Muzza80

iTrader: (3)

Hi all,
So my 2006 WRX has done 37k and I've just had it mapped a couple of weeks back to 285/355ish.

In the last few days I've been increasingly aware of quite a high pitched whine which increases with speed, not rpm.

I noticed it especially today when driving back to Glasgow from Helensburgh on the dual carrigeway, you can barely hear it with the stereo on but with it off it's pretty noticeable. It's still there when I dip the clutch so I'm assuming driveline rather than engine as it does not follow engine RPM, at about 70-80 it's loud enough to worry me having read all about the 5 speed woes

I've had no issues with the gearbox, I'm pretty easy on it to be fair and all changes are very slick with no crunching or other funny noises.

It almost sounds like a higher pitched wheel bearing noise to me, I've uploaded a sound clip and would really appreciate it if you could have a listen and let me know what you think.



https://docs.google.com/file/d/0B-2I...it?usp=sharing



Cheers

Murray.

scoobymikepic

iTrader: (3)

hi muzza.
sorry to be bearer of bad news.
i had the same on my 2006 wrx. went back to subaru as it was still under warrenty, 3 times it was fixed, was diff bearings in front diff. got feed up with it in end part ex for another scoob

Muzza80

iTrader: (3)

Just a little update which may be useful information for anyone else having the same issue.

Seems from my investigating the noise is from the bearings related to the transfer gear and shaft at the rear of the gearbox. I had been quoted £840 from a local gearbox specialist to sort it but they insisted it was a gearbox out job and the bulk of the cost was the associated labour.

I've done quite a bit of reading and apparently you don't need to remove the box to replace the bearings as it can all be accessed/removed by removing the rear gearbox casing having first removed the propshaft, exhaust section and a few other bits.

Here's the details I've found of this issue online.

Firstly this a 6 page thread on NASIOC with lots of very helpful information and a pictorial guide on changing out the bearing set and oil seal. I had a quick check and it seemed the US 5-speed although different in ratio's essentially was the same box but I could be completely wrong about that.

http://forums.nasioc.com/forums/show....php?t=2071286

And another couple from Aus:

http://www.rexnet.com.au/forum/index...-gear-bearings

http://forum.wrx.com.au/viewtopic.ph...=77497&start=0


Reassuringly Dave at API seemed to confirm this issue on Scoobynet too:

https://www.scoobynet.com/drivetrain...box-noise.html


I've also found that Subaru have apparently recently changed the bearings to address the durability problems http://www.autoserviceprofessional.c...-gear-bearings

These should be the part numbers for the complete set although from speaking to Dave @ API and from what I've read it's usually just the first two bearings on the list that are problematic, the third may need replacing but highly unlikely the fourth would need changed, they've not had one fail yet.


Transfer Driven Shaft front bearing, Subaru Part #806322080
Transfer Driven Shaft rear bearing, Subaru Part #806330120
Transfer drive gear bearing, Subaru Part #806230170
Center Diff Front bearing, Subaru Part #806255010
Transfer Case Output Shaft Seal, Subaru Part #806735210



So £245.40 inc VAT from the first dealer I spoke to, could probably better that from Import Car Parts or the likes.


So I'm trying to work out if it's something I can do myself, albeit taking the bits to a specialist to have the old bearings removed and new ones pressed in.

Anyway, hope it's useful, I'll let you know what I decide to do and how I get on with it.

Muzza80

iTrader: (3)

Not that anyone seems interested going on the lack of replies lol but I fixed my whining gearbox this weekend.

Started it Saturday evening and took me about 2 and a half hours to get the car jacked up and everything stripped off then about another 4 hours today to remove the old bearings, replace them and assemble everything. I was working alone under axle stands which made things pretty tricky, I also changed the engine oil and filter at the same time.

For the record you DONT need a bearing press at all, I put the shafts in freezer for a hour and the bearings in the oven at 120C for 10 mins the bearings literally dropped on to their seats. The centre diff bearing came off and back on very easily with a brass drift and a few taps with a hammer. You don't actually usually need to change the center diff bearing but I thought I might as well while I had it out, seems logical.

