Subaru Impreza 3 / Impreza WRX / Impreza WRX STI. Service manual — part 440
6MT-97
Drive Pinion Shaft Assembly
MANUAL TRANSMISSION AND DIFFERENTIAL
8) Using the ST, measure drive pinion measure-
ment B.
ST 398643600
GAUGE
9) Calculate from the calculation below to select 1
or 2 drive pinion shims from the following table.
6.5±0.0625 mm – (B – A) [0.26±0.0025 in – (B – A)]
NOTE:
A: Measurement value in step 1)
B: Measurement value in step 8)
10) Apply transmission gear oil to the side face of
the taper roller bearing, and attach the drive pinion
shaft and the selected shims to the adapter plate.
Tightening torque:
54 N·m (5.5 kgf-m, 39.8 ft-lb)
11) Install the oil guide A.
Tightening torque:
18 N·m (1.8 kgf-m, 13.3 ft-lb)
E: INSPECTION
1) Using a spring scale, measure the starting
torque. If the starting torque is outside the specifi-
cation range, replace the taper roller bearing.
Starting torque:
0 — 0.95 N (0 — 0.097 kgf, 0 — 0.21 lbf)
2) Gear
Replace gears in the following cases.
• The gear teeth surface is damaged or excessive-
ly worn.
3) 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.
4) Adapter plate
Replace the adapter plate in the following cases:
• Wear, rusting or damage of the bearings
• Damage of the adapter plate
5) Check that the pipes and pipe chambers are not
damaged or clogged. Repair or replace if damaged
or clogged.
Drive pinion shim
Part No.
Thickness mm (in)
32295AA270
0.15 (0.0059)
32295AA280
0.175 (0.0069)
32295AA290
0.20 (0.0079)
32295AA300
0.225 (0.0089)
32295AA310
0.25 (0.0098)
32295AA320
0.275 (0.0108)
MT-00650
B
ST
MT-00642
(A) Oil guide A
MT-01624
(A)
MT-00651
6MT-98
Drive Pinion Shaft Assembly
MANUAL TRANSMISSION AND DIFFERENTIAL
F: ADJUSTMENT
1) Inspect and adjust the hypoid driven gear-to-
drive pinion backlash. <Ref. to 6MT-105, HYPOID
GEAR BACKLASH, ADJUSTMENT, Front Differ-
2) Apply a thin uniform coat of lead-free red dye on
the surfaces of 3 or 4 hypoid driven gear teeth.
3) Install the drive pinion shaft assembly to the
clutch housing, and tighten at least 4 bolts.
NOTE:
Install with the remaining liquid gasket, so that the
clutch housing and the adapter plate will not be
damaged.
Tightening torque:
50 N·m (5.1 kgf-m, 36.9 ft-lb)
4) Turn a few times using the ST.
ST 18631AA000 HANDLE
5) Remove the drive pinion shaft assembly, and in-
spect the mating condition of the teeth. If the tooth
contact is not correct, adjust the backlash or shim
thickness.
• Correct tooth contact
Check item: Tooth contact surface is slightly
shifted toward the toe side under a no-load con-
dition. (When driving, it moves towards the heel
side.)
• Face contact
Check item: Backlash is too large.
Contact pattern
Corrective action: Tighten the side retainer to move
the driven gear closer to the drive pinion shaft.
MT-00652
MT-00653
ST
(A) Toe side
(B) Heel side
(A)
(B)
MT-01401
AT-00208
AT-01253
6MT-99
Drive Pinion Shaft Assembly
MANUAL TRANSMISSION AND DIFFERENTIAL
• Flank contact
Check item: Backlash is too small.
Contact pattern
Corrective action: Loosen the side retainer to move
the driven gear away from the drive pinion shaft.
• Toe contact (inside contact)
Check item: Teeth contact area is too small.
Contact pattern
Adjustment: Reduce the thickness of the drive pin-
ion shim according to the procedure for moving the
drive pinion away from the driven gear.
• Heel contact (outside end contact)
Check item: Teeth contact area is too small.
Contact pattern
Adjustment: Increase thickness of the drive pinion
shim according to the procedures for moving the
drive pinion closer to the driven gear.
AT-00209
AT-01254
AT-00210
AT-00213
AT-00211
AT-00212
6MT-100
Front Differential Assembly
MANUAL TRANSMISSION AND DIFFERENTIAL
21.Front Differential Assembly
A: REMOVAL
1) Remove the manual transmission assembly.
<Ref. to 6MT-31, REMOVAL, Manual Transmis-
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,
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. <Ref.
to 6MT-94, REMOVAL, Drive Pinion Shaft Assem-
10) Remove the lock plates on both sides.
11) Remove the differential side retainers on both
sides using the ST.
ST1 18630AA010
WRENCH COMPL RETAIN-
ER (RH SIDE)
ST2 18630AA000
WRENCH ASSY (LH SIDE)
NOTE:
Be careful not to damage the section where the
clutch case retainer will be attached.
12) Remove the front differential.
B: INSTALLATION
1) Install the differential assembly to the clutch
housing.
2) Apply oil to the screw threads of the side retain-
er.
3) Remove the O-rings on both sides of the side re-
tainer.
(A) Lock plate
MT-01022
(A)
(A) LH side
(B) RH side
(A)
(B)
MT-00657
ST1
ST2
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