Content .. 440 441 442 443 ..

Subaru Impreza 3 / Impreza WRX / Impreza WRX STI. Manual - part 442

6MT-105

Front Differential Assembly

MANUAL TRANSMISSION AND DIFFERENTIAL

F: ADJUSTMENT

1. HYPOID GEAR BACKLASH

1) Attach the RH and LH side retainers.

ST1 18630AA010

WRENCH COMPL RETAIN-

ER (RH SIDE)

ST2 18630AA000

WRENCH ASSY (LH SIDE)

NOTE:

• Twist in the side retainer on RH side a little fur-

ther than on LH side.

• WRENCH ASSY (499787000) can also be used.

2) Attach the drive pinion shaft assembly, and affix

with 5 bolts.
NOTE:

Use old gaskets and washers to prevent the mating

surfaces of the housing from becoming damaged.
Tightening torque:

50 N·m (5.1 kgf-m, 36.9 ft-lb)

3) Using the ST, loosen the differential side retainer

RH, and twist in the differential side retainer LH un-

til the hypoid driven gear just contacts the drive pin-

ion.

ST1 18630AA010

WRENCH COMPL RETAIN-

ER (RH SIDE)

ST2 18630AA000

WRENCH ASSY (LH SIDE)

4) Use the ST to turn the drive pinion shaft a few

times.

ST 18631AA000 HANDLE

5) Repeat steps 3) and 4) until differential side re-

tainer LH does not turn anymore. For differential

side retainer RH, screw in until the inner race and

outer race just comes into contact. This is the “ze-

ro” backlash state.

6) Mark the mating positions of the left and right

side retainers and the clutch housing.

7) Turn the back differential side retainer LH by 3

notches, and screw in the differential side retainer

RH by 3 notches.

8) Temporarily attach the LH side retainer lock

plate.

9) Turn the differential side retainer RH by 1.25

notches.

10) Temporarily attach the RH side retainer lock

plate.
NOTE:

• If the lock plate cannot be aligned, adjust the po-

sition toward the tightened side.

• The notch on the lock plate moves by 0.5 notch if

the lock plate is turned upside down when installed.

11) Use the ST to fix the drive pinion shaft in place.

ST 18621AA000 ADAPTER WRENCH

12) Install the SUBARU genuine axle shaft to the

front differential left and right sides.

Part No. 38415AA000

Axle shaft

MT-00653

MT-00658

MT-00674

6MT-106

Front Differential Assembly

MANUAL TRANSMISSION AND DIFFERENTIAL

13) Move the axle shaft, and measure the hypoid

gear backlash.

ST1 498255400

PLATE

ST2 498247001

MAGNET BASE

ST3 498247100

DIAL GAUGE

Hypoid gear backlash:

0.13 — 0.18 mm (0.0051 — 0.0071 in)

14) If the backlash is out of specified range, re-

move the left and right retainer lock plates and

loosen RH side differential side retainer. Then, ad-

just the LH side differential side retainer by turning

it, and attach the LH side retainer lock plate.

15) Screw in the RH side differential side retainer

until the inner race and outer race just come into

contact.

2. TOOTH CONTACT OF HYPOID GEAR

Regarding teeth contact conditions, refer to the

drive pinion section. <Ref. to 6MT-104, TOOTH

CONTACT OF HYPOID GEAR, INSPECTION,

Front Differential Assembly.>

MT-00675

ST2

ST1

ST3

6MT-107

Shifter Fork and Rod

MANUAL TRANSMISSION AND DIFFERENTIAL

22.Shifter Fork and Rod

A: REMOVAL

1) Remove the manual transmission assembly

from the vehicle. <Ref. to 6MT-31, REMOVAL,

Manual Transmission Assembly.>

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,

REMOVAL, Extension Case.>

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.>

B: INSTALLATION

1) Install the individual gear assemblies all at once.

<Ref. to 6MT-66, INSTALLATION, Main Shaft As-

sembly.>

2) Install the transmission case. <Ref. to 6MT-60,

INSTALLATION, Transmission Case.>

3) Install the center differential. <Ref. to 6MT-57,

INSTALLATION, Center Differential.>

4) Install the transfer driven gear. <Ref. to 6MT-55,

INSTALLATION, Transfer Driven Gear.>

5) Install the extension case. <Ref. to 6MT-43, IN-

STALLATION, Extension Case.>

6) Install the neutral position switch, back-up light

switch and harness. <Ref. to 6MT-41, INSTALLA-

TION, Neutral Position Switch.> <Ref. to 6MT-39,

INSTALLATION, Back-up Light Switch.>

7) Install the manual transmission assembly to the

vehicle. <Ref. to 6MT-33, INSTALLATION, Manual

Transmission Assembly.>

C: DISASSEMBLY

1. REVERSE SHIFTER FORK

1) Remove the reverse fork using the ST.

ST 398791700

REMOVER

2) Remove the reverse shifter arm using the ST.

ST 398791700

REMOVER

2. 1ST-2ND, 3RD-4TH SHIFTER FORK

1) Using the ST, remove the 3rd-4th shifter fork.

ST 398791700

REMOVER

2) Using the ST, remove the 3rd-4th shifter arm.

ST 398791700

REMOVER

MT-00680

MT-00681

MT-00682

MT-00683

6MT-108

Shifter Fork and Rod

MANUAL TRANSMISSION AND DIFFERENTIAL

3) Using the ST, remove the 1st-2nd shifter arm

and 1st-2nd shifter fork.

ST 398791700

REMOVER

3. 5TH-6TH SHIFTER FORK

1) Using the ST, remove the 5th-6th shifter fork.

ST 398791700

REMOVER

2) Using the ST, remove the 5th-6th shifter arm.

ST 398791700

REMOVER

4. SHIFTER ARM SHAFT

Remove the selector arm using the ST.

ST 398791700

REMOVER

5. STRIKING ROD

1) Remove the reverse interlock block and the in-

terlock block from the striking rod.

2) Remove the reverse interlock arm using the ST.

ST 398791700

REMOVER

(A) 1st-2nd shifter arm
(B) 1st-2nd shifter fork

MT-00684

(A)

(B)

MT-00685

MT-00686

(A) Reverse interlock block
(B) Interlock block

(A) Reverse interlock arm
(B) Interlock arm

MT-01095

MT-00688

(A)

(B)

MT-00689

(A)

(B)

Content .. 440 441 442 443 ..