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Subaru IMPREZA 2004 Service Manual
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Subaru IMPREZA 2004 Service Manual

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2004 IMPREZA SERVICE MANUAL
TRANSMISSION SECTION
This service manual has been prepared
to provide SUBARU service personnel
with the necessary information and data
for the correct maintenance and repair
of SUBARU vehicles.
This manual includes the procedures
for maintenance, disassembling, reas-
sembling, inspection and adjustment of
components and diagnostics for guid-
ance of experienced mechanics.
Please peruse and utilize this manual
fully to ensure complete repair work for
satisfying our customers by keeping
their vehicle in optimum condition.
When replacement of parts during
repair work is needed, be sure to use
SUBARU genuine parts.
All information, illustration and specifi-
cations contained in this manual are
based on the latest product information
available at the time of publication
approval.
FUJI HEAVY INDUSTRIES LTD.
QUICK REFERENCE INDEX
CONTROL SYSTEMS
AUTOMATIC TRANSMISSION
AUTOMATIC TRANSMISSION
(DIAGNOSTICS)
MANUAL TRANSMISSION AND
DIFFERENTIAL
MANUAL TRANSMISSION AND
DIFFERENTIAL
MANUAL TRANSMISSION AND
DIFFERENTIAL (DIAGNOSTICS)
CLUTCH SYSTEM
CS
4AT
4AT(diag)
5MT
6MT
6MT(diag)
CL
G1870GE4

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Summary of Contents for Subaru IMPREZA 2004

  • Page 1 AUTOMATIC TRANSMISSION 4AT(diag) (DIAGNOSTICS) MANUAL TRANSMISSION AND DIFFERENTIAL This service manual has been prepared to provide SUBARU service personnel MANUAL TRANSMISSION AND with the necessary information and data DIFFERENTIAL for the correct maintenance and repair of SUBARU vehicles. MANUAL TRANSMISSION AND...
  • Page 2 MANUAL TRANSMISSION AND DIFFERENTIAL Page General Description ..................2 Transmission Gear Oil ................31 Oil Seal......................32 Vehicle Speed Sensor................33 Transmission Mounting System ..............34 Manual Transmission Assembly ...............36 Preparation for Overhaul................41 Air Breather Hose..................42 Oil Pipe......................43 Back-up Light Switch.................44 Neutral Position Switch ................46 Extension Case ..................48 Reverse Checking System................54 Transfer Drive Gear ..................57...

