2004 impreza service manual quick reference index
Contents
1. MT 00257 10 Install the lock washer Install the lock nut and tighten to the specified torque using ST ST 499987300 SOCKET WRENCH 50 Tightening torque 260 N m 26 5 kgf m 191 7 ft lb MT 00258 NOTE e Stake the lock nut at two points e Using the spring balancer check that starting torque of roller bearing is 0 1 to 1 5 N 0 01 to 0 15 kgf 0 02 to 0 33 ft MT 00259 11 Install the roller bearing onto drive pinion NOTE When installing the roller bearing note its direc tions front and rear because the knock pin hole in outer race is offset B MT 00260 A Roller bearing B Knock pin hole 12 Install the washer using ST1 ST2 and press NOTE e Discard the old lock nuts replace with new ones e Secure the lock nut in four places ST1 499277100 BUSH 1 2 INSTALLER ST2 499277200 INSTALLER MT 00261 5MT 96 Drive Pinion Shaft Assembly MANUAL TRANSMISSION AND DIFFERENTIAL 13 Install the thrust bearing and needle bearing Install the driven shaft assembly Ge MT 00262 14 Install the drive pinion collar needle bearing adjusting washer No 2 thrust bearing adjusting washer No 1 and differential bevel gear sleeve in that order NOTE Be careful bec2. Main Shaft Assembly for Dual Range MANUAL TRANSMISSION AND DIFFERENTIAL NOTE e Face the grooved side toward input gear e Align the high low baulk ring s groove with shift ing insert MT 00225 A Ball B Input low gear spacer C Needle bearing Low input gear E Friction damper High low baulk ring G Sleeve and hub ASSY nanan n el anaana TI 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 Thickness mm in 2 42 0 0953 805025052 2 47 0 0972 805025053 2 52 0 0992 805025054 2 57 0 1012 805025055 2 62 0 1031 805025056 2 67 0 1051 805025057 2 72 0 1071 805025058 2 37 0 0933 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 e Worn bearings e Bearings that fail to turn smoothly or make ab normal noise when turned after gear oil lubrication e Bearings having other defects 2 Bushing each gear Replace the bushing in the following cases e When the sliding surf
3. Standard backlash 0 13 0 18 mm 0 0051 0 0071 in 5MT 106 Front Differential Assembly 2 HYPOID GEAR BACKLASH Adjust backlash by turning the holder in right side case ST 499787000 WRENCH ASSY MT 00176 NOTE Each time holder rotates one tooth backlash changes by 0 05 mm 0 0020 in MT 00296 3 TOOTH CONTACT OF HYPOID GEAR 1 Adjust until the tooth contact is correct 2 Check and adjust the tooth contact with follow ing e Tooth contact Checking item Tooth contact pattern is slightly shifted toward to toe side under no load rotation When loaded contact pattern moves toward heel AT 00207 A Toe side B Heel side MANUAL TRANSMISSION AND DIFFERENTIAL e Face contact Checking item Backlash is too large Contact pattern AT 00208 Corrective action Reduce thickness of drive pinion shim in order to bring drive pinion close to driven gear et Ka AT 00212 e Flank contact Checking item Backlash is too small Contact pattern AT 00209 5MT 107 Front Differential Assembly MANUAL TRANSMISSION AND DIFFERENTIAL Corrective action Increase thickness of drive pin ion shim in order to move drive pinion away from driven gear d gt E AT 00213 e Toe contact Inside end contact Checking item Contact areas is small
4. bly gt 5 Install the transmission case lt Ref to 5MT 68 INSTALLATION Transmission Case gt 6 Install the transfer case with extension case as sembly lt Ref to 5MT 53 INSTALLATION Trans fer Case and Extension Case Assembly gt 7 Install the manual transmission assembly to ve hicle lt Ref to 5MT 41 INSTALLATION Manual Transmission Assembly gt C DISASSEMBLY 1 Put vinyl tape around the main shaft splines to protect oil seal from damage Then pull out the oil seal and needle bearing by hand 2 Remove the lock nut from transmission main shaft assembly NOTE Remove the caulking before taking off lock nut ST1 498937000 TRANSMISSION HOLDER ST2 499987003 SOCKET WRENCH 35 MT 00186 3 Remove the 5th Rev sleeve and hub assembly baulk ring 5th drive gear and needle bearing MT 00187 A 5th Rev sleeve and hub ASSY B Baulk ring C 5th drive gear 4 Remove the snap ring and synchro cone stopper from 5th Rev sleeve and hub assembly MT 00188 A Synchro cone stopper B Snap ring 5 Using the ST1 ST2 and a press remove the ball bearing synchro cone and baulk ring Rev NOTE e Replace the sleeve and hub with new ones Do not attempt to disassemble because they must en gage at a specified point If they should be disas sembled mark engagement point on splines beforehand 5MT 82 Main Shaft Assembly for Dual Range MA
5. Contact pattern i Soy AT 00210 Corrective action Increase thickness of drive pin ion shim in order to bring drive pinion close to driv en gear ea We oF AT 00213 e Heel contact Outside end contact Checking item Contact areas is small Contact pattern e ee AT 00211 Corrective action Reduce thickness of drive pinion shim in order to move drive pinion away from driven gear gt Ze AT 00212 5MT 108 Speedometer Gear MANUAL TRANSMISSION AND DIFFERENTIAL 21 Speedometer 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 transmission case lt Ref to 5MT 66 REMOVAL Transmission Case gt 5 Remove the vehicle speed sensor lt Ref to 5MT 51 REMOVAL Vehicle Speed Sensor gt 6 Remove the outer snap ring and pull out speed ometer driven gear Next remove the oil seal speedometer shaft and washer MT 00301 A Outer snap ring B Speedometer driven gear B INSTALLATION 1 Install the washer and speedometer shaft and pres
6. gt 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 lt Ref to 5MT 99 INSPECTION Drive Pinion Shaft Assembly gt 11 Install the transmission case lt Ref to 5MT 68 INSTALLATION Transmission Case gt 12 Install the transfer case with extension case as sembly lt Ref to 5MT 53 INSTALLATION Trans fer Case and Extension Case Assembly gt 13 Install the manual transmission assembly to ve hicle lt Ref to 5MT 38 Manual Transmission As sembly gt 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 Y MT 00244 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 MT 00245 A Differe
7. 00305 2 After installing a suitable reverse shifter lever shift into neutral Inspect the clearance between re verse idler gear and transmission case wall If out of specification select the appropriate washer and adjust Clearance 0 0 5 mm 0 0 020 in eA MT 00306 3 Check the reverse idler gear and shaft for dam age Replace if damaged D ADJUSTMENT 1 Select the appropriate reverse shifter lever from the table below and adjust until the gap between the reverse idler gear and transmission case wall is within specification Clearance A 6 0 7 5 mm 0 236 0 295 in Ss H TT H D UI D Reverse shifter lever Part No Mark Remarks 32820AA070 Further from case wall 32820AA080 Standard 32820AA090 Closer to case wall 2 Select the appropriate washer from the table be low and adjust until the gap between the reverse idler gear and transmission case wall is within specification Clearance 0 0 5 mm 0 0 020 in f MT 00306 Washer Part No Thickness mm in 803020151 0 4 0 016 803020152 1 1 0 043 803020153 1 5 0 059 803020154 1 9 0 075 803020155 5MT 111 2 3 0 091 Shifter Fork and Rod MANUAL TRANSMISSION AND DIFFERENTIAL 23 Shifter Fork and Rod A REMOVAL 1 Remove the manual transmission asse
8. Drive the oil seal into input shaft holder NOTE Apply a coat of grease to sealing lips before install ing oil seal ST 398507703 DUMMY COLLAR MT 00235 A 5MT 88 Input Shaft Assembly MANUAL TRANSMISSION AND DIFFERENTIAL 7 Wind vinyl tape around the shaft splines and in sert input shaft into holder by lightly tapping it by hand MT 00236 A Vinyl tape B Input shaft 8 Install the snap ring to input shaft holder NOTE Select a suitable snap ring so that clearance be tween snap ring and bearing is held within 0 to 0 12 mm 0 to 0 0047 in ST 398663600 PLIERS MT 00227 Snap ring Part No Thickness mm in 805168020 1 84 0 0724 805168030 1 92 0 0756 805168040 2 00 0 0787 9 Install the O ring to input shaft holder MT 00238 A O ring B Input shaft holder E INSPECTION Disassembled parts should be washed clean first and then inspected carefully 1 Bearings Replace the bearings in the following cases e Bearings whose balls outer races and inner rac es are broken or rusty e Worn bearings e Bearings that fail to turn smoothly or make ab normal noise when turned after gear oil lubrication e Bearings having other defects 2 Bushing each gear Replace the bushing in the following cases e When the sliding surface is damaged or abnor mally worn e When the inner wall is abn
