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DIY 5EAT Transmission Rebuild


ClimberDHexMods

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Thanks to some simple words from Rao :eek: and some timely motivation from Apex-GT, and of course the Factory Service Manual, I feel confident now that I can tear down and rebuild my 5eat, which suffers from a worn clutch packs= and perhaps some other issues that I believe are limited to wear parts. I may screw it up altogether, but you never get to find out if you don't try.

 

I have some other very exciting 5eat stuff in the pipeline, but one thing at a time is enough :)

 

So it's time to pick a kit. I will contact FBP to see what they would sell a 2005 LGT 5eat rebuild kit for. There are other ones online. Please weigh in if you know anything about this kind of thing.

 

Parts needed:

 

Snap-ring plyers

Transmission spring compressor used to get the snap ring out of there (example http://store.boxwrench.net/KD-Tool-2398-Automatic-Transmission-Universal-Clutch-Spring-Compressor-Transmission-Rebuilding-DVD_p_84.html)

OR some people just borrow or buy a cheaper one, or use a couple C-clamps if you are very careful.

Angle feeler gauges

A perfectly flat bar of some sort (to measure tolerances off the transmission front end)

Caliper or depth gauge to measure distances to .0001"

E-Star wrench to separate front diff case from main AT case

A home-made wrench to twist off the front diff bearing seals

Lead pen for checking front diff ring/pinion fitment.

Vaseline

 

E20 torx socket - $10 shipped, eBay

Various male torx sockets (I don't remember what size(s) you will need once in the trans, but there is one needed for removing a bolt that holds on the front pinion.

 

Subaru 5AT manual:

http://www.spooledupracing.com/download/Manuals/FSM/Subaru/Impreza%2006/Mechanism%20and%20Function/5AT%20Auto%20Trans.pdf or

http://guibo.com/~guibo/subaru_doc/Impreza_2005/Mechanism%20And%20Function/5AT%20Auto%20Trans.pdf

 

Vacation Pics: http://legacygt.com/forums/showpost.php?p=3227194&postcount=300

 

Subaru 5eat part numbers: http://opposedforces.com/parts/legacy/us_b13/type_26/automatic_transmission/

 

Aftermarket Spare Parts:

 

Raybestos Catalog (Ctrl+F, type in Subaru, and there is a 5 speed EAT listing of products towards the bottom of the PDF) http://www.raybestospowertrain.com/pdf/catalogs/raybestos_catalog.pdf

 

RE5405A Spare Parts (many are interchangeable with Subaru 5eat) http://www.automaticchoice.com/Catalogue/re5r05a.pdf

Courtesy of rubberman.

 

Replacement solenoids, Repair manual (claims full teardown/rebuild instructions for RE5R05A):

http://www.makcotransmissionparts.com/RE5R05A.html

Courtesy of rubberman.

 

 

Rebuild Kits:

 

AutoTransSpecialists $340 + Ship http://www.autotransparts.com/cart.php?m=product_detail&p=891

This is a 7-bay trans shop in NJ, who get their rebuild kits from Precision International. I called them and talked to a head tech who is looking into getting thinner steels and maybe thinner clutch packs in order to fit more of them in. More clutches = more grip.

See the 5eat rebuild kit section from Precision International here bottom of page 53 http://www.transmissionkits.com/catalogs/fknd.pdf

See the 5eat individual parts section on page 319 http://www.transmissionkits.com/catalogs/PI_Parts.pdf

 

IPT $830 + ship http://www.importperformancetrans.com/catalog/subaru-transmission-rebuild-kit/5eat-subaru-performance-transmission-rebuild-kit-1717.html

 

Alto (jump to PAGE 416) http://www.altousa.com/images/uploads/Alto_AutomotiveCatalog.pdf

For reference, the different Alto kit levels http://www.altousa.com/am/automotive

 

Makco http://www.makcotransmissionparts.com/5EAT.html

 

 

Additional Info:

 

5EAT manual from the 2006 Nissan 350Z: http://www.myzroadster.com/files/2006%20service%20manual/AT.pdf

Courtesy of Apex-XT

 

Titan forums (several pdf's with some useful part info & a few recommendations from a trans shop for what to look/watchout for, adjust, etc:

http://www.clubtitan.org/forums/showthread.php?t=30192

Courtesy of rubberman

 

