Subaru Impreza 2003 Service Manual page 1878

MANUAL TRANSMISSION AND DIFFERENTIAL
11) Remove the weight and screw in the retainer
without O-ring on upper side and stop at the point
where slight resistance is felt.
NOTE:
At this point, the backlash between hypoid gear
and drive pinion shaft is zero.
ST 499787000 WRENCH ASSY
ST
12) Fit the lock plate. Loosen the retainer on the
lower side by 1-1/2 notches of lock plate and turn in
the retainer on upper side by the same amount in
order to obtain the backlash.
NOTE:
The notch on the lock plate moves by 1/2 notch if
the plate is turned upside down.
13) Turn in the retainer on the upper side addition-
ally by 1 notch in order to apply preload on taper
roller bearing.
14) Tighten temporarily both the upper and lower
lock plates and mark both holder and lock plate for
later readjustment.
15) Turn the transmission main shaft several times
while tapping around the retainer lightly with plastic
hammer.
16) Inspect and adjust the backlash and tooth con-
tact of hypoid gear. <Ref. to 5MT-107, INSPEC-
TION, Front Differential Assembly.>
17) After checking the tooth contact of hypoid
gears, remove the lock plate. Then loosen the re-
tainer until the O-ring groove appears. Fit the O-
ring into groove and tighten the retainer into the po-
sition where retainer has been tightened in.
Tighten the lock plate.
TRANSMISSION CASE
NOTE:
Carry out this job on both upper and lower retain-
ers.
Tightening torque:
T: 25 N·m (2.5 kgf-m, 18.1 ft-lb)
18) Selecting of main shaft rear plate. <Ref. to
MT-00176
5MT-82, ADJUSTMENT, Main Shaft Assembly for
Single-Range.>
19) Install the clutch release lever and bearing.
<Ref. to CL-26, INSTALLATION, Release Bearing
and Lever.>
20) Install the transfer case with extension case as-
sembly. <Ref. to 5MT-53, INSTALLATION, Trans-
fer Case and Extension Case Assembly.>
21) Install the manual transmission assembly into
the vehicle.<Ref. to 5MT-41, INSTALLATION,
Manual Transmission Assembly.>
2. DUAL-RANGE
1) Wipe off grease, oil and dust on the mating sur-
faces of transmission cases with white gasoline.
2) Install the front differential assembly.
3) Install the main shaft assembly and input shaft
assembly.
Connect the main shaft assembly and input the
shaft assembly, and install needle bearing knock
pin hole into transmission case knock pin.
4) Install the drive pinion shaft assembly.
Install the roller bearing knock pin hole into trans-
mission case knock pin.
5) Apply liquid gasket, and then put the case right
side and left side together.
Liquid gasket:
THREE BOND 1215 or equivalent
6) Tighten the seventeen bolts with bracket, clip,
etc. as shown in the figure.
NOTE:
• Insert the bolts from bottom and tighten the nuts
at top.
• Put the cases together so that the drive pinion
shim and input shaft holder shim are not caught up
in between.
• Confirm that the speedometer gear is meshed.
5MT-70
T
MT-00177