9. L model 11 Remove the 1st driven gear 2nd gear bushing gear and hub using ST1 and ST2 NOTE Replace the gear and hub if necessary Do not at tempt to disassemble if at all possible because they must engage at a specified point If they should be disassembled mark engagement point before hand ST1 499757002 ST2 899714110 INSTALLER REMOVER MT 00251 12 Remove the sub gear for 1st driven gear 2 FWD MODEL 1 Loosen lock nut using ST1 and ST2 ST1 49987100 or 499987003 or 899984103 SOCKETWRENCH 35 ST2 899884100 HOLDER 5MT 93 Drive Pinion Shaft Assembly MANUAL TRANSMISSION AND DIFFERENTIAL NOTE Remove caulking before taking off lock nut MT 00822 2 Remove 5th driven gear using ST and press ST 498077000 5TH DRIVEN GEAR REMOV ER MT 00823 3 Remove woodruff key 4 Remove roller bearing and 3rd 4th driven gear using ST1 and ST2 ST1 499757002 SNAP RING GUIDE ST2 899714110 REMOVER MT 00824 5 Remove 2nd driven gear assembly 6 Remove 3rd 4th driven gear key 7 Remove 1st driven gear 2nd gear bushing and gear amp hub assembly using ST1 and ST2 Replace gear and hub if necessary Do not attempt to disassemble if at all possible because they must engage at a specified point If they have to be dis assembled mark the
10. PLATE 2 Install the SUBARU genuine axle shafts to both side rotate in the inversion direction so that the gauge contact with the tooth surface and read the dial gauge Part No 38415AA100 AXLE SHAFT Backlash 0 13 0 18 mm 0 0051 0 0071 in ST2 MT 00293 NOTE If the backlash is outside specified range adjust it by turning the holder in right side case 3 TOOTH CONTACT OF HYPOID GEAR Check the tooth contact of hypoid gear as follows Apply a uniform thin coat of red lead on both tooth surfaces of 3 or 4 teeth of the hypoid gear Move the hypoid gear back and forth by turning the trans mission main shaft until a definite contact pattern is developed on hypoid gear and judge whether face contact is correct If it is inaccurate make adjust ment lt Ref to 5MT 106 ADJUSTMENT Front Dif ferential Assembly gt e Tooth contact is correct A vies KEE MT 00294 Toe Coast side Heel Drive side F ADJUSTMENT 1 BEVEL PINION GEAR BACKLASH 1 Disassemble the front differential lt Ref to 5MT 102 REMOVAL Front Differential Assembly gt 2 Select a differential washer from the table and install Washer Part No Thickness mm in 803038021 0 925 0 950 0 0364 0 0374 803038022 0 975 1 000 0 0384 0 0394 803038023 1 025 1 050 0 0404 0 0413 3 Adjust until the specified value is obtained
11. drive shaft using ST and press ST 499277100 INSTALLER 5MT 98 Drive Pinion Shaft Assembly MANUAL TRANSMISSION AND DIFFERENTIAL CAUTION e Face 5th driven gear in the correct direction e Be careful not to dislocate woodruff key while installing 5th driven gear MT 00834 MT 00835 11 Install lock washer and tighten lock nut to the specified torque using ST1 and ST2 ST1 49987100 or 499987003 or 899984103 SOCKETWRENCH 35 ST2 899884100 HOLDER CAUTION e Discard old lock nuts replace with new ones e Secure lock nut in four places Tightening torque 120 N m 12 2 kgf m 88 5 ft lb MT 00822 E INSPECTION Disassembled parts should be washed clean first and then inspected carefully 1 Bearings Replace the bearings in the following cases e Bearings whose balls outer races and inner rac es are broken or rusty e Worn bearings e Bearings that fail to turn smoothly or make ab normal noise when turned after gear oil lubrication e The ball bearing on the rear side of the drive pin ion shaft should be checked for smooth rotation be fore the drive pinion assembly is disassembled In this case because a preload is working on the bearing its rotation feels like it is slightly dragging unlike the other bearings MT 00264 A Drive pinion shaft B Ball bearing e Bearings havin
12. drive gear and needle bearing MT 00187 A 5th Rev sleeve and hub ASSY B Baulk ring C 5th drive gear 5MT 72 Main Shaft Assembly for Single Range 4 Remove the snap ring and synchro cone stopper from 5th Rev sleeve and hub assembly MT 00188 A Synchro cone stopper B Snap ring 5 Using the ST1 ST2 and a press remove the ball bearing synchro cone and baulk ring Rev NOTE e Replace the sleeve and hub with new ones Do not attempt to disassemble because they must en gage at a specified point If they should be disas sembled mark engagement point on splines beforehand e Do not reuse the ball bearing ST1 499757002 INSTALLER ST2 498077400 SYNCHRO CONE REMOV ER ST1 B ST2 A C MT 00189 A Ball bearing B Synchro cone C Baulk ring MANUAL TRANSMISSION AND DIFFERENTIAL 6 Using the ST1 and ST2 remove rest of the parts NOTE Replace the sleeve and hub with new ones Do not attempt to disassemble because they must engage at a specified point If they should be disassem bled mark engagement point on splines before hand ST1 899864100 REMOVER ST2 899714110 REMOVER A ST1 wail ST2 MT 00190 A Press 2 FWD MODEL 1 Put vinyl tape around main shaft splines to p
13. gear e Straight pin e Snap ring 3 Install the transmission case lt Ref to 5MT 68 INSTALLATION Transmission Case gt 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 on ve hicle lt Ref to 5MT 41 INSTALLATION Manual Transmission Assembly gt NOTE e Make sure that the cut out end surface of counter gear shaft does not protrude above the end surface of the case e Position the cut out portion of counter gear shaft C INSPECTION 1 After installing the snap ring measure the clear ance between snap ring and counter washer Clearance 0 05 0 35 mm 0 0020 0 0138 in 2 If the clearance is out of measured value select a snap ring and install to put clearance within mea sured value lt Ref to 5MT 116 ADJUSTMENT Counter Gear gt 5MT 115 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 General Diagnostic MANUAL TRANSMISSION AND DIFFERENTIAL 25 General Diagnostic A INSPECTION 1 MANUAL TRANSMISSION Symptom Possible cause 1 Gears are difficult to intermesh NOTE The cause for difficulty in shifting
14. gear side C 5th Rev hub ASSY D 5th gear side 5MT 76 Main Shaft Assembly for Single Range MANUAL TRANSMISSION AND DIFFERENTIAL 2 Install the 3rd drive gear outer baulk ring syn chro cone inner baulk ring sleeve and hub assem bly for 3rd needle bearing on transmission main shaft NOTE Align the groove in baulk ring with shifting insert A R MT 00200 A 3rd needle bearing B 3rd drive gear C Inner baulk ring S el Synchro cone Outer baulk ring Sleeve and hub ASSY E F anann 3 Install the 4th needle bearing race onto trans mission main shaft using ST1 ST2 and a press NOTE Do not apply pressure in excess of 10 kN 1 ton 1 1 US ton 1 0 Imp ton ST1 899714110 REMOVER ST2 499877000 RACE 4 5 INSTALLER MT 00192 A 4th needle bearing race 4 Install the baulk ring needle bearing 4th drive gear and 4th gear thrust washer to transmission main shaft NOTE Align the baulk ring and gear amp hub assembly with key groove MT 00193 X B A Groove B 4th gear side 5 Drive the ball bearing onto the rear section of transmission main shaft using ST1 ST2 and a press NOTE Do not apply pressure in excess of 10 kN 1 ton 1 1 US ton 1 0 Imp ton ST1 899714110 REMOVER ST2 499877000 RACE 4 5 INSTALLER MT 00194 5MT 77 Main Shaft Assembl
15. mm 0 0051 0 0071 in KE m NA o D Sa ai o MT 00285 3 Align the pinion shaft and differential case at their holes and drive the straight pin into holes from the hypoid driven gear side using ST NOTE Lock the straight pin after installing ST 899904100 REMOVER MT 00286 A Pinion shaft B Differential case C Straight pin 4 Install the roller bearing to differential case NOTE e Do not apply pressure in excess of 10 KN 1 ton 1 1 US ton 1 0 Imp ton es Be careful because the roller bearing outer races are used as a Set ST1 499277100 BUSH 1 2 INSTALLER ST2 398497701 ADAPTER ST1 TUDO ZS ST2 7 MT 00287 5MT 104 Front Differential Assembly MANUAL TRANSMISSION AND DIFFERENTIAL 5 Install the hypoid driven gear to differential case using twelve bolts Tightening torque T 62 N m 6 3 kgf m 45 6 ft lb MT 00288 A Hypoid driven gear B Differential case 2 SIDE RETAINER 1 Install a new oil seal ST 18675AA000 DIFFERENTIAL SIDE OIL SEAL INSTALLER Se ST i MT 00289 NOTE For press fitting of oil seal to retainer make tap ping with plastic hammer etc es Do not use press 2 Install a new O ring NOTE Do not stretch or damage the O ring MT 00279 E INSPECTION Repair or replace t
