Subaru 2004 Impreza Service Manual page 23

MANUAL TRANSMISSION AND DIFFERENTIAL
Drive pinion shim
Part No.
32295AA031
32295AA041
32295AA051
32295AA061
32295AA071
32295AA081
32295AA091
32295AA101
9) Install the differential assembly. <Ref. to 5MT-
102, INSTALLATION, Front Differential Assem-
bly.>
10) Set the transmission main shaft assembly and
drive pinion assembly in position. (So there is no
clearance between the two when moved all the way
to the front). Inspect the suitable 1st-2nd, 3rd-4th
and 5th shifter fork so that coupling sleeve and re-
verse driven gear are positioned in the center of
their synchronizing mechanisms. <Ref. to 5MT-99,
INSPECTION, Drive Pinion Shaft Assembly.>
11) Install the transmission case. <Ref. to 5MT-68,
INSTALLATION, Transmission Case.>
12) Install the transfer case with extension case as-
sembly. <Ref. to 5MT-53, INSTALLATION, Trans-
fer Case and Extension Case Assembly.>
13) Install the manual transmission assembly to ve-
hicle. <Ref. to 5MT-38, Manual Transmission As-
sembly.>
C: DISASSEMBLY
1. AWD MODEL
NOTE:
Attach a cloth to the end of driven shaft (on the fric-
tional side of thrust needle bearing) to prevent
damage during disassembly or reassembly.
1) Straighten the lock nut at staked portion. Re-
move the lock nut using ST1, ST2 and ST3.
ST1 899884100 HOLDER
ST2 498427100 STOPPER
ST3 899988608 SOCKET WRENCH (27)
Drive Pinion Shaft Assembly
Thickness mm (in)
0.150 (0.0059)
0.175 (0.0069)
0.200 (0.0079)
0.225 (0.0089)
0.250 (0.0098)
0.275 (0.0108)
0.300 (0.0118)
0.500 (0.0197)
ST1
ST2
ST3
MT-00244
5MT-92
2) Withdraw the drive pinion from driven shaft.
Remove the differential bevel gear sleeve, adjust-
ing washer No. 1, adjusting washer No. 2, thrust
bearing, needle bearing, drive pinion collar, needle
bearing and thrust bearing.
( E )
( F )
( G )
( H )
(A) Differential bevel gear sleeve
(B) Washer No. 1 (25 × 37.5 × t)
(C) Thrust bearing (25 × 37.5 × 3)
(D) Washer No. 2 (25 × 37.5 × 4)
(E) Needle bearing (25 × 30 × 20)
(F) Drive pinion collar
(G) Needle bearing (30 × 37 × 23)
(H) Thrust bearing (33 × 50 × 3)
3) Remove the roller bearing and washer using ST
and press.
NOTE:
Do not reuse the roller bearing.
ST 498077000 REMOVER
4) Straighten the lock nut at staked portion. Re-
move the lock nut using ST1 and ST2.
( A )
( B )
( C )
( D )
MT-00245
ST
MT-00246