An exploded view of the Subaru 5EAT

http://www.makcotransmissionparts.com/mm5/graphics/Catalog-pdf/5EAT.pdf

 

An exploded view of the Jatco RE5R05A (Nissan) 5EAT (for comparison)http://www.makcotransmissionparts.com/mm5/graphics/Catalog-pdf/RE5R05A.pdf

Courtesy of Apex-XT

 

Solenoid Info:

http://www.sonnax.com/system/pdfs/145/original/TASC-TIP-12-09.pdf?1289926276

Courtesy of rubberman

 

Ford DIY AT rebuild youtube series http://www.youtube.com/view_play_list?p=D69D572AAF5C7959

 

There are tons of other trans rebuild videos on youtube, but I have not found any specific to the Jatco 5eat family.

 

Some 350Z fluff reading http://www.freshalloy.com/forums/showthread.php?t=150651

Edited by ClimberD@HexMods
[CENTER][B][I] Front Limited Slip Racing Differentials for the 5EAT now available for $1895 shipped, please inquire for details! [/I][/B][/CENTER]
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Good luck. Ive took apart and put back transmissions when I was school, easier when you try to keep track of how it came apart. You are also gonna need lots of room to lay everything out

 

Cant wait for a brief walkthrough or at least pics, fellow 5eat here

 

may do the same to if I need to in the future

5eat downshift rev match:):wub:

Powder coated wheels: completed:)

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Good thread ClimberD! This could give us the opportunity to collectively pool all of the tech/repair info that's out there on the JATCO RE5R05A trans.

I've found a few links that provide a little more tech info (parts, function, etc):

 

Trans Spring Compressor tool (seems to be something like this...):

http://store.boxwrench.net/KD-Tool-2398-Automatic-Transmission-Universal-Clutch-Spring-Compressor-Transmission-Rebuilding-DVD_p_84.html

 

Titan forums (several pdf's with some useful part info & a few recommendations from a trans shop for what to look/watchout for, adjust, etc:

http://www.clubtitan.org/forums/showthread.php?t=30192

 

Solenoid Info:

http://www.sonnax.com/system/pdfs/145/original/TASC-TIP-12-09.pdf?1289926276

 

Replacement solenoids, Repair manual (claims full teardown/rebuild instructions):

http://www.makcotransmissionparts.com/RE5R05A.html

 

Parts:

http://www.automaticchoice.com/Catalogue/re5r05a.pdf

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Sucker :lol:

 

I am not sure that I would buy a rebuild kit until you know what you want to replace. Spend a lot of time here http://opposedforces.com/parts/legacy/us_b13/type_6/automatic_transmission/ to see what parts are available from Subaru.

 

Also, while you will need some of the specialized tools, a lot of times you don't so spend a lot of time studying the service manual - it will tell you exactly what to do and DO NOT skip ANY words - it is translated so it reads weird, but there isn't a lot of extra stuff in there so make sure you understand what they are saying or you will miss things.

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Way to go ClimberD!

 

I'm in. I'll give it a go as well. I'm researching kits at the moment and your lead to Alto looks pretty good. They have a wide variety of kits. I'll give them a call on Tues to go into variations and pricing. Anyone up for a group buy?

 

On another note, I used FreeSSM to reset the learned memory (Memory 2) on the 5EAT and took it for a drive. The shift personality did change. I have to drive it a bit more for it to relearn. Then we'll see whether that solves anything.

Edited by Apex-XT
300k miles, BNR 16g, CryoTune, 'Bullet-Proofed' IC, Motor rebuild @ 250k b/c of a cracked exhaust valve. Original 5 EAT. Oil changed religiously @ 3,000 mi.
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I've rebuilt more than my fare share of manual transmissions, but never a 5EAT.

 

Absolutely the most critical thing to do on disassembly and reassembly, is to measure EVERYTHING. If you don't have a high quality digital caliper, get one. The very last thing you need to do is get the trans apart, rebuilt, and put back into the car only to find out that something is binding.

[URL="http://legacygt.com/forums/showthread.php/proper-flip-key-interesti-159894.html"]Flip Key Development Thread[/URL] "Genius may have its limitations, but stupidity is not thus handicapped." - E. Hubbard
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More interesting stuff....

 

upgraded / performance valves for a valve body rebuild. Note the Instructions link...

