Need a 2004 FSTi 6 speed manual gearbox...anyone?

Need a 2004 FSTi 6 speed manual gearbox...anyone?

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BreakingBad

Original Poster:

325 posts

118 months

Monday 26th November 2018
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Just what you need on the run-up to Crimbo, a lunched gearbox!

My FSTi delivered the above prezzie the other night on the way home from work and now I need a good replacement one but can’t find any. Serial part number is TY856WL4CC.

I have tried the obvious so just hope someone on here has one sitting around or can help?

Thank you.

BreakingBad

Original Poster:

325 posts

118 months

Monday 26th November 2018
quotequote all
Thanks for the suggestions - the garage which currently has the car (a good, local independent Subaru specialist) has offered to strip it down to determine exactly what has failed but this is going to be up to c £500 and then repair and reinstall on top

If another decent box were available, at least I would know in advance roughly how much it was going to cost to replace. Strip down and repair is a bit more uncertain but would almost certainly be less than £2k anyway. I had hoped to find a decent replacement for less than £1k but beginning to think that’s unlikely, it being a JDM only item.

Decisions, decisions!

I’m thinking that, on balance and due to the availability issue, it may be best to get it stripped down and repaired. I will mention the specialist garages to my local guy, too.

Thanks for the input everyone.

BreakingBad

Original Poster:

325 posts

118 months

Tuesday 27th November 2018
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Hmmm, a little of each, I guess.

It’s done about 96k miles and although not running big power, I did get it remapped to run better on U.K. fuel which may have - quite by chance, obviously - liberated a few extra horses. I’ve not had the car dyno’d.

BreakingBad

Original Poster:

325 posts

118 months

Tuesday 27th November 2018
quotequote all
PS I’m going to speak to the garage this afternoon and agree the best way forward with him. Almost certainly a rebuild, just whether he does it or one of the specialists. I’ll post again afterwards.

BreakingBad

Original Poster:

325 posts

118 months

Tuesday 27th November 2018
quotequote all
I’ve spoken to the garage and agreed that it looks likely that a strip down to identify the exact problem is the way forward but another garage (the one which did the remap) has suggested that it is more likely the clutch than the gearbox but, if the gearbox is being removed anyway, that would be a good time to ensure it is or isn’t the clutch.

Frankly, I’d be surprised if garage A didn’t know the difference between a failed clutch and gearbox but it’s got to be worth double-checking first, hasn’t it?

Also, he has already contacted many gearbox specialists who are either unable to help or unable to cost anything without understanding the problem (which makes sense imo). Apparently RPI went out of business some time ago and Clark would be ££££. I’ve looked on the websites of various others without success.

Will report back as things progress...

BreakingBad

Original Poster:

325 posts

118 months

Wednesday 28th November 2018
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frown

Chap at the garage assures me it is the gearbox, not the clutch AND he can’t find any availability even for parts for the ‘box so, even if he removes it from the car, strips it down and identifies the broken bits, it’s looking unlikely we’ll be able to source those required to rebuild it.

Between us, we have tried every potential source we can think of or that has been suggested and come up blank, so far at least. I spoke to Darren at Torque GT where I bought the car - he said they may be able to get one from Japan but it would be very expensive (obviously, I suppose) and may take 2 to 3 months to ship over.

We haven’t given up all hope yet and maybe someone will come forward with the right box or parts for it. Otherwise, I’m wondering if it would be worth (or even possible) to replace the whole drivetrain with one from an Impreza (or an LS crate engine with rwd biglaughsilly)

BreakingBad

Original Poster:

325 posts

118 months

Thursday 29th November 2018
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Progress!

First, thank you all for your suggestions and advice: I really appreciate that there are always such helpful and knowledgeable people on here who are willing to share. Thank you.

I managed to spend a bit more time phoning and emailing today and you are quite right enginebuilder, help is out there: I did manage to find a ‘box at East Kent Subaru which is apparently a super, rebuilt 6 speed. The only issue (other than the price!) is that although it is a JDM item, it’s from the Impreza with the DCCD diff, not the Foz / viscous type. This means that the “old” diff from the Foz would have to be used inside the DCCD casing and my garage is not entirely sure that is a good idea.(We don’t know how good the diff is).

Following Vixpy’s advice, I gave TEGSport a ring and they are confident they can rebuild it and it will cost less than half the other option. My garage has to remove the box, send it up to TEG who will rebuild it and return it to be put back in, hopefully all before Xmas!

I will update to let you all know what happens...
smile

BreakingBad

Original Poster:

325 posts

118 months

Wednesday 5th December 2018
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My local garage, Bentens, has now removed the gearbox (about 3 hours labour) and sent it up to TEG Sport In Lancashire for a rebuild - should have arrived there today

We still don’t know what specifically is wrong so I’m waiting for TEG to strip it down and let me know what it is and how much the requisite work will come to - obviously hoping it is not too serious / expensive and that they do have the bits in stock. They had told me there shouldn’t be anything they can’t handle but...

With any luck, it will be repaired, sent back down to Bentens and refitted (another 3 hours or so) in the next week to 10 days.

Looking forward to getting the STi back although using the old STurbo is definitely no hardship - I still love that car!

BreakingBad

Original Poster:

325 posts

118 months

Tuesday 18th December 2018
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Aaaaaaggggghhhhh!

Gearbox came back at the end of last week and my local garage phoned this morning to say he’s put it back in the car but it’s not right - still making some horrible noises, apparently!

Going over there tomorrow morning to have a look for myself and a chat but not happy. I will reserve judgement on where the responsibility lies until we have determined what and where the problem is. The garage who rebuilt the gearbox believes that the problem must lie elsewhere in the drivetrain - which is still a possibility, I admit - but my local thinks there are bearings which have not been replaced in the rebuild.

Annoyingly, it means the car is still not properly driveable and the way I see it, it is likely that the gearbox will have to come out again and be dismantled to find the fault. B****r!

BreakingBad

Original Poster:

325 posts

118 months

Friday 21st December 2018
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Right - Clive has gone over the car again and, although he still feels that it is not as it should be, there’s not much more he can do so I picked the car up this afternoon.

I just had a few miles to drive it home and it is a bit more noisy than it used to be but works well enough. The change is certainly short and “snickety” (compared to the STurbo or Disco Sport I’ve been driving meanwhile anyway) while being quite smooth but there are one or two more background grumbles that didn’t used to be there. Having said that, it was never the quietest or most refined car so not the end of the world.

I’ll be using it over the next couple of weeks and putting a few miles on it before making a final decision but, unless it seems much worse than my initial impression, I think I can live with it and wouldn’t relish the prospect of opening that can of worms again (unless absolutely necessary).

BreakingBad

Original Poster:

325 posts

118 months

Friday 21st December 2018
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.Well, no, not as I’ve seen so far. I do know what he means - it’s noisier than it was and probably noisier than it should be but IMO, it seems to be acceptable.

Realistically, I don’t think it would be unreasonable to expect a re-fettled gearbox to be better than it was beforehand and, being critical, you could say it’s not. On the other hand, it’s not a new gearbox so where do you draw the line? If it was a high-end, luxury car, I think it wouldn’t really pass muster. As a 14 year old, 100,000 mile pocket rocket, I’m inclined to consider it acceptable - so far at least. I’m prepared to drive it over the next couple of weeks whilst both garages are closed anyway, and see if it gets better, worse or whatever..

If anybody has any thoughts, advice or input, feel free to contribute. smile