AT trans problem 'after' motor pulled - now won't reinstall.

[tmarcel]

When I pulled the motor out I did not bother to pull the TC (torque converter) off the flexplate. Yes I read about the hollow guide tube and C-clip. It was left in there, which I got out and are now attached to the TC. I thought, "great, now it will go all the way in". However, it would not and sits .75"-1.00" too far out for the starter to engage it. I determined that the smaller splined center shaft (the one inside the larger splined shaft) was to blame. They both go into the torque converter.

I noticed that when the motor came out originally, it pulled that center shaft out a bit too. I did a test fit where I pulled the smaller splined center shaft out 'completely'. I then installed the TC and guide shaft and it went all the way will in as it should. After a few google image searches, I noticed that other Subaru ATs have this small center shaft sitting a little deeper back into the larger splined shaft.

My question is, what exactly does this small splined center shaft engage in the trans? On the other end of it, there are two (2) sets of splines. Not sure if this shaft is the pump or drive shaft? Either way something is screwed up. I don't see any other option at this point other than banging it in I hate ATs LOL!

Anybody seen this before? What is hanging it up on the inside of the trans. Anyone have diagrams from the FSM? Need to get this going ASAP! Motor is on the lift waiting to go in and family coming in town.

[tmarcel]

Found a PDF online. The shaft in question is called the "turbine shaft". I can not tell what it actually slides into though.

[SemperGuard]

One spline goes to the High clutch drum I think, and the other to the rear sun gear. I think. Just keep working it back and forth, up and down until it goes it all the way, do the same with the torque converter. Don't force anything though, you may make things worse.

[Hocrest]

Put the TC in as far as you can, then use a small screwdriver or round pin as a handle in one of the flex plate screw holes and crank the TC clockwise for 4-5 turns. Spin it fairly quickly.
Then push up and in as you rotate it CCW, it should seat in a little further.

Repeat the 4-5 CW, and the push and CCW until it won't go in any further.

The mating face of the flex plate tabs should stick about 1/8" beyond the edge of the bell housing.

btw... I learned the hard way that you should replace the oil seal on the front of the transmission any time you have the TC out. I'm not saying that it will fail, but do you want to have to pull the engine or trans again when it does??

[tmarcel]

hocrest,

Yeah I replaced the seal too. But were you following what I was saying the problem is? The turbine shaft, which apparently attaches internally in the transmission is the problem. The small shaft itself is literally getting hung up on a point inside the trans and won't go in any further. I'm wondering if the splines got damaged on the inside of the trans.

[Hocrest]

Yeah, as long as you get the shaft almost all the way in, the spinning will help seat it completely.

If you want to get the shaft in on it's own, do it in the same way. Install as far as you can go, rotate it and then try to push it further in.

[tmarcel]

Okay problem fixed. I thought for sure the shaft had messed up something inside the trans but it appears to be fine. When I pulled the motor originally and didn't unbolt the TC first it must have been at such an angle that it grabbed the turbine shaft and pulled it out.

[tmarcel]

I'll even add a second nice ending. The bastard motor started just a moment ago! I still need to get the exhaust fitted to the new downpipe, which I'll get done tomorrow.