Subaru 2004 Impreza Service Manual page 11

MANUAL TRANSMISSION AND DIFFERENTIAL
7) Install the following parts to the rear section
transmission main shaft.
ST1 499987003 SOCKET WRENCH
ST2 498937000 TRANSMISSION HOLDER
NOTE:
• Align groove in baulk ring with shifting insert.
• Be sure to fit pawl of insert stopper plate into 4
mm (0.16 in) dia. hole in the boss section of syn-
chronizer hub.
(A) (B)
(A) Needle bearing
(B) 5th drive gear
(C) Baulk ring
(D) Sleeve and hub ASSY
(E) Insert stopper plate
(F) Lock washer
(G) Lock nut
8) Tighten lock nuts (22 × 13) to the specified
torque using ST1 and ST2.
NOTE:
Secure lock nuts in two places after tightening.
Tightening torque:
120 N·m (12.2 kgf-m, 88.5 ft-lb)
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.
Main Shaft Assembly for Single-Range
(C) (D)
(E)
(F)
(G)
MT-00821
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.
F: ADJUSTMENT
Selection of main shaft rear plate:
Using the ST, measure the amount (A) of ball bear-
ing protrusion from transmission main case surface
and select the proper plate in the following table:
NOTE:
Before measuring, tap the end of main shaft with a
plastic hammer lightly in order to make the clear-
ance zero between the main case surface and the
moving flange of bearing.
ST 498147000
5MT-80
MT-00208
DEPTH GAUGE