2004 impreza service manual quick reference index
Contents
1. 5MT 52 Transfer Case and Extension Case Assembly 9 Transfer Case and Extension Case Assembly A REMOVAL 1 Remove the manual transmission assembly from vehicle lt Ref to 5MT 38 REMOVAL Manual Transmission Assembly gt 2 Remove the back up light switch and neutral po sition switch lt Ref to 5MT 48 REMOVAL Switch es and Harness gt 3 Remove the transfer case with extension case assembly MT 00116 4 Remove the shifter arm 5 Remove the extension case assembly MT 00117 B INSTALLATION 1 Install the center differential and transfer driven gear into transfer case MT 00118 MANUAL TRANSMISSION AND DIFFERENTIAL 2 Remove the bearing outer race from extension case B OR A Bearing outer race B Extension case 3 While pressing the bearing outer race horizontal ly turn the driven shaft ten rotations 4 Measure the height W between transfer case and taper roller bearing on the transfer driven gear MT 00120 5 Measure the depth X NOTE Measure with bearing cone and thrust washer re moved MT 00121 6 Calculate the washer thickness t using the fol lowing equation t X W 0 2 to 0 3 mm 0 008 to 0 012 in 7 Select the nearest washer in the following table Preload between thrust washer and taper roller bearing 0 2 0 3 mm T 0 008 0 012 in T 5MT 532. 2 Install the ball spring washer and plug to trans fer case Tightening torque 10 N m 1 0 kgf m 7 2 ft lb ea SN W a A 3 Install the shifter arm to transfer case assembly 4 Install the transfer case with extension case as sembly lt Ref to 5MT 53 INSTALLATION Trans fer Case and Extension Case Assembly gt 5 Install the manual transmission assembly to ve hicle lt Ref to 5MT 41 INSTALLATION Manual Transmission Assembly gt C DISASSEMBLY 1 Cover the reverse check sleeve with a rag and remove the snap ring using a screwdriver NOTE Replace the snap ring with a new one if deformed or weakened MT 00149 MT 00153 A Snap ring 5MT 63 Reverse Check Sleeve MANUAL TRANSMISSION AND DIFFERENTIAL 2 Remove the reverse check plate reverse check spring reverse check cam return spring 5th Rev reverse accent shaft return spring cap and return spring 1st 2nd A ee get SH MT 00154 A B C Reverse check plate Reverse check spring Return spring 5th Rev Reverse check cam am el E F G Reverse accent shaft Return spring cap Return spring 1st 2nd Lak Se Eier 3 Remove the O ring NOTE e Reverse check sleeve assembly uses an O ring which should not be scratched e Be careful not to break the adjustment shim placed between reverse check sleeve assembly and case D ASSEM
3. 49 Switches and Harness MANUAL TRANSMISSION AND DIFFERENTIAL Gear shift position Terminal No Specified resistance LO position 1 and2 Less than 1 Q HIGH position More than 1 MQ MT 00112 4 Replace defective parts 5MT 50 Vehicle Speed Sensor 7 Vehicle Speed Sensor A REMOVAL 1 Disconnect the ground cable from battery 2 Lift up the vehicle 3 Remove the front center rear exhaust pipes and muffler 4 Disconnect the connector from vehicle speed sensor 5 Turn and remove the vehicle speed sensor Q Qys B INSTALLATION Gap S S MT 00113 NOTE e Discard the vehicle speed sensor and after re moval replace with a new one e Ensure the sensor mounting hole is clean and free of foreign matter e Align the tip end of key with key groove on end of speedometer shaft during installation 1 Hand tighten the vehicle speed sensor 2 Tighten the vehicle speed sensor using suitable tool Tightening torque 5 9 N m 0 6 kgf m 4 3 ft lb 3 Connect the connector to vehicle speed sensor 4 Install the front center exhaust pipes and muf fler 5 Lower the vehicle 6 Connect the battery ground cable to battery C INSPECTION Inspect the vehicle speed sensor Without OBD lt Ref to EN H4SOw oOBD diag 80 DTC 33 VE HICLE SPEED SIGNAL Diagnostic Procedure with Diagnostic Trouble Code DTC gt With OBD Non turbo model l
4. Transfer Case and Extension Case Assembly MANUAL TRANSMISSION AND DIFFERENTIAL NOTE Be sure to observe preload Thrust washer 50 x 61 x t Part No Thickness mm in 803050060 0 50 0 0197 803050061 0 55 0 0217 803050062 0 60 0 0236 803050063 0 65 0 0256 803050064 0 70 0 0276 803050065 0 75 0 0295 803050066 0 80 0 0315 803050067 0 85 0 0335 803050068 0 90 0 0354 803050069 803050070 803050071 1 05 0 0413 803050072 1 10 0 0433 803050073 1 15 0 0453 803050074 1 20 0 0472 803050075 1 25 0 0492 803050076 1 30 0 0512 803050077 1 35 0 0531 803050078 1 40 0 0551 803050079 0 95 0 0374 1 00 0 0394 1 45 0 0571 8 Fit the thrust washers on transfer drive shaft 9 Install the bearing cone into extension case 10 Measure the depth S between transfer case and center differential ST 398643600 GAUGE MT 00122 11 Measure the depth T between extension case and transfer drive gear ST 398643600 GAUGE MT 00123 12 Calculate the space U using the following equation U 15 mm 0 59 in T S 15 mm 0 59 in 0 15 0 35 mm 0 0059 0 0138 in 13 Select the suitab
