Subaru Impreza 2003, Service Manual

Page: 1877 / 3610

5MT-69
MANUAL TRANSMISSION AND DIFFERENTIAL
TRANSMISSION CASE
B: INSTALLATION
1. SINGLE-RANGE
1) Wipe off grease, oil and dust on the mating sur-
faces of transmission cases with white gasoline.
2) Install the front differential assembly.
3) Install the main shaft assembly.
Install the transmission case knock pin into needle
bearing knock pin hole.
4) Install the drive pinion shaft assembly.
Install the transmission case knock pin into roller
bearing knock pin hole.
5) Apply liquid gasket, and then put the case right
side and left side together.
Liquid gasket:
THREE BOND 1215 or equivalent
6) Tighten the seventeen bolts with bracket, clip,
etc. as shown in the figure.
NOTE:
• Insert the bolts from bottom and tighten the nuts
at top.
• Put the cases together so that drive pinion shim
and input shaft holder shim are not caught up in be-
tween.
• Confirm that the speedometer gear is meshed.
Tightening torque:
8 mm bolt
25 N·m (2.5 kgf-m, 18.1 ft-lb)
★
★ ★
★
10 mm bolt
39 N·m (4.0 kgf-m, 28.9 ft-lb)
7) Tighten the ball bearing attachment bolts.
Tightening torque:
29 N·m (3.0 kgf-m, 21.7 ft-lb)
8) Backlash adjustment of hypoid gear and preload
adjustment of roller bearing:
NOTE:
Support the drive pinion assembly with ST.
ST
498427100 STOPPER
9) Place the transmission with case left side facing
downward and put ST1 on bearing cup.
10) Screw the retainer assembly into left case from
the bottom using ST2. Fit the ST3 on transmission
main shaft. Shift the gear into 4th or 5th and turn
the shaft several times. Screw in the retainer while
turning ST3 until a slight resistance is felt on ST2.
This is the contact point of hypoid gear and drive
pinion shaft. Repeat the above sequence several
times to ensure the contact point.
ST1
399780104 WEIGHT
ST2 499787000 WRENCH ASSY
ST3 499927100 HANDLE
(9)
(7)
(5)
(1)
(2)
(16)
(17)
(11)
(3)
(4)
(12)
(8)
(6)
(10)
(14)
(15)
(13)
MT-00172
MT-00158
MT-00174
ST
MT-00175
ST3
ST2
ST1