 

http://www.sonnax.com/product-lines/transmission/parts/1944

 

(source:http://www.clubtitan.org/forums/showthread.php?t=30192&page=3)

 

and this info on the 5EAT implementation in the 2006 Nissan 350Z: http://www.myzroadster.com/files/2006%20service%20manual/AT.pdf

 

and finally, an exploded view of the Jatco RE5R05A 5EAT - what a monster! http://www.makcotransmissionparts.com/mm5/graphics/Catalog-pdf/RE5R05A.pdf

Edited by Apex-XT
300k miles, BNR 16g, CryoTune, 'Bullet-Proofed' IC, Motor rebuild @ 250k b/c of a cracked exhaust valve. Original 5 EAT. Oil changed religiously @ 3,000 mi.
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Hey everyone, thank you for all the replies. It is a lot to digest, so it will take some time before I can reply individually.

 

But in order to steer this a bit more the right way, I just wanted to comment that the Nissan/Jatco RE5405A 5eat and the Subaru 5eat are in fact a little different in the main case (my bad). By comparing this

and finally, an exploded view of the Jatco RE5R05A 5EAT - what a monster! http://www.makcotransmissionparts.co...df/RE5R05A.pdf

vs the blowouts I have seen for the Subaru 5eat, I see now that SOME of the MAIN CASE INTERNALS are different. For example, there is a band for the front drum in the RE5405A, which I have never seen in LGT 5eat blowouts.

 

However, many parts are still the same.

Example, if you find that you only burned up the "High, Low & Reverse Clutch" (long name for one single assembly), then you could buy this Nissan/Subaru 5eat interchangeable part from Raybestos http://www.raybestospowertrain.com/pdf/nissan/R573575.pdf

 

All the part numbers for each "clutch pack" assembly are right where Rao said:

http://opposedforces.com/parts/legacy/us_b13/type_26/automatic_transmission/

 

Thus, a RE5405A kit would leave you with extra pieces and missing pieces. Just an FYI so I don't mislead anyone about that any longer.

Edited by ClimberD@HexMods
[CENTER][B][I] Front Limited Slip Racing Differentials for the 5EAT now available for $1895 shipped, please inquire for details! [/I][/B][/CENTER]
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and this info on the 5EAT implementation in the 2006 Nissan 350Z: http://www.myzroadster.com/files/2006%20service%20manual/AT.pdf

 

This thing is a freaking gold mine. It is almost exactly the same format as the LGT version, but at first glance it explains all the gaps that are left in the Subaru 5eat version.

 

I need to reverse engineer all the stock TCU settings so I can implement them in a stand-alone TCU, and this manual may save a lot of trouble.

[CENTER][B][I] Front Limited Slip Racing Differentials for the 5EAT now available for $1895 shipped, please inquire for details! [/I][/B][/CENTER]
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Alright, first post underwent major update. And my wife has "given me" a small corner of the apartment to do this, since I gave up my garage for uptown life.

 

I'm in the same boat... except I'm not uptown, but my apartment is on a golf course :D

 

That's why I'm going to rent out a 10x15 garage for a year or so.. it'll cost me only $60/mo

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I'm in the same boat... except I'm not uptown, but my apartment is on a golf course :D

 

That's why I'm going to rent out a 10x15 garage for a year or so.. it'll cost me only $60/mo

 

Really?

 

Does it have a lift?

[URL="http://legacygt.com/forums/showthread.php/proper-flip-key-interesti-159894.html"]Flip Key Development Thread[/URL] "Genius may have its limitations, but stupidity is not thus handicapped." - E. Hubbard
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I'm in the same boat... except I'm not uptown, but my apartment is on a golf course :D

 

That's why I'm going to rent out a 10x15 garage for a year or so.. it'll cost me only $60/mo

 

Funny, $60/mo is what I pay for a 10x10 climate controlled storage unit to hold all our nice junk we have no room for. Can someone PM me if you know how to sell 1980s art at a decent price without too much trouble?

 

Anyways, great move on the garage. Can't fit a car in there though.

[CENTER][B][I] Front Limited Slip Racing Differentials for the 5EAT now available for $1895 shipped, please inquire for details! [/I][/B][/CENTER]
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I called Fred Beans Parts. They do not offer a "rebuild kit" or anything like that, but they will sell individual clutch assemblies or random parts. The Subaru FSM says each clutch assembly cannot be disassembled. This is of course not true. You need a spring compressor and a snap-ring plyers, and then each one can come apart.