5. assembly to ve hicle lt Ref to 5MT 41 INSTALLATION Manual Transmission Assembly gt C DISASSEMBLY 1 Remove the reverse check assembly lt Ref to 5MT 63 REMOVAL Reverse Check Sleeve gt 2 Remove oil guide MT 00942 MT 00943 MANUAL TRANSMISSION AND DIFFERENTIAL D ASSEMBLY 1 Install oil seal 2 Install oil guide Tightening torque 6 4 N m 0 65 kgf m 4 7 ft lb 3 Install the reverse check assembly lt Ref to 5MT 63 INSTALLATION Reverse Check Sleeve gt 5MT 57 Transfer Drive Gear MANUAL TRANSMISSION AND DIFFERENTIAL 11 Transfer Drive Gear A REMOVAL 1 Remove the manual transmission assembly from vehicle lt Ref to 5MT 38 REMOVAL Manual Transmission Assembly gt 2 Remove the back up light switch and neutral po sition switch lt Ref to 5MT 48 REMOVAL Switch es and Harness gt 3 Remove the transfer case with extension case assembly lt Ref to 5MT 53 REMOVAL Transfer Case and Extension Case Assembly gt 4 Remove the extension case assembly 5 Remove the transfer driven gear 6 Remove the transfer drive gear MT 00133 B INSTALLATION 1 Install the transfer drive gear Tightening torque 26 N m 2 7 kgf m 20 ft lb MT 00133 2 Install the transfer driven gear 3 Install the extension case assembly 4 Install the transfer case and extension case as sembly lt Ref to 5MT 53 INSTALLATION Trans
6. battery 2 HIGH LOW SWITCH 1 Install the high low switch Tightening torque 24 5 N m 2 5 kgf m 18 1 ft lb 2 Install the high low switch cable to clamp 3 Connect the connector of high low switch 4 Install the air intake duct and cleaner case lt Ref to IN H4SO 5 INSTALLATION Air Cleaner Case gt and lt Ref to IN H4SO 6 INSTALLATION Air Intake Duct gt 5 Connect the battery ground cable to battery C INSPECTION 1 BACK UP LIGHT SWITCH Inspect the back up light switch lt Ref to LI 7 IN SPECTION Back up Light System gt MANUAL TRANSMISSION AND DIFFERENTIAL 2 NEUTRAL POSITION SWITCH 1 Turn the ignition switch to OFF 2 Disconnect the connector of neutral position switch 3 Measure the resistance between neutral posi tion switch terminals Non turbo model Gear shift position Neutral position Other positions Terminal No Specified resistance Less than 1 Q More than 1 MQ 1and2 Turbo model Gear shift position Neutral position Other positions e NON TURBO MODEL Terminal No Specified resistance Less than 1 Q More than 1 MQ 1 and 3 MT 00110 e TURBO MODEL MT 00111 4 Replace defective parts 3 HIGH LOW SWITCH 1 Turn ignition switch to OFF 2 Disconnect connector high low switch 3 Measure the resistance between high low switch terminals 5MT
7. is a non disassemble part Remove the ball bearing using ST NOTE Do not reuse the ball bearing ST 498077300 CENTER DIFFERENTIAL BEARING REMOVER MT 00147 D ASSEMBLY Install the ball bearing to center differential assem bly NOTE Do not apply pressure in excess of 10 KN 1 ton 1 1 US ton 1 0 Imp ton MT 00148 A Ball bearing E INSPECTION 1 Bearings Replace the bearings in the following cases e Broken or rusty bearings e Worn or damaged e Bearings that fail to turn smoothly or make ab normal noise when turned after gear oil lubrication e Bearings having other defects 2 Center differential Replace the center differential assembly in the fol lowing case e Worn or damaged 5MT 62 Reverse Check Sleeve MANUAL TRANSMISSION AND DIFFERENTIAL 14 Reverse Check Sleeve A REMOVAL 1 Remove the manual transmission assembly from vehicle lt Ref to 5MT 38 REMOVAL Manual Transmission Assembly gt 2 Remove the transfer case with extension case assembly lt Ref to 5MT 53 REMOVAL Transfer Case and Extension Case Assembly gt 3 Remove the shifter arm 4 Remove the plug spring washer and reverse check ball MT 00149 5 Remove the reverse check sleeve MT 00150 B INSTALLATION 1 Install the reverse check sleeve Tightening torque 6 4 N m 0 65 kgf m 4 7 ft lb MT 00150
8. mechanism operates prop erly 2 Also check to see if the arm returns to neutral when released from reverse position If the arm does not return properly replace the reverse check plate Reverse check plate Part No ta Angle Remarks No 0 o Arm stops closer to 32189AA000 0 28 5th gear 32189AA010 1 au Atm stops closer to 5th gear 32189AA020 2 34 e stops in the cen 32189AA030 3 3yo Arm stops closer to reverse gear 32189AA040 4 Am Atm stops closer to reverse gear MT 00157 5MT 65 Transmission Case MANUAL TRANSMISSION AND DIFFERENTIAL 15 Transmission Case A REMOVAL 1 SINGLE RANGE 1 Remove the manual transmission assembly from vehicle lt Ref to 5MT 38 REMOVAL Manual Transmission Assembly gt 2 Remove the clutch release lever lt Ref to CL 26 REMOVAL Release Bearing and Lever gt 3 Remove the transfer case with extension case assembly lt Ref to 5MT 53 REMOVAL Transfer Case and Extension Case Assembly gt 4 Remove the bearing mounting bolts X Ss JE ZA S o PKU MT 00159 A Main shaft rear plate 6 Separate the transmission case into right and left cases by loosening the coupling bolts and nuts MT 00160 7 Remove the drive pinion shaft assembly from left side transmission case NOTE Use a hammer handle e
