Subaru Impreza 3 / Impreza WRX / Impreza WRX STI. Manual — part 439

6MT-93

Reverse Idler Gear Assembly

MANUAL TRANSMISSION AND DIFFERENTIAL

12) Match the protrusion of the reverse synchro

cone to the hole on the reverse idler gear, and in-

stall the reverse idler gear.

13) Point the groove towards the reverse idler gear,

and attach the counter high & low washer and the

washer.

14) Using the ST, install the snap ring.

ST 18672AA000 GUIDE CLIP

15) Inspect and adjust the clearance between the

snap ring and the washer. <Ref. to 6MT-93, IN-

SPECTION, Reverse Idler Gear Assembly.>

16) Install a new straight pin.

E: INSPECTION

Disassembled parts should be washed with clean-

ing solvent first, then inspected carefully.

1) Bearing

Replace the bearings in the following cases.

• Wear, rusting or damage of the bearings

• The bearing does not rotate smoothly or an ab-

normal noise is emitted when turning.

• The bearing has other defects.

2) Bushing (each gear)

Replace the bushing in following cases.

• The sliding surface is damaged or abnormally

worn.

3) Gear

Replace gears in the following cases.

• The gear teeth surface is damaged or excessive-

ly worn.

• The contact area of the baulk ring is damaged.

• The inner face of the gear is worn.

4) Baulk ring, synchro cone

Replace the baulk ring and synchro cone in the fol-

lowing cases.

• Wear, rusting or damage of the baulk ring

5) Shifting insert key

Replace the shifting insert key if deformed, exces-

sively worn or defective in any way.

6) Check clearance between the snap ring and

washer.
Clearance specification:

0.1 — 0.3 mm (0.0039 — 0.0118 in)

If the clearance is out of the specification, select a

snap ring from the following table and replace it.

After replacing the snap ring, inspect the clearance.

(A) Protrusion on the reverse synchro cone
(B) Hole of the reverse idler gear

MT-01508

(A)

(B)

MT-00638

ST

Snap ring

Part No.

Thickness mm (in)

031319000

1.50 (0.059)

805019030

1.60 (0.062)

805019010

1.72 (0.068)

MT-00581

MT-00639

6MT-94

Drive Pinion Shaft Assembly

MANUAL TRANSMISSION AND DIFFERENTIAL

20.Drive Pinion Shaft Assembly

A: REMOVAL

1) Remove the manual transmission assembly

from the vehicle. <Ref. to 6MT-31, REMOVAL,

Manual Transmission Assembly.>

2) Prepare the transmission for overhaul. <Ref. to

6MT-37, Preparation for Overhaul.>

3) Remove the neutral position switch, back-up

light switch and harness. <Ref. to 6MT-41, RE-

MOVAL, Neutral Position Switch.> <Ref. to 6MT-

39, REMOVAL, Back-up Light Switch.>

4) Remove the extension case. <Ref. to 6MT-43,

REMOVAL, Extension Case.>

5) Remove the transfer driven gear. <Ref. to 6MT-

55, REMOVAL, Transfer Driven Gear.>

6) Remove the center differential. <Ref. to 6MT-57,

REMOVAL, Center Differential.>

7) Remove the transmission case. <Ref. to 6MT-

58, REMOVAL, Transmission Case.>

8) Remove the individual gear assemblies. <Ref. to

6MT-65, REMOVAL, Main Shaft Assembly.>

9) Remove the drive pinion shaft assembly.

B: INSTALLATION

1) Remove any remaining gasket material from the

drive plate and clutch housing.