I found the bearing race inside the transfer box was hard to get in, access is tight and it took a while with the hammer and brass drifts to get it seated but got there eventually.

I almost had myself convinced that I'd miss-diagnosed the noise as my bearings all looked ok to be honest, there was no obvious deterioration to be seen but thankfully I continued and the noise is gone, very pleased

Arch

iTrader: (59)

You can remove the rear transfer case easily on these boxes as you have just found. I have done it at sprint events to replace damaged drop gears while the car is on axle stands. If you had access to a ramp it would be a simple enough job.
Glad to see you got it sorted.

big_wasa

iTrader: (4)

Stuff like this is great for anyone that can hold a spanner but hasn't done one before.

I Put a new clutch in a mates skyline the week before last after reading up on the downfalls from a couple of posts like yours.

korgua

Thanks for this really useful article. I was fearing the worse, in that I would have to replace my gearbox (again!). At the moment it looks like it is the roller bearings in the centre diff.

Symptoms were a speed related whine, independent of RPM and whether car was in gear.

I sourced the four bearings from

https://www.importcarparts.co.uk/

My local garage took the transfer case off and confirmed that the front of shaft roller bearing was knackered. The replacement 806322080 is the modified version so I am hoping it is more robust.

One part of the jigsaw that does not appear to be covered is how to shim up the transfer gears.

The garage have put the transfer case back together and note the shaft is tight when rotating by hand.

There appear to be two different shims - is there a procedure that covers getting the clearances right?

Guesswork would soon see the bearings get chewed up.

Thanks

Andy

korgua

Good evening,

Some Internet research led me to the following article

http://ken-gilbert.com/wrx/STi_Manua...20Assembly.pdf

I am very fortunate my garage is so diligent in its work. They were not happy with the clearance and this procedure highlights what steps are needed. Ultimately it was decided to use an alternative method to measure the clearance and decide on the shim required. Following this the conclusion is that the two new improved roller bearings on the transfer driven gear will affect clearances.

It seems like this is a common fault that was recognised by Subaru with the introduction of new bearings. My garage has highlighted that in addition to the improved bearings it is crucial to get the clearances right.

The two new improved bearings are 806322080 and 806330120. The shims are shown in the PDF link above. In my case the garage have identified that the bearing changes mean we need to remove the factory supplied shim and use a smaller one.

Thank you

Andy

evil.soup

iTrader: (1)

Extremely useful information and thanks for posting.

I have a quick question as to the type of sound you had. I also have a sound that isn't affected by revs or gears, it just increases with the speed of the car. The sound I have sounds a lot like a push bike free wheeling, does that sound familiar to the sound you had or is it different?
​​​​​​​cheers

johned

Excellent info.

korgua

Glad to help, I can only describe the sound as a bearing whine, like a failed wheel bearing except the noise/pitch does not change when you change direction.

It is very simple for a mechanic to remove transfer case and feel the bearings. Leave it too late and one might break up and do more damage.

Worth re-iterating that clearances must be remeasured especially on driven shaft. The garage identified that re-assembling transfer case and using feeler gauges between case and box was enough. The bearings will not last long if this is not done. Once you have fitted the correct shim and reassembled you will be able to confirm there is no play or if it is too tight, simply by rotating the shaft by hand.

evil.soup

iTrader: (1)

​​​​​​​thanks for that, I just need to get an expert eye on it

R666ORY+1

Slightly different topic but is related, I had a "transmission whine" that increased with RPM. I was not looking forward to the ensuing bill for repair. Turned out to be the AC pulley was on its way out. Was literally a 30 min job to sort and not a lot of cash. Apparently it's pretty common and some garages have been known to suggest individuals have big bills coming their way when in reality they have a 30 min job and £30 bill to pay! Worth checking out just in case 👍🏼

MoggyNinja

Just out of curiosity im getting a whine, and it is only when the car is going over 30mph, and when you touch the accelerator, if you release the accelerator it goes, or you cant hear it, and it it sounds like it is coming from the front left of the car , is this the symptoms anyone else had

cheers