16. onto 5th Rev sleeve and hub assembly using ST and a press NOTE es Do not apply pressure in excess of 10 KN 1 ton 1 1 US ton 1 0 Imp ton e Use anew ball bearing es After press fitting make sure the synchro cone rotates freely ST 499757002 INSTALLER ST MT 00196 E Baulk ring Synchro cone Ball bearing cg 5MT 75 Main Shaft Assembly for Single Range MANUAL TRANSMISSION AND DIFFERENTIAL 9 Install the synchro cone stopper and snap ring to 5th Rev sleeve and hub assembly MT 00188 A Synchro cone stopper B Snap ring 10 Install rest of the parts to the rear section of transmission main shaft NOTE Align the groove in baulk ring with shifting insert A B C D 1 3 gt F ie MT 00198 A Needle bearing B 5th drive gear C Baulk ring a ES 5th Rev sleeve and hub ASSY Lock washer Lock nuts el E F anann 11 Tighten the lock nuts to the specified torque us ing ST1 and ST2 NOTE Secure the lock nuts in two places after tightening ST1 499987003 SOCKET WRENCH ST2 498937000 TRANSMISSION HOLDER Tightening torque 120 N m 12 2 kgf m 88 5 ft Ib 2 AWD TURBO MODEL 1 Assemble each sleeve and hub assembly NOTE Position the open ends of spring 120 apart MT 00191 A 3rd 4th hub ASSY B 3rd
17. starting torque range cannot be obtained when a No 1 adjusting washer is used then select a suitable No 2 adjusting washer from those listed in the following table Repeat steps 1 through 4 to adjust starting torque MT 00270 A Adjusting washer No 1 B Adjusting washer No 2 Washer No 2 Select thicker one Select thinner one Starting torque Dimension H Low Small High Large Adjusting washer No 2 Part No Thickness mm in 803025059 3 850 0 1516 803025054 4 000 0 1575 803025058 4 150 0 1634 6 Recheck that the starting torque is within speci fied range then clinch the lock nut at four positions 5MT 101 Front Differential Assembly MANUAL TRANSMISSION AND DIFFERENTIAL 20 Front Differential Assembly 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 transmission case lt Ref to 5MT 66 REMOVAL Transmission Case gt 4 Remove the drive pinion shaft assembly lt Ref to 5MT 91 REMOVAL Drive Pinion Shaft Assem bly gt 5 Remove the main shaft assembly Single range model lt Ref to 5MT 72 REMOVAL Main Shaft Assembly for Single Range gt Dual range model lt Ref to 5MT 82 REMOVAL Main Shaft Assembly fo
18. 0829 A 1st 2nd driven gear bushing 4 Measure outside diameter of ist driven gear bushing to determine suitable 1st driven gear 1st driven gear Outer diameter of bushing mm in 42 019 42 033 1 6543 1 6548 42 005 42 018 1 6537 1 6543 41 990 42 004 1 6531 1 6537 Part number 32231AA841 32231AA851 32231 AA861 5 Install 1st driven gear 1st 2nd balk ring and gear and hub assembly already assembled in previous step to drive pinion shaft by hand NOTE Align ring groove with insert E MT 00830 6 Install 1st 2nd driven gear bushing to drive pin ion shaft using ST1 and ST2 ST1 499877000 RACE 4 5 INSTALLER ST2 499277100 BUSH 1 2 INSTALLER MT 00831 A 1st 2nd driven gear bushing 7 Install 2nd driven gear and 1st 2nd balk ring to drive pinion shaft by hand 8 Install key into the groove on drive pinion shaft and install 3rd 4th driven gear NOTE Ball bearing may be installed without using the tool There should be no problem ST 499877000 RACE 4 5 INSTALLER MT 00832 A 3rd 4th driven gear 9 Install ball bearing 29 x 74 x 38 on drive pinion shaft with ST ST 499277100 BUSH 1 2 INSTALLER MT 00833 10 Position woodruff key in groove on the rear of drive pinion shaft Install 5th driven gear onto
19. 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 Position the washer 18 3 x 30 x 4 and lock washer 18 x 30 x 2 and install the lock nut 18 x 13 5 MT 00267 2 Using the ST1 ST2 and ST3 tighten the lock nut to specified torque ST1 899884100 HOLDER ST2 498427100 STOPPER ST3 899988608 SOCKET WRENCH 27 Tightening torque 120 N m 12 2 kgf m 88 5 ft lb MT 00268 3 After removing the ST2 measure the starting torque using torque driver ST1 899884100 HOLDER ST3 899988608 SOCKET WRENCH 27 5MT 100 Drive Pinion Shaft Assembly MANUAL TRANSMISSION AND DIFFERENTIAL Starting torque 0 3 0 8 N m 0 03 0 08 kgf m 0 2 0 6 ft lb MT 00269 4 If the starting torque is not within specified limit select a new adjusting washer No 1 and recheck starting torque MT 00270 A Adjusting washer No 1 B Adjusting washer No 2 Adjusting washer No 1 Part No Thickness mm in 803025051 3 925 0 1545 803025052 3 950 0 1555 803025053 3 975 0 1565 803025054 4 000 0 1575 803025055 4 025 0 1585 803025056 4 050 0 1594 803025057 4 075 0 1604 5 If the specified
20. 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
21. 287 in 32804AA080 MT 00940 A 3rd drive gear B Coupling sleeve C 4th drive gear 3rd 4th shifter fork Part No Mark Remarks Approach to 4th gear by 0 2 mm 0 008 in Standard Become distant from 3rd gear by 0 2 mm 0 008 in 32810AA061 1 32810AA071 32810AA101 5 Inspect the clearance between 5th drive gear and coupling sleeve If any clearance is not within specifications replace the shifter fork as required Clearance a 9 3 mm 0 366 in A D d Di BE MT 00315 A 5th drive gear B Coupling sleeve 5th shifter fork Non turbo Part No Mark Remarks Approach to 5th gear seni ed by 0 2 mm 0 008 in 32812AA211 Standard Become distant from 32812AA221 9 5th gear by 0 2 mm 0 008 in 5th shifter fork Turbo Part No Mark Remarks Approach to 5th gear by 0 2 mm 0 008 in Standard Become distant from 5th gear by 0 2 mm 0 008 in 32812AA231 7 32812AA241 32812AA251 6 Inspect the rod end clearances A and B If any clearance is not within specifications replace the rod or fork as required Clearance A 3rd 4th to 5th 0 5 1 3 mm 0 020 0 051 in Clearance B 1st 2nd to 3rd 4th 0 4 1 4 mm 0 016 0 055 in MT 00
22. 316 5MT 114 Counter Gear MANUAL TRANSMISSION AND DIFFERENTIAL 24 Counter Gear 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 transmission case lt Ref to 5MT 66 REMOVAL Transmission Case gt 4 Move the counter gear shaft until it touches transmission case and remove the snap ring with a suitable tool MT 00317 A Snap ring 5 Slide the washer at rear of high low counter shaft and remove the straight pin from counter shaft MT 00318 A Straight pin B Counter gear 6 Remove the counter shaft from transmission case taking care not to drop the counter gear and two washers NOTE e Be careful not to damage the O ring e Be careful not to drop the straight pin on front side e Be careful not to drop the two needle bearings and collar contained in counter gear MT 00319 A Counter shaft B Counter gear C Washers B INSTALLATION 1 Install the O ring and straight pin onto counter gear shaft 2 Install the following parts in main case Right side and push the shaft perfectly into case es Counter gear shaft e Two counter gear washers e Two needle bearings e Counter gear collar e Counter
23. 77200 ST2 499587000 INSTALLER INSTALLER ST1 ST2 MT 00253 5 Install the 2nd driven gear inner baulk ring syn chro cone outer baulk ring and insert onto driven shaft Except 1 6 L model MT 00254 A 2nd driven gear B Inner baulk ring C Synchro cone D Outer baulk ring 6 Install the 2nd driven gear 1st 2nd bulk ring and insert onto driven shaft 1 6 L model 7 After installing the key on driven shaft install the 3rd 4th driven gear using ST and press NOTE es Do not apply pressure in excess of 10 KN 1 ton 1 1 US ton 1 0 Imp ton e Align the groove in baulk ring with insert ST 499277200 INSTALLER iC d i ET D 9 T A SA MT 00255 5MT 95 Drive Pinion Shaft Assembly MANUAL TRANSMISSION AND DIFFERENTIAL 8 Install a set of roller bearings onto the driven shaft using ST and press NOTE Do not apply pressure in excess of 10 KN 1 ton 1 1 US ton 1 0 Imp ton ST 499277200 INSTALLER MT 00256 9 Position the woodruff key in groove on the rear of driven shaft Install the 5th driven gear onto driv en shaft using ST and press NOTE Do not apply pressure in excess of 10 KN 1 ton 1 1 US ton 1 0 Imp ton ST 499277200 INSTALLER