  • Page 3: Main Shaft Assembly

    Main Shaft Assembly MANUAL TRANSMISSION AND DIFFERENTIAL 19.Main Shaft Assembly NOTE: Do not reuse the gasket. A: REMOVAL 1) Remove the manual transmission assembly from vehicle. <Ref. to 6MT-36, REMOVAL, Manual Transmission Assembly.> 2) Prepare the transmission for overhaul. <Ref. to 6MT-41, Preparation for Overhaul.>...
  • Page 4 Main Shaft Assembly MANUAL TRANSMISSION AND DIFFERENTIAL 2) Turn the sub gear counterclockwise for approx. 4) Install the main shaft assembly to 3rd-4th shifter three teeth. Align the sub gear and reverse idler fork, and then assemble to driven gear assembly. gear hole, then insert the ST.
  • Page 5 Main Shaft Assembly MANUAL TRANSMISSION AND DIFFERENTIAL 6) Install the reverse shifter fork assembly to re- Tightening torque: verse idler gear assembly. 37 N·m (3.8 kgf-m, 27.3 ft-lb) MT-00551 (A) Reverse idler gear assembly (B) Reverse shifter fork (C) Reverse sleeve 7) Install the reverse idler gear assembly.
  • Page 6 Main Shaft Assembly MANUAL TRANSMISSION AND DIFFERENTIAL 11) Install the checking ball, checking spring, new 14) Install the reverse idler holder gasket and checking plug. Tightening torque: 37 N·m (3.8 kgf-m, 27.3 ft-lb) MT-00544 (A) Reverse idler holder 15) Install the striking rod. 16) Install the transmission case.
  • Page 7 Main Shaft Assembly MANUAL TRANSMISSION AND DIFFERENTIAL 6) Remove the 5th-6th sleeve, 6th needle bearing NOTE: and 6th baulk ring. Use a 38 mm (1.50 in) socket wrench. MT-00558 MT-00556 4) Remove the main shaft assembly from ST. (A) Needle bearing 5) Set the ST1 on 6th drive gear, then remove the (B) 6th baulk ring taper roller bearing, bush and 6th drive gear using...
  • Page 8 Main Shaft Assembly MANUAL TRANSMISSION AND DIFFERENTIAL D: ASSEMBLY NOTE: Install the 3rd synchro cone, by aligning protrusion NOTE: portions of the 3rd synchro cone with 3rd drive gear Replace the following parts as a set. hole portion. • Sleeve and hub •...
  • Page 9 Main Shaft Assembly MANUAL TRANSMISSION AND DIFFERENTIAL (2) Set to the main shaft, taking care not to NOTE: overlap the main shaft oil hole and 4th bush oil When pressing in 3rd-4th hub and 4th bush, align hole. the protrusion portion of outer baulk ring and cutout portion of 3rd-4th bush by moving the outer baulk ring.
  • Page 10 Main Shaft Assembly MANUAL TRANSMISSION AND DIFFERENTIAL 6) Install the 3rd-4th shifting insert key in proper 8) Install the 4th baulk ring. place of 3rd-4th sleeve. NOTE: Angle of each shifting insert key is 120° apart. MT-00564 9) Sufficiently apply gear oil to the main shaft, 4th needle bearing and inner periphery of 4th drive gear.
  • Page 11 Main Shaft Assembly MANUAL TRANSMISSION AND DIFFERENTIAL 11) Install the 5th bush. 14) Install the 5th needle bearing and 5th drive gear. (1) Set to the main shaft, taking care not to overlap the main shaft oil hole and 5th bush oil hole.
  • Page 12 Main Shaft Assembly MANUAL TRANSMISSION AND DIFFERENTIAL 18) Install the 5th-6th shifting insert key in proper NOTE: place of 5th-6th sleeve. When pressing in 5th-6th hub, align the protrusion portion of outer baulk ring and cutout portion of 5th- NOTE: 6th bush by moving the outer baulk ring.
  • Page 13 Main Shaft Assembly MANUAL TRANSMISSION AND DIFFERENTIAL 20) Install the 6th baulk ring. 24) Set the 6th bush to main shaft, taking care not to overlap the 6th bush oil hole and main shaft oil hole. MT-00573 21) Sufficiently apply gear oil to the main shaft, 6th MT-00576 needle bearing and inner periphery of 6th drive gear.
  • Page 14 Main Shaft Assembly MANUAL TRANSMISSION AND DIFFERENTIAL 28) Using the ST, install the retainer and outer 31) Set the main shaft assembly to ST, then tighten bearing inner race. the lock nut. ST1 18651AA000 INSTALLER ST1 18665AA000 HOLDER ST2 398177700 INSTALLER ST2 18664AA000 BASE CAUTION:...
  • Page 15 Main Shaft Assembly MANUAL TRANSMISSION AND DIFFERENTIAL E: INSPECTION 2) Set the height gauge to adapter plate. Lower the indicator of height gauge to mating surface of Disassembled parts should be washed clean first adapter plate and case, then set to zero point. and then inspected carefully.
  • Page 16 Main Shaft Assembly MANUAL TRANSMISSION AND DIFFERENTIAL 3) Measure the height to edge surface of ball bear- 4) According to measurement value, select the ing (height A1). snap ring and washer from the following table. Snap ring Thickness: mm A1: mm (in) Part No.

