Hello all,
I have gained lots of valuable information from this forum about pulling my engine and replacing the head gaskets on my leaking 99 Forester. Thanks. This is my first ever engine pull so it has been a learning process. Hopefully someone can help with this new problem.
I tried to mate the engine and transmission (auto) yesterday and could not close the last 1/4 inch gap. After pulling them back apart and doing a little research I realized that my torque converter is not seated all the way into the bell housing. Hopefully I didn't crush anything inside which apparently is a common result from what I did, I'll find out I guess. After hours of fusing I have determined that the input shaft (inner shaft) is not seated all the way into the transmission and is thus keeping the torque converter pushed out. I have tried many things including polishing the teeth on the shaft and doing some light taping with a mallet. It is still sticking out 2.6 inches when it should sit out no more than about 2 inches. Looking down inside the transmission it appears as if it should slide in as nothing is sticking out that would stop it. I really don't want to pull the transmission but am starting to think it is my only option. Any suggestions or ideas would be appreciated in regards to seating the input shaft the last half inch.
Thanks Aaron,
Yes, the TC apparently moved out of the transmission a little when I pulled the engine off, which I didn't notice until way too late. Since then I have taken it off and put it back on countless times trying to figure things out. Always sticks out 1/2 inch too far.
So there are three "shafts" that connect to the TC. The outer most shaft has two notches that line up with the oil pump. The middle shaft with a toothed end appears to be fixed in place. The inner shaft (input shaft) can be pulled in and out of the Torque converter and in and out of the transmission. The input shaft does not want to go back into the transmission as far as it should. It is sticking out a 1/2 inch too far according the the FSM. Something in there is keeping it from seating all the way. It could be one of the two sets of teeth not lining up, but I'm starting to suspect that there is something else way down in there that I don't know about that is keeping it from sliding in. It feels pretty firm when it stops sliding in. Like the end of it is hitting something. It feels like the two sets of teeth are matched up and then it just stops. Like I said, I've even tried tapping the input shaft lightly with a hammer and it doesn't move at all. I've looked down there with a flashlight, and there is nothing obvious in the way.
I know it is the input shaft that is the problem because if I remove it and instal the TC with just the pump shaft and the middle shaft, it seats no problem. AAARG.
Hopefully someone here has solved this problem and can share their solution.
Thanks Aaron,
Yes, the TC apparently moved out of the transmission a little when I pulled the engine off, which I didn't notice until way too late. Since then I have taken it off and put it back on countless times trying to figure things out. Always sticks out 1/2 inch too far.
So there are three "shafts" that connect to the TC. The outer most shaft has two notches that line up with the oil pump. The middle shaft with a toothed end appears to be fixed in place. The inner shaft (input shaft) can be pulled in and out of the Torque converter and in and out of the transmission. The input shaft does not want to go back into the transmission as far as it should. It is sticking out a 1/2 inch too far according the the FSM. Something in there is keeping it from seating all the way. It could be one of the two sets of teeth not lining up, but I'm starting to suspect that there is something else way down in there that I don't know about that is keeping it from sliding in. It feels pretty firm when it stops sliding in. Like the end of it is hitting something. It feels like the two sets of teeth are matched up and then it just stops. Like I said, I've even tried tapping the input shaft lightly with a hammer and it doesn't move at all. I've looked down there with a flashlight, and there is nothing obvious in the way.
I know it is the input shaft that is the problem because if I remove it and instal the TC with just the pump shaft and the middle shaft, it seats no problem. AAARG.
Hopefully someone here has solved this problem and can share their solution.
It's not THAT shaft that's the problem, the problem is inside of the trans...
This is the problem, it's the high pressure pump shaft and sits in the "ears" of the TC.. it's been pulled out of the pump and has misaligned/fallen internally, about 8-9" inside the trans...
This is also the "fishing" tool I made to get the shaft out... There is also a wire "clip" that has to be pulled out, prior to using a tool... replacing the outter seal isn't a bad idea...
The ears of the pump shaft mate to the TC and use the wire clip to loosely hold them together, which is WHY the pump shaft pulls out when you pull the TC with the motor..
You can see when I put mine together, I doinked the ears on the TC.. You can ALSO see that one cut out is different than the other on the TC.. one has notches for the spring clip to sit into, one doesn't... look at the base of the "ears"
The spring clip sits in the grove around the end of the pump shaft..
The pump shaft has 2 flats on the fat end, that align into the pump...
Being that you are 1/2" out, that is about the mating distance for the pump to pump shaft, so you likely need to go fishing...
I wish that pump shaft was my problem. However, that shaft came out still attached to the torque converter with the wire ring still in place. Like I said, I pulled the input shaft out and installed the TQ with the pump shaft attached and it seated no problem. It is that input shaft that is sticking out too far which is creating the problem. I called a local shop i have worked with and they say that they always check that the TQ is reseated and so had no advice for me. Anyone have any other ideas?
The inner shaft on mine felt like it would move in/out about 1/4-1/2" but it never came out, and with it pushed back all the way, everything lined up...
I cant say why yours is doing that, missalignment, maybe theres a spring clip on the end of the shaft like the rear axles, maybe a bop with a deadblow
Sent from the other side using mind bullets...(YapaTalk)
So what happened here? I'm going to replace my torque converter and this is the best thread out there I can find. If you have any more pics / vids to send please send them!
I dont show the wire clip but if you look at the TC you will see 2 notches cut into the bottom of the cut outs in the TC for the "ears" of the clip (you'll get it when you get there) actually I looked and there's an example of the cut outs in the second pic I posted.. upper cutout there's 2 red dots of fluid that the lower cutout doesnt show.. that's where the clip resides on the TC
As long as you unbolt the TC/FP bolts prior to removing the motor/trans, the pump shaft should come out of the trans with the TC no problem..
Re-seating it is just like any other besides having the pump shaft hanging off the TC.. slide it into place, turn and push, one way, then the other and back, might take a minute, but whe it slides home you know..
The TC should stick out from the leadimg edge of the bell housing ~3/8" and the flex plate should be sunken into the motor THE SAME DISTANCE..
SO if the TC is out more than the FP is IN... you're not seated.... again this will make sense when doimg the work.. I dont have picture examples..
I just pulled the same trick - I dropped the tranny out of a '99 junkyard Forester (to replace the one that's gone bad in mine - hope the new one's good), and though it unbolted cleanly, the ^&*^%$ torque converter unseated on the ride home - I didn't think to lash it in. It slid out with the pump shaft, if I understand correctly that it's the one loosely clipped to the TC shaft.
I've read the above posts, but it's still not clear to me how to reseat that shaft in the trans.
Is there a prescribed rotation sequence that'll get the two flats on the end of the shaft to reengage with the pump?
The problem with getting this torque converter to sit is almost always the inner pump shaft. When you think it's there, it often isn't. The way to tell easy is to look through the starter hole. You should be wondering whether it isn't too far in because it should look like it should be rubbing on the bell housing. And, it would be except that subaru shaved a bit off right there at the starter hole to give it just enough room to spin freely. If that's not where the torque converter is sitting, hold it up at that front nipple and turn it slowly as you lightly but quickly tap that thing. I've also turned it slowly while smacking it good with my palms. You shouldn't have to beat it hard and there really isn't any need to measure a bunch of poop. It's either in or it isn't. If you're in doubt, it isn't in.
I find the 4EAT to be very reliable; it has never let me down and my vehicle has had a very hard off-road life.
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