Tackling car repairs yourself can be daunting, but incredibly rewarding. For my Subaru, a slipping clutch signaled a high-priority repair. The big question was identifying the right Car Part Transmission components for the job. Since I wasn’t planning major power upgrades, an aggressive racing clutch wasn’t necessary. Luck was on my side when I found a deal on the RS25 forums for a used ACT Streetlite Flywheel and Exedy Stage 1 Organic Clutch combo. The seller claimed only 5,000 to 10,000 miles of use, and at just $300 for both shipped, it was worth the gamble.
With the parts secured, the next step was transmission removal. This involved dropping the exhaust, driveshaft, and transmission crossmember to gain access. Separating the transmission from the engine proved to be a bit stubborn, requiring some persuasion to break the seal. Once free, a jack assisted in safely lowering and removing the transmission from under the car.
The initial inspection of the removed 5-speed Subaru transmission immediately revealed a worn throwout bearing. It felt gritty, moved roughly, and was clearly past its prime. Further disassembly involved removing the pressure plate to examine the clutch disc and flywheel. The flywheel itself appeared to be in acceptable condition, but the pressure plate showed noticeable burn marks, further confirming the clutch slippage issue.
Turning attention back to the car part transmission itself, a significant leak was evident, originating from the shifter rod seal. Consulting the factory service manual, I assessed the complexity of replacing this seal. The procedure required removing the transmission extension and center differential housing. Confident in tackling the task, I proceeded with disassembly.
Disassembling the car part transmission further revealed the internal condition. Despite 205,000 miles, the internal components were remarkably clean. There were no signs of metal shavings or broken parts, a testament to the durability of the Subaru transmission.
Closer inspection around the leaking shifter rod seal uncovered another issue. The leaking seal had allowed moisture to enter the transmission, causing rust to develop on the adjacent main shaft rear plate. What initially seemed like a minor seal replacement was now revealing itself as a more critical preventative measure.
To address the rust on the main shaft rear plate, I carefully hand-sanded the surface to remove the corrosion. It was crucial to remove the rust without altering the part’s thickness, as this plate acts as a critical spacer for the main shaft extension. These plates come in 5.50mm and 5.63mm variations to precisely adjust for bearing protrusion, emphasizing the importance of maintaining the correct thickness.
After cleaning the internal components of the car part transmission and reinstalling the sanded main shaft rear plate, the new shifter rod seal was installed. Reassembling the transmission extension case began, but a setback occurred when a bolt snapped while torquing it to specification. This required disassembling the case again to extract the broken bolt – a frustrating delay late into the night.
Lacking a clutch alignment tool, I ordered one online, which arrived a few days later. With the correct tool finally in hand, the new clutch and flywheel were installed, completing the car part transmission repair for this stage.
Stay tuned for the next installment, where the focus shifts to brake work, including ABS removal and rotor upgrades. For in-car racing action, subscribe and follow our YouTube channel!