24. 877000 RACE 4 5 INSTALLER MT 00195 A Face this surface to 5th gear side 7 Install the bearing onto synchro cone 8 Install the baulk ring and synchro cone onto 5th Rev sleeve and hub assembly using ST and a press NOTE e Use a new ball bearing es After press fitting make sure the synchro cone rotates freely ST 499757002 INSTALLER MT 00196 E Baulk ring Synchro cone Ball bearing cg 9 Install the synchro cone stopper and snap ring to 5th Rev sleeve and hub assembly MT 00188 A Synchro cone stopper B Snap ring 10 Install rest of the parts to the rear section of transmission main shaft NOTE Align the groove in baulk ring with shifting insert MT 00198 KS Needle bearing 5th drive gear B Baulk ring Keck 5th Rev sleeve and hub ASSY Lock washer Lock nuts SI E F 11 Tighten the lock nuts to the specified torque us ing ST1 and ST2 NOTE Secure the lock nuts in two places after tightening ST1 499987003 SOCKET WRENCH ST2 498937000 TRANSMISSION HOLDER Tightening torque 120 N m 12 2 kgf m 88 5 ft lb 12 Install the needle bearing on main shaft 13 Install rest of the parts to the front section of transmission main shaft NOTE Be careful not to damage the graded section of transmission main shaft when installing the needle bearing 5MT 85
25. 90 Drive Pinion Shaft Assembly MANUAL TRANSMISSION AND DIFFERENTIAL 19 Drive Pinion Shaft Assembly 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 transmission case lt Ref to 5MT 66 REMOVAL Transmission Case gt 4 Remove the drive pinion shaft assembly NOTE Use a hammer handle etc to remove if too tight A Main shaft assembly B Drive pinion shaft assembly B INSTALLATION 1 Remove the differential assembly 2 Alignment marks numbers on hypoid gear set The upper number on drive pinion is the match number for combining it with hypoid driven gear The lower number is for shim adjustment If no low er number is shown the value is zero The number on hypoid driven gear indicates a number for com bination with drive pinion MT 00241 1 Drive pinion 2 Hypoid driven gear 3 Place the drive pinion shaft assembly on right hand transmission main case without shim and tighten the bearing mounting bolts 4 Inspection and adjustment of ST NOTE e Loosen the two bolts and adjust so that the scale indicates 0 5 correctly when the plate end and the scale end are on the same level e Tighten the two bolts ST 499917500 DRIVE PINION GAUGE
26. ASSY A ST B MT 00242 A Plate B Scale 5 Position the ST by inserting the knock pin of ST into the knock hole in transmission case ST 499917500 DRIVE PINION GAUGE ASSY 6 Slide the drive pinion gauge scale with finger tip and read the value at the point where it matches with the end face of drive pinion ST 499917500 DRIVE PINION GAUGE ASSY MT 00243 A Adjust clearance to zero without shim 7 The thickness of shim shall be determined by adding the value indicated on drive pinion to the value indicated on ST Add if the number on drive pinion is prefixed by and subtract if the number is prefixed by ST 499917500 DRIVE PINION GAUGE ASSY 8 Select one to three shims from the next table for the value determined as described above and take a shim thickness which is closest to the indicated value 5MT 91 Drive Pinion Shaft Assembly MANUAL TRANSMISSION AND DIFFERENTIAL Drive pinion shim Thickness mm in Part No 32295AA031 0 150 0 0059 32295AA041 0 175 0 0069 32295AA051 0 200 0 0079 32295AA061 0 225 0 0089 32295AA071 32295AA081 0 275 0 0108 32295AA091 0 300 0 0118 0 250 0 0098 32295AA101 0 500 0 0197 9 Install the differential assembly lt Ref to 5MT 102 INSTALLATION Front Differential Assem bly
27. NUAL TRANSMISSION AND DIFFERENTIAL es Do not reuse the ball bearing 7 Remove the snap ring from main shaft ST1 499757002 INSTALLER ST 899474100 EXPANDER ST2 498077400 SYNCHRO CONE REMOV ER Sr B ST2 A 0 MT 00215 MT 00189 A Snap ring A Ball bearing 8 Remove rest of the parts B Synchro cone C Baulk ring 6 Using the ST1 and ST2 remove rest of the parts NOTE Replace the sleeve and hub with new ones Do not attempt to disassemble because they must engage at a specified point If they should be disassem bled marking engagement point on splines before hand MT 00216 ST1 899864100 REMOVER A Sleeve and hub ASSY ST2 899714110 REMOVER B High low baulk ring C Friction damper A Low input gear Needle bearing Input low gear spacer Ball aaa m D E eh a E ST1 MT 00190 5MT 83 Main Shaft Assembly for Dual Range MANUAL TRANSMISSION AND DIFFERENTIAL D ASSEMBLY 1 Assemble when each sleeve and hub assembly are disassembled NOTE Position the open ends of spring 120 apart nN E os G N S 7 1 H HES ai as S N O P z E 2 MT 00217 High low coupling sleeve Shifting insert High
28. ace is damaged or abnor mally worn e When the inner wall is abnormally worn 3 Gears e Replace the gears with new ones if their tooth surfaces are broken damaged or excessively worn e Correct or replace if the cone that contacts the baulk ring is rough or damaged e Correct or replace if the inner surface or end face is damaged 4 Baulk ring Replace the ring in the following cases e When the inner surface and end face are dam aged e When the ring inner surface is abnormally or par tially worn down e 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 lt Ref to 5MT 80 ADJUSTMENT Main Shaft Assembly for Single Range gt 5MT 86 Input Shaft Assembly MANUAL TRANSMISSION AND DIFFERENTIAL 18 Input Shaft Assembly 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
29. aft 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 DEPTH GAUGE 5MT 80 Main Shaft Assembly for Single Range MANUAL TRANSMISSION AND DIFFERENTIAL Dimension A Part No mm in 4 00 4 13 0 1575 32294AA041 0 1626 3 87 3 99 0 1524 32294AA051 0 1571 MT 00209 5MT 81 Main Shaft Assembly for Dual Range MANUAL TRANSMISSION AND DIFFERENTIAL 17 Main Shaft Assembly for Dual Range 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 transmission case lt Ref to 5MT 66 REMOVAL Transmission Case gt 4 Remove the drive pinion shaft assembly lt Ref to 5MT 91 REMOVAL Drive Pinion Shaft Assem bly gt 5 Remove the main shaft assembly and input shaft assembly B INSTALLATION 1 Install the needle bearing onto the front of trans mission main shaft assembly 2 Connect the main shaft assembly and input shaft assembly 3 Install the needle bearing outer race knock pin hole into transmission case knock pin 4 Install the drive pinion assembly lt Ref to 5MT 91 INSTALLATION Drive Pinion Shaft Assem
30. and ST2 NOTE Secure the lock nuts in two places after tightening ST1 499987003 SOCKET WRENCH ST2 498937000 TRANSMISSION HOLDER Tightening torque 120 N m 12 2 kgf m 88 5 ft lb 5MT 78 Main Shaft Assembly for Single Range MANUAL TRANSMISSION AND DIFFERENTIAL 3 FWD MODEL 1 Assemble sleeve and hub assembly for 3rd 4th and 5th Rev NOTE Position open ends of spring 120 apart MT 00191 3rd 4th hub ASSY 3rd gear side 5th Rev hub ASSY 5th gear side 2 Install 3rd drive gear baulk ring and sleeve and hub assembly for 3rd 4th needle bearing 32 x 36 x 25 7 on transmission main shaft NOTE Align groove in baulk ring with shifting insert 3 Install 4th needle bearing race onto transmission main shaft using ST1 ST2 and a press ST1 899714110 REMOVER ST2 499877000 RACE 4 5 INSTALLER MT 00192 A 4th needle bearing 4 Install baulk ring needle bearing 82 x 30 x 25 7 4th drive gear and 4th gear thrust washer to transmission main shaft NOTE Face thrust washer in the correct direction MT 00193 X B A Groove B 4th gear side 5 Drive ball bearing onto the rear section of trans mission main shaft using ST1 ST2 and a press ST1 899714110 REMOVER ST2 499877000 RACE 4 5 INSTALLER ST2 ST1 OSR TTH TTT MT 00194 6 Using the same tools as in step 5 above install the
