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Subaru 2004 Impreza 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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  • Page 1 2004 IMPREZA SERVICE MANUAL QUICK REFERENCE INDEX TRANSMISSION SECTION CONTROL SYSTEMS AUTOMATIC TRANSMISSION 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...

  • Page 2: Table Of Contents

    MANUAL TRANSMISSION AND DIFFERENTIAL Page General Description ..................2 Transmission Gear Oil ................37 Manual Transmission Assembly ...............38 Transmission Mounting System ..............45 Oil Seal......................47 Switches and Harness ................48 Vehicle Speed Sensor................51 Preparation for Overhaul................52 Transfer Case and Extension Case Assembly..........53 Rear Case ....................57 Transfer Drive Gear ..................58 Transfer Driven Gear ................60 Center Differential ..................62...

  • Page 3: Manual Transmission Assembly

    Main Shaft Assembly for Single-Range MANUAL TRANSMISSION AND DIFFERENTIAL 16.Main Shaft Assembly for Sin- C: DISASSEMBLY gle-Range 1. AWD MODEL A: REMOVAL 1) Put vinyl tape around the main shaft splines to protect oil seal from damage. Then pull out the oil 1) Remove the manual transmission assembly seal and needle bearing by hand.
  • Page 4 Main Shaft Assembly for Single-Range MANUAL TRANSMISSION AND DIFFERENTIAL 4) Remove the snap ring and synchro cone stopper 6) Using the ST1 and ST2, remove rest of the from 5th-Rev sleeve and hub assembly. parts. NOTE: Replace the sleeve and hub with new ones. Do not attempt to disassemble because they must engage at a specified point.
  • Page 5 Main Shaft Assembly for Single-Range MANUAL TRANSMISSION AND DIFFERENTIAL 3) Remove the insert stopper plate, sleeve and hub D: ASSEMBLY assembly No. 2, baulk ring, 5th drive gear and nee- 1. AWD NON-TURBO MODEL dle bearing. 1) Assemble when each sleeve and hub assembly are disassembled.
  • Page 6 Main Shaft Assembly for Single-Range MANUAL TRANSMISSION AND DIFFERENTIAL ST1 899714110 REMOVER 6) Using the ST1 and ST2, install the 5th gear thrust washer and 5th needle bearing race onto the ST2 499877000 RACE 4-5 INSTALLER rear section of transmission main shaft. NOTE: •...
  • Page 7 Main Shaft Assembly for Single-Range MANUAL TRANSMISSION AND DIFFERENTIAL 9) Install the synchro cone stopper and snap ring to 2. AWD TURBO MODEL 5th-Rev sleeve and hub assembly. 1) Assemble each sleeve and hub assembly. NOTE: Position the open ends of spring 120° apart. MT-00188 (A) Synchro cone stopper (B) Snap ring...
  • Page 8 Main Shaft Assembly for Single-Range MANUAL TRANSMISSION AND DIFFERENTIAL 2) Install the 3rd drive gear, outer baulk ring, syn- 4) Install the baulk ring, needle bearing, 4th drive chro cone, inner baulk ring, sleeve and hub assem- gear and 4th gear thrust washer to transmission bly for 3rd needle bearing on transmission main main shaft.
  • Page 9 Main Shaft Assembly for Single-Range MANUAL TRANSMISSION AND DIFFERENTIAL 6) Using the ST1 and ST2, install the 5th gear 9) Install the synchro cone stopper and snap ring to thrust washer and 5th needle bearing race onto the 5th-Rev sleeve and hub assembly. rear section of transmission main shaft.
  • Page 10 Main Shaft Assembly for Single-Range MANUAL TRANSMISSION AND DIFFERENTIAL 4) Install baulk ring, needle bearing (32 × 30 × 3. FWD MODEL 25.7), 4th drive gear and 4th gear thrust washer to 1) Assemble sleeve and hub assembly for 3rd-4th transmission main shaft.
  • Page 11 Main Shaft Assembly for Single-Range MANUAL TRANSMISSION AND DIFFERENTIAL 7) Install the following parts to the rear section 3) Gears transmission main shaft. • Replace the gears with new ones if their tooth ST1 499987003 SOCKET WRENCH surfaces are broken, damaged, or excessively worn.
  • Page 12 Main Shaft Assembly for Single-Range MANUAL TRANSMISSION AND DIFFERENTIAL Dimension (A) Part No. Mark mm (in) 4.00 — 4.13 (0.1575 — 32294AA041 0.1626) 3.87 — 3.99 (0.1524 — 32294AA051 0.1571) MT-00209 5MT-81...

