Subaru Impreza 2004 User manual

FUJI HEAVY INDUSTRIES LTD. G1870GE4

2004 IMPREZA SERVICE MANUAL QUICK REFERENCE INDEX

TRANSMISSION SECTION

This service manual has been prepared

to provide SUBARU service personnel

with the necessary information and data

for the correct maintenance and repair

of SUBARU vehicles.

This manual includes the procedures

for maintenance, disassembling, reas-

sembling, inspection and adjustment of

components and diagnostics for guid-

ance of experienced mechanics.

Please peruse and utilize this manual

fully to ensure complete repair work for

satisfying our customers by keeping

their vehicle in optimum condition.

When replacement of parts during

repair work is needed, be sure to use

SUBARU genuine parts.

All information, illustration and specifi-

cations contained in this manual are

based on the latest product information

available at the time of publication

approval.

CONTROL SYSTEMS CS

AUTOMATIC TRANSMISSION 4AT

AUTOMATIC TRANSMISSION

(DIAGNOSTICS) 4AT(diag)

MANUAL TRANSMISSION AND

DIFFERENTIAL 5MT

MANUAL TRANSMISSION AND

DIFFERENTIAL 6MT

MANUAL TRANSMISSION AND

DIFFERENTIAL (DIAGNOSTICS) 6MT(diag)

CLUTCH SYSTEM CL

MANUAL TRANSMISSION AND

DIFFERENTIAL

6MT

Page

1. General Description ....................................................................................2

2. Transmission Gear Oil ..............................................................................31

3. Oil Seal......................................................................................................32

4. Vehicle Speed Sensor...............................................................................33

5. Transmission Mounting System ................................................................34

6. Manual Transmission Assembly ...............................................................36

7. Preparation for Overhaul...........................................................................41

8. Air Breather Hose......................................................................................42

9. Oil Pipe......................................................................................................43

10. Back-up Light Switch.................................................................................44

11. Neutral Position Switch .............................................................................46

12. Extension Case .........................................................................................48

13. Reverse Checking System........................................................................54

14. Transfer Drive Gear ..................................................................................57

15. Transfer Driven Gear ................................................................................59

16. Center Differential .....................................................................................61

17. Oil Pump ...................................................................................................62

18. Transmission Case ...................................................................................66

19. Main Shaft Assembly ................................................................................71

20. Driven Gear Assembly ..............................................................................85

21. Reverse Idler Gear Assembly ...................................................................93

22. Drive Pinion Shaft Assembly.....................................................................98

23. Front Differential Assembly .....................................................................104

24. Speedometer Gear..................................................................................110

25. Shifter Fork and Rod ...............................................................................112

26. Clutch Housing........................................................................................125

27. G Sensor .................................................................................................127

28. Driver’s Control Center Differential Control Module ................................129

29. General Diagnostic Table........................................................................130

6MT-71

MANUAL TRANSMISSION AND DIFFERENTIAL

Main Shaft Assembly

19.Main Shaft Assembly

A: REMOVAL

1) Remove the manual transmission assembly

from vehicle. <Ref. to 6MT-36, REMOVAL, Manual

Transmission Assembly.>

2) Prepare the transmission for overhaul. <Ref. to

6MT-41, Preparation for Overhaul.>

3) Remove the oil pipe, neutral position switch,

back-up light switch and harness. <Ref. to 6MT-43,

REMOVAL, Oil Pipe.>, <Ref. to 6MT-46, REMOV-

AL, Neutral Position Switch.>, <Ref. to 6MT-44,

REMOVAL, Back-up Light Switch.>

4) Remove the extension case. <Ref. to 6MT-48,

REMOVAL, Extension Case.>

5) Remove the transfer driven gear. <Ref. to 6MT-

59, REMOVAL, Transfer Driven Gear.>

6) Remove the center differential. <Ref. to 6MT-61,

REMOVAL, Center Differential.>

7) Remove the oil pump. <Ref. to 6MT-62, RE-

MOVAL, Oil Pump.>

8) Remove the transmission case. <Ref. to 6MT-

66, REMOVAL, Transmission Case.>

9) Remove the striking rod.

10) Using a screwdriver, shift to 4th gear position.

11) Remove the reverse idler holder.

12) Remove all checking plug, gasket, checking

spring, plunger and checking ball from adapter

plate.

NOTE:

Do not reuse the gasket.

13) Remove the bolt and gasket installing reverse

idler shaft.

14) Press the main shaft assembly, driven gear as-

sembly, reverse idler gear and each shifter fork,

then remove from the adapter plate at once.

NOTE:

Two people should do the work.

