Subaru - Forester :: 2011 - Grinding Noise When Try To Engage 2nd Gear In Cold


Feb 5, 2011

I have a brand new (2 months old) 2011 Subaru Forester 2.5x that has a 4 cyl engine and a 5 speed manual transmission. This past week it's been cold here in New Hampshire and in the morning when I first drive the car, I have trouble shifting from 1st to second gear. When I shift from 1st to 2nd, I hear/feel some grinding noise as I try to engage 2nd gear. This only seems to happen when the car has been sitting around in the cold for a long period of time. Our garage has been cold (34 deg this AM) for the past week and when I drive out of our driveway and on our street I encounter this problem.

Normally, this problem only happens the first time you shift out of first and into 2nd. However, the other day, when it was very cold (5 degrees out) it happened several times as I drove down the street. After it happened the first time that morning, I stopped the car and drove from a dead stop, shifting from 1st to 2nd. I had problems 3 or 4 times trying to shift to 2nd. I ended up double clutching the car to avoid making the grinding sound. I took the car to the dealer. The couldn't repeat it but I didn't expect it to, because the car was warmed up and it was warmer during the day (low 30's by the time I got to the dealer that afternoon). The mechanic changed the transmission oil and checked the magnet in the pan to see if there were any metal pieces. He did not find any metal pieces. That was two days ago.

Unfortunately, every morning since then the car has had the same problem. Once the transmission has been warmed up it runs flawlessly and I have no problems shifting. I've made sure I am fully depressing the clutch for each shift. The past few days I've been taking the car out on an early morning test run and like clockwork, it has problems on the first shift into second, and it usually works fine after that. I have an appointment next week to leave the car with the dealer overnight. They will test drive it to see if they can reproduce the problem. What might be wrong? I have a workaround solution to avoid grinding the gears. I simply double clutch shift into 2nd for the first few times that I shift after the car has been sitting in the cold for a while. However, this is less than ideal for a brand new car.

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Is there something besides the brakes we should be having inspected? Does this sound safe to drive?

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It all started when I pulled over for gas and noticed a giant puddle of water under my car. Then when I got back on the road, the system was still blowing air, but it was no longer cold (yes the AC was still on). A few miles later the fan stopped blowing all together. Then windows down, riding through the desert, a passerby shouted through my window that my car was smoking, I pulled over to find my AC compressor belt lying on the road under my car.

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We've had the shifter bushings replaced and that tightened things somewhat. But it is still very loose.

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He has to use the smoke tracer to find where it is leaking and replacing hose. On both occasions he urged me to make the repair immediately as it could be extremely dangerous. (Makes sense if I am smelling gas.)

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A year or two ago, I replaced the front oxygen sensor and spark plugs (prior to problem). This winter, I took it to a mechanic who couldn't explain the problem and replaced the spark plug wires.

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