  • Page 17: Driven Gear Assembly

    Driven Gear Assembly MANUAL TRANSMISSION AND DIFFERENTIAL 20.Driven Gear Assembly B: INSTALLATION 1) Adjust the main shaft snap ring. <Ref. to 6MT- A: REMOVAL 83, ADJUSTMENT, Main Shaft Assembly.> 1) Remove the manual transmission assembly 2) Adjust the 1st-2nd shifter rod. <Ref. to 6MT-116, from vehicle.
  • Page 18 Driven Gear Assembly MANUAL TRANSMISSION AND DIFFERENTIAL 3) Install the ST3 to lock nut, set the driven gear as- 6) Remove the 2nd gear. sembly on ST, then remove the lock nut and wash- ST1 18666AA000 HOLDER ST2 18664AA000 BASE ST3 18620AA000 ADAPTER WRENCH MT-00591 7) Remove the needle bearing and 1st-2nd sleeve.
  • Page 19 Driven Gear Assembly MANUAL TRANSMISSION AND DIFFERENTIAL 9) Using the ST, remove each parts. 2) Install the 1st needle bearing. ST 18754AA000 REMOVER MT-00595 3) Install the 1st driven gear to driven shaft. MT-00596 MT-00594 4) Install the inner baulk ring. (A) 2nd bush (B) 1st-2nd hub (C) Outer baulk ring...
  • Page 20 Driven Gear Assembly MANUAL TRANSMISSION AND DIFFERENTIAL 6) Install the outer baulk ring. CAUTION: Do not apply pressure in excess of 40 kN (4.0 ton, 4.4 US ton, 3.9 lmp ton). MT-00599 7) Install the 1st-2nd hub. MT-00601 NOTE: • Align the protrusion portion of outer baulk ring (A) 2nd bush and cutout portion of 1st-2nd hub, then install.
  • Page 21 Driven Gear Assembly MANUAL TRANSMISSION AND DIFFERENTIAL 11) Install the 1st-2nd sleeve to 1st-2nd hub. 14) Install the inner baulk ring. NOTE: Make sure to install the 1st-2nd sleeve in proper di- rection. MT-00606 15) Sufficiently apply gear oil to the bush, 2nd nee- dle bearing and inner periphery of 2nd drive gear.
  • Page 22 Driven Gear Assembly MANUAL TRANSMISSION AND DIFFERENTIAL 18) Using the ST, install the 3rd-4th driven gear. 21) Using the ST, install the 5th-6th driven gear. ST 18654AA000 INSTALLER ST 18654AA000 INSTALLER CAUTION: CAUTION: Do not apply pressure in excess of 40 kN (4.0 •...
  • Page 23 Driven Gear Assembly MANUAL TRANSMISSION AND DIFFERENTIAL 25) Install the ST3 to lock nut, then install the ST to 26) Using the ST, caulk four portions on the lock driven gear assembly and tighten lock nut. nut to obtain dimension A 44±0.5 mm (1.73±0.02 ST1 18666AA000 HOLDER in).
  • Page 24 Driven Gear Assembly MANUAL TRANSMISSION AND DIFFERENTIAL E: INSPECTION F: ADJUSTMENT Disassembled parts should be washed clean first 1) Measure length “H”, which is from transmission and then inspected carefully. case and oil pump cover mating surface to ball bearing edge. 1) Bearing Replace the bearings in the following cases.

