Subaru Impreza 3 / Impreza WRX / Impreza WRX STI. Service manual — part 409
5MT-57
Main Shaft Assembly for Single-Range
MANUAL TRANSMISSION AND DIFFERENTIAL
• When the ring inner surface is abnormally or par-
tially worn down.
• When the contact surface of the synchronizer
ring insert section is cracked or abnormally worn.
• If the gap between the end faces of the ring and
the gear splined part is excessively small, check
the clearance (A) while pressing the ring against
the cone.
Clearance (A):
0.5 mm (0.020 in) or more
Single cone
Double cone
• Apply gear oil to the cone of the gear and while
press-fitting the baulk ring, check there is no rota-
tion in the circumferential direction.
5) Shifting insert key
Replace the insert key if deformed, excessively
worn or defective in any way.
6) Oil seal
Replace the oil seal if the lip is deformed, hard-
ened, worn or defective in any way.
7) Coupling sleeve and synchronizer hub
• Check the slipping condition of the coupling
sleeve.
• Check the splines on the coupling sleeve and
synchronizer hub for wear.
8) O-ring
Replace the O-ring if the sealing face is deformed,
hardened, damaged, worn or defective in any way.
9) 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:
Measure the protrusion amount (A) of double taper
roller bearing from transmission main case surface,
and select a suitable plate in the following table.
NOTE:
Before measuring, tap the end of main shaft with a
plastic hammer lightly in order to make the clear-
ance zero between the main case surface and
moving flange of bearing.
MT-01673
(A)
MT-01674
(A)
Dimension (A)
mm (in)
Part No.
Mark
4.00 — 4.13
(0.1575 — 0.1626)
32294AA041
1
3.87 — 4.00
(0.1524 — 0.1575)
32294AA051
2
MT-01807
(A)
5MT-58
Drive Pinion Shaft Assembly
MANUAL TRANSMISSION AND DIFFERENTIAL
16.Drive Pinion Shaft Assembly
A: REMOVAL
1) Remove the manual transmission assembly
from the vehicle. <Ref. to 5MT-23, REMOVAL,
Manual Transmission Assembly.>
2) Remove the transfer case together with the ex-
tension case assembly. <Ref. to 5MT-35, REMOV-
AL, Transfer Case and Extension Case
3) Remove the transmission case. <Ref. to 5MT-
49, REMOVAL, Transmission Case.>
4) Remove the drive pinion shaft assembly.
NOTE:
Use a hammer handle, etc. to remove if too tight.
B: INSTALLATION
1) Remove the front differential assembly.
2) Hypoid gear set match mark/No.: The number
(A) on top of the drive pinion, and the number on
the hypoid driven gear are set numbers for the two
gears. Use a pair having the same numbers.
The figure (B) below shows a number for shim ad-
justment. If no number is shown, the value is zero.
3) Place the drive pinion shaft assembly on trans-
mission main case RH without shim and tighten the
bearing mounting bolts.
4) Check and adjust the ST.
(1) 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.
(2) Tighten the two bolts.
ST 499917500
DRIVE PINION GAUGE
ASSY
5) Position the ST by inserting the knock pin of ST
into the knock hole of 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
7) The thickness of shim shall be determined by
adding the value indicated on drive pinion to the
value indicated on the 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
(A) Main shaft ASSY for single-range
(B) Drive pinion shaft ASSY
(A) Set number
(B) Number for shim adjustment
MT-00161
( A )
( B )
MT-00990
(A)
(B)
(A)
+0.1
(A) Plate
(B) Scale
(A) Adjust the clearance to zero without shim.
MT-00242
(A)
(B)
ST
MT-00243
(A)
ST
5MT-59
Drive Pinion Shaft Assembly
MANUAL TRANSMISSION AND DIFFERENTIAL
8) Select one to three shims in the following table
for the value determined as described above, and
take the shim(s) which thickness is closest to the
said value.
