks for any help!

[Guest keltik]

 falco said:

Hi - my father has a problem with his 2000 TS-R. It makes a weird noise from the transfer case, a strange buzz that changes with road speed. I've been under it with a stethoscope, I'm 99% sure it's coming from inside the transfer case (not the gearbox itself or the driveshaft). The car still seems to drive OK. So here's a few questions:

Is this a common failure? Anyone had this happen before? Any ideas what's gone wrong?

I have a transfer case off a 1990 Legacy RS. Will that be a bolt-on replacement?

Is it possible to remove the transfer case with the gearbox in the car, by removing the rear gearbox mounts and engine steady, and dropping the box down at the back?

And lastly, an unrelated question. My old PC died, so I didn't log on here for ages. Now, it looks like my account vanished, I had to remake it! Do accounts get deleted after a while of inactivity?

Thanks for any help!

Forum went down at the start of last year so everything got wiped.

I dont believe the 1990RS box tail shaft will be able to fit the one in your TSR. Easiest fix would be to just change the whole gearbox. Its a non turbo so theres not a lot of work involved.

[falco]

 keltik said:

I dont believe the 1990RS box tail shaft will be able to fit the one in your TSR. Easiest fix would be to just change the whole gearbox. Its a non turbo so theres not a lot of work involved.

Thanks for the info - I have a couple of boxes out of BG5 GTs, reckon they'd bolt in? They look the same, but I'd like to be more certain than that. Though ideally, I'd like to sort out the original box, it hasn't done many Ks and still drives well, even with the weird noise.

[kamineko]

also remember the gearbox front diff ratio must match the rear diff ratio

[Guest keltik]

Yes the BG5 gearboxes will bolt straight in. They most likely are the same ratio but if you can find the transmission codes (stamped on the bellhousing) then its a simple matter of looking up the ratios to be certain. I believe 1994-1996 GT's had a 4.111 final. I know turbo 1999-2003 models use a 4.111 but im not sure what the non turbo models got.

If your TS-R uses a cable clutch - then you would need to change to a turbo flywheel, clutch kit and install a hydraulic clutch pedal and pipe work. Clutch pedal from any 1994-2003 Subaru will fit.

[falco]

Yes, the TS-R has a hydraulic clutch, was the first thing I checked. Sure, I'd have to check the diff ratio, that's OK. I guess my plan of attack will be to pull the original box and see what's wrong with it; if it's not easily repairable, just put one of the GT boxes in.

Thanks for the info - keen to hear from anyone with more info, especially if anyone has any idea what the noise from the transfer case could be!

[Guest keltik]

You might still need to change your clutch as the turbo GT ones are a pull clutch whereas the non turbo ones are push. My best guess to the noise in your transfer case would be a damaged center differential or 5th gear. Not hard to change as it doesnt require the case to be split.