9. the contact point of hypoid gear and drive pinion shaft Repeat the above sequence several times to ensure the contact point ST1 399780104 WEIGHT ST2 499787000 WRENCH ASSY ST3 499927100 HANDLE MT 00175 11 Remove the weight and screw in the retainer without O ring on upper side and stop at the point where slight resistance is felt NOTE At this point the backlash between hypoid gear and drive pinion shaft is zero ST 499787000 WRENCH ASSY MT 00176 12 Fit the lock plate Loosen the retainer on the lower side by 1 1 2 notches of lock plate and turn in the retainer on upper side by the same amount in order to obtain the backlash NOTE The notch on the lock plate moves by 1 2 notch if the plate is turned upside down 13 Turn in the retainer on the upper side addition ally by 1 notch in order to apply preload on taper roller bearing 14 Tighten temporarily both the upper and lower lock plates and mark both holder and lock plate for later readjustment 15 Turn the transmission main shaft several times while tapping around the retainer lightly with plastic hammer 16 Inspect and adjust the backlash and tooth con tact of hypoid gear lt Ref to 5MT 105 INSPEC TION Front Differential Assembly gt 17 After checking the tooth contact of hypoid gears remove the lock plate Then loosen the re tainer until the O ring groove ap
10. 2004 IMPREZA SERVICE MANUAL QUICK REFERENCE INDEX TRANSMISSION SECTION CONTROL SYSTEMS cs AUTOMATIC TRANSMISSION 4AT AUTOMATIC TRANSMISSION PUNCHES DIAGNOSTICS MANUAL TRANSMISSION AND EMT DIFFERENTIAL This service manual has been prepared to provide SUBARU service personnel MANUAL TRANSMISSION AND 6MT with the necessary information and data DIFFERENTIAL for the correct maintenance and repair of SUBARU vehicles MANUAL TRANSMISSION AND AVE CIES This manual includes the procedures DIFFERENTIAL DIAGNOSTICS for maintenance disassembling reas sembling inspection and adjustment of CLUTCH SYSTEM CL 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 G1870GE4 i MANUAL TRANSMISSION AND DIFFERENTIAL 1 General Description eseu ENN see cesessdecnssccuesasensdeasdseanesesbasinchendsttneneiess 2 Transmission Gear UE 3 Manual Transmission Assembly 4 Transmission Mounting System IE O Eelt E 6 Switches and Bt Ts Vehicle Sp ed SONSOM cic
11. BLY 1 Install the return spring 1st 2nd return spring cap reverse accent shaft check cam return spring and check spring onto reverse check sleeve NOTE Be sure the bent section of reverse check spring is positioned in the groove in check cam A SS j ed E G Ge MT 00154 Reverse check plate Reverse check spring Return spring 5th Rev Reverse check cam Reverse accent shaft Return spring cap Return spring 1st 2nd KS 6G aa mm D UE EE 9 2 Hook the bent section of reverse check spring over reverse check plate 3 Rotate the cam so that the protrusion of reverse check cam is at the opening in plate 4 With the cam held in that position install the plate onto reverse check sleeve and hold with snap ring 5 Position the O ring in groove in sleeve 5MT 64 Reverse Check Sleeve MANUAL TRANSMISSION AND DIFFERENTIAL E INSPECTION e Make sure the cutout section of reverse accent shaft is aligned with the opening in reverse check sleeve e Spin the cam by hand for smooth rotation e Move the cam and shaft all the way toward plate and release If the cam does not return properly replace the re verse check spring if shaft does not check for scratches on the inner surface of sleeve If sleeve is in good order replace the spring MT 00156 A Snap ring B Reverse check plate C Check spring D Check cam e Select a suitable reverse accent s
12. E BOND 1215 or equivalent 6 Tighten the seventeen bolts with bracket clip etc as shown in the figure NOTE e Insert the bolts from bottom and tighten the nuts at top e Put the cases together so that the drive pinion shim and input shaft holder shim are not caught up in between e Confirm that the speedometer gear is meshed Tightening torque 8 mm bolt 25 N m 2 5 kgf m 18 1 ft lb 10 mm bolt 39 N m 4 0 kgf m 28 9 ft lb MT 00178 7 Tighten the ball bearing attachment bolts Tightening torque 29 N m 3 0 kgf m 21 7 ft lb 8 Tighten the input shaft holder attaching bolts Tightening torque 20 N m 2 0 kgf m 14 5 ft lb A Input shaft holder B Input shaft 9 Backlash adjustment of hypoid gear and preload adjustment of roller bearing NOTE Support the drive pinion assembly with ST ST 498427100 STOPPER MT 00174 10 Place the transmission with case left side fac ing downward and put ST1 on bearing cup 11 Screw the retainer assembly into left case from the bottom using ST2 Fit the ST3 on transmission main shaft Shift the gear into 4th or 5th and turn the shaft several times Screw in the retainer while turning ST3 until a slight resistance is felt on ST2 This is the contact point of hypoid gear and drive pinion shaft Repeat the above sequence several times to ensure the contact point 5MT 70 Trans