31. ause the spacer must be installed in proper direction C D E F G H A B C MT 00263 Driven shaft Drive shaft Drive pinion collar Needle bearing 25 x 30 x 20 Washer No 2 25 x 36 x 4 om OO Dm Thrust bearing 25 x 37 5 x 3 Washer No 1 25 x 36 x t Differential bevel gear sleeve G H 2 FWD MODEL 1 Assemble gear and hub assembly NOTE e Use new gear and hub assembly if gear or hub have been replaced e Be sure the insert keys are correctly located in the insert key grooves inside the reverse driven gear MT 00827 Key grooves Reverse driven gear 1st driven gear side gt B 6G 2nd driven gear side Flush surface Stepped surface Gel E F Lob em 2 Drive roller bearing onto drive pinion shaft and 1st driven gear thrust washer using ST1 and ST2 ST1 499277000 RACE 4 5 INSTALLER ST2 499277100 BUSH 1 2 INSTALLER CAUTION Use new roller bearing 1st gear thrust washer ST1 MT 00828 A Thrust washer 3 Install 1st 2nd driven gear bushing onto drive pinion shaft 5MT 97 Drive Pinion Shaft Assembly MANUAL TRANSMISSION AND DIFFERENTIAL NOTE Bushing may be installed with either side up ST1 499877000 RACE 4 5 INSTALLER ST2 499277100 BUSH 1 2 INSTALLER ST1 MT 0
32. e and Extension Case Assembly gt 4 Remove the transmission case lt Ref to 5MT 91 REMOVAL Drive Pinion Shaft Assembly gt 5 Remove the drive pinion shaft assembly lt Ref to 5MT 91 REMOVAL Drive Pinion Shaft Assem bly gt 6 Remove the main shaft assembly Single range model lt Ref to 5MT 72 REMOVAL Main Shaft Assembly for Single Range gt Dual range model lt Ref to 5MT 82 REMOVAL Main Shaft Assembly for Dual Range gt 7 Remove the differential assembly lt Ref to 5MT 102 REMOVAL Front Differential Assembly gt 8 Remove the shifter forks and rods lt Ref to 5MT 112 REMOVAL Shifter Fork and Rod gt 9 Pull out the straight pin and remove the idler gear shaft reverse idler gear and washer MT 00303 A Straight pin B Idler gear shaft C Idler gear D Washer el 10 Remove the reverse shifter lever B INSTALLATION 1 Install the reverse shifter lever reverse idler gear and reverse idler gear shaft and secure with straight pin NOTE Be sure to install the reverse idler shaft from rear side MT 00304 Reverse shifter lever Reverse idler gear Reverse idler gear shaft Straight pin 2 Inspect and adjust the clearance between re verse idler gear and transmission case wall lt Ref to 5MT 110 INSTALLATION Reverse Idler Gear gt and lt Ref to 5MT 111 ADJUSTMENT Reverse Idler Gear gt 3 Install the shift
33. engaging point beforehand ST1 499757002 SNAP RING GUIDE ST2 899714110 REMOVER MT 00825 8 Remove 1st gear bushing 1st driven gear thrust plate and roller bearing using ST and press ST 498517000 REPLACER CAUTION Replace roller bearing 41 x 71 x 23 with a new one if this disassembly is performed MT 00826 A 1st gear bushing 5MT 94 Drive Pinion Shaft Assembly MANUAL TRANSMISSION AND DIFFERENTIAL D ASSEMBLY 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 A Ge d C IESSEN IK B Bos i MT 00252 A 1st gear side B 2nd gear side C Flush surface D Stepped surface 2 Install the washer snap ring and sub gear to 1st driven gear 3 Install the 1st driven gear 1st baulk ring gear and hub assembly onto driven shaft NOTE e Take care to install the gear and hub assembly in proper direction e Align the baulk ring and gear amp hub assembly with key groove 4 Install the 2nd driven gear bushing onto driven shaft using ST1 ST2 and press NOTE es Do not apply pressure in excess of 10 kN 1 ton 1 1 US ton 1 0 Imp ton e Attach a cloth to the end of driven shaft to pre vent damage e When press fitting align the oil holes of shaft and bush ST1 4992
34. er forks and rods lt Ref to 5MT 112 INSTALLATION Shifter Fork and Rod gt 4 Install the differential assembly lt Ref to 5MT 102 INSTALLATION Front Differential Assem bly gt 5 Install the main shaft assembly Single range model lt Ref to 5MT 72 INSTALLATION Main Shaft As sembly for Single Range gt Dual range model lt Ref to 5MT 82 INSTALLATION Main Shaft As sembly for Dual Range gt 6 Install the drive pinion shaft assembly lt Ref to 5MT 91 INSTALLATION Drive Pinion Shaft As sembly gt 7 Install the transmission case lt Ref to 5MT 68 INSTALLATION Transmission Case gt 8 Install the transfer case with extension case as sembly lt Ref to 5MT 53 INSTALLATION Trans fer Case and Extension Case Assembly gt 9 Install the back up light switch and neutral posi tion switch lt Ref to 5MT 49 INSTALLATION Switches and Harness gt 10 Install the manual transmission assembly to ve hicle lt Ref to 5MT 41 INSTALLATION Manual Transmission Assembly gt 5MT 110 Reverse Idler Gear MANUAL TRANSMISSION AND DIFFERENTIAL C INSPECTION 1 Move the reverse shifter rod toward the reverse side Inspect the clearance between reverse idler gear and transmission case wall If out of specification select the appropriate re verse shifter lever and adjust Clearance A 6 0 7 5 mm 0 236 0 295 in No Old O i CE MT
35. extension case assembly lt Ref to 5MT 53 REMOVAL Transfer Case and Extension Case Assembly gt 3 Remove the transmission case lt Ref to 5MT 66 REMOVAL Transmission Case gt 4 Remove the drive pinion shaft assembly lt Ref to 5MT 91 REMOVAL Drive Pinion Shaft Assem bly gt 5 Remove the main shaft assembly and input shaft assembly B INSTALLATION 1 Install the needle bearing onto the front of trans mission main shaft assembly 2 Connect the main shaft assembly and input shaft assembly 3 Install the needle bearing outer race knock pin hole into transmission case knock pin 4 Install the drive pinion assembly lt Ref to 5MT 91 INSTALLATION Drive Pinion Shaft Assem bly gt 5 Install the transmission case lt Ref to 5MT 68 INSTALLATION Transmission Case gt 6 Install the transfer case with extension case as sembly lt Ref to 5MT 53 INSTALLATION Trans fer Case and Extension Case Assembly gt 7 Install the manual transmission assembly on ve hicle lt Ref to 5MT 41 INSTALLATION Manual Transmission Assembly gt C DISASSEMBLY 1 Remove the O ring from input shaft holder Also remove the input shaft holder shim NOTE e Use anew O ring e Number of shims used varies from zero to two B C MT 00226 A Input shaft holder B O ring C Input shaft holder shim 2 Put vinyl tape around the input shaft splines to protect oil seal from damage 3 Re
36. following parts onto the rear section of trans mission main shaft NOTE Face thrust washer in the correct direction ST1 899714110 REMOVER ST2 499877000 RACE 4 5 INSTALLER MT 00195 A Face this surface to 5th gear side 5MT 79 Main Shaft Assembly for Single Range 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 e Align groove in baulk ring with shifting insert e 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 MT 00821 A Needle bearing 5th drive gear Baulk ring B Sleeve and hub ASSY C anana is E F G 8 Tighten lock nuts 22 x 13 to the specified torque using ST1 and ST2 NOTE Secure lock nuts in two places after tightening Insert stopper plate Lock washer Lock nut anan Tightening torque 120 N m 12 2 kgf m 88 5 ft Ib E INSPECTION Disassembled parts should be washed clean first and then inspected carefully 1 Bearings Replace the bearings in the following cases e Bearings whose balls outer races and inner rac es are broken or rusty e Worn bearings e Bearings that fail to turn smoothly or make ab normal noise when turned after gear oil lubrication e Bearings havin
37. g Adjust d Improper adjustment of drive pinion and hypoid driven gear Adjust e Excessive backlash due to worn dif ferential side gear washer or differential pinion vehicle under severe operating conditions Add recommended oil to specified level Do not use the vehicle under severe oper ating conditions f Loose hypoid driven gear clamping bolts Tighten 2 Differential and hypoid gear noises Troubles of the differential and hypoid gear always appear as noise problems Therefore noise is the first indication of the trouble However noises from the engine muffler tire exhaust gas bear ing body etc are easily mistaken for the differential noise Pay special attention to the hypoid gear noise because it is easily confused with other gear noises There are the following four kinds of noises e Gear noise when driving If noise increases as vehicle speed increases it may be due to insufficient gear oil incor rect gear engagement damaged gears etc e Gear noise when coasting Damaged gears due to maladjusted bearings and incorrect shim adjustment e Bearing noise when driving or when coasting Cracked broken or damaged bearings e Noise which mainly occurs when turn ing Unusual noise from differential side gear differential pinion differential pinion shaft etc a Insufficient oil Lubricate b Improper adjustment of hypoid driven gear and drive pinion Check tooth co
