Subaru Impreza 3 / Impreza WRX / Impreza WRX STI. Service manual — part 427
6MT-45
Extension Case
MANUAL TRANSMISSION AND DIFFERENTIAL
5) Select the thrust washer of the bearing, and at-
tach to the extension case. <Ref. to 6MT-45, AD-
6) Apply a thin coat of oil to the outer surface of the
bearing cone, and attach to the extension case.
7) Install the shift bracket.
Tightening torque:
25 N·m (2.5 kgf-m, 18.4 ft-lb)
8) Attach the oil guide and the transfer driven gear.
<Ref. to 6MT-53, INSTALLATION, Transfer Drive
E: INSPECTION
1) Check to make sure there is no damage or
cracks on the extension case. If damage or crack-
ing is found, replace the extension case.
2) Inspect for oil leaks at the extension case and
transmission case oil seals and mating surfaces. If
there are oil leaks, replace the oil seal and liquid
gasket.
F: ADJUSTMENT
1. TRANSFER DRIVEN GEAR BEARING
THRUST WASHER ADJUSTMENT
1) Remove the bearing cone from the extension
case using the ST.
ST 18758AA000 PULLER
2) Remove the adjusting washer.
3) Measure depth “Z” between the extension case
end area and bearing cone contact area.
ST 398643600
GAUGE
NOTE:
When measuring depth “Z”, subtract the thickness
of the ST [15 mm (0.59 in)] from the measured val-
ue.
4) Remove the transfer driven gear. <Ref. to 6MT-
55, REMOVAL, Transfer Driven Gear.>
5) Remove the center differential. <Ref. to 6MT-57,
REMOVAL, Center Differential.>
6) Remove the oil guides G and H.
(A) Bearing cone
MT-00478
MT-00479
(A)
ST
(A) 15 mm (0.59 in)
(A) Oil guide G
(B) Oil guide H
MT-01420
(A)
Z
ST
ST
MT-01728
(A)
(B)
6MT-46
Extension Case
MANUAL TRANSMISSION AND DIFFERENTIAL
7) Remove the snap ring and flat washer from the
selector arm area.
8) Using an ST, remove the neutral set spring and
support.
ST1 18756AA000
CLAW
ST2 399893600
PLIER
9) Lift the striking rod, and remove the straight pin.
10) Remove the selector arm No. 2, shifter arm, se-
lector plunger and spring.
11) Attach the bearing cone to the transfer driven
gear.
12) Set the ST.
ST 18831AA000 GAUGE
13) Turn the transfer driven gear 10 or more times
to seat the bearing properly.
(A) Snap ring
(B) Flat washer
(A) Striking rod
(B) Straight pin
MT-01616
(B)
(A)
MT-01092
ST2
ST1
MT-01307
(A)
(B)
(A) Selector arm No. 2
(B) Shifter arm
(C) Selector plunger
MT-02713
(B)
(A)
(C)
MT-00489
ST
6MT-47
Extension Case
MANUAL TRANSMISSION AND DIFFERENTIAL
14) Measure depth “Y” between the end of the ST
and the bearing cone.
ST 18831AA000 GAUGE
15) Using the following calculation, calculate the
transfer driven gear bearing adjusting washer value
“t”.
t = Z – (100 – Y) – {0.02 — 0.11 mm (0.0008 —
0.0043 in)}
16) Refer to the calculated value “t” to select the
closest thrust washer from the following table.
Standard clearance between the adjusting
washer and taper roller bearing
0.02 — 0.11 mm (0.0008 — 0.0043 in)
NOTE:
Match to be within the standard clearance range.
t
mm (in)
Transfer driven gear bearing adjust-
ing washer thickness
Y
mm (in)
Depth between the end of the ST
and the bearing cone
Z
mm (in)
Depth between the end of the
extension case and the bearing
cone contact area
0.02 — 0.11 mm
(0.0008 — 0.0043 in)
Standard clearance between the
adjusting washer and taper roller
bearing
100 mm
(3.94 in)
Height of ST
MT-00490
Y
ST
Adjusting washer (50 × 61 × t)
Part No.
Thickness t 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 (0.0570)
6MT-48
Extension Case
MANUAL TRANSMISSION AND DIFFERENTIAL
17) Install the selector arm No. 2, shifter arm, se-
lector plunger and spring.
18) Install a new straight pin.
19) Using the ST, install the neutral set spring and
support.
ST1 18756AA000
CLAW
ST2 399893600
PLIER
20) Install the flat washer and snap ring to the se-
lector arm area.
21) Install the center differential. <Ref. to 6MT-57,
INSTALLATION, Center Differential.>
2. TRANSFER DRIVE GEAR THRUST
WASHER SELECTION
1) Measure height “Z” between the transmission
case end area and ST.
ST 398643600
GAUGE
(A) Selector arm No. 2
(B) Shifter arm
(C) Selector plunger
MT-02713
(B)
(A)
(C)
MT-01092
ST2
ST1
(A) Snap ring
(B) Flat washer
MT-01616
(B)
(A)
Z
ST
MT-00949
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