yep , But I know a machinist

around 70% of the 5MT gear boxes I have stripped down have failed due to poor lubrication .This mainly afects the side thrust of the gear. The gear is normaly seizes > welded to another mating gear , hence not been able to select another gear. Failure is due to the above oil separating ( layering out ) in the main shaft & no oil being able to be feed to the bearings areas.

The oil holes on the main shaft are around 2mm in od & splash feed off the top of the box via oil tray down the main shaft. Even a small bit of plastic off of a selector fork will block the hole. With the oil separating out ( looking like icing on a cake ) there is no chance for lubrication in the oil galleries, thats were disaster sets in. Dropping the clutch & ripping teeth off is another story.

my self I keep well away from the stuff

What $$ are we looking at for a 5MT replacement? or a 6MT? or some stronger gear sets (forget who did them on here)?

Second hand 5 speeds are usually around $1000-$2000 depending on age and ratios. 4.44 boxes are generally worth more than 3.9 boxes

6 speed non DCCD usually is around $4500. DCCD is usually around $5500. Budget an extra $1000 for extra conversion parts and install labour.

Second hand upgraded 5 speeds with stronger gearsets usually around $3000-$5000 depending on brand of gearset and age.

Rebuilding a 5 speed with stronger gears costs around $4500 for 1st/2nd and up around $6500 for 1st to 4th. Other things to consider are billet shift forks and interlocks if you decide on a dog engagement gearset.

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RS Liberty - Because WRX's are only good for parts...

Cheers. Where can I get the stronger gearsets to chuck in my box? (Perth naturally)

dougie is really diggin it.. lol

i had the same problem as u as well when i had my dodgey 5 spd in my wrx. driving slowly @ around 40km/h and my gearstick popped out from 2nd and got stuck in between netural and 2nd and clank clank... 2nd gear teeth was farked.

managed to shift into every other gear and had it replaced the following day with a 4.44 box.

however, 5spds are all fragile pussies and i will stay away from them unless it's a dog-box.

went for a 6spd and no dramas at all.. just tt i enjoyed it so much till my 5spd clutch is starting to shag out....

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GO APR

So safely 7k would get a 6 speed, dccd installed?

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Yamaha FZ1N - Purchased

i have taken the box out and 3 gear is missin about 5 teeth booth cogs
should i just replace the cogs or buy complete new shaft

Unless there's chips on second gear you don't have to replace the mainshaft, saving you about $400. I can get you a brand new 3/4 set (genuine Subaru) for $480.
3 and 4 must be changed as a pair. You'll need a couple of gaskets as well, which I also have if you need them.

what is the cog right oposite to the 3 gear cog because it missing teeth aswell