38. g other defects 2 Bushing each gear Replace the bushing in the following cases e When the sliding surface is damaged or abnor mally worn e When the inner wall is abnormally worn 3 Gears e Replace the gears with new ones if their tooth surfaces are broken damaged or excessively worn e Correct or replace if the cone that contacts the baulk ring is rough or damaged e Correct or replace if the inner surface or end face is damaged 4 Baulk ring Replace the ring in the following cases e When the inner surface and end face are dam aged e When the ring inner surface is abnormally or par tially worn down e 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 MT 00208 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 sh
39. g other defects 2 Bushing each gear Replace the bushing in the following cases e When the sliding surface is damaged or abnor mally worn e When the inner wall is abnormally worn 3 Gears e Replace the gears with new ones if their tooth surfaces are broken damaged or excessively worn e Correct or replace if the cone that contacts the baulk ring is rough or damaged e Correct or replace if the inner surface or end face is damaged 4 Baulk ring Replace the ring in the following cases e When the inner surface and end face are dam aged e When the ring inner surface is abnormally or par tially worn down es If the gap between the end faces of the ring and the gear splined part is excessively small when the ring is pressed against the cone 5MT 99 Drive Pinion Shaft Assembly MANUAL TRANSMISSION AND DIFFERENTIAL Clearance A 0 5 1 0 mm 0 020 0 040 in T A mjam C e 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 MT 00265 MT 00208 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 F ADJUSTMENT 1 THRUST BEARING PRELOAD
40. gears can be classified into two kinds one is malfunction of the gear shift system and the other is malfunction of the transmis sion However if the operation is heavy and engagement of the gears is difficult defective clutch disengagement may also be responsible Check whether the clutch is correctly functioning before checking the gear shift system and transmission a Worn damaged or burred chamfer of internal spline of sleeve and reverse driven gear Replace b Worn damaged or burred chamfer of spline of gears Replace c Worn or scratched bushings Replace d Incorrect contact between synchro nizer ring and gear cone or wear Correct or replace 2 Gear slips out e Gear slips out when coasting on rough road e Gear slips out during acceleration a Defective pitching stopper adjustment Adjust b Loose engine mounting bolts Tighten or replace ail spring Replace c Worn fork shifter broken shifter fork i d Worn or damaged ball bearing Replace e Excessive clearance between splines of synchronizer hub and synchronizer sleeve Replace responsible for slip out of 3rd gear Replace Worn 1st driven gear and driven shaft Replace f Worn tooth step of synchronizer hub Replace g h Worn 2nd driven gear and bushing i Worn 3rd drive gear and needle bear ing Replace j Worn 4th dr
41. he differential gear in the follow ing cases e The hypoid drive gear and drive pinion shaft tooth surface are damaged excessively worn or seized e The roller bearing on the drive pinion shaft has a worn or damaged roller path e There is damage wear or seizure of the differ ential bevel pinion differential bevel gear washer pinion shaft and straight pin e The differential case has worn or damaged slid ing surfaces MT 00814 Drive pinion shaft Hypoid driven gear Pinion shaft Straight pin E Washer Differential bevel gear Differential bevel pinion Snap ring Roller bearing Differential case 1 BEVEL PINION GEAR BACKLASH Measure the backlash between bevel gear and pin ion If it is not within specifications install a suitable washer to adjust it NOTE Be sure the pinion gear tooth contacts adjacent gear teeth during measurement 5MT 105 Front Differential Assembly MANUAL TRANSMISSION AND DIFFERENTIAL ST1 498247001 MAGNET BASE ST2 498247100 DIAL GAUGE Standard backlash 0 13 0 18 mm 0 0051 0 0071 in F det V5 o by Si A ai o MT 00285 2 HYPOID GEAR BACKLASH 1 Set the ST1 ST2 and ST3 Insert the needle through transmission oil drain plug hole so that the needle comes in contact with the tooth surface at a right angle and check the backlash ST1 498247001 MAGNET BASE ST2 498247100 DIAL GAUGE ST3 498255400
42. he transfer case with extension case as sembly lt Ref to 5MT 53 INSTALLATION Trans fer Case and Extension Case Assembly gt 15 Install the back up light switch and neutral po sition switch lt Ref to 5MT 49 INSTALLATION Switches and Harness gt 16 Install the manual transmission assembly to ve hicle lt Ref to 5MT 41 INSTALLATION Manual Transmission Assembly gt C INSPECTION 1 Check the shift shaft and shift rod for damage Replace if damaged 2 Gearshift mechanism Repair or replace the gearshift mechanism if ex cessively worn bent or defective in any way 3 Inspect the clearance between 1st 2nd driven gear and reverse driven gear If any clearance is not within specifications replace the shifter fork as required Clearance a and b 9 5 mm 0 374 in MT 00313 A 1st driven gear B Reverse driven gear C 2nd driven gear 1st 2nd shifter fork Part No Mark Remarks Approach to 1st gear by 0 2 mm 0 008 in 32804AA060 1 5MT 113 Shifter Fork and Rod MANUAL TRANSMISSION AND DIFFERENTIAL 1st 2nd shifter fork Part No Mark 32804AA070 Remarks Standard Become distant from 2nd gear by 0 2 mm 0 008 in 4 Inspect the clearance between 3rd 4th drive gear and coupling sleeve If any clearance is not within specifications replace the shifter fork as re quired Clearance a and b 7 3 mm 0
43. in shaft assembly B INSTALLATION 1 Install the needle bearing and oil seal onto the front of transmission main shaft assembly NOTE e Wrap the clutch splined section with vinyl tape to prevent damage to oil seal e Apply grease Unilube 2 or equivalent to the sealing lip of oil seal e Use a new one 2 Install the needle bearing outer race knock pin hole into transmission case knock pin NOTE Align the end face of seal with surface A when in stalling oil seal aide MT 00185 3 Install the drive pinion assembly lt Ref to 5MT 91 INSTALLATION Drive Pinion Shaft Assem bly gt 4 Install the transmission case lt Ref to 5MT 68 INSTALLATION Transmission Case gt 5 Install the transfer case with extension case as sembly lt Ref to 5MT 53 INSTALLATION Trans fer Case and Extension Case Assembly gt 6 Install the manual transmission assembly to ve hicle lt Ref to 5MT 41 INSTALLATION Manual Transmission Assembly gt C DISASSEMBLY 1 AWD MODEL 1 Put vinyl tape around the main shaft splines to protect oil seal from damage Then pull out the oil seal and needle bearing by hand 2 Remove the lock nut from transmission main shaft assembly NOTE Remove the caulking before removing lock nut STi 499987000 TRANSMISSION HOLDER ST2 498937003 SOCKET WRENCH 35 MT 00186 3 Remove the 5th Rev sleeve and hub assembly baulk ring 5th
44. ive gear and needle bear ing Replace Replace 3 Unusual noise comes from transmis sion NOTE If an unusual noise is heard when the ve hicle is parked with its engine idling and if the noise ceases when the clutch is disen gaged it may be considered that the noise comes from the transmission k Worn reverse idler gear and bushing a Insufficient or improper lubrication Lubricate or replace with specified oil b Worn or damaged gears and bearings NOTE If the trouble is only wear of the tooth sur faces merely a high roaring noise will oc cur at high speeds but if any part is broken rhythmical knocking sound will be heard even at low speeds 5MT 117 Replace General Diagnostic MANUAL TRANSMISSION AND DIFFERENTIAL 2 DIFFERENTIAL Symptom Possible cause Remedy 1 Broken differential case gear bear ing etc NOTE Abnormal noise will develop and finally it will become impossible to continue to run due to broken pieces obstructing the gear revolution a Insufficient or improper oil Disassemble the differential and replace broken components and at the same time check other components for any trouble and replace if necessary b Use of vehicle under severe condi tions such as excessive load and improper use of clutch Readjust the bearing preload and back lash and face contact of gears c Improper adjustment of taper roller bearin