13. Install the drive pinion shaft assembly Install the transmission case knock pin into roller bearing knock pin hole 5 Apply liquid gasket and then put the case right side and left side together Liquid gasket THREE BOND 1215 or equivalent 6 Tighten the seventeen bolts with bracket clip etc as shown in the figure NOTE e Insert the bolts from bottom and tighten the nuts at top es Put the cases together so that drive pinion shim and input shaft holder shim are not caught up in be tween e Confirm that the speedometer gear is meshed Tightening torque 8 mm bolt 25 N m 2 5 kgf m 18 1 ft lb x 10 mm bolt 39 N m 4 0 kgf m 28 9 ft lb MT 00172 7 Tighten the ball bearing attachment bolts Tightening torque 29 N m 3 0 kgf m 21 7 ft lb MT 00158 8 Backlash adjustment of hypoid gear and preload adjustment of roller bearing NOTE Support the drive pinion assembly with ST ST 498427100 STOPPER MT 00174 5MT 68 Transmission Case MANUAL TRANSMISSION AND DIFFERENTIAL 9 Place the transmission with case left side facing downward and put ST1 on bearing cup 10 Screw the retainer assembly into left case from the bottom using ST2 Fit the ST3 on transmission main shaft Shift the gear into 4th or 5th and turn the shaft several times Screw in the retainer while turning ST3 until a slight resistance is felt on ST2 This is
14. fer Case and Extension Case Assembly gt 5 Install the back up light switch and neutral posi tion switch lt Ref to 5MT 49 INSTALLATION Switches and Harness gt 6 Install the manual transmission assembly from vehicle lt Ref to 5MT 41 INSTALLATION Manual Transmission Assembly gt C DISASSEMBLY 1 Remove the snap ring MT 00135 MT 00136 D ASSEMBLY 1 Set the ST applying to inner race of bearing and install to drive shaft ST 398177700 NOTE Do not apply pressure in excess of 10 KN 1 ton 1 1 US ton 1 0 Imp ton INSTALLER ee Sg 2 Install the snap ring on transfer drive shaft 3 Check the clearance between snap ring and ball bearing lt Ref to 5MT 59 INSPECTION Transfer Drive Gear gt MT 00137 5MT 58 Transfer Drive Gear MANUAL TRANSMISSION AND DIFFERENTIAL E INSPECTION 1 Bearings Replace the bearings in the following cases e Broken or rusty bearings e Worn or damaged e Bearings that fail to turn smoothly or make ab normal noise when turned after gear oil lubrication 2 Drive gear Replace the drive gear in the following cases e H their tooth surfaces and shaft are excessively broken or damaged 3 Measure the clearance between snap ring and inner race of ball bearing with a thickness gauge Clearance 0 01 0 15 mm 0 0004 0 0059 in MT 00138 If the measurement is not within specificat
15. following cases e H their tooth surfaces and shaft are excessively broken or damaged 5MT 61 Center Differential MANUAL TRANSMISSION AND DIFFERENTIAL 13 Center Differential A REMOVAL 1 Remove the manual transmission assembly from vehicle lt Ref to 5MT 38 REMOVAL Manual Transmission Assembly gt 2 Remove the transfer case with extension case assembly lt Ref to 5MT 53 REMOVAL Transfer Case and Extension Case Assembly gt 3 Remove the extension case assembly lt Ref to 5MT 53 REMOVAL Transfer Case and Extension Case Assembly gt 4 Remove the transfer driven gear lt Ref to 5MT 60 REMOVAL Transfer Driven Gear gt 5 Remove the center differential B INSTALLATION 1 Install the center differential into transfer case 2 Install the transfer driven gear lt Ref to 5MT 60 INSTALLATION Transfer Driven Gear gt 3 Install the extension case assembly lt Ref to 5MT 53 INSTALLATION Transfer Case and Ex tension Case Assembly gt 4 Install the transfer case with extension case as sembly lt Ref to 5MT 53 REMOVAL Transfer Case and Extension Case Assembly gt 5 Install the back up light switch and neutral posi tion switch lt Ref to 5MT 48 REMOVAL Switches and Harness gt 6 Install the manual transmission assembly to ve hicle lt Ref to 5MT 41 INSTALLATION Manual Transmission Assembly gt C DISASSEMBLY NOTE Do not disassemble the center differential because it