  • Page 25: Reverse Idler Gear Assembly

    Reverse Idler Gear Assembly MANUAL TRANSMISSION AND DIFFERENTIAL 21.Reverse Idler Gear Assembly 1) Remove the spring pin. A: REMOVAL 1) Remove the manual transmission assembly from vehicle. <Ref. to 6MT-36, REMOVAL, Manual Transmission Assembly.> 2) Prepare the transmission for overhaul. <Ref. to 6MT-41, Preparation for Overhaul.>...
  • Page 26 Reverse Idler Gear Assembly MANUAL TRANSMISSION AND DIFFERENTIAL 5) Remove the collar. 9) Remove the washer and needle bearing. 6) Remove the reverse sleeve. MT-00625 MT-00622 (A) Needle bearing 7) Remove the outer baulk ring, reverse synchro (B) Washer cone and inner baulk ring from reverse sleeve. 10) Remove the knock pin.
  • Page 27 Reverse Idler Gear Assembly MANUAL TRANSMISSION AND DIFFERENTIAL 12) Remove the sub gear and spring. 2) Install the friction plate and snap ring. NOTE: Make sure to install the friction plate in proper di- rection. MT-00628 (A) Sub gear (B) Spring MT-00630 (C) Punch mark (mark A) (A) Friction plate...
  • Page 28 Reverse Idler Gear Assembly MANUAL TRANSMISSION AND DIFFERENTIAL 6) Install the reverse idler gear No. 2. 8) Install the reverse sleeve to reverse idler gear No. 2. NOTE: Make sure to install the reverse sleeve in proper di- rection. MT-00632 7) Install the shifting insert key in proper place of reverse sleeve.
  • Page 29 Reverse Idler Gear Assembly MANUAL TRANSMISSION AND DIFFERENTIAL 12) Align the protrusion portion of reverse synchro Replace the gears in the following cases: cone with reverse idler gear hole, then install the • The gear teeth surfaces are broken or excessive- reverse idler gear.

  • Page 30: Drive Pinion Shaft Assembly

    Drive Pinion Shaft Assembly MANUAL TRANSMISSION AND DIFFERENTIAL 22.Drive Pinion Shaft Assembly 3) Install each gear assembly. <Ref. to 6MT-71, IN- STALLATION, Main Shaft Assembly.> A: REMOVAL 4) Install the transmission case. <Ref. to 6MT-67, 1) Remove the manual transmission assembly INSTALLATION, Transmission Case.>...
  • Page 31 Drive Pinion Shaft Assembly MANUAL TRANSMISSION AND DIFFERENTIAL 4) Lift the caulking of lock nut. CAUTION: 5) Install the ST3 to lock nut, then set drive pinion Do not apply pressure in excess of 40 kN (4.0 shaft to ST. Remove the lock nut and washer. ton, 4.4 US ton, 3.9 lmp ton).
  • Page 32 Drive Pinion Shaft Assembly MANUAL TRANSMISSION AND DIFFERENTIAL Tightening torque: 7) Using the ST, caulk two portions on the lock nut to obtain dimension A 37±0.5 mm (1.46±0.02 in). 265 N·m (27.0 kgf-m, 195 ft-lb) ST 18670AA000 PUNCH NOTE: Do not crack the caulking part of lock nut. MT-00648 NOTE: •...
  • Page 33 Drive Pinion Shaft Assembly MANUAL TRANSMISSION AND DIFFERENTIAL 9) Calculate the following equation, then select one E: INSPECTION or two pieces of drive pinion shim from the table be- 1) Using the spring balancer, measure the starting low. torque. If the starting torque is out of specification, 6.5±0.0625 mm —...
  • Page 34 Drive Pinion Shaft Assembly MANUAL TRANSMISSION AND DIFFERENTIAL Corrective action: Verify the backlash again, and NOTE: then adjust it. Install with the liquid gasket remaining to prevent the mating surface of clutch housing and adapter plate from damaging. Tightening torque: 50 N·m (5.1 kgf-m, 36.9 ft-lb) 4) Using the ST, rotate several times.
  • Page 35 Drive Pinion Shaft Assembly MANUAL TRANSMISSION AND DIFFERENTIAL Corrective action: Reduce thickness of drive pinion shim in order to move drive pinion away from crown gear. AT-00213 • Heel contact (Outside end contact) Checking item: Contact areas is small. Contact pattern AT-00211 Corrective action: Increase thickness of drive pin- ion shim in order to bring drive pinion close to...