B: INSTALLATION

1) Adjust the 3rd-4th, and 5th-6th shifter fork rod.

<Ref. to 6MT-116, ADJUSTMENT, Shifter Fork

and Rod.>

(A) 3rd-4th shift rod

(A) Reverse idler holder

(A)

MT-00543

(A)

MT-00544

(A) Checking plug

(B) Gasket

(D) Plunger

(E) Checking ball

(D) (E)

(A)

(B)

MT-00545

MT-00546

6MT-72

MANUAL TRANSMISSION AND DIFFERENTIAL

Main Shaft Assembly

2) Turn the sub gear counterclockwise for approx.

three teeth. Align the sub gear and reverse idler

gear hole, then insert the ST.

ST 18757AA000 STRAIGHT PIN

3) Install the driven gear assembly to 1st-2nd

shifter fork assembly.

4) Install the main shaft assembly to 3rd-4th shifter

fork, and then assemble to driven gear assembly.

5) Install the 5th-6th shifter fork assembly to main

shaft assembly.

(A) Sub gear

(B) Reverse idler gear

(A) 1st-2nd shifter fork

(B) Driven gear assembly

(A)

(B)

MT-00547

MT-00548

(A)

(B)

(C)

(A) 3rd-4th shifter fork

(B) 3rd-4th sleeve

(D) Main shaft assembly

(A) 5th-6th shifter fork

(B) 5th-6th sleeve

MT-00549

(C)

(A) (B)

(C)

(D)

(A) (B)

MT-00550

(B)

(A)

(C)

6MT-73

MANUAL TRANSMISSION AND DIFFERENTIAL

Main Shaft Assembly

6) Install the reverse shifter fork assembly to re-

verse idler gear assembly.

7) Install the reverse idler gear assembly.

8) Install the thrust bearing of driven gear assem-

bly.

9) Press each shifter fork, main shaft assembly,

driven gear assembly and reverse idler gear as-

sembly, then install to the adapter plate at once.

NOTE:

Two people should do the work.

10) Install the plunger, checking spring, new gasket

and checking plug.

Tightening torque:

37 N·m (3.8 kgf-m, 27.3 ft-lb)

(A) Reverse idler gear assembly

(B) Reverse shifter fork

(A) Reverse idler gear assembly

(B) 1st drive gear

MT-00551

(A)

(B)

(C)

MT-00552

(B)

(A)

(C)

(A) Checking plug

(B) Gasket

(D) Plunger

MT-00553

(D)

(A)

(B)

(C)

6MT-74

MANUAL TRANSMISSION AND DIFFERENTIAL

Main Shaft Assembly

11) Install the checking ball, checking spring, new

gasket and checking plug.

Tightening torque:

37 N·m (3.8 kgf-m, 27.3 ft-lb)

12) Install the bolt and new gasket.

Tightening torque:

25 N·m (2.5 kgf-m, 18.1 ft-lb)

13) Using a screwdriver, shift to 4th gear position.

14) Install the reverse idler holder

15) Install the striking rod.

16) Install the transmission case. <Ref. to 6MT-67,

INSTALLATION, Transmission Case.>

17) Install the selected main shaft snap ring and

washer.

18) Install the oil pump. <Ref. to 6MT-63, INSTAL-

LATION, Oil Pump.>

19) Install the center differential. <Ref. to 6MT-61,

INSTALLATION, Center Differential.>

20) Install the transfer driven gear. <Ref. to 6MT-

59, INSTALLATION, Transfer Driven Gear.>

21) Install the extension case. <Ref. to 6MT-48, IN-

STALLATION, Extension Case.>

22) Install the oil pipe, neutral position switch,

back-up light switch and harness. <Ref. to 6MT-43,

INSTALLATION, Oil Pipe.>, <Ref. to 6MT-46, IN-

STALLATION, Neutral Position Switch.>, <Ref. to

6MT-44, INSTALLATION, Back-up Light Switch.>

23) Install the manual transmission assembly to ve-

hicle. <Ref. to 6MT-38, INSTALLATION, Manual

Transmission Assembly.>

C: DISASSEMBLY

NOTE:

Each sleeve and hub engage at a specified point.

Mark an engagement point on the sleeve and hub

before disassembly.

1) Secure the ST on workbench.

ST 18664AA000 BASE

2) Lift the caulking of lock nut.

3) Set the main shaft assembly on ST, then remove

the lock nut and washer.