16. haft and re verse check plate lt Ref to 5MT 65 ADJUST MENT Reverse Check Sleeve gt F ADJUSTMENT 1 NEUTRAL POSITION ADJUSTMENT 1 Shift the gear into 3rd gear position 2 Shifter arm turns lightly toward the 1st 2nd gear side but heavily toward the reverse gear side be cause of the function of return spring until arm con tacts the stopper 3 Make adjustment so that the heavy stroke re verse side is a little more than the light stroke 1st 2nd side 4 To adjust remove the bolts holding reverse check sleeve assembly to the case move the sleeve assembly outward and place adjustment shim 0 to 1 ea between sleeve assembly and case to adjust the clearance CAUTION Be careful not to break the O ring when placing shim s NOTE e When the shim is removed the neutral position will move closer to reverse when shim is added the neutral position will move closer to 1st gear e f the shims alone cannot adjust clearance re place the reverse accent shaft and re adjust Adjustment shim Thickness mm in 0 15 0 0059 0 30 0 0118 Part No 32190AA000 32190AA010 Reverse accent shaft Part No Mark Remarks Neutral position is closer to 1st gear Standard Neutral position is closer to reverse gear 32188AA130 32188AA140 32188AA150 2 REVERSE CHECK PLATE ADJUST MENT 1 Shift the shifter arm to 5th and then to reverse to see if reverse check
17. ion se lect a suitable snap ring Snap ring Outer 30 Part No Thickness mm in 805030041 1 53 0 0602 805030042 1 65 0 0650 805030043 1 77 0 0697 5MT 59 Transfer Driven Gear MANUAL TRANSMISSION AND DIFFERENTIAL 12 Transfer Driven Gear A REMOVAL 1 Remove the manual transmission assembly from vehicle lt Ref to 5MT 38 REMOVAL Manual Transmission Assembly gt 2 Remove the back up light switch and neutral po sition switch lt Ref to 5MT 48 REMOVAL Switch es and Harness gt 3 Remove the transfer case with extension case assembly lt Ref to 5MT 53 REMOVAL Transfer Case and Extension Case Assembly gt 4 Remove the extension case assembly 5 Remove the transfer driven gear MT 00118 6 Remove the bearing outer race from extension case and transfer case MT 00140 A Bearing outer race transfer case B Bearing outer race extension case B INSTALLATION 1 Install the bearing outer race to extension case and transfer case MT 00141 A B Cc D Bearing outer race Bearing outer race Transfer case Extension case A B C D 2 Install the transfer driven gear MT 00118 3 Install the transfer case and extension case as sembly lt Ref to 5MT 53 INSTALLATION Trans fer Case and Extension Case Assembly gt 4 Install the back up light switch and
18. le washer in the following ta ble Standard clearance 0 15 0 35 mm 0 0059 0 0138 in Thrust washer Part No Thickness mm in 803036050 0 9 0 035 803036054 1 0 0 039 803036051 1 1 0 043 803036055 1 2 0 047 803036052 1 3 0 051 803036056 1 4 0 055 1 5 1 6 1 7 803036053 0 059 803036057 0 063 803036058 0 067 14 Fit the thrust washer on center differential 15 Apply proper amount of liquid gasket to the transfer case mating surface Liquid gasket THREE BOND 1215 5MT 54 Transfer Case and Extension Case Assembly 16 Install the extension assembly into transfer case Tightening torque 40 N m 4 1 kgf m 29 7 ft lb MT 00117 17 Install the shifter arm to transfer case MT 00126 18 Hang the shifter arm on 3rd 4th fork rod MT 00127 A Shifter arm B 3rd 4th fork rod 19 Install the transfer case with extension case as sembly to transmission case MANUAL TRANSMISSION AND DIFFERENTIAL Tightening torque 25 N m 2 5 kgf m 18 1 ft lb MT 00116 C DISASSEMBLY 1 TRANSFER CASE 1 Remove the reverse check assembly lt Ref to 5MT 63 REMOVAL Reverse Check Sleeve gt 2 Remove the oil guide MT 00129 2 EXTENSION CASE 1 Remove the transfer drive gear assembly lt Ref to 5MT 58 REMOVAL Tran
19. m 7 0 kgf m 50 6 ft lb 8 Install the propeller shaft lt Ref to DS 17 IN STALLATION Propeller Shaft gt ei gl 9 Install the heat shield cover 10 Install the rear exhaust pipe and muffler 11 Pour gear oil and check the oil level lt Ref to 5MT 37 REPLACEMENT Transmission Gear Oil gt e Se MT 00097 3 Remove the rear exhaust pipe and muffler 4 Remove the heat shield cover If equipped 5 Remove the propeller shaft lt Ref to DS 16 RE MOVAL Propeller Shaft gt 6 Using the ST remove the oil seal ST 398527700 PULLER ASSY MT 00098 A Oil seal 7 Using the ST install the oil seal 5MT 47 Switches and Harness MANUAL TRANSMISSION AND DIFFERENTIAL 6 Switches and Harness A REMOVAL 1 BACK UP LIGHT AND NEUTRAL POSI TION SWITCH 1 Disconnect the ground cable from battery 2 Remove the air intake duct and cleaner case Non turbo model lt Ref to IN H4SO 5 REMOV AL Air Cleaner Case gt and lt Ref to IN H4SO 6 REMOVAL Air Intake Duct gt 3 Remove the intercooler Turbo model lt Ref to IN H4DOTC 10 REMOVAL Intercooler gt 4 Disconnect the connector of back up light switch and neutral position switch e Non turbo MODEL MT 00104 A Neutral switch Brown B Back up light switch Gray e Turbo MODEL 5 Lift up the vehicle 6 Remove the back up light switch and neutral