  • Page 36: Front Differential Assembly

    Front Differential Assembly MANUAL TRANSMISSION AND DIFFERENTIAL 23.Front Differential Assembly NOTE: Be careful not to damage the part of clutch case A: REMOVAL where the retainer is to be installed. 1) Remove the manual transmission assembly. <Ref. to 6MT-36, REMOVAL, Manual Transmis- sion Assembly.>...
  • Page 37 Front Differential Assembly MANUAL TRANSMISSION AND DIFFERENTIAL 10) Install the differential side retainer to both side. NOTE: Be careful not to damage the oil seal. NOTE: Install the side retainer by screwing in the same ro- tating number of time till removal, and then align the mark.
  • Page 38 Front Differential Assembly MANUAL TRANSMISSION AND DIFFERENTIAL 20) Install the extension case. <Ref. to 6MT-48, IN- NOTE: STALLATION, Extension Case.> Be careful not to damage the differential case. 21) Install the oil pipe, neutral position switch, back-up light switch and harness. <Ref. to 6MT-43, INSTALLATION, Oil Pipe.>, <Ref.
  • Page 39 Front Differential Assembly MANUAL TRANSMISSION AND DIFFERENTIAL 3) Remove the claw of ST1, and then install the D: ASSEMBLY claw of ST2. 1. DIFFERENTIAL CASE ST1 398527700 PULLER ASSY ST2 18760AA000 CLAW 1) Using the ST, install a new speedometer drive gear and right and left side bearing inner race to dif- ferential case.
  • Page 40 Front Differential Assembly MANUAL TRANSMISSION AND DIFFERENTIAL 3) Install a new O-ring. Tightening torque: 50 N·m (5.0 kgf-m, 36.9 ft-lb) 4) Rotate the drive pinion shaft to right and left for several times. 5) Remove the drive pinion shaft assembly, and then check tooth contact.
  • Page 41 8) Using the ST, secure the drive pinion shaft. ST 18621AA000 ADAPTER WRENCH MT-00674 9) Install the SUBARU genuine axle shafts to both sides of front differential. Parts No. 38415AA000 AXLE SHAFT 10) After rotating the drive pinion shaft several...

  • Page 42: Speedometer Gear

    Speedometer Gear MANUAL TRANSMISSION AND DIFFERENTIAL 24.Speedometer Gear 15) Remove the oil seal, speedometer shaft and washer. A: REMOVAL 1) Remove the manual transmission assembly from vehicle. <Ref. to 6MT-36, REMOVAL, Manual Transmission Assembly.> 2) Prepare the transmission for overhaul. <Ref. to 6MT-41, Preparation for Overhaul.>...
  • Page 43 Speedometer Gear MANUAL TRANSMISSION AND DIFFERENTIAL 3) Install the speedometer driven gear and snap ring. MT-00676 (A) Snap ring (B) Speedometer driven gear 4) Install the vehicle speed sensor. <Ref. to 6MT- 33, INSTALLATION, Vehicle Speed Sensor.> 5) Install the front differential assembly. <Ref. to 6MT-104, INSTALLATION, Front Differential As- sembly.>...

