Subaru IMPREZA 2004 Service Manual page 29

12) Align the protrusion portion of reverse synchro
cone with reverse idler gear hole, then install the
reverse idler gear.
(B)
(A) Protrusion portion of reverse synchro cone
(B) Reverse idler gear hole
13) Install the washer with groove facing to reverse
idler gear.
14) Using the ST, install the snap ring.
ST 18672AA000 GUIDE CLIP
15) Inspect and adjust the clearance between snap
ring and washer. <Ref. to 6MT-97, INSPECTION,
Reverse Idler Gear Assembly.>
16) Install a new spring pin.
E: INSPECTION
Disassembled parts should be washed clean first
and then inspected carefully.
1) Bearings
Replace the bearings in the following cases.
• Worn, rusted and damaged bearing
• Bearings that fail to turn smoothly or make ab-
normal noise when turned
• Bearings having other defects
2) Bushing (each gear)
Replace the bushings in the following case:
• When the sliding surface is damaged or abnor-
mally worn.
3) Gears
Reverse Idler Gear Assembly
(A)
MT-00637
ST
MT-00638
6MT-97
MANUAL TRANSMISSION AND DIFFERENTIAL
Replace the gears in the following cases:
• The gear teeth surfaces are broken or excessive-
ly worn.
• The parts that contact the baulk ring is damaged.
• The inner surface of gear is damaged.
4) Baulk ring, synchro cone
Replace the baulk ring and synchro cone in the fol-
lowing case:
• Worn, rusted and damaged baulk ring
5) Shifting insert key
Replace the shifting insert key if deformed, exces-
sively worn or defective in any way.
6) Inspect the clearance between snap ring and
washer.
Specification of clearance:
0.1 — 0.3 mm (0.0039 — 0.0118 in)
Select and replace the snap ring from the following
table if clearance is out of specification.
Snap ring
Parts No.
031319000
805019030
805019010
Inspect the clearance again after replacing snap
ring.
MT-00581
MT-00639
Thickness mm (in)
1.50 (0.059)
1.60 (0.062)
1.72 (0.068)