ST1 18665AA000 HOLDER

ST2 18664AA000 BASE

(A) Checking plug

(B) Gasket

(D) Checking ball

MT-00554

(D)

(A)

(B)

(C)

MT-00546

(A) Reverse idler holder

(A)

MT-00544

6MT-75

MANUAL TRANSMISSION AND DIFFERENTIAL

Main Shaft Assembly

NOTE:

Use a 38 mm (1.50 in) socket wrench.

4) Remove the main shaft assembly from ST.

5) Set the ST1 on 6th drive gear, then remove the

taper roller bearing, bush and 6th drive gear using

press.

ST1 18722AA000 REMOVER

(TY856WX···model)

ST1 18722AA010 REMOVER

(TY856WN···model)

ST2 899864100 REMOVER

6) Remove the 5th-6th sleeve, 6th needle bearing

and 6th baulk ring.

7) Set the ST on 3rd drive gear, then remove each

part using press.

ST 18720AA000 REMOVER

(A) Taper roller bearing

(B) Bush

MT-00556

ST2

ST1

MT-00557

(A)

(B) (C)

ST1

ST2

ST1

(A) Needle bearing

(B) 6th baulk ring

(A) 3rd drive gear

(B) 3rd-4th sleeve

(A)

(B)

(C)

MT-00558

MT-00559

(A)

(B)

6MT-76

MANUAL TRANSMISSION AND DIFFERENTIAL

Main Shaft Assembly

D: ASSEMBLY

NOTE:

Replace the following parts as a set.

•Sleeve and hub

•Outer baulk ring, 3rd synchro cone and inner

baulk ring

•Taper roller bearing

1) Sufficiently apply gear oil to the main shaft, 3rd

needle bearing and inner periphery of 3rd drive

gear.

2) Install the 3rd needle bearing and 3rd drive gear

to main shaft.

3) Install the inner baulk ring, 3rd synchro cone and

outer baulk ring.

NOTE:

Install the 3rd synchro cone, by aligning protrusion

portions of the 3rd synchro cone with 3rd drive gear

hole portion.

4) Install the 3rd-4th hub and 4th bush.

(1) Set to the main shaft, taking care of 3rd-4th

hub installing direction.

(A) 3rd needle bearing

(B) 3rd drive gear

(A) Inner baulk ring

(B) Outer baulk ring

(A)

(B)

MT-00560

(A)

(B)

MT-00561

(A) Main shaft

(B) 3rd-4th hub

MT-00562

MT-00884

(A)

(B)

(C)

6MT-77

MANUAL TRANSMISSION AND DIFFERENTIAL

Main Shaft Assembly

(2) Set to the main shaft, taking care not to

overlap the main shaft oil hole and 4th bush oil

hole.

(3) Using the ST, press in the 3rd-4th hub and

4th bush at once.

ST1 18651AA000 INSTALLER

ST2 398177700 INSTALLER

CAUTION:

Do not apply pressure in excess of 40 kN (4.0

ton, 4.4 US ton, 3.9 Imp ton).

NOTE:

When pressing in 3rd-4th hub and 4th bush, align

the protrusion portion of outer baulk ring and cutout

portion of 3rd-4th bush by moving the outer baulk

ring.

5) Make sure the 3rd drive gear is smoothly turned

by hand. If not, reassemble.

(A) 4th bush

(B) 3rd-4th hub

(D) Main shaft oil hole

MT-00885

(A)

(B)

(D)

(C)

A - A

(A)

(A) 3rd-4th hub

(B) Outer baulk ring

(D) Protrusion portion of outer baulk ring

(E) 4th bush

MT-00555

(D)

(C)

(A)

(E)

(A)

(B)

ST1

ST2

6MT-78

MANUAL TRANSMISSION AND DIFFERENTIAL

Main Shaft Assembly

6) Install the 3rd-4th shifting insert key in proper

place of 3rd-4th sleeve.

NOTE:

Angle of each shifting insert key is 120°apart.

7) Install the 3rd-4th sleeve to 3rd-4th hub.

NOTE:

•3rd-4th sleeve has a groove for identification.

•Install the 3rd-4th sleeve with groove facing to

3rd drive gear side.

8) Install the 4th baulk ring.

9) Sufficiently apply gear oil to the main shaft, 4th

needle bearing and inner periphery of 4th drive

gear.

10) Install the 4th needle bearing and 4th drive

gear.

(A) 3rd-4th sleeve

(B) 3rd-4th shifting insert key

(A) 3rd drive gear

(B) Groove (1) for identification of 3rd-4th sleeve

MT-00673

(B)

(A)

MT-00563

(A)

(B)

(A) 4th needle bearing

(B) 4th drive gear

MT-00564

(A)

(B)

MT-00565

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