  • Page 44: Shifter Fork And Rod

    Shifter Fork and Rod MANUAL TRANSMISSION AND DIFFERENTIAL 25.Shifter Fork and Rod ST 398791700 REMOVER A: REMOVAL 1) Remove the manual transmission assembly from vehicle. <Ref. to 6MT-36, REMOVAL, Manual Transmission Assembly.> 2) Prepare the transmission for overhaul. <Ref. to 6MT-41, Preparation for Overhaul.>...
  • Page 45 Shifter Fork and Rod MANUAL TRANSMISSION AND DIFFERENTIAL ST 398791700 REMOVER 4. SHIFT ARM SHAFT Using the ST, remove the selector arm. ST 398791700 REMOVER MT-00684 (A) 1st-2nd shifter arm MT-00687 (B) 1st-2nd shifter fork 5. STRIKING ROD 3. 5th-6th SHIFTER FORK 1) Remove the reverse interlock block and interlock 1) Using the ST, remove the 5th-6th shifter fork.
  • Page 46 Shifter Fork and Rod MANUAL TRANSMISSION AND DIFFERENTIAL ST 398791700 REMOVER NOTE: Make sure to install the reverse arm and rod in proper direction. MT-00690 (A) Interlock arm MT-00692 D: ASSEMBLY (A) Reverse arm 1. REVERSE SHIFTER FORK (B) Reverse rod (C) Spring pin 1) Using the ST, install the reverse fork.
  • Page 47 Shifter Fork and Rod MANUAL TRANSMISSION AND DIFFERENTIAL 2) Using the ST, install the 1st-2nd shifter arm. 5) Using the ST, install the 3rd-4th shifter fork. ST 398791700 REMOVER ST 398791700 REMOVER NOTE: NOTE: Make sure to install the 1st-2nd shifter arm and fork Make sure to install the 3rd-4th shifter fork in proper in proper direction.
  • Page 48 Shifter Fork and Rod MANUAL TRANSMISSION AND DIFFERENTIAL 2) Using the ST, install the 5th-6th shifter fork. • Make sure to install the interlock arm and rod in proper direction. ST 398791700 REMOVER NOTE: Make sure to install the 5th-6th shifter fork and arm in proper direction.
  • Page 49 Shifter Fork and Rod MANUAL TRANSMISSION AND DIFFERENTIAL 1) Insert the drive pinion assembly in adapter plate. NOTE: • Set the indicator of height gauge near measuring NOTE: object, then lock the dial (1) as shown in the figure. Make sure the thrust bearing outer race is not re- Turn dial (2) to set the indicator to edge surface of moved and drive pinion is not lift-up.
  • Page 50 Shifter Fork and Rod MANUAL TRANSMISSION AND DIFFERENTIAL NOTE: mm (in) Lot No. (Mark) • Set the indicator of height gauge near measuring 62.93 — 63.23 32801AA111 (1) object, then lock the dial (1) as shown in the figure. (2.4776 — 2.4894) Turn dial (2) to set the indicator to edge surface of 63.23 —...
  • Page 51 Shifter Fork and Rod MANUAL TRANSMISSION AND DIFFERENTIAL 3) Using the height gauge, measure “C1” and “C2” • Measure five points of the sleeve turning every shown in the figure. approx. 72°. Round off each two upper and lower measurement value. Use the remaining center val- ue as measurement value.
  • Page 52 Shifter Fork and Rod MANUAL TRANSMISSION AND DIFFERENTIAL • Measure five points of the sleeve turning every Lot No. (Mark) approx. 72°. Round off each two upper and lower M.SFT M.SFT M.SFT measurement value. Use the remaining center val- Snap ring Snap ring Snap ring ue as measurement value.
  • Page 53 Shifter Fork and Rod MANUAL TRANSMISSION AND DIFFERENTIAL • Do not place the height gauge on shaded area in (1) Shift the 5th-6th sleeve to 6th main gear the figure during the measurement. side, then press up to the stopper and measure “D2”.
  • Page 54 Shifter Fork and Rod MANUAL TRANSMISSION AND DIFFERENTIAL (3) Shift the 5th-6th sleeve to 5th main gear NOTE: side, then press down to the stopper and mea- The indicator is installed upside down compared to sure “D1”. the setting procedure of zero point. Add d1 [fixing value: 55 mm (2.17 in)] from the following figure to “D1”, to obtain measurement value of “D1”.
  • Page 55 Shifter Fork and Rod MANUAL TRANSMISSION AND DIFFERENTIAL 2) Tighten the base COMPL fixing bolt. 4) Press the reverse sleeve to reverse side idler gear No. 2, then measure “T”. Tightening torque: 25 N·m (2.5 kgf-m, 18.1 ft-lb) MT-00715 MT-00546 (A) Reverse idler gear No.
  • Page 56 Shifter Fork and Rod MANUAL TRANSMISSION AND DIFFERENTIAL 5) According to measurement, calculate the re- verse sleeve neutral position. Select the fork rod which applies to the calculated value from following equation. Equation: T + 4.8 mm (0.189 in) T + 4.8 mm (0.189 in) mm (in) Lot No.

