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1991 Forester Manual
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Discussion Starter · #1 ·
I've got a '99 with a 5spd manual trans that's giving me a lot of racket from the transfer case and I was wondering if anyone knew how difficult it was to rebuild, and if it requires any special tools. Appreciate any insight you could offer. Otherwise I'm gonna have to pull it and take it to a transmission shop and one place already gave a worst case quote of $1,600...
 

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Sort of depends on what is causing the noise......the work is not difficult per say. Easier for someone mechanically inclined and harder for someone less so. There are shims that require measurement to determine if you need different thickness or reuse the existing ones. You will also need a method to R&R the bearings.
failed center diff (new ~$500) (used ~$150)
broken transfer gears (new ~$300) (used ??)
new bearings I think are around $150 new
tube of Ultra Gray
new trans oil
FSM procedure and knowledge on how to perform the work
 

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1991 Forester Manual
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Discussion Starter · #3 ·
Thanks for the info, I found a used transmission with 20,000 less miles on it, I think I'm going to pull my transmission and see what it'll cost at AAMCO and decide what to do from there. Thanks again!
 
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