2) Apply liquid gasket to the clutch housing.
Liquid gasket:

THREE BOND 1215 (Part No. 004403007) or

equivalent

3) Install the individual gear assemblies. <Ref. to

6MT-66, INSTALLATION, Main Shaft Assembly.>

4) Install the transmission case. <Ref. to 6MT-60,

INSTALLATION, Transmission Case.>

5) Install the center differential. <Ref. to 6MT-57,

INSTALLATION, Center Differential.>

6) Install the transfer driven gear. <Ref. to 6MT-55,

INSTALLATION, Transfer Driven Gear.>

7) Install the extension case. <Ref. to 6MT-43, IN-

STALLATION, Extension Case.>

8) Install the neutral position switch, back-up light

switch and harness. <Ref. to 6MT-41, INSTALLA-

TION, Neutral Position Switch.> <Ref. to 6MT-39,

INSTALLATION, Back-up Light Switch.>

9) Install the manual transmission assembly to the

vehicle. <Ref. to 6MT-33, INSTALLATION, Manual

Transmission Assembly.>

C: DISASSEMBLY

NOTE:

Replace the drive pinion shaft and hypoid driven

gear as a set.

1) Remove the oil guide A.

2) Remove the drive pinion shaft and shim from the

adapter plate.

3) Affix the ST to the work table.

ST 18664AA000 BASE

4) Flatten the tab of the lock nut.

MT-00640

MT-00532

(A) Oil guide A

MT-01624

(A)

MT-00642

6MT-95

Drive Pinion Shaft Assembly

MANUAL TRANSMISSION AND DIFFERENTIAL

5) Attach ST3 to the lock nut, and set the drive pin-

ion shaft to ST. Remove the lock nut and lock

washer.

ST1 18667AA000

HOLDER

ST2 18664AA000

BASE

ST3 18621AA000

ADAPTER WRENCH

6) Using the ST, remove the double taper roller

bearing assembly.

ST 18723AA000 REMOVER

D: ASSEMBLY

1) Using the ST, measure drive pinion measure-

ment A.
NOTE:

When selecting the drive pinion shim, refer to mea-

surement A.

ST 398643600

GAUGE

2) Using the ST and a press, attach the inner bear-

ing of the double taper roller bearing to the drive

pinion shaft.

ST 18723AA000 REMOVER
CAUTION:

Do not apply pressure in excess of 40 kN (4.0

ton, 4.4 US ton, 3.9 Imp ton).

3) Using the ST and a press, attach the outer race

and the double taper roller bearing to the drive pin-

ion shaft.

ST 18723AA000 REMOVER
NOTE:

• Use a new double taper roller bearing.

• Push in to a position where the bearing rotates

smoothly.

MT-00643

ST2

ST3

ST1

ST

MT-00644

MT-00645

A

ST

(A) Outer race

MT-00646

ST

MT-00647

(A)

ST

6MT-96

Drive Pinion Shaft Assembly

MANUAL TRANSMISSION AND DIFFERENTIAL

4) Attach a new lock washer and a new lock nut.

5) Set the ST to the drive pinion, and tighten the

lock nut.

ST1 18667AA000

HOLDER

ST2 18664AA000

BASE

ST3 18621AA000

ADAPTER WRENCH

ST4 18852AA000

TORQUE WRENCH

NOTE:

• Tighten using the ST and the straight line torque

wrench.

• Make sure the lock washer is installed in the

proper direction.
Tightening torque:

265 N·m (27.0 kgf-m, 195.4 ft-lb)

NOTE:

When using a torque wrench other than ST4, use

the calculation below to calculate and tighten the

lock nut.

Tighten using the ST and the straight line torque

wrench.

T = L1/(0.1 + L1) × 285

6) Measure the starting torque. <Ref. to 6MT-97,

INSPECTION, Drive Pinion Shaft Assembly.>

7) Using the ST, crimp the lock nut in 2 locations,

with dimensions within A 37±0.5 mm (1.46±0.02

in).

ST 18670AA000 PUNCH
NOTE:

Do not damage the crimp area of the lock nut.

(A) Lock washer
(B) Lock nut

(C) Nut side

MT-02715

(B)

(A)

(C)

ST2

ST4

ST3

ST1

T

N·m (kgf-m, ft-lb) Torque wrench setting

L1

m (in) Torque wrench length

0.1 m (3.94 in)

Length of ST

285 N·m (29.0 kgf-m, 210 ft-lb) Tightening torque (lock nut)

(A) 0.1 m (3.94 in)

MT-00614

(A)

L1

MT-00649

A

ST