I decided to try remove the engine on my recently purchased 2003 Outback to replace the head gaskets. Its an EJ253 I believe with the original factory HG and 83k on the clock. Coolant is leaking out the Driver's side HG. After spending a good bit of time researching and reading the internet I learned this is a common issue. I have some mechanical skills and felt confident I could handle the project. So it was time to tear it apart and get dirty. I followed a DIY thread and for the most part all went well, that was until the removal of the engine.
I made two mistakes during removal that I believe ultimately led to my current situation. I did not pull the transmission pitch mount and I tried to raise/support the transmission on the pan instead of the lower bell housing (pan is slightly pushed in now from this) Using this method I ended up raising the engine and transmission together and everything shifted left. This put extreme tension on the transmission pitch mount which actually resulted in it stress cracking. I also believe at this point I was raising the complete vehicle with the engine hoist as the crane and car made some very loud and pronounced creaks and thud like sound. There was about a 2" gap between the block and bell housing when all of this occurred but no complete separation of the units. I lowered everything down quickly. Hopeful that nothing besides the pitch mount is broke.
I then spent some time searching on the web and found that I should raise the transmission directly below the bell housing to about the firewall to achieve correct alignment so the lower pins can release from the bellhousing. When I did this it popped right apart but seperated with the Torque Converter engaged to the flywheel. I'm now left with what looks like this;
I was able to slid this part off the spline;
So I have some questions that I'm hoping some of you experienced Subaru Guys or even Gals can help with as this is all new to me. The last picture of the shaft I have posted, should I be concerned that there's one area of smooth wear and then two dark burnt looking areas, is this normal? This piece I slid of the spline of the transmission along with the clip after the first picture.
The teeth on the spline and inside the TC look to be fine with no burs or such I tried to search for info about TC coming out of the transmission during engine removal and I found only very little info. I know from that researching that re-installing the TC can be tricky and if not done correctly can ruin the transmission oil pump and transmission. I'm not sure what I should do so I'm hoping some of you with more knowledgeable could chime in and advise me on how best to proceed. I don't have funds for a transmission so I'm hoping this isn't a major fubar but at the same time I don't want to slap it all back together if it is.
