Subaru 2004 Impreza Service Manual page 17

MANUAL TRANSMISSION AND DIFFERENTIAL
NOTE:
• Face the grooved side toward input gear.
• Align the high-low baulk ring's groove with shift-
ing insert.
(F)
(G)
(A) Ball
(B) Input low gear spacer
(C) Needle bearing
(D) Low input gear
(E) Friction damper
(F) High-low baulk ring
(G) Sleeve and hub ASSY
14) Install a new snap ring to the rod section of
transmission main shaft using ST1 and ST2.
NOTE:
Select a suitable outer snap ring so that axial clear-
ance between snap ring and hub is held within
0.060 to 0.100 mm (0.0024 to 0.0039 in).
ST1 499757002 INSTALLER
ST2 499757001 SNAP RING GUIDE
Snap ring
Part No.
805025051
805025052
805025053
805025054
805025055
805025056
805025057
805025058
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
Main Shaft Assembly for Dual-Range
(A)
(B)
(C)
(D)
(E)
(F)
MT-00225
Thickness mm (in)
2.42 (0.0953)
2.47 (0.0972)
2.52 (0.0992)
2.57 (0.1012)
2.62 (0.1031)
2.67 (0.1051)
2.72 (0.1071)
2.37 (0.0933)
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.
F: ADJUSTMENT
Choose the main shaft rear plate. <Ref. to 5MT-80,
ADJUSTMENT, Main Shaft Assembly for Single-
Range.>
5MT-86