45. low synchronizer spring High low synchronizer hub Sleeve Insert key rd 4th synchronizer hub H Sleeve Insert key 5th Rev synchronizer hub High side Low side 8rd side 4th side 5th side Rev side 2 Install the 3rd drive gear baulk ring sleeve and hub assembly for 3rd 4th needle bearing on trans mission main shaft NOTE Align the groove in baulk ring with shifting insert 3 Install the 4th needle bearing race onto trans mission main shaft using ST1 ST2 and a press ST1 899714110 REMOVER ST2 499877000 RACE 4 5 INSTALLER ST1 MT 00201 A 4th needle bearing race 4 Install the baulk ring needle bearing 4th drive gear and 4th gear thrust washer to transmission main shaft NOTE Face the thrust washer in correct direction MT 00193 X B A Groove B 4th gear side 5 Drive the ball bearing onto the rear section of transmission main shaft using ST1 ST2 and a press ST1 899714110 REMOVER ST2 499877000 RACE 4 5 INSTALLER ST2 ST1 SS O N MT 00194 6 Using the ST1 and ST2 install the 5th gear thrust washer and 5th needle bearing race onto the rear section of transmission main shaft 5MT 84 Main Shaft Assembly for Dual Range MANUAL TRANSMISSION AND DIFFERENTIAL NOTE Face the thrust washer in correct direction ST1 899714110 REMOVER ST2 499
46. mbly 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 transmission case lt Ref to 5MT 66 REMOVAL Transmission Case gt 5 Remove the drive pinion shaft assembly lt Ref to 5MT 91 REMOVAL Drive Pinion Shaft Assem bly gt 6 Remove the main shaft assembly Single range model lt Ref to 5MT 72 REMOVAL Main Shaft Assembly for Single Range gt Dual range model lt Ref to 5MT 82 REMOVAL Main Shaft Assembly for Dual Range gt 7 Remove the differential assembly lt Ref to 5MT 102 REMOVAL Front Differential Assembly gt 8 Drive out the straight pin with ST and 5th shifter fork ST 398791700 STRAIGHT PINREMOVER MT 00309 A Straight pin B 5th shifter fork 9 Remove the plugs springs and checking balls 10 Drive out the straight pin and pull out 3 4 fork rod and shifter fork NOTE When removing the rod keep other rods in neutral Also when pulling out the straight pin remove it to ward the inside of case so that it does not hit against the case A Straight pin B 3 4 fork rod C Shifte
47. move the inner snap ring PLIERS ST 398663600 MT 00227 4 Hold the input shaft holder stationary and re move the input shaft by tapping its end with a plas tic hammer MT 00228 A Input shaft holder B Input shaft 5 Remove the outer snap ring Then remove the oil squeeze plate and straight pin MT 00229 A Snap ring B Oil squeeze plate 5MT 87 Input Shaft Assembly MANUAL TRANSMISSION AND DIFFERENTIAL 6 Remove the snap ring MT 00230 A Snap ring 7 Using a press and ST remove the ball bearing NOTE Remove the inner snap ring before pressing ST 498077000 REMOVER MT 00231 8 Remove the oil seal from input shaft holder D ASSEMBLY 1 Install the ball bearing onto input shaft NOTE Place the snap ring between input shaft gear and ball bearing beforehand Use the table at 8 as a guide in selecting a suitable snap ring ST1 899580100 INSTALLER ST2 399513600 INSTALLER ST1 ST2 MT 00232 2 Install the snap ring on input shaft MT 00230 A Snap ring 3 Inspect the clearance between ball bearing and snap ring lt Ref to 5MT 89 INSPECTION Input Shaft Assembly gt 4 Install the straight pin and oil squeeze plate to in put shaft MT 00234 A Straight pin B Oil squeeze plate 5 Install the snap ring 6
48. n the rear of transmission case 7 Align the holes in rod and fork and new drive straight pin into these holes NOTE e Set the reverse fork rod to neutral e Make sure the interlock plunger installing be fore is on the reverse fork rod side ST 398791700 STRAIGHT PINREMOVER 8 Install the 5th shifter fork onto the rear of reverse fork rod Align holes in the two parts and new drive straight pin into place ST 398791700 STRAIGHT PINREMOVER MT 00311 A 5th shifter fork B Reverse fork rod C Straight pin 9 Position the balls checking ball springs and new gaskets into 3 4 and 1 2 rod holes and install plugs Ail Cac 0 o JA D Se Sr 0 o 0 o 0 5 SAN fer a 200 A SSS C MT 00311 A 5th shifter fork B Reverse fork rod C Straight pin 10 Install the differential assembly lt Ref to 5MT 102 INSTALLATION Front Differential Assem bly gt 11 Install the main shaft assembly Single range model lt Ref to 5MT 72 INSTALLATION Main Shaft As sembly for Single Range gt Dual range model lt Ref to 5MT 82 INSTALLATION Main Shaft As sembly for Dual Range gt 12 Install the drive pinion shaft assembly lt Ref to 5MT 91 INSTALLATION Drive Pinion Shaft As sembly gt 13 Install the transmission case lt Ref to 5MT 68 INSTALLATION Transmission Case gt 14 Install t
49. 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 Main Shaft Assembly for Single Range MANUAL TRANSMISSION AND DIFFERENTIAL 16 Main Shaft Assembly for Sin gle Range 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 transmission case lt Ref to 5MT 53 REMOVAL Transfer Case and Extension Case Assembly gt 4 Remove the drive pinion shaft assembly lt Ref to 5MT 91 REMOVAL Drive Pinion Shaft Assem bly gt 5 Remove the ma
50. ntact c Worn teeth of hypoid driven gear and drive pinion Replace as a set Readjust the bearing preload d Loose roller bearing Readjust the hypoid driven gear to drive pinion backlash and check tooth contact e Distorted hypoid driven gear or differ ential case Replace f Worn washer and differential pinion shaft 5MT 118 Replace
51. ntial bevel gear sleeve Washer No 1 25 x 37 5 x t Thrust bearing 25 x 37 5 x 3 Washer No 2 25 x 37 5 x 4 Needle bearing 25 x 30 x 20 Drive pinion collar Needle bearing 30 x 37 x 23 Thrust bearing 33 x 50 x 3 GOB Cam 3 Remove the roller bearing and washer using ST and press NOTE Do not reuse the roller bearing ST 498077000 REMOVER D SES H 2 ST 9 eg 4 Straighten the lock nut at staked portion Re move the lock nut using ST1 and ST2 fe MT 00246 5MT 92 Drive Pinion Shaft Assembly ST1 499987300 SOCKET WRENCH 50 ST2 899884100 HOLDER MT 00247 5 Remove the 5th driven gear using ST ST 499857000 5THDRIVEN GEAR REMOV ER MT 00248 6 Remove the woodruff key 7 Remove the roller bearing 3rd 4th driven gear using ST1 and ST2 ST1 499757002 INSTALLER ST2 899714110 REMOVER ea ST1 i ST2 oa Bie an 8 Remove the key MT 00249 MANUAL TRANSMISSION AND DIFFERENTIAL 9 Remove the 2nd driven gear inner baulk ring synchro cone and outer baulk ring Except 1 6 L model MT 00250 A 2nd driven gear B Inner baulk ring C Synchro cone D Outer baulk ring 10 Remove the 2nd driven gear assembly 1 6
52. ormally worn 3 Gears e Replace the gears with new ones if their tooth surfaces are broken damaged or excessively worn e Correct or replace if the cone that contacts the baulk ring is rough or damaged e Correct or replace if the inner surface or end face is damaged 4 Baulk ring Replace the ring in the following cases e When the inner surface and end face are dam aged e When the ring inner surface is abnormally or par tially worn down e 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 5MT 89 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 Clearance 0 0 12 mm 0 0 0047 in MT 00239 A Snap ring If the measurement is not within specification se lect a suitable snap ring Snap ring Part No Thickness mm in 805028050 2 48 0 0976 805028060 2 56 0 1008 805028070 2 64 0 1039 5MT