9) Install the front differential assembly. <Ref. to
5MT-69, INSTALLATION, Front Differential As-
10) Fit the transmission case knock pin to the
knock pin hole of the roller bearing and install the
drive pinion shaft assembly.
11) Install the main shaft assembly for single-
range. <Ref. to 5MT-53, INSTALLATION, Main
Shaft Assembly for Single-Range.>
12) Check each shifter fork. <Ref. to 5MT-81, IN-
SPECTION, Shifter Fork and Rod.>
13) Install the transmission case. <Ref. to 5MT-50,
INSTALLATION, Transmission Case.>
14) Install the transfer case together with the exten-
sion case assembly. <Ref. to 5MT-35, INSTALLA-
TION, Transfer Case and Extension Case
15) Install the manual transmission assembly to the
vehicle. <Ref. to 5MT-26, INSTALLATION, Manual
C: DISASSEMBLY
NOTE:
Attach a cloth to the end of driven shaft (on the fric-
tional side of the thrust needle bearing) to prevent
damage during disassembly or reassembly.
1) Flatten the tab of the lock nut. Remove the lock
nut with ST1, ST2 and ST3.
ST1 899884100
HOLDER
ST2 498427100
STOPPER
ST3 899988608
SOCKET WRENCH (27)
2) Draw out the drive pinion shaft from driven shaft.
Remove the differential bevel gear sleeve, adjust-
ing washer No. 1, adjusting washer No. 2, thrust
bearing, needle bearing and drive pinion collar.
Drive pinion shim
Part No.
Thickness mm (in)
32295AA031
0.150 (0.0059)
32295AA041
0.175 (0.0069)
32295AA051
0.200 (0.0079)
32295AA061
0.225 (0.0089)
32295AA071
0.250 (0.0098)
32295AA081
0.275 (0.0108)
32295AA091
0.300 (0.0118)
32295AA101
0.500 (0.0197)
(A) Differential bevel gear sleeve
(B) Adjusting washer No. 1 (25 × 37.5 × t)
(C) Thrust bearing (25 × 37.5 × 3)
(D) Adjusting washer No. 2 (25 × 37.5 × t)
(E) Needle bearing (25 × 30 × 20)
(F) Drive pinion collar
(G) Needle bearing (30 × 37 × 23)
(H) Thrust bearing (33 × 50 × 3)
MT-00244
ST1
ST2
ST3
MT-00245
( B )
( D )
( C )
( A )
( F )
( H )
( G )
( E )
5MT-60
Drive Pinion Shaft Assembly
MANUAL TRANSMISSION AND DIFFERENTIAL
3) Remove the roller bearing and washer using ST
and a press.
ST 498077000
REMOVER
4) Flatten the tab of the lock nut. Remove the lock
nut using ST1 and ST2.
ST1 499987300
SOCKET WRENCH (50)
ST2 899884100
HOLDER
5) Remove the 5th driven gear using ST.
ST 499857000
5TH DRIVEN GEAR REMOV-
ER
6) Remove the woodruff key.
7) Remove the double taper roller bearing and 3rd-
4th driven gear using ST1 and ST2.
ST1 499757002
INSTALLER
ST2 899714110
REMOVER
8) Remove the key.
9) Remove the 2nd driven gear, inner baulk ring,
synchro cone and outer baulk ring.
10) Remove the 1st driven gear, inner baulk ring,
synchro cone, outer baulk ring, 2nd gear bushing
and gear & hub assembly using ST1 and ST2.
MT-00246
ST
MT-00247
ST1
ST2
MT-00248
S T
(A) 2nd driven gear
(B) Synchro cone
(C) Inner baulk ring
(D) Outer baulk ring
(A) 1st driven gear
(B) Synchro cone
(C) Inner baulk ring
(D) Outer baulk ring
(E) Gear & hub ASSY
(F) 2nd gear bushing
MT-00249
ST1
ST2
(A)
(B)
(C)
(D)
MT-02396
MT-02397
(D)
(E)
(F)
(C)
(B)
(A)
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