Subaru Impreza 3 / Impreza WRX / Impreza WRX STI. Service manual — part 411
5MT-65
Drive Pinion Shaft Assembly
MANUAL TRANSMISSION AND DIFFERENTIAL
14) Install the drive pinion collar, needle bearing,
adjusting washer No. 2, thrust bearing, adjusting
washer No. 1 and differential bevel gear sleeve in
this order.
NOTE:
Be careful to install the spacer in the proper direc-
tion.
15) Adjust the thrust bearing preload. <Ref. to
5MT-66, THRUST BEARING PRELOAD, AD-
JUSTMENT, Drive Pinion Shaft Assembly.>
E: INSPECTION
Disassembled parts should be washed with clean-
ing solvent first, then inspected carefully.
1) Bearing
Replace the bearings in the following cases.
• When the bearing balls, outer races and inner
races are broken or rusty.
• When the bearing is worn.
• When the bearings fail to turn smoothly or emit
noise in rotation after gear oil lubrication.
• The ball bearing on the rear side of the drive pin-
ion shaft should be checked for smooth rotation be-
fore the drive pinion shaft assembly is
disassembled. In this case, because a preload is
working on the bearing, its rotation feels like it is
slightly dragging unlike other bearings.
• When bearing has other defects.
2) Bushing (each gear)
Replace the bushing in following cases.
• When the sliding surface is damaged or abnor-
mally worn.
• When the inner wall is abnormally worn.
3) Gear
Replace gears in the following cases.
• Replace the gear with new part if its tooth surfac-
es are broken, damaged or excessively worn.
• Correct or replace if the cone that contacts the
baulk ring is rough or damaged.
• Correct or replace if the inner surface or end face
is damaged.
4) Baulk ring, synchro cone
Replace the baulk ring and synchro cone in the fol-
lowing cases.
• When the inner surface and end face are dam-
aged.
• When the baulk ring inner surface is abnormally
or partially worn down.
• When the contact surface of the baulk ring insert
section is cracked or abnormally worn.
(A) Driven shaft
(B) Drive shaft
(C) Drive pinion collar
(D) Needle bearing (25 × 30 × 20)
(E) Adjusting washer No. 2 (25 × 36 × t)
(F) Thrust bearing (25 × 37.5 × 3)
(G) Adjusting washer No. 1 (25 × 36 × t)
(H) Differential bevel gear sleeve
MT-00263
(A) (B)
(C) (D) (E) (F) (G) (H)
(A) Drive pinion shaft
(B) Ball bearing
MT-00264
(A)
(B)
5MT-66
Drive Pinion Shaft Assembly
MANUAL TRANSMISSION AND DIFFERENTIAL
• If the gap between the end faces of the baulk 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
• 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) 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.
6) Shifting insert key
Replace the shifting insert key if deformed, exces-
sively worn or defective in any way.
7) Ball detent
Replace the ball detent if deformed, excessively
worn or defective in any way.
8) Oil seal
Replace the oil seal if the lip is deformed, hard-
ened, worn or defective in any way.
9) O-ring
Replace the O-ring if the sealing face is deformed,
hardened, damaged, worn or defective in any way.
F: ADJUSTMENT
1. THRUST BEARING PRELOAD
1) Select a suitable adjusting washer No. 1 so that
dimension (H) will be zero in a visual check. Posi-
tion the washer (18.3 × 30 × t) and lock washer (18
× 30 × 2) and attach the lock nut.
MT-01674
(A)
MT-00267
(H)
5MT-67
Drive Pinion Shaft Assembly
MANUAL TRANSMISSION AND DIFFERENTIAL
2) Using the ST1, ST2 and ST3, tighten the new
lock nut to the specified torque.
NOTE:
• Use new lock nuts and lock washers.
• Make sure the lock washer is installed in the
proper direction.
Tightening torque:
120 N·m (12.2 kgf-m, 88.5 ft-lb)
ST1 899884100
HOLDER
ST2 498427100
STOPPER
ST3 899988608
SOCKET WRENCH (27)
3) After removing the ST2, measure the starting
torque using torque driver.
ST1 899884100
HOLDER
ST3 899988608
SOCKET WRENCH (27)
Starting torque:
0.3 — 0.8 N·m (0.03 — 0.08 kgf-m, 0.22 — 0.59
ft-lb)
4) If the starting torque is not within the specified
limit, select new adjusting washer No. 1 and re-
check starting torque.
(A) Lock nut
(B) Lock washer
(C) Nut side
ST1
ST2
ST3
MT-02392
(C)
(A)
(B)
(A) Adjusting washer No. 1
(B) Adjusting washer No. 2
Adjusting washer No. 1
Part No.
Thickness mm (in)
803025051
3.925 (0.1545)
803025052
3.950 (0.1555)
803025053
3.975 (0.1565)
803025054
4.000 (0.1575)
803025055
4.025 (0.1585)
803025056
4.050 (0.1594)
803025057
4.075 (0.1604)
MT-00269
ST1
ST3
MT-00270
( A )
( B )
5MT-68
Drive Pinion Shaft Assembly
MANUAL TRANSMISSION AND DIFFERENTIAL
5) If the specified starting torque cannot be ob-
tained by the selection of adjusting washer No. 1,
select adjusting washer No. 2 from the list below.
Repeat steps 1) through 4) to adjust starting
torque.
6) Recheck that the starting torque is within the
specified range, then crimp the lock nut at four po-
sitions.
CAUTION:
When crimping the lock nut, be careful not to
crack it.
(A) Adjusting washer No. 1
(B) Adjusting washer No. 2
Starting torque
Dimension H
Adjusting washer No. 2
Low
Small
Select thicker one.
High
Large
Select thinner one.
Adjusting washer No. 2
Part No.
Thickness mm (in)
803025059
3.850 (0.1516)
803025054
4.000 (0.1575)
803025058
4.150 (0.1634)
MT-00270
( A )
( B )
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