Instead, Subaru sells individual pre-assembled clutch packs (ex: Direct clutch assembly for $~300).

 

Also if you are like me and might have burned up your torque converter clutch, a new torque converter is $509. Many shops can cut open the existing torque converter, replace the clutches, and perhaps braze the fins for around that cost or somewhat more (though we really don't have an issue with the torque converter fins folding over).

Edited by ClimberD@HexMods
[CENTER][B][I] Front Limited Slip Racing Differentials for the 5EAT now available for $1895 shipped, please inquire for details! [/I][/B][/CENTER]
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Updated 1st post with Precision International as a rebuild kit manufacturer distributed by this shop named AutoTransSpecialists.

 

I would love to know the quality and performance of the overhaul kits from each of these companies.

[CENTER][B][I] Front Limited Slip Racing Differentials for the 5EAT now available for $1895 shipped, please inquire for details! [/I][/B][/CENTER]
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I took a little time to better understand the differences between the Jatco RE5R05A Nissan and the Jatco 5EAT Subaru.

 

Some sections are entirely identical, while other sections are different.

 

Subaru has a Front Brake Clutch (to stop the Over Drive planet from turning). Nissan does this instead with a Band/servo. It is activated in all forward gears except 4th, but it only actually transmits power in 3rd and 5th. So it is activated almost all the time. Bands are normally reserved for low power applications such as overdrive or reverse. The front brake clutch pack only has 2 friction clutches, so it is VERY light duty.

 

Input clutch is almost the same between the two, but the Nissan variant gets an extra friction (7 Nissan vs 6 on the Subaru) and every bit helps there. The input clutch holds 4th and 5th gears, so that's what is slipping when people lose 4th and 5th. Parts for Input clutch piston/frictions/steels are all the same.

 

Same story for the High, Low & Reverse Clutch. Nissan has one more friction and steel than Subaru. This bugger holds 3rd, 4th, 5th. It locks up in 1st only sometimes to provide some engine braking.

 

Direct Clutch, Nissan gets one more friction, again. Bitches.

This one holds 2nd, 3rd and 4th.

 

Reverse clutch. Nissan gets one more than Subaru. 6v5. Kill me. The Nissan has more grip surface area for going in REVERSE. Why...

 

Forward clutch. This one is engaged 100% of the time in all forward gears. SAME NUMBER OF CLUTCHES FOR SUBARU AND NISSAN!!! There is hope.

 

Low Coast Brake. Again, same between Nissan and Subaru. 3 and 3. When you're in manual mode or Sport mode, 1st or 2nd gear, this clutch pack is what causes the severe feeling of engine braking. It really slows the car down quick.

 

Transfer case differential clutch. Subaru 4. Nissan ZERO. suck it.

 

I would guesstimate without counting that 90% of the parts inside the Nissan case can swap right into the Subaru case. I do not know if the drums from the Nissan can be swapped into the Subaru case to allow for an extra friction and steel in various clutch packs. My gut says yes, but it would probably be cheaper to machine down the pistons and seats and make thinner whatever else you can like they do at IPT or any other performance trans shop, so you can fit in more frictions and steels. Thinner steels and thinner clutches are also an option, but those are hard to find for the Jatco.

 

I saw some 4L40E builds where they were taking out one clutch pack of 5 frictions, and through extensive modification with aftermarket parts, were putting in 13 frictions. That would be nice here...

 

Or you can swap to a PCS controller and just speed up the shifts and jack up the line pressure to 250psi at wot and hope it lasts (my plan).

[CENTER][B][I] Front Limited Slip Racing Differentials for the 5EAT now available for $1895 shipped, please inquire for details! [/I][/B][/CENTER]
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ClimberD, did you order your parts from Makco? How was your experience with them?

 

I have not ordered from Makco, and I don't know that I will. I am having a hard time finding out which company makes the "best" rebuild parts. Well that's not quite true. It appears that Borg Warner might make the best high performance rebuild kits, with superior frictions to Raybestos Z-pack, Alto Red Eagle, etc. But of course they don't make anything for 5-speed Jatcos. I suppose I could go part number hunting since there is a slight chance of 4-speed Jatco interchangeability with the 5at.

