Manual Transaxle & Differential: Adjustments Subaru Outback BR рестайлинг

ADJUSTMENT

Selection of main shaft rear plate

Measure the protrusion amount (A) of bearing from transmission main case surface, and select a suitable plate in the following table.

Note. Before measuring, tap the end of main shaft with a plastic hammer lightly in order to make the clearance zero between the main case surface and moving flange of bearing.

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1. Remove the manual transmission assembly from the vehicle. Refer to «REMOVAL»(ref-565169-S30911287192013071000000) .
2. Remove the transfer case together with the extension case assembly. Refer to «REMOVAL»(ref-565169-S07285510272013071000000) .
3. Remove the transmission case. Refer to «REMOVAL»(ref-565169-S22535976422013071000000) .
4. Remove the drive pinion shaft assembly. NOTE: Use a hammer handle, etc. to remove if too tight.

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1. Remove the front differential assembly.
2. Hypoid gear set match mark/No.: The number (A) on top of the drive pinion, and the number on the hypoid driven gear are set numbers for the two gears. Use a pair having the same numbers. The figure (B) below shows a number for shim adjustment. If no number is shown, the value is zero.
3. Place the drive pinion shaft assembly on transmission main case RH without shim and tighten the bearing mounting bolts.
4. Perform the adjustment of ST. NOTE: Loosen the two bolts and adjust so that the scale indicates 0.5 correctly when the plate end and the scale end are on the same level. Tighten the two bolts. ST 499917500 DRIVE PINION GAUGE ASSY
5. Position the ST by inserting the knock pin of ST into the knock hole of transmission case. ST 499917500 DRIVE PINION GAUGE ASSY
6. Slide the drive pinion gauge scale with finger tip and read the value at the point where it matches with the end face of drive pinion. ST 499917500 DRIVE PINION GAUGE ASSY
7. The thickness of shim shall be determined by adding the value indicated on drive pinion to the value indicated on the ST. (Add if the number on drive pinion is prefixed by +, and subtract if the number is prefixed by -.)
8. Select one to three shims in the following table for the value determined as described above, and take the shim(s) whose thickness is closest to the said value. NOTE: Install the shim with it's cut in facing the shifter fork & rod side. Drive pinion shim Part No. Thickness mm (in) 32295AA031 0.150 (0.0059) 32295AA041 0.175 (0.0069) 32295AA051 0.200 (0.0079) 32295AA061 0.225 (0.0089) 32295AA071 0.250 (0.0098) 32295AA081 0.275 (0.0108) 32295AA091 0.300 (0.0118) 32295AA101 0.500 (0.0197)
9. Install the front differential assembly. Refer to «INSTALLATION»(ref-565169-S01989304132013071000000) .
10. Fit the transmission case knock pin to the knock pin hole of the roller bearing and install the drive pinion shaft assembly.
11. Install the main shaft assembly for single-range. Refer to «INSTALLATION»(ref-565169-S13942481032013071000000) .
12. Check each shifter fork. Refer to «INSPECTION»(ref-565169-S31911988092013071000000) .
13. Install the transmission case. Refer to «INSTALLATION»(ref-565169-S23259143902013071000000) .
14. Install the transfer case together with the extension case assembly. Refer to «INSTALLATION»(ref-565169-S33457416632013071000000) .
15. Install the manual transmission assembly to the vehicle. Refer to «INSTALLATION»(ref-565169-S38873152692013071000000) .

1. Select the appropriate reverse idler gear bushing from the table below, and adjust until the clearance between the reverse idler gear and reverse idler gear washer is within specification. Clearance (a): 0.1 - 0.3 mm (0.004 - 0.012 in) Reverse idler gear bushing Part No. Length mm (in) Groove for identification 32289AA080 27.75 (1.093) None 32289AA090 27.90 (1.098) 1 32289AA100 28.05 (1.104) 2 32289AA110 28.20 (1.110) 3 32289AA120 28.35 (1.116) 4

