Subaru Impreza 3 / Impreza WRX / Impreza WRX STI. Manual — part 414

5MT-77

Reverse Idler Gear

MANUAL TRANSMISSION AND DIFFERENTIAL

18.Reverse Idler Gear

A: REMOVAL

1) Remove the manual transmission assembly

from the vehicle. <Ref. to 5MT-23, REMOVAL,

Manual Transmission Assembly.>

2) Remove the back-up light switch and the neutral

position switch. <Ref. to 5MT-33, REMOVAL,

Switches and Harness.>

3) Remove the transfer case together with the ex-

tension case assembly. <Ref. to 5MT-35, REMOV-

AL, Transfer Case and Extension Case

Assembly.>

4) Remove the transmission case. <Ref. to 5MT-

49, REMOVAL, Transmission Case.>

5) Remove the drive pinion shaft assembly. <Ref.

to 5MT-58, REMOVAL, Drive Pinion Shaft Assem-

bly.>

6) Remove the main shaft assembly for single-

range. <Ref. to 5MT-53, REMOVAL, Main Shaft

Assembly for Single-Range.>

7) Remove the front differential assembly. <Ref. to

5MT-69, REMOVAL, Front Differential Assembly.>

8) Remove the shifter forks and rods. <Ref. to 5MT-

79, REMOVAL, Shifter Fork and Rod.>

9) Pull out the straight pin, and remove the reverse

idler gear shaft, washer, reverse idler gear and

washer.

10) Remove the reverse shifter lever.

B: INSTALLATION

1) Install the reverse shifter lever, washer, reverse

idler gear, washer and reverse idler gear shaft, and

secure them with the straight pin.
NOTE:

• Be sure to install the reverse idler gear shaft from

rear side.

• Use a new straight pin.

2) Check and adjust clearance between the re-

verse idler gear and the timing case wall surface.

<Ref. to 5MT-77, INSTALLATION, Reverse Idler

Gear.> <Ref. to 5MT-78, ADJUSTMENT, Reverse

Idler Gear.>

3) Install the shifter forks and rods. <Ref. to 5MT-

80, INSTALLATION, Shifter Fork and Rod.>

4) Install the front differential assembly. <Ref. to

5MT-69, INSTALLATION, Front Differential As-

sembly.>

5) Install the main shaft assembly for single-range.

<Ref. to 5MT-53, INSTALLATION, Main Shaft As-

sembly for Single-Range.>

6) Install the drive pinion shaft assembly. <Ref. to

5MT-58, INSTALLATION, Drive Pinion Shaft As-

sembly.>

7) Install the transmission case. <Ref. to 5MT-50,

INSTALLATION, Transmission Case.>

8) Install the transfer case together with the exten-

sion case assembly. <Ref. to 5MT-35, INSTALLA-

TION, Transfer Case and Extension Case

Assembly.>

9) Install the back-up light switch and the neutral

position switch. <Ref. to 5MT-33, INSTALLATION,

Switches and Harness.>

10) Install the manual transmission assembly to the

vehicle. <Ref. to 5MT-26, INSTALLATION, Manual

Transmission Assembly.>

(A) Straight pin
(B) Reverse idler gear shaft

(C) Reverse idler gear
(D) Washer

(E) Washer

(F) Reverse shifter lever

MT-01565

(A)

(B)

(C)

(D)

(F)

(E)

(A) Straight pin
(B) Reverse idler gear shaft

(C) Reverse idler gear
(D) Washer

(E) Washer

(F) Reverse shifter lever

MT-01565

(A)

(B)

(C)

(D)

(F)

(E)

5MT-78

Reverse Idler Gear

MANUAL TRANSMISSION AND DIFFERENTIAL

C: INSPECTION

1) Move the reverse shifter rod toward the reverse

side. Check the clearance between the reverse

idler gear and the transmission case wall surface.

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)

2) After installing a suitable reverse shifter lever,

shift into neutral. Check the clearance between the

reverse idler gear and the transmission case wall

surfaces.

If out of specification, select the appropriate adjust-

ing washer and adjust.
Clearance:

0 — 0.5 mm (0 — 0.020 in)

3) Check the reverse idler gear and shaft for dam-

age. Replace if it is damaged.

D: ADJUSTMENT

1) Select the appropriate reverse shifter lever from

the table below, and adjust until the clearance be-

tween the reverse idler gear and transmission case

wall is within specification.
Clearance A:

6.0 — 7.5 mm (0.236 — 0.295 in)

2) Select the appropriate adjusting washer from the

table below, and adjust until the clearance between

the reverse idler gear and transmission case wall is

within specification.
Clearance:

0 — 0.5 mm (0 — 0.020 in)

MT-00305

A

MT-00306

Reverse shifter lever

Part No.

