5MT BAD noises!

[Tommio RS]

OK.

So i have performed a 5mt swap into my 93SS and she makes some bad BAD noises!!

The trans is out of a 96 outback 2.2L high roof line. So from what i remember its a 4.11 FD
Diff is a hybrid 93SS mixed with a 04 RS diff giving me a 4.11 FD
Clutch is a ACT SB2-HDSS
Flywheel is a stock 96 outback.

Shifter linkage is from a 2013 WRX STi with the cable removed and some shackle/bushing changes.


So the problem.

It does not really matter what you do here.
If you in a gear or moving at all there is a metal rubbing noise.

The faster you go the MORE loud it gets!
Its very VERY loud at any speed over 60KM's
So loud you CANT have a conversation with some one.

I have only driven the car once then parked it for winter.

I got all the parts to swap in a 5mt for about $600 NOT including the clutch.....


My thoughts are:

Trans is just crap and needs to be fixed. AKA buy a better 5mt
Shifter might be tooo short for the trans. AKA get a 5mt shiter ass.

The REAL problem:

I have dumped like $700 in the clutch!
I would LOVE to sell that clutch and buy a whole new setup for my car....$3000 6MT
What it the most TUFF 5mt that was in a NA car? My clutch is for a NA.



Thoughts???

Am i just crazy??

Thanks


Tom

[cj91legss]

Does the sound seem like it's coming from the around the shifter or the rear end?

[alexandermf]

I recently swapped mine too and had a horrible metal on metal noise coming from the clutch area. We tore it down to find out the flywheel was 1cm thicker than the wrx oem flywheel we thought we were putting in... Anytime out or in gear it'd make the noise, here's what it did to the trans housing. Everything is good now after getting right flywheel in! Worse noises I had ever heard from a trans

[wtdash]

HI,
I agree w/that above that it's probably something to do w/the FW/Clutch.

But I looked HERE on opposedforces.com and the early '96 Outbacks w/the 2.2 and 5-speeds were 3.90 FD ratio (under gear set hypoid). That likely wouldn't make the noise you're referring to but would cause other issues.

What is part number/code on the bell housing? Should be like: TY752VABCA
TD

[Tommio RS]

wtdash I think your right in the FD ratio.

The gear box I stuck in is a 96 outback high roof line with a 2.2L

As for this noise.

Its not in the clutch area.
I have all the 96 NA factory parts there but the upgraded clutch.

If the car is dead cold like -20C there is no noise.
The hotter it gets the louder it becomes.

If its hot and i push the clutch in. The noise will change and become less due to spin down.



I had a 5MT out of a 98 legacy GT with the stock rear diff and THAT made some of the most unholy sounds i have ever hurd come from a car! 4.11 vs 3.90!

Ill try to make a video or something if i get some time here and there.

I think its the big bearing where the center diff rides around on.....maybe

[Legacy777]

I would recommend checking the final drive ratio match. Jack the car up, try putting the trans in neutral, hold one side of the wheels stationary, and then rotate the front wheel. The rear wheel should rotate at the same speed and complete the same revolution.

The fact the noise gets worse when hot would point me towards the final drive being different and the viscous coupling is heating up and not very happy.