20. mission Case MANUAL TRANSMISSION AND DIFFERENTIAL ST1 399780104 WEIGHT ST2 499787000 WRENCH ASSY ST3 499927100 HANDLE MT 00175 12 Remove the weight and screw in the retainer without O ring on upper side and stop at the point where slight resistance is felt NOTE At this point the backlash between hypoid gear and drive pinion shaft is zero ST 499787000 WRENCH ASSY Lu MT 00176 13 Fit the lock plate Loosen the retainer on the lower side by 1 1 2 notches of lock plate and turn in the retainer on upper side by the same amount in order to obtain the backlash NOTE The notch on the lock plate moves by 1 2 notch if the plate is turned upside down 14 Turn in the retainer on the upper side addition ally by 1 notch in order to apply preload on taper roller bearing 15 Tighten temporarily both the upper and lower lock plates and mark both holder and lock plate for later readjustment 16 Turn the transmission main shaft several times while tapping around the retainer lightly with plastic hammer 17 Inspect and adjust the backlash and tooth con tact of hypoid gear lt Ref to 5MT 105 INSPEC TION Front Differential Assembly gt 18 After checking the tooth contact of hypoid gears remove the lock plate Then loosen the re tainer until the O ring groove appears Fit the O ring into groove and tighten the retainer into the po
21. ncaskincecsenehdweed ie aai ine eiae 8 Preparation ee un 9 Transfer Case and Extension Case Aesembhy 53 by Dt Rear Case E 57 Ft Ttansfer irgendee N ia 58 12 Transfer Driven Gear pennsoner a E ER 60 13 Center BEE 62 14 Reverse Check Sleeve minea ea aa E n A E 63 IS TranSMiSSiONn CaSe ie a a a eaa EEE ea NELS 66 16 Main Shaft Assembly for Single Range sesssseeesssreeeesennsssrresrrrressrrrnsee 72 17 Main Shaft Assembly for Dual Range c cccceeeeeeeeeteeeeeeeeeeeeeeeeeeeeenee 82 18 Input Shaft eebe eet ee 87 19 Drive Pinion Shaft reegrgblt eiate enges Seeerei geen 91 20 Front Differential Assembly AAA 102 21 reegt ee ii e a i ia 109 22 REVERSE IDE Bet nsnsi a aa tee Eder 110 23 Shifter Fork and EE 112 24 Co nterGea EE 115 25 General DlSgnoeie 222 de EREENEEE adage ace ieee 117 Transmission Mounting System 4 Transmission Mounting Sys tem A REMOVAL 1 PITCHING STOPPER 1 Disconnect the ground cable from battery 2 Remove the air intake duct Non turbo model lt Ref to IN H4SO 6 REMOVAL Air Intake Duct gt 3 Remove the air cleaner case Non turbo model lt Ref to IN H4SO 5 REMOVAL Air Cleaner Case gt 4 Remove the intercooler Turbo model lt Ref to IN H4DOTC 10 REMOVAL Intercooler gt 5 Remove the pitching stopper MT 00069 2 CROSSMEMBER AND CUSHION RUB BER 1 Disconnect the ground cable from battery 2 Jack up the vehicle and suppor
22. neutral posi tion switch lt Ref to 5MT 49 INSTALLATION Switches and Harness gt 5 Install the manual transmission assembly to ve hicle lt Ref to 5MT 41 INSTALLATION Manual Transmission Assembly gt 5MT 60 Transfer Driven Gear MANUAL TRANSMISSION AND DIFFERENTIAL C DISASSEMBLY 1 Using the ST remove the roller bearing exten sion case side ST 498077000 REMOVER MT 00143 A Roller bearing 2 Using the ST1 and ST2 remove the roller bear ing transfer case side ST1 498077000 REMOVER ST2 899864100 REMOVER ST1 MT 00144 A Roller bearing D ASSEMBLY 1 Using the ST install the roller bearing extension case side ST1 398177700 INSTALLER ST2 899864100 REMOVER NOTE Do not apply pressure in excess of 10 KN 1 ton 1 1 US ton 1 0 Imp ton ST2 A s we ST GES MT 00145 A Roller bearing 2 Using the ST install the roller bearing transfer case side ST 499757002 NOTE Do not apply pressure in excess of 10 KN 1 ton 1 1 US ton 1 0 Imp ton INSTALLER MT 00146 A Roller bearing E INSPECTION 1 Bearings Replace the bearings in the following cases e Broken or rusty bearings e Worn or damaged e Bearings that fail to turn smoothly or make ab normal noise when turned after gear oil lubrication 2 Driven gear Replace the drive gear in the
23. ning the seventeen coupling bolts and nuts MT 00160 9 Remove the drive pinion shaft assembly from left side transmission case NOTE Use a hammer handle etc to remove if too tight A Main shaft assembly B Drive pinion shaft assembly 10 Removing high low shifter fork Raise the main shaft assembly slightly and remove the high low shifter fork together with high low shifter shaft and washer NOTE Be careful not to drop the two high low shifter piec es MT 00169 A High low shifter fork B Input shaft ASSY 5MT 67 Transmission Case MANUAL TRANSMISSION AND DIFFERENTIAL 11 Remove the main shaft assembly and input shaft assembly NOTE Be careful not to drop the input shaft and main shaft as they are separable MT 00170 A Main shaft ASSY B Input shaft ASSY 12 Remove the differential assembly NOTE e Be careful not to confuse the right and left roller bearing outer races Be careful not to damage the retainer oil seal MT 00162 B INSTALLATION 1 SINGLE RANGE 1 Wipe off grease oil and dust on the mating sur faces of transmission cases with white gasoline 2 Install the front differential assembly 3 Install the main shaft assembly Install the transmission case knock pin into needle bearing knock pin hole 4
