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Subaru Impreza 3 / Impreza WRX / Impreza WRX STI. Manual - part 437

6MT-85

Driven Gear Assembly

MANUAL TRANSMISSION AND DIFFERENTIAL

14) Install the inner baulk ring.

15) Apply adequate transmission gear oil to the

bushing, 2nd needle bearing and 2nd driven gear

inner surface.

16) Install the 2nd needle bearing and 2nd driven

gear.
NOTE:

Match the protrusion of the 2nd synchro cone to the

hole of the 2nd driven gear, then install.

17) Attach the key.

18) Using the ST, install the 3rd-4th driven gear.

ST 18654AA000 INSTALLER
CAUTION:

Do not apply pressure in excess of 40 kN (4.0

ton, 4.4 US ton, 3.9 Imp ton).
NOTE:

• Make sure that the 3rd-4th driven gear is in-

stalled in the correct direction.

• Match the groove on the 3rd-4th driven gear to

the key.

19) Make sure that the 2nd driven gear can be

turned smoothly by hand. If it does not turn smooth-

ly, reassemble.

20) Attach the key.

(A) 2nd needle bearing
(B) 2nd driven gear

MT-00606

MT-00607

(A)

(C)

(B)

MT-00608

(A) 4th gear
(B) 3rd gear

MT-00609

(A)

(C)

(B)

MT-00610

6MT-86

Driven Gear Assembly

MANUAL TRANSMISSION AND DIFFERENTIAL

21) Using the ST, install the 5th-6th driven gear.

ST 18654AA000 INSTALLER
CAUTION:

Do not apply pressure in excess of 40 kN (4.0

ton, 4.4 US ton, 3.9 Imp ton).
NOTE:

• Make sure that the 5th-6th driven gear is in-

stalled in the correct direction.

• Match the groove on the 5th-6th driven gear to

the key.

22) Using the ST, install the ball bearing.

ST 18654AA000 INSTALLER
CAUTION:

Do not apply pressure in excess of 40 kN (4.0

ton, 4.4 US ton, 3.9 Imp ton).
NOTE:

Face the sealing section of the ball bearing to the

lock nut side, and install the ball bearing.

23) Make sure that the ball bearing turns smoothly

by hand. If it does not turn smoothly, reassemble.

24) Install a new lock nut.

(A) 6th gear
(B) 5th gear

MT-00611

(B)

(A)

(C)

(A) Sealing

MT-02108

(A)

6MT-87

Driven Gear Assembly

MANUAL TRANSMISSION AND DIFFERENTIAL

25) Attach ST3 to the lock nut, attach ST to the driv-

en gear assembly, and tighten the lock nut.

ST1 18666AA000

HOLDER

ST2 18664AA000

BASE

ST3 18620AA000

ADAPTER WRENCH

ST4 18852AA000

TORQUE WRENCH

Tightening torque:

530 N·m (54.0 kgf-m, 390.9 ft-lb)

NOTE:

When using a torque wrench other than ST4, use

the calculation below to calculate and tighten the

lock nut.

T = L1/(0.1 + L1) × 570

26) Using the ST, crimp the lock nut in 4 locations,

with dimensions within A 44±0.5 mm (1.73±0.02

in).

ST 18669AA000 PUNCH DRIVEN SHAFT
NOTE:

Do not damage the crimp area of the lock nut.

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

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

m (in) Torque wrench length

0.1 m (3.94 in)

Length of ST

570 N·m (58.1 kgf-m, 420 ft-lb) Tightening torque (lock nut)

(A) 0.1 m (3.94 in)

MT-00613

ST1

ST2

ST4

ST3

MT-00614

(A)

MT-00615

6MT-88

Driven Gear Assembly

MANUAL TRANSMISSION AND DIFFERENTIAL

5) Shifting insert key

Replace the shifting insert key if deformed, exces-

sively worn or defective in any way.

F: ADJUSTMENT

1) Measure the length “H” from the transmission

case and transfer bearing holder mating surface, to

the end face of the ball bearing.

2) Using the following calculation, calculate the

thickness of the driven gear assembly adjusting

washer.

T = H – {5.8±0.05 mm (0.23±0.002 in)} – {0.1 — 0.3

mm (0.0039 — 0.0118 in)}

3) Select 0 to 3 adjusting washers from the follow-

ing table, and adjust to the backlash that is closest

to the standard value.
Driven gear assembly axial direction backlash

standard:

0.1 — 0.3 mm (0.0039 — 0.0118 in)

(A) Transmission case
(B) Ball bearing

Adjusting washer thickness

Length from the transmission case
and transfer bearing holder mating
surface to the end face of the ball
bearing

5.8±0.05 mm

(0.23±0.002 in)

Collar thickness

0.1 — 0.3 mm

(0.0039 — 0.0118 in)

Driven gear assembly axial direc-
tion backlash standard

MT-00581

MT-00616

(A)

(C)

(B)

Adjusting washer

Part No.

Thickness T mm (in)

803072030

0.15 (0.0059)

803072031

0.30 (0.0118)

803072032

0.45 (0.0177)

803072033

0.60 (0.0236)

Content .. 435 436 437 438 ..