  • Page 13: Main Shaft Assembly For Dual-Range

    Main Shaft Assembly for Dual-Range MANUAL TRANSMISSION AND DIFFERENTIAL 17.Main Shaft Assembly for ST1 498937000 TRANSMISSION HOLDER ST2 499987003 SOCKET WRENCH (35) Dual-Range A: REMOVAL 1) Remove the manual transmission assembly from vehicle. <Ref. to 5MT-38, REMOVAL, Manual Transmission Assembly.> 2) Remove the transfer case with extension case assembly.
  • Page 14 Main Shaft Assembly for Dual-Range MANUAL TRANSMISSION AND DIFFERENTIAL • Do not reuse the ball bearing. 7) Remove the snap ring from main shaft. ST 899474100 EXPANDER ST1 499757002 INSTALLER ST2 498077400 SYNCHRO CONE REMOV- ( A ) MT-00215 (A) Snap ring MT-00189 8) Remove rest of the parts.
  • Page 15 Main Shaft Assembly for Dual-Range MANUAL TRANSMISSION AND DIFFERENTIAL D: ASSEMBLY ST1 899714110 REMOVER ST2 499877000 RACE 4-5 INSTALLER 1) Assemble when each sleeve and hub assembly are disassembled. NOTE: Position the open ends of spring 120° apart. ( C ) ( B ) ( A ) ( F ) ( E ) ( I )
  • Page 16 Main Shaft Assembly for Dual-Range MANUAL TRANSMISSION AND DIFFERENTIAL 9) Install the synchro cone stopper and snap ring to NOTE: 5th-Rev sleeve and hub assembly. Face the thrust washer in correct direction. ST1 899714110 REMOVER ST2 499877000 RACE 4-5 INSTALLER MT-00188 (A) Synchro cone stopper MT-00195...
  • Page 17 Main Shaft Assembly for Dual-Range MANUAL TRANSMISSION AND DIFFERENTIAL 2) Bushing (each gear) NOTE: Replace the bushing in the following cases: • Face the grooved side toward input gear. • When the sliding surface is damaged or abnor- • Align the high-low baulk ring’s groove with shift- mally worn.

  • Page 18: Input Shaft Assembly

    Input Shaft Assembly MANUAL TRANSMISSION AND DIFFERENTIAL 18.Input Shaft Assembly 2) Put vinyl tape around the input shaft splines to protect oil seal from damage. A: REMOVAL 3) Remove the inner snap ring. 1) Remove the manual transmission assembly ST 398663600 PLIERS from vehicle.
  • Page 19 Input Shaft Assembly MANUAL TRANSMISSION AND DIFFERENTIAL 6) Remove the snap ring. 2) Install the snap ring on input shaft. ( A ) ( A ) MT-00230 MT-00230 (A) Snap ring (A) Snap ring 7) Using a press and ST, remove the ball bearing. 3) Inspect the clearance between ball bearing and snap ring.
  • Page 20 Input Shaft Assembly MANUAL TRANSMISSION AND DIFFERENTIAL 7) Wind vinyl tape around the shaft splines and in- 9) Install the O-ring to input shaft holder. sert input shaft into holder by lightly tapping it by hand. MT-00238 MT-00236 (A) O-ring (B) Input shaft holder (A) Vinyl tape E: INSPECTION...
  • Page 21 Input Shaft Assembly MANUAL TRANSMISSION AND DIFFERENTIAL 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. 9) Measure the clearance between snap ring and ball bearing using thickness gauge.