24. pears Fit the O ring into groove and tighten the retainer into the po sition where retainer has been tightened in Tighten the lock plate NOTE Carry out this job on both upper and lower retain ers Tightening torque T 25 N m 2 5 kgf m 18 1 ft lb MT 00177 18 Selecting of main shaft rear plate lt Ref to 5MT 80 ADJUSTMENT Main Shaft Assembly for Single Range gt 19 Install the clutch release lever and bearing lt Ref to CL 26 INSTALLATION Release Bearing and Lever gt 20 Install the transfer case with extension case as sembly lt Ref to 5MT 53 INSTALLATION Trans fer Case and Extension Case Assembly gt 21 Install the manual transmission assembly into the vehicle lt Ref to 5MT 41 INSTALLATION Manual Transmission Assembly gt 2 DUAL RANGE 1 Wipe off grease oil and dust on the mating sur faces of transmission cases with white gasoline 2 Install the front differential assembly 3 Install the main shaft assembly and input shaft assembly Connect the main shaft assembly and input the shaft assembly and install needle bearing knock pin hole into transmission case knock pin 4 Install the drive pinion shaft assembly Install the roller bearing knock pin hole into trans mission case knock pin 5MT 69 Transmission Case MANUAL TRANSMISSION AND DIFFERENTIAL 5 Apply liquid gasket and then put the case right side and left side together Liquid gasket THRE
25. po sition switch with harness MT 00106 A Neutral switch Brown B Back up light switch Gray 2 HIGH LOW SWITCH 1 Disconnect the ground cable from battery 2 Remove the air intake duct and cleaner case Non turbo model lt Ref to IN H4SO 5 REMOV AL Air Cleaner Case gt and Pei to IN H4SO 6 REMOVAL Air Intake Duct gt 3 Disconnect the connector of high low switch L 4 LT x Ge MG N Een 9 SeN e ROSE RST N eS S C C DZ MT 00107 A Neutral switch Brown B Back up light switch Gray C High low switch Black 4 Remove the high low switch cable from clamp 5 Remove the high low switch A Clamp B High low switch 5MT 48 Switches and Harness B INSTALLATION 1 BACK UP LIGHT SWITCH AND NEU TRAL POSITION SWITCH 1 Install the back up light switch and neutral posi tion switch with harness Tightening torque 24 5 N m 2 5 kgf m 18 1 ft lb MT 00106 A Neutral switch B Back up light switch 2 Connect the connector of back up light switch and neutral position switch 3 Install the air intake duct and cleaner case Non turbo model lt Ref to IN H4SO 5 INSTAL LATION Air Cleaner Case gt and Hei to IN H4SO 6 INSTALLATION Air Intake Duct gt 4 Install the intercooler Turbo model lt Ref to IN H4DOTC 10 INSTALLATION Inter cooler gt 5 Connect the battery ground cable to
26. sfer Drive Gear gt 2 Remove the shift bracket 3 Remove the oil seal from extension case lt Ref to 5MT 47 Oil Seal gt 5MT 55 Transfer Case and Extension Case Assembly MANUAL TRANSMISSION AND DIFFERENTIAL D ASSEMBLY 1 EXTENSION CASE 1 Using the ST install the oil seal to extension case lt Ref to 5MT 47 Oil Seal gt NOTE Use a new oil seal 2 Install the shift bracket to extension case Tightening torque 25 N m 2 5 kgf m 18 1 ft lb MT 00130 3 Install the transfer drive gear to extension case lt Ref to 5MT 58 INSTALLATION Transfer Drive Gear gt 2 TRANSFER CASE 1 Install the oil guide to transfer case Tightening torque 6 4 N m 0 65 kgf m 4 7 ft lb MT 00129 2 Install the reverse check sleeve assembly to transfer case lt Ref to 5MT 63 INSTALLATION Reverse Check Sleeve gt 5MT 56 Rear Case 10 Rear Case A REMOVAL 1 Remove the manual transmission assembly from vehicle lt Ref to 5MT 38 REMOVAL Manual Transmission Assembly gt 2 Remove back up light switch and neutral posi tion switch lt Ref to 5MT 48 REMOVAL Switches and Harness gt 3 Remove rear case B INSTALLATION 1 Install rear case Tightening torque 24 5 N m 2 5 kgf m 18 1 ft lb 2 Install back up light switch and neutral position switch lt Ref to 5MT 49 INSTALLATION Switch es and Harness gt 3 Install the manual transmission
27. sition where retainer has been tightened in Tighten the lock plate NOTE Carry out this job on both upper and lower retain ers Tightening torque T 25 N m 2 5 kgf m 18 1 ft lb MT 00177 19 Selection of main shaft rear plate lt Ref to 5MT 80 ADJUSTMENT Main Shaft Assembly for Sin gle Range gt 20 Install the transfer case with extension case as sembly lt Ref to 5MT 53 INSTALLATION Trans fer Case and Extension Case Assembly gt 21 Install the clutch release lever and bearing lt Ref to CL 26 INSTALLATION Release Bearing and Lever gt 22 Install the manual transmission assembly into the vehicle lt Ref to 5MT 41 INSTALLATION Manual Transmission Assembly gt C INSPECTION Check the transmission case for cracks damage and oil leaks 5MT 71