I'll probably end up with Alto or Precision International, but don't know yet.

 

I'm going to take Rao's advice and pull apart the trans and find out exactly what I need BEFORE ordering.

 

I might even be able to dodge dealing with piston seals by just leaving them in there. My current trans that will get the rebuild has about 31k miles, and fresh fluid. So most of the lip seals are probably going to be fine. We will see...

 

I don't drive my car because I don't want to hurt it :cool:

[CENTER][B][I] Front Limited Slip Racing Differentials for the 5EAT now available for $1895 shipped, please inquire for details! [/I][/B][/CENTER]
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So FHI took the RE5R05A from JATCO and modded it to allow for an awd drivetrain. Just like they told me they did. Well, indirectly anyways. They said they source the parts from JATCO but they build them in-house.
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So, brief update on my slipping/slammy shift 5EAT..

 

I always drive in the 'Sport' mode. I've driven it the last 2 weeks in the normal mode and the shifts have been much better. Not like new, but much better. Would this indicate that the line pressure solenoid is faulty?

 

I'm thinking about replacing just that one solenoid and buttoning it back up. It's relatively easy to get to - just under the bottom cover plate on the VB. It would involve draining, removing the pan, replacing the solenoid and reverse procedure.

 

Any thoughts on whether this might work?

 

ClimberD, any thoughts on moding our 5EAT to beef it up ala the Nissan? Sounds like a major cool mod. If you work through this and get it working, I'm considering getting a junk 5EAT and going through it with the beef mod, then installing. Daydreaming, but it would be cool...

Edited by Apex-XT
300k miles, BNR 16g, CryoTune, 'Bullet-Proofed' IC, Motor rebuild @ 250k b/c of a cracked exhaust valve. Original 5 EAT. Oil changed religiously @ 3,000 mi.
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I have not ordered from Makco, and I don't know that I will. I am having a hard time finding out which company makes the "best" rebuild parts. Well that's not quite true. It appears that Borg Warner might make the best high performance rebuild kits, with superior frictions to Raybestos Z-pack, Alto Red Eagle, etc. But of course they don't make anything for 5-speed Jatcos. I suppose I could go part number hunting since there is a slight chance of 4-speed Jatco interchangeability with the 5at.

 

I got Borg Warner Clutches with my rebuild. :)

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Would this indicate that the line pressure solenoid is faulty?

 

I'm thinking about replacing just that one solenoid and buttoning it back up. It's relatively easy to get to - just under the bottom cover plate on the VB. It would involve draining, removing the pan, replacing the solenoid and reverse procedure.

 

Any thoughts on whether this might work?

 

ClimberD, any thoughts on moding our 5EAT to beef it up ala the Nissan? Sounds like a major cool mod. If you work through this and get it working, I'm considering getting a junk 5EAT and going through it with the beef mod, then installing. Daydreaming, but it would be cool...

 

1- I don't know.

2- It would work, it is not hard to do, but it may not change anything.

3- The Nissan RE5R05A has an extra friction/steel in a couple drums, but I don't see any points where it is otherwise better. The real performance and durability is in the TCU tuning and, to a lesser extent, the quality of the clutch material.

 

I got Borg Warner Clutches with my rebuild. :)

 

I'll be calling Jeff to inquire :)

[CENTER][B][I] Front Limited Slip Racing Differentials for the 5EAT now available for $1895 shipped, please inquire for details! [/I][/B][/CENTER]
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The Nissan RE5R05A has an extra friction/steel in a couple drums, but I don't see any points where it is otherwise better. The real performance and durability is in the TCU tuning and, to a lesser extent, the quality of the clutch material.

 

More clutches = more surface clamping area. Which means you can hold more power

5eat downshift rev match:):wub:

Powder coated wheels: completed:)

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Executor485 and I spent the whole day yanking out the suspect transmission. Conveniently, my custom EWG is in the way of the installation of the replacement trans. It is very hard to remove my EWG. I blame inexperience.

 

So it's coming along. The candidate for rebuild is out, but still in one piece.

[CENTER][B][I] Front Limited Slip Racing Differentials for the 5EAT now available for $1895 shipped, please inquire for details! [/I][/B][/CENTER]
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