53. ove the differ ential bevel pinion and gear and washer 1 DIFFERENTIAL CASE ASSEMBLY E 1 Loosen the twelve bolts and remove the hypoid Base C driven gear A Ze MT 00277 A Pinion shaft B Bevel pinion C Bevel gear D Washer 4 Remove the roller bearing using ST ST 399527700 PULLER SET MT 00275 A Hypoid driven gear 2 Drive out the straight pin from differential assem bly toward hypoid driven gear ST 899904100 REMOVER 2 SIDE RETAINER 1 Remove the O ring MT 00278 MT 00276 2 Remove the oil seal 5MT 103 Front Differential Assembly MANUAL TRANSMISSION AND DIFFERENTIAL NOTE Do not reuse the oil seal Prepare a new oil seal o AT 00220 D ASSEMBLY 1 DIFFERENTIAL CASE ASSEMBLY 1 Install the bevel gear and bevel pinion together with washers and insert pinion shaft NOTE Face the chamfered side of washer toward gear MT 00284 A Bevel pinion B Bevel gear C Pinion shaft 2 Measure the backlash between bevel gear and pinion If it is not within specifications install a suit able washer to adjust it lt Ref to 5MT 106 AD JUSTMENT Front Differential Assembly gt NOTE Be sure the pinion gear tooth contacts adjacent gear teeth during measurement ST1 498247001 MAGNET BASE ST2 498247100 DIAL GAUGE Standard backlash 0 13 0 18
54. r Dual Range gt 6 Remove the differential assembly NOTE e Be careful not to confuse the right and left roller bearing outer races e Be careful not to damage the retainer oil seal 7 Remove the differential side retainers using ST ST 499787000 WRENCH ASSY MT 00176 B INSTALLATION 1 Install the differential side retainers using ST ST 499787000 WRENCH ASSY 2 Install the bearing outer race to transmission case 3 Install the differential assembly NOTE Be careful not to fold the sealing lip of oil seal 4 Install the main shaft assembly Single range model lt Ref to 5MT 72 INSTALLATION Main Shaft As sembly for Single Range gt Dual range model lt Ref to 5MT 82 INSTALLATION Main Shaft As sembly for Dual Range gt 5 Install the drive pinion assembly lt Ref to 5MT 91 INSTALLATION Drive Pinion Shaft Assem bly gt 6 Install the transmission case lt Ref to 5MT 68 INSTALLATION Transmission Case gt 7 Install the transfer case with extension case as sembly lt Ref to 5MT 53 INSTALLATION Trans fer Case and Extension Case Assembly gt 8 Install the manual transmission assembly to ve hicle lt Ref to 5MT 41 INSTALLATION Manual Transmission Assembly gt 5MT 102 Front Differential Assembly MANUAL TRANSMISSION AND DIFFERENTIAL C DISASSEMBLY 3 Pull out the pinion shaft and rem
55. r fork 11 Drive out the straight pin and pull out 1 2 fork rod and shifter fork 12 Remove the outer snap ring and pull out the reverse shifter rod arm from reverse fork rod Then take out the ball spring and interlock plunger from rod And then remove the rod NOTE When pulling out the reverse shifter rod arm be careful not to let the ball pop out of arm 13 Remove the reverse shifter lever B INSTALLATION 1 Install the reverse arm fork spring ball and inter lock plunger to reverse fork rod arm Insert the re verse fork rod into hole in reverse fork rod arm and hold it with outer snap ring using ST NOTE Apply grease to plunger to prevent it from falling ST 399411700 ACCENT BALL INSTALLER 2 Position the ball spring and new gasket in re verse shifter rod hole on left side transmission case and tighten the checking ball plug 3 Install the 1 2 fork rod into 1 2 shifter fork via the hole on the rear of transmission case 4 Align the holes in rod and fork and new drive straight pin into these holes using ST NOTE e Set other rods to neutral e Make sure the interlock plunger is on the 3 4 fork rod side ST 398791700 STRAIGHT PINREMOVER 5 Install the interlock plunger onto 3 4 fork rod 5MT 112 Shifter Fork and Rod MANUAL TRANSMISSION AND DIFFERENTIAL NOTE Apply a coat of grease to plunger to prevent it from falling 6 Install the 3 4 fork rod into 3 4 shifter fork via the hole o
56. ro tect oil seal from damage Then pull out oil seal and needle bearing by hand 2 Remove lock nut NOTE Remove caulking before taking off lock nut ST1 498937000 TRANSMISSION HOLDER ST2 499987003 SOCKET WRENCH 35 ST1 MT 00818 5MT 73 Main Shaft Assembly for Single Range MANUAL TRANSMISSION AND DIFFERENTIAL 3 Remove the insert stopper plate sleeve and hub assembly No 2 baulk ring 5th drive gear and nee dle bearing MT 00819 A Insert stopper plate B Sleeve and hub ASSY No 2 C Baulk ring D E el 5th drive gear Needle bearing 4 Using ST1 ST2 and a press remove the rest of parts NOTE Replace sleeve and hub with ones Do not attempt to disassemble because they must engage at a specified point If they should be disassembled mark engagement point on splines before hand ST1 899864100 REMOVER ST2 899714110 REMOVER A d ST1 ST2 MT 00820 A Press D ASSEMBLY 1 AWD NON TURBO MODEL 1 Assemble when each sleeve and hub assembly are disassembled NOTE Position the open ends of spring 120 apart MT 00191 3rd 4th hub ASSY 3rd gear side 5th Rev hub ASSY 5th gear side 2 Install the 3rd drive gear baulk ring sleeve and hub assembly for 3rd needle bearing on transmis sion main shaft NOTE Align the groove in baulk ring wi
57. s fit the oil seal with ST NOTE Use a new oil seal if it has been removed ST 899824100 or 499827000 PRESS 2 Install the vehicle speed sensor lt Ref to 5MT 51 INSTALLATION Vehicle Speed Sensor gt 3 Install the speedometer driven gear and snap ring NOTE Use a new snap ring if it has been removed MT 00301 A Outer snap ring B Speedometer driven gear 4 Install the transmission case lt Ref to 5MT 68 INSTALLATION Transmission Case gt 5 Install the transfer case with extension case as sembly lt Ref to 5MT 53 INSTALLATION Trans fer Case and Extension Case Assembly gt 6 Install the back up light switch and neutral posi tion switch lt Ref to 5MT 49 INSTALLATION Switches and Harness gt 7 Install the manual transmission assembly to ve hicle lt Ref to 5MT 41 INSTALLATION Manual Transmission Assembly gt C INSPECTION Check the speedometer gear oil seal and speed ometer shaft for damage Replace if damaged 5MT 109 Reverse Idler Gear MANUAL TRANSMISSION AND DIFFERENTIAL 22 Reverse Idler 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 Cas
58. th shifting insert 3 Install the 4th needle bearing race onto trans mission main shaft using ST1 ST2 and a press NOTE Do not apply pressure in excess of 10 KN 1 ton 1 1 US ton 1 0 Imp ton 5MT 74 Main Shaft Assembly for Single Range MANUAL TRANSMISSION AND DIFFERENTIAL ST1 899714110 REMOVER ST2 499877000 RACE 4 5 INSTALLER ST2 ST1 MT 00192 A 4th needle bearing race 4 Install the baulk ring needle bearing 4th drive gear and 4th gear thrust washer to transmission main shaft NOTE Align the baulk ring and gear amp hub assembly with key groove MT 00193 X B A Groove B 4th gear side 5 Drive the ball bearing onto the rear section of transmission main shaft using ST1 ST2 and a press NOTE Do not apply pressure in excess of 10 kN 1 ton 1 1 US ton 1 0 Imp ton ST1 899714110 REMOVER ST2 499877000 RACE 4 5 INSTALLER MT 00194 6 Using the ST1 and ST2 install the 5th gear thrust washer and 5th needle bearing race onto the rear section of transmission main shaft NOTE e Do not apply pressure in excess of 10 KN 1 ton 1 1 US ton 1 0 Imp ton e Face the thrust washer in correct direction ST1 899714110 REMOVER ST2 499877000 RACE 4 5 INSTALLER MT 00195 A Face this surface to 5th gear side 7 Install the bearing onto synchro cone 8 Install the baulk ring and synchro cone
59. y for Single Range MANUAL TRANSMISSION AND DIFFERENTIAL 6 Using the ST1 and ST2 install the 5th gear thrust washer and 5th needle bearing race onto the rear section of transmission main shaft NOTE es Do not apply pressure in excess of 10 KN 1 ton 1 1 US ton 1 0 Imp ton e Face the thrust washer in correct direction ST1 899714110 REMOVER ST2 499877000 RACE 4 5 INSTALLER MT 00195 A Face this surface to 5th gear side 7 Install the bearing onto synchro cone 8 Install the baulk ring and synchro cone onto 5th Rev sleeve and hub assembly using ST and a press NOTE es Do not apply pressure in excess of 10 kN 1 ton 1 1 US ton 1 0 Imp ton e Use a new ball bearing es After press fitting make sure the synchro cone rotates freely ST 499757002 INSTALLER MT 00196 E Baulk ring Synchro cone Ball bearing OG 9 Install the synchro cone stopper and snap ring to 5th Rev sleeve and hub assembly MT 00188 A Synchro cone stopper B Snap ring 10 Install the rest parts to the rear section of trans mission main shaft NOTE Align the groove in baulk ring with shifting insert MT 00198 KS Needle bearing 5th drive gear Baulk ring B 5th Rev sleeve and hub ASSY GOB E F Lock washer Lock nuts 11 Tighten the lock nuts to the specified torque us ing ST1
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