I have ran into a couple occurrences where the release bearing completely comes apart and damages the input shaft housing or also known as the transmission snout. At first glance you would assume that the transmission case is completely destroyed, time for transmission rebuild right?
Well that’s not exactly true, I have found a couple companies that make repair kits for this. Take a look at the before and after pictures of this Subaru MT Transmission, this particular model was out of a 2006 Subaru Outback Turbo 2.5 DOHC. The first time I ran into this problem I did not know about this repair kit and we had to replace the transmission case. That was not an easy job, doing a rebuild is fine your just building the shafts and replacing bearings but when you have to replace the case there are a few other things that come into play that you may not have anticipated. First there is the shift forks, these can be a pain in the ass changing over. Then you have the differential pre-load that has to be re-set so you’ll have to put the case together a couple times with the differential to make sure both the gear mesh and backlash are correct. When doing a rebuild all you would have out do is mark the pre-load adjusters then just verify the pre-load and backlash is still correct upon assembly. There are set screws on the kit shown so the sleeve can be easily removed in the future if you need to repair the transmission. Other kits are pressed on and would have to be cut off. The only down side would be that you have to use an over sized release bearing. The reason I say this is because you may need to do another clutch at a later time. If the mechanic is not aware of this then i could be a problem. Luckily, the company i purchased the repair kit from came with a sticker warning you of this and where to purchase the over sized release bearing from, of course they’re only available from the company you purchased the snout repair kit from. I do not know if other companies kits would be able to interchange the release bearings or not. Just hope the company doesn’t go out of business right?
Here is the company I purchased the repair kit from: Subaru WRX Parts
Here is a you tube video on the repair kit: Snout Repair Video