Mark

Contents

32820AA070

7

Far from case wall

32820AA080

8

Standard

32820AA090

9

Closer to case wall

Adjusting 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

2.3 (0.091)

MT-00305

A

MT-00306

5MT-79

Shifter Fork and Rod

MANUAL TRANSMISSION AND DIFFERENTIAL

19.Shifter Fork and Rod

A: REMOVAL

1) Remove the manual transmission assembly

from the vehicle. <Ref. to 5MT-23, REMOVAL,

Manual Transmission Assembly.>

2) Remove the back-up light switch and the neutral

position switch. <Ref. to 5MT-33, REMOVAL,

Switches and Harness.>

3) Remove the transfer case together with the ex-

tension case assembly. <Ref. to 5MT-35, REMOV-

AL, Transfer Case and Extension Case

Assembly.>

4) Remove the transmission case. <Ref. to 5MT-

49, REMOVAL, Transmission Case.>

5) Remove the drive pinion shaft assembly. <Ref.

to 5MT-58, REMOVAL, Drive Pinion Shaft Assem-

bly.>

6) Remove the main shaft assembly for single-

range. <Ref. to 5MT-53, REMOVAL, Main Shaft

Assembly for Single-Range.>

7) Remove the front differential assembly. <Ref. to

5MT-69, REMOVAL, Front Differential Assembly.>

8) Drive out the straight pin by tapping with the ST,

and remove the 5th shifter fork.

ST 398791700

STRAIGHT PIN REMOVER 2

9) Remove the plugs, springs and check balls.

10) Drive out the straight pin by tapping with the

ST, and remove the 3rd – 4th fork rod and shifter

fork.
NOTE:

• When removing the rod, keep other rods in neu-

tral.

• When removing the straight pin, remove it to-

ward the inside of case so that it does not hit

against the case.

ST 398791700

STRAIGHT PIN REMOVER 2

11) Drive out the straight pin by tapping with the

ST, and remove the 1st – 2nd fork rod and shifter

fork.

ST 398791700

STRAIGHT PIN REMOVER 2

12) Remove the snap ring (outer), and pull out the

reverse fork rod from the reverse fork rod arm.

Then take out the ball, spring and interlock plunger

from the reverse fork rod arm.

And then remove the rod.
NOTE:

When pulling out the reverse fork rod arm, be care-

ful not to let the ball pop out of arm.

13) Remove the reverse shifter lever.

(A) Straight pin
(B) 5th shifter fork

MT-00309

( A )

( B )

(A) Straight pin
(B) 3rd-4th fork rod

(C) Shifter fork

MT-00994

(A)

(B)

(C)

5MT-80

Shifter Fork and Rod

MANUAL TRANSMISSION AND DIFFERENTIAL

B: INSTALLATION

1) Install the spring and ball to the reverse fork rod

arm, and press in the ST.

ST 399411700

ACCENT BALL INSTALLER

2) Install the reverse fork rod through the hole on

the rear of the transmission case. Press out the ST

using the reverse fork rod, and fix with outer snap

ring.

3) Install the interlock plunger to reverse fork rod

arm.
NOTE:

Apply grease to the plunger to prevent it from fall-

ing.

4) Position the ball, spring and gasket in the re-

verse fork rod hole on the left side of transmission

case, and tighten the checking ball plug.
NOTE:

Use a new gasket.
Tightening torque:

20 N·m (2.0 kgf-m, 14.8 ft-lb)

5) Install the 1st-2nd fork rod to the 1st-2nd shifter

fork through the hole on the rear of the transmis-

sion case.
NOTE:

• Set other rods to neutral.

• Check that the positions of interlock plunger is

correct.

6) Align the holes in the rod and the fork, and drive

in the straight pin using the ST.
NOTE:

Use a new straight pin.

ST 398791700

STRAIGHT PIN REMOVER 2

7) Install the interlock plunger (thin) onto the 3rd-

4th fork rod.
NOTE:

Apply grease to the plunger to prevent it from fall-

ing.

8) Install the 3rd-4th fork rod to the 3rd-4th shifter

fork and reverse fork rod arm through the hole on

the rear of the transmission case.

9) Align the holes in the rod and the fork, and drive

the straight pin into these holes.
NOTE:

• Use a new straight pin.

• Set other fork rods to neutral.

• Check that the positions of interlock plunger is

correct.

ST 398791700

STRAIGHT PIN REMOVER 2

10) Install the 5th shifter fork onto the rear of re-

verse fork rod. Align the holes in the two parts and

drive straight pin into the specified place.
NOTE:

Use a new straight pin.

ST 398791700

STRAIGHT PIN REMOVER 2

11) Position the balls, checking ball springs and

gaskets to the 3rd-4th fork rod and 1st-2nd fork rod

holes, and install plugs.
NOTE:

Use a new gasket.
Tightening torque:

20 N·m (2.0 kgf-m, 14.8 ft-lb)

12) Install the front differential assembly. <Ref. to

5MT-69, INSTALLATION, Front Differential As-

sembly.>

13) Install the main shaft assembly for single-

range. <Ref. to 5MT-53, INSTALLATION, Main

Shaft Assembly for Single-Range.>

14) Install the drive pinion shaft assembly. <Ref. to

5MT-58, INSTALLATION, Drive Pinion Shaft As-

sembly.>

15) Install the transmission case. <Ref. to 5MT-50,

INSTALLATION, Transmission Case.>

16) Install the transfer case together with the exten-

sion case assembly. <Ref. to 5MT-35, INSTALLA-

TION, Transfer Case and Extension Case

Assembly.>

(A) 5th shifter fork
(B) Reverse fork rod

(C) Straight pin

MT-00311

( C )

( A )

( B )

MT-00366