Subaru Impreza 3 / Impreza WRX / Impreza WRX STI. Manual — part 403

5MT-33

Switches and Harness

MANUAL TRANSMISSION AND DIFFERENTIAL

7. Switches and Harness

A: REMOVAL

1. BACK-UP LIGHT AND NEUTRAL POSI-

TION SWITCH

1) Disconnect the ground cable from battery.

2) Remove the intercooler. <Ref. to IN(w/o STI)-12,

REMOVAL, Intercooler.>

3) Disconnect the connector back-up light switch &

neutral position switch.

4) Lift up the vehicle.

5) Remove the back-up light switch & neutral posi-

tion switch with the harness.

B: INSTALLATION

1. BACK-UP LIGHT AND NEUTRAL POSI-

TION SWITCH

1) Install the back-up light switch & neutral position

switch with the harness.
Tightening torque:

32.3 N·m (3.3 kgf-m, 23.8 ft-lb)

2) Connect the connectors of back-up light switch &

neutral position switch.

3) Install the intercooler. <Ref. to IN(w/o STI)-12,

INSTALLATION, Intercooler.>

4) Connect the battery ground terminal.

C: INSPECTION

1. BACK-UP LIGHT SWITCH

Check the back-up light switch. <Ref. to LI-8, IN-

SPECTION, Back-up Light System.>

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.

4) Replace faulty parts.

(A) Neutral position switch and back-up light switch

connector

(A) Neutral position switch
(B) Back-up light switch

MT-01659

(A)

MT-02615

(A)

(B)

(A) Neutral position switch
(B) Back-up light switch

Gear shift position

Terminal No.

Specified resistance

Neutral position

1 and 3

Less than 1 Ω

Other positions

1 MΩ or more

MT-02615

(A)

(B)

MT-00111

1

2

3

4

5MT-34

Preparation for Overhaul

MANUAL TRANSMISSION AND DIFFERENTIAL

8. Preparation for Overhaul

A: PROCEDURE

1) Clean oil, grease, dirt and dust from the trans-

mission.

2) Using the TORX

®

bit T70, remove the transmis-

sion gear oil drain plug, and drain the transmission

gear oil completely.

3) Using the TORX

®

bit T70, tighten the transmis-

sion gear oil drain plug.
NOTE:

Use a new gasket.
Tightening torque:

44 N·m (4.5 kgf-m, 32.5 ft-lb) (Aluminum gas-

ket silver)

70 N·m (7.1 kgf-m, 51.6 ft-lb) (Copper gasket

brown)

70 N·m (7.1 kgf-m, 51.6 ft-lb) (Metal gasket

black)

4) Attach the transmission to the ST.

ST 499937100

TRANSMISSION STAND

5) Apply oil to rotating parts before assembly.

6) All disassembled parts, if to be reused, should

be reinstalled in the original positions and direc-

tions.

7) Gaskets, lock washers and lock nuts must be re-

placed with new ones.

8) Apply liquid gasket to the specified areas to pre-

vent leakage.

MT-01548

MT-00115

S T

5MT-35

Transfer Case and Extension Case Assembly

MANUAL TRANSMISSION AND DIFFERENTIAL

9. Transfer Case and Extension

Case Assembly

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.

4) Remove the gasket.

5) Remove the shifter arm.

6) Remove the extension case assembly.

B: INSTALLATION

1) Apply a coat of grease to the front roller bearing

and rear roller bearing of the transfer driven gear.
Grease:

NICHIMOLY N-130 or equivalent

2) Install the center differential and transfer driven

gear into the transfer case.

3) Remove the bearing outer race, dish plate and

adjusting washer from the extension case.

4) Install the bearing outer race to transfer driven

gear.

5) While pressing the bearing outer race horizontal-

ly, rotate the driven shaft for ten turns.

6) Measure the height “W” between transfer case

and taper roller bearing on the transfer driven gear.

7) Measure depth “X” of bearing insertion part of

the extension case.
NOTE:

Measure with bearing outer race, dish plate and ad-

justing washer removed.

MT-02614

MT-00117

MT-00118

(A) Bearing outer race
(B) Dish plate

(C) Thrust washer
(D) Extension case

(1) Paint side

MT-03047

(B)

(C)

(C)

(D)

(B)

(A)

(1)

MT-00120

W

MT-00121

X

5MT-36

Transfer Case and Extension Case Assembly

MANUAL TRANSMISSION AND DIFFERENTIAL

8) Calculate the adjusting washer thickness “t” us-

ing the following calculation.

t = X – W – (1.715 — 1.765 mm (0.0686 — 0.0706

in))

9) Select the washer with the nearest value in the

following table.

10) Install the selected adjusting washer, dish plate

and bearing outer race (A) into the extension case.

11) Measure the depth “S” between the transfer

case + ST and the center differential.

ST 398643600

GAUGE

12) Measure the height “T” between the extension

case + ST and the transfer drive gear.

ST 398643600

GAUGE

13) Calculate the thrust washer thickness “U” using

the following calculation.

U = S + T – 30 mm (1.18 in) – (0.15 — 0.35 mm

(0.0059 — 0.0138 in))

S: Depth between the transfer case + ST and the

center differential

T: Height between the extension case + ST and the

transfer drive gear

30 mm (1.18 in): Thickness of ST (× 2 pieces)

0.15 — 0.35 mm (0.0059 — 0.0138 in): Clearance

14) Select a suitable washer in the following table.
Standard clearance:

0.15 — 0.35 mm (0.0059 — 0.0138 in)

Adjusting washer (61 × 50 × 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

0.95 (0.0374)

803050070

1.00 (0.0394)

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

1.45 (0.0571)

(A) Bearing outer race
(B) Dish plate

(C) Thrust washer
(D) Extension case

(1) Paint side

MT-03047

(B)

(C)

(C)

(D)

(B)

(A)

(1)

Adjusting 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)

803036053

1.5 (0.059)

803036057

1.6 (0.063)

803036058

1.7 (0.067)

803036080

1.8 (0.071)

803036081

1.9 (0.075)

MT-00122

ST

S

MT-00123

T

ST