  • Page 22: Drive Pinion Shaft Assembly

    Drive Pinion Shaft Assembly MANUAL TRANSMISSION AND DIFFERENTIAL 19.Drive Pinion Shaft Assembly 4) Inspection and adjustment of ST: NOTE: A: REMOVAL • Loosen the two bolts and adjust so that the scale 1) Remove the manual transmission assembly indicates 0.5 correctly when the plate end and the from vehicle.
  • Page 23 Drive Pinion Shaft Assembly MANUAL TRANSMISSION AND DIFFERENTIAL 2) Withdraw the drive pinion from driven shaft. Drive pinion shim Remove the differential bevel gear sleeve, adjust- Part No. Thickness mm (in) ing washer No. 1, adjusting washer No. 2, thrust 32295AA031 0.150 (0.0059) bearing, needle bearing, drive pinion collar, needle...
  • Page 24 Drive Pinion Shaft Assembly MANUAL TRANSMISSION AND DIFFERENTIAL ST1 499987300 SOCKET WRENCH (50) 9) Remove the 2nd driven gear, inner baulk ring, synchro cone and outer baulk ring. (Except 1.6 L ST2 899884100 HOLDER model) MT-00247 MT-00250 5) Remove the 5th driven gear using ST. ST 499857000 5TH DRIVEN GEAR REMOV- (A) 2nd driven gear...
  • Page 25 Drive Pinion Shaft Assembly MANUAL TRANSMISSION AND DIFFERENTIAL ST1 499757002 SNAP RING GUIDE NOTE: ST2 899714110 REMOVER Remove caulking before taking off lock nut. MT-00825 MT-00822 8) Remove 1st gear bushing, 1st driven gear thrust 2) Remove 5th driven gear using ST and press. plate and roller bearing using ST and press.
  • Page 26 Drive Pinion Shaft Assembly MANUAL TRANSMISSION AND DIFFERENTIAL D: ASSEMBLY ST1 499277200 INSTALLER ST2 499587000 INSTALLER 1. AWD MODEL 1) Install the sleeve and hub assembly by matching alignment marks. NOTE: Use a new gear and hub assembly, if gear or hub have been replaced.
  • Page 27 Drive Pinion Shaft Assembly MANUAL TRANSMISSION AND DIFFERENTIAL 8) Install a set of roller bearings onto the driven NOTE: shaft using ST and press. • Stake the lock nut at two points. • Using the spring balancer, check that starting NOTE: torque of roller bearing is 0.1 to 1.5 N (0.01 to 0.15 Do not apply pressure in excess of 10 kN (1 ton, 1.1...
  • Page 28 Drive Pinion Shaft Assembly MANUAL TRANSMISSION AND DIFFERENTIAL 13) Install the thrust bearing and needle bearing. • Be sure the insert keys are correctly located in Install the driven shaft assembly. the insert key grooves inside the reverse driven gear. MT-00262 14) Install the drive pinion collar, needle bearing, adjusting washer No.
  • Page 29 Drive Pinion Shaft Assembly MANUAL TRANSMISSION AND DIFFERENTIAL ST1 499877000 RACE 4-5 INSTALLER NOTE: ST2 499277100 BUSH 1-2 INSTALLER Bushing may be installed with either side up. ST1 499877000 RACE 4-5 INSTALLER ST2 499277100 BUSH 1-2 INSTALLER MT-00831 (A) 1st-2nd driven gear bushing MT-00829 7) Install 2nd driven gear and 1st-2nd balk ring to (A) 1st-2nd driven gear bushing...
  • Page 30 Drive Pinion Shaft Assembly MANUAL TRANSMISSION AND DIFFERENTIAL E: INSPECTION CAUTION: • Face 5th driven gear in the correct direction. Disassembled parts should be washed clean first • Be careful not to dislocate woodruff key while and then inspected carefully. installing 5th driven gear.
  • Page 31 Drive Pinion Shaft Assembly MANUAL TRANSMISSION AND DIFFERENTIAL Clearance (A): F: ADJUSTMENT 0.5 — 1.0 mm (0.020 — 0.040 in) 1. THRUST BEARING PRELOAD 1) After completing the preceding steps 1) through 3), select the adjusting washer No. 1 so that dimen- sion (H) is zero through visual check.
  • Page 32 Drive Pinion Shaft Assembly MANUAL TRANSMISSION AND DIFFERENTIAL Starting torque: 5) If the specified starting torque range cannot be obtained when a No. 1 adjusting washer is used, 0.3 — 0.8 N·m (0.03 — 0.08 kgf-m, 0.2 — 0.6 ft-lb) then select a suitable No.

  • Page 33: Front Differential Assembly

    Front Differential Assembly MANUAL TRANSMISSION AND DIFFERENTIAL 20.Front Differential Assembly B: INSTALLATION 1) Install the differential side retainers using ST. A: REMOVAL ST 499787000 WRENCH ASSY 1) Remove the manual transmission assembly 2) Install the bearing outer race to transmission from vehicle.
  • Page 34 Front Differential Assembly MANUAL TRANSMISSION AND DIFFERENTIAL C: DISASSEMBLY 3) Pull out the pinion shaft, and remove the differ- ential bevel pinion and gear and washer. 1. DIFFERENTIAL CASE ASSEMBLY 1) Loosen the twelve bolts and remove the hypoid driven gear. MT-00277 (A) Pinion shaft (B) Bevel pinion...
  • Page 35 Front Differential Assembly MANUAL TRANSMISSION AND DIFFERENTIAL Standard backlash: NOTE: 0.13 — 0.18 mm (0.0051 — 0.0071 in) Do not reuse the oil seal. Prepare a new oil seal. MT-00285 AT-00220 3) Align the pinion shaft and differential case at D: ASSEMBLY their holes, and drive the straight pin into holes 1.
  • Page 36 Front Differential Assembly MANUAL TRANSMISSION AND DIFFERENTIAL 5) Install the hypoid driven gear to differential case E: INSPECTION using twelve bolts. Repair or replace the differential gear in the follow- ing cases: Tightening torque: • The hypoid drive gear and drive pinion shaft T: 62 N·m (6.3 kgf-m, 45.6 ft-lb) tooth surface are damaged, excessively worn, or seized.
  • Page 37 (A) Toe ST3 498255400 PLATE (B) Coast side 2) Install the SUBARU genuine axle shafts to both (C) Heel side, rotate in the inversion direction so that the (D) Drive side gauge contact with the tooth surface and read the dial gauge.
  • Page 38 Front Differential Assembly MANUAL TRANSMISSION AND DIFFERENTIAL 2. HYPOID GEAR BACKLASH • Face contact Checking item: Backlash is too large. Adjust backlash by turning the holder in right side Contact pattern case. ST 499787000 WRENCH ASSY AT-00208 Corrective action: Reduce thickness of drive pinion MT-00176 shim in order to bring drive pinion close to driven NOTE:...
  • Page 39 Front Differential Assembly MANUAL TRANSMISSION AND DIFFERENTIAL Corrective action: Increase thickness of drive pin- • Heel contact (Outside end contact) ion shim in order to move drive pinion away from Checking item: Contact areas is small. driven gear. Contact pattern AT-00213 AT-00211 •...

