Torque converter hell!

[Boostedballs]

I am having some serious issues installing the torque converter in my 1993 Legacy AWD. It goes into the trans all but the last 1/2" or so then stops solid.

I tried installing the engine thinking the torque converter must be all the way in but the engine wouldn't mate up.

Pulled the engine back out and tried installing the torque converter again, no luck.

Tried pulling the oil pump shaft from the trans but it is locked into place. (The manual says to pull the shaft and install it in the TC before fitting the TC to the transmission.)

Pulled the transmission and stood it on the output shaft and the torque converter still wouldn't go on all the way!

I noticed that a c-clip was loose around the input shaft in the trans, it was a little buggered up and I can't tell where it's supposed to go. I'm doubting that the clip is keeping this thing from going on all the way though.

This torque converter came out of this same transmission just a couple days ago, what could be the problem?

I'm about ready to roll this thing off a cliff!!! Please help me!!!!!

-Chuck- Portland, OR

[magicmike]

This is becoming a common problem, search for posts under my name, "TC no fitty" is the topic

[Bheinen74]

Make sure you pull out the outer "hollow shaft" of the tranny, pull it out a good enough ways and make sure the clip is still attached. then with that hollow shaft out, you will see 2 notches. Line those notches up with the notch in the Tq Conv, and slide the converter on, and make sure it locks on with the clip-has to line up so the clip fits into the notch of the TC. Then push it back into the tranny, slowly rotating it several times, it will eventually find the correct placement, tge first notch is easy, the second nothce you may need to wiggle it a little as you rotate slowly. and mounting plate will stick out about 1/4 to a 1/3 inch from the tranny, then it is in all the way.

[Boostedballs]

I did read all the posts about the TC no fitty and that's where I got my ideas for my futile attempts. I didn't realize that the "hollow shaft" was the outer shaft. Both shafts are hollow, I assumed it meant to pull the inner shaft. OOPS
I guess I'll replace that duty solenoid "D" while it's out. It controlls the % of drive to the rear wheels as mine acts like it's in 4wd all the time. You can feel it binding when I make a sharp corner on dry tarmac.

I tried installing the fuse to disable the AWD but the car handled like crap, especially while passing someone on the freeway.

I'll update the forum with my finds. I'm extremely thankful for your replies, you might have saved this car from a real beating with a BFH.
-Chuck-

[Legacy777]

The duty c solenoid controls the rear power transfer

[Boostedballs]

ok, I tried to remove the outter shaft by welding a pipe to it and attaching it to a fabricated puller with 1/2" threads. The 2"x2" angle iron bent like it had about 3000lbs on it and the outter shaft wouldn't budge, the weld finally let go and took a deep chunk of shaft with it. I have a picture of this. Truly unbelievable.

This sucker is going to the transmission shop tomorrow, I give up. This was just an engine replacement, the trans was fine! I'm so defeated.
-Chuck-[/img]

[Legacy777]

chuck,

If you want to email the pic I'll host it, or you can use thawa's image gallary. (info in the stuff you need to know thread)