  • Page 57: Clutch Housing

    Clutch Housing MANUAL TRANSMISSION AND DIFFERENTIAL 26.Clutch Housing B: INSTALLATION 1) Install the pitching stopper bracket. A: REMOVAL Tightening torque: 1) Remove the manual transmission assembly 41 N·m (4.2 kgf-m, 30.2 ft-lb) from vehicle. <Ref. to 6MT-36, REMOVAL, Manual Transmission Assembly.> 2) Install the speedometer gear.
  • Page 58 Clutch Housing MANUAL TRANSMISSION AND DIFFERENTIAL 2) Remove the oil seal. ST 398527700 PULLER ASSY NOTE: Do not reuse the oil seal. MT-00718 D: ASSEMBLY 1) Install the oil seal into clutch housing without damaging. ST 399513600 INSTALLER MT-00719 2) Install the clutch release bearing guide. Tightening torque: 6.4 N·m (0.65 kgf-m, 4.7 ft-lb) MT-00717...
  • Page 59 G Sensor MANUAL TRANSMISSION AND DIFFERENTIAL 27.G Sensor A: REMOVAL 1) Disconnect the ground cable from battery. FU-00009 2) Remove the console cover. <Ref. to EI-42, Console Box.> 3) Disconnect the connector from G sensor. 4) Remove the G sensor from body. CAUTION: Do not drop or bump the G sensor.
  • Page 60 G Sensor MANUAL TRANSMISSION AND DIFFERENTIAL C: INSPECTION Step Check CHECK G SENSOR. Is the voltage 2.3±0.2 V when Go to step 2. Replace the G 1)Turn the ignition switch to OFF. G sensor is horizontal? sensor. 2)Remove the G sensor from vehicle. 3)Connect the connector to G sensor.
  • Page 61 Driver’s Control Center Differential Control Module MANUAL TRANSMISSION AND DIFFERENTIAL 28.Driver’s Control Center Dif- ferential Control Module A: REMOVAL 1. LHD MODEL 1) Remove the ground cable from battery. 2) Remove the glove box. <Ref. to EI-48, REMOVAL, Rear Quarter Trim.> 3) Disconnect the connector after removing the bolt from the inside of glove box, and then remove the control module.

  • Page 62: General Diagnostic Table

    General Diagnostic Table MANUAL TRANSMISSION AND DIFFERENTIAL 29.General Diagnostic Table A: INSPECTION 1. MANUAL TRANSMISSION Symptom Possible cause Remedy 1. Gears are difficult to intermesh. (a) Worn, damaged or burred chamfer of Replace. internal spline of sleeve and reverse NOTE: The cause for difficulty in shifting gears driven gear can be classified into two kinds: one is...
  • Page 63 General Diagnostic Table MANUAL TRANSMISSION AND DIFFERENTIAL 2. DIFFERENTIAL Symptom Possible cause Remedy 1. Broken differential (case, gear, bear- (a) Insufficient or improper oil Disassemble differential and replace bro- ing, etc.) ken components and at the same time NOTE: check other components for any trouble, Abnormal noise will develop and finally it and replace if necessary.
  • Page 64 General Diagnostic Table MANUAL TRANSMISSION AND DIFFERENTIAL 6MT-132...