Subaru 2002 IMPREZA Service Manual page 1809

E: INSPECTION
Disassembled parts should be washed clean first
and then inspected carefully.
1) Bearings
Replace the bearings in the following cases:
• Bearings whose balls, outer races and inner rac-
es are broken or rusty.
• Worn bearings
• Bearings that fail to turn smoothly or make ab-
normal noise when turned after gear oil lubrication.
• Bearings having other defects
2) Bushing (each gear)
Replace the bushing in the following cases:
• When the sliding surface is damaged or abnor-
mally worn.
• When the inner wall is abnormally worn.
3) Gears
• Replace the gears with new ones if their tooth
surfaces are broken, damaged, or excessively
worn.
• Correct or replace if the cone that contacts the
baulk ring is rough or damaged.
• Correct or replace if the inner surface or end face
is damaged.
4) Baulk ring
Replace the ring in the following cases:
• When the inner surface and end face are dam-
aged.
• When the ring inner surface is abnormally or par-
tially worn down.
• When the contact surface of the synchronizer
ring insert is scored or abnormally worn down.
5) Shifting insert key
Replace the insert if deformed, excessively worn,
or defective in any way.
6) Oil seal
Replace the oil seal if the lip is deformed, hard-
ened, damaged, worn, or defective in any way.
7) O-ring
Replace the O-ring if the sealing face is deformed,
hardened, damaged, worn, or defective in any way.
8) Gearshift mechanism
Repair or replace the gearshift mechanism if ex-
cessively worn, bent, or defective in any way.
INPUT SHAFT ASSEMBLY
9) Measure the clearance between snap ring and
ball bearing using thickness gauge.
Clearance:
If the measurement is not within specification, se-
lect a suitable snap ring.
MT-85
MANUAL TRANSMISSION AND DIFFERENTIAL
0 — 0.12 mm (0 — 0.0047 in)
(A) Snap ring
Snap ring
Part No.
805028050
805028060
805028070
S3M0160C
Thickness mm (in)
2.48 (0.0976)
2.56 (0.1008)
2.64 (0.1039)