  • Page 40: Speedometer Gear

    Speedometer Gear MANUAL TRANSMISSION AND DIFFERENTIAL 21.Speedometer Gear NOTE: Use a new snap ring, if it has been removed. A: REMOVAL 1) Remove the manual transmission assembly from vehicle. <Ref. to 5MT-38, REMOVAL, Manual Transmission Assembly.> 2) Remove the back-up light switch and neutral po- sition switch.

  • Page 41: Reverse Idler Gear

    Reverse Idler Gear MANUAL TRANSMISSION AND DIFFERENTIAL 22.Reverse Idler Gear B: INSTALLATION 1) Install the reverse shifter lever, reverse idler A: REMOVAL gear and reverse idler gear shaft, and secure with 1) Remove the manual transmission assembly straight pin. from vehicle. <Ref. to 5MT-38, REMOVAL, Manual NOTE: Transmission Assembly.>...
  • Page 42 Reverse Idler Gear MANUAL TRANSMISSION AND DIFFERENTIAL C: INSPECTION D: ADJUSTMENT 1) Move the reverse shifter rod toward the reverse 1) Select the appropriate reverse shifter lever from side. Inspect the clearance between reverse idler the table below, and adjust until the gap between gear and transmission case wall.

  • Page 43: Shifter Fork And Rod

    Shifter Fork and Rod MANUAL TRANSMISSION AND DIFFERENTIAL 23.Shifter Fork and Rod NOTE: When removing the rod, keep other rods in neutral. A: REMOVAL Also, when pulling out the straight pin, remove it to- 1) Remove the manual transmission assembly ward the inside of case so that it does not hit from vehicle.
  • Page 44 Shifter Fork and Rod MANUAL TRANSMISSION AND DIFFERENTIAL 11) Install the main shaft assembly. NOTE: Single-range model Apply a coat of grease to plunger to prevent it from <Ref. to 5MT-72, INSTALLATION, Main Shaft As- falling. sembly for Single-Range.> 6) Install the 3-4 fork rod into 3-4 shifter fork via the Dual-range model hole on the rear of transmission case.
  • Page 45 Shifter Fork and Rod MANUAL TRANSMISSION AND DIFFERENTIAL Clearance (a): 1st-2nd shifter fork 9.3 mm (0.366 in) Part No. Mark Remarks 32804AA070 — Standard Become distant from 32804AA080 2nd gear by 0.2 mm (0.008 in). 4) Inspect the clearance between 3rd, 4th drive gear and coupling sleeve.

  • Page 46: Counter Gear

    Counter Gear MANUAL TRANSMISSION AND DIFFERENTIAL 24.Counter Gear • Be careful not to drop the two needle bearings and collar contained in counter gear. A: REMOVAL 1) Remove the manual transmission assembly from vehicle. <Ref. to 5MT-38, REMOVAL, Manual Transmission Assembly.> 2) Remove the transfer case with extension case assembly.
  • Page 47 Counter Gear MANUAL TRANSMISSION AND DIFFERENTIAL D: ADJUSTMENT Selection of snap ring: If the measurement is not within specification, se- lect suitable snap ring. Snap ring Part No. Thickness mm (in) 031319000 1.50 (0.0591) 805019010 1.72 (0.0677) 5MT-116...

  • Page 48: General Diagnostic

    General Diagnostic MANUAL TRANSMISSION AND DIFFERENTIAL 25.General Diagnostic 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 (b) Worn, damaged or burred chamfer of...
  • Page 49 General Diagnostic MANUAL TRANSMISSION AND DIFFERENTIAL 2. DIFFERENTIAL Symptom Possible cause Remedy 1. Broken differential (case, gear, bear- (a) Insufficient or improper oil Disassemble the differential and replace ing, etc.) broken components and at the same time NOTE: check other components for any trouble, Abnormal noise will develop and finally it and replace if necessary.

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