28. t Ref to EN H4SO diag 185 DTC P0502 VEHI CLE SPEED SENSOR CIRCUIT LOW INPUT Di agnostic Procedure with Diagnostic Trouble Code DTC gt lt Ref to EN H4SO diag 186 DTC P0503 VEHICLE SPEED SENSOR INTERMIT TENT ERRATIC HIGH Diagnostic Procedure with Diagnostic Trouble Code DTC gt MANUAL TRANSMISSION AND DIFFERENTIAL Turbo model lt Ref to EN H4DOTC diag 200 DTC P0502 VE HICLE SPEED SENSOR CIRCUIT LOW INPUT Diagnostic Procedure with Diagnostic Trouble Code DTC gt lt Ref to EN H4DOTC diag 202 DTC P0503 VEHICLE SPEED SENSOR INTER MITTENT ERRATIC HIGH Diagnostic Procedure with Diagnostic Trouble Code DTC gt 5MT 51 Preparation for Overhaul MANUAL TRANSMISSION AND DIFFERENTIAL 8 Preparation for Overhaul A PROCEDURE 1 Clean oil grease dirt and dust from transmis sion 2 Remove the drain plug to drain oil After drain ing retighten it as before NOTE Replace the gasket with a new one Tightening torque 69 N m 7 0 kgf m 50 6 ft lb Se MT 00097 3 Attach the transmission to ST ST 499937100 TRANSMISSION STAND MT 00115 4 Rotating parts should be coated with oil prior to assembly 5 All disassembled parts if to be reused should be reinstalled in the original positions and direc tions 6 Gaskets lock washers and lock nut must be re placed with new ones 7 Liquid gasket should be used where specified to prevent leakage
29. t it with sturdy racks 3 Remove the front and center exhaust pipes Non turbo model Without OBD lt Ref to EX H4SOw oOBD 6 REMOVAL Front Exhaust Pipe gt With OBD lt Ref to EX H4SO 6 REMOVAL Front Exhaust Pipe gt 4 Remove the center exhaust pipe Turbo model lt Ref to EX H4DOTC 9 REMOVAL Center Ex haust Pipe gt 5 Remove the rear exhaust pipe and muffler 6 Remove the heat shield cover If equipped 7 Set the transmission jack under the transmission body CAUTION Always support the transmission case with a transmission jack MANUAL TRANSMISSION AND DIFFERENTIAL 8 Remove the rear crossmember H E 9 Remove the rear cushion rubber B INSTALLATION 1 PITCHING STOPPER 1 Install the pitching stopper Tightening torque T1 50 N m 5 1 kgf m 37 ft lb T2 58 N m 5 9 kgf m 43 ft lb 2 Install the air intake duct and cleaner case Non turbo model lt Ref to IN H4SO 5 INSTALLATION Air Cleaner Case gt and lt Ref to IN H4SO 6 INSTALLATION Air Intake Duct gt 3 Install the intercooler Turbo model lt Ref to IN H4DOTC 10 INSTALLATION Inter cooler gt 4 Connect the battery ground cable to battery 2 CROSSMEMBER AND CUSHION RUB BER 1 Install the rear cushion rubber Tightening torque 35 N m 3 6 kgf m 26 ft lb 2 Install the rear crossmember Tightening torque T1 70 N m 7 1 kgf m 51 ft lb T2 140 N m 14 3 kgf m 103 f
30. t lb MT 00081 3 Remove the transmission jack 4 Install the heat shield cover If equipped 5MT 45 Transmission Mounting System MANUAL TRANSMISSION AND DIFFERENTIAL 5 Install the front and center exhaust pipes Non turbo model Without OBD lt Ref to EX H4SOw oOBD 7 INSTALLATION Front Exhaust Pipe gt With OBD lt Ref to EX H4SO 7 INSTALLATION Front Ex haust Pipe gt 6 Install the center exhaust pipe Turbo model lt Ref to EX H4DOTC 10 INSTALLATION Center Exhaust Pipe gt 7 Install the rear exhaust pipe and muffler C INSPECTION Repair or replace parts if the results of the inspec tion below are not satisfactory 1 PITCHING STOPPER Make sure the pitching stopper is not bent or dam aged Make sure the rubber is not stiff cracked or otherwise damaged 2 CROSSMEMBER AND CUSHION RUB BER Make sure the crossmember is not bent or dam aged Make sure the cushion rubber is not stiff cracked or otherwise damaged 5MT 46 Oil Seal MANUAL TRANSMISSION AND DIFFERENTIAL 5 Oil Seal ST 498057300 INSTALLER A INSPECTION Check the oil seal portion for leakage If leakage is found replace the oil seal with a new one B REPLACEMENT 1 Clean the transmission exterior 2 Drain the gear oil completely NOTE Tighten the drain plug after draining gear oil MT 00099 Tightening torque 69 N
31. tc to remove if too tight V VW SO A Main shaft assembly B Drive pinion shaft assembly 8 Remove the main shaft assembly 9 Remove the differential assembly NOTE e Be careful not to confuse the right and left roller bearing outer races es Be careful not to damage the retainer oil seal 2 DUAL RANGE 1 Remove the manual transmission assembly from vehicle lt Ref to 5MT 38 REMOVAL Manual Transmission Assembly gt 2 Remove the clutch release lever lt Ref to CL 26 REMOVAL Release Bearing and Lever gt 3 Remove the transfer case with extension case assembly lt Ref to 5MT 53 REMOVAL Transfer Case and Extension Case Assembly gt 5MT 66 Transmission Case 4 Remove the input shaft holder A Input shaft holder B Input shaft 5 Remove the high low switch lt Ref to 5MT 48 REMOVAL Switches and Harness gt 6 Using the ST drive out the straight pin and re move high low shifter lever ST 398791700 STRAIGHT PINREMOVER 2 NOTE When driving out the straight pin remove it in the direction that it does not butt against transmission case S MT 00164 A Straight pin B High low shifter lever 7 Remove the main shaft rear plate MT 00165 A Main shaft rear plate MANUAL TRANSMISSION AND DIFFERENTIAL 8 Separate the transmission case into right and left cases by loose
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