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1. Remove the manual transmission assembly from the vehicle. Refer to «REMOVAL»(ref-565169-S30911287192013071000000) .
2. Remove the back-up light switch and the neutral position switch. Refer to «REMOVAL»(ref-565169-S11680300332013071000000) .
3. Remove the transfer case together with the extension case assembly. Refer to «REMOVAL»(ref-565169-S07285510272013071000000) .
4. Remove the transmission case. Refer to «REMOVAL»(ref-565169-S22535976422013071000000) .
5. Remove the drive pinion shaft assembly. Refer to «REMOVAL»(ref-565169-S36664000142013071000000) .
6. Remove the main shaft assembly for single-range. Refer to «REMOVAL»(ref-565169-S03737328332013071000000) .
7. Remove the front differential assembly. Refer to «REMOVAL»(ref-565169-S10223591122013071000000) .
8. Remove the reverse idler gear assembly. Refer to «REMOVAL»(ref-565169-S36603484582013071000000) .
9. Remove the check ball plugs, check ball springs and check balls.
10. Use the ST to push out the spring pin of 5th-6th shifter fork and reverse shifter fork, and remove the 5th-6th shifter fork, reverse shifter fork, 5th-6th fork rod and reverse fork rod. NOTE: Tap out the reverse shifter fork spring pin, after setting the gear into reverse position. In the neutral position, removing is impossible because the clearance between transmission case is narrow. ST 398791700 SPRING PIN REMOVER 2
11. Drive out the spring pin by tapping it with the ST, and remove the 3rd-4th shifter fork and fork rod. NOTE: When removing the rod, keep other rods in neutral. ST 398791700 SPRING PIN REMOVER 2
12. Drive out the spring pin tapping by the ST, and remove the 1st-2nd shifter fork and fork rod. ST 398791700 SPRING PIN REMOVER 2

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1. Install the 1st-2nd fork rod to the 1st-2nd shifter fork through the hole on the rear of the transmission case.
2. Align the holes in the rod and the fork, and drive the spring pin into these holes using the ST to fix. NOTE: Use new spring pin. ST 398791700 SPRING PIN REMOVER 2
3. Install the 3rd-4th fork rod to the 3rd-4th shifter fork through the hole on the rear of the transmission case.
4. Align the holes in the rod and the fork, and drive the spring pin into these holes using the ST to fix. NOTE: Use new spring pin. Set other rods to neutral. Check that the positions of interlock plunger is correct. ST 398791700 SPRING PIN REMOVER 2
5. Install the 5th-6th fork rod into 5th-6th shifter fork, then insert through the hole on the rear of transmission case. Align the hole of the 5th-6th shifter fork with the hole on the transmission case, then insert the reverse fork rod to install the reverse shifter fork.
6. Align the holes in the rod and the fork, and drive the spring pin into these holes using the ST to fix. NOTE: Use new spring pin. Set other rods to neutral. Check that the positions of interlock plunger is correct. ST 398791700 SPRING PIN REMOVER 2
7. Install the check ball plugs, check ball springs and check balls. Tightening torque: 20 N.m (2.0 kgf-m, 14.8 ft-lb)
8. Install the reverse idler gear assembly. Refer to «INSTALLATION»(ref-565169-S42782538492013071000000) .
9. Install the front differential assembly. Refer to «INSTALLATION»(ref-565169-S01989304132013071000000) .
10. Install the main shaft assembly for single-range. Refer to «INSTALLATION»(ref-565169-S13942481032013071000000) .
11. Install the drive pinion shaft assembly. Refer to «INSTALLATION»(ref-565169-S15449717172013071000000) .
12. Install the transmission case. Refer to «INSTALLATION»(ref-565169-S23259143902013071000000) .
13. Install the transfer case together with the extension case assembly. Refer to «INSTALLATION»(ref-565169-S33457416632013071000000) .
14. Install the back-up light switch and the neutral position switch. Refer to «INSTALLATION»(ref-565169-S21935947142013071000000) .
15. Install the manual transmission assembly to the vehicle. Refer to «INSTALLATION»(ref-565169-S38873152692013071000000) .

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1. Check the fork and rod for damage. Replace if it is damaged.
2. Gearshift mechanism Repair or replace the gearshift mechanism if excessively worn, bent or defective in any way.
3. Inspect the clearance between 2nd driven gear and coupling sleeve. If any clearance is not within specifications, replace the shifter fork as required. Clearance (a): 7.4 - 7.8 mm (0.291 - 0.307 in) 1st-2nd shifter fork Part No. Mark Contents 32804AA120 1 Approaches 2nd gear by 0.2 mm (0.008 in) 32804AA130 No mark Standard 32804AA140 2 Approaches 1st gear by 0.2 mm (0.008 in).
4. Inspect the clearance between the 3rd, 4th drive gear and the coupling sleeve. If any clearance is not within specifications, replace the shifter fork as required. Clearance (a), (b): 7.5 mm (0.295 in) 3rd-4th shifter fork Part No. Mark Contents 32810AA061 1 Approaches 4th gear by 0.2 mm (0.008 in). 32810AA071 No mark Standard 32810AA101 3 Approaches 3rd gear by 0.2 mm (0.008 in)
5. Inspect the clearance between 5th, 6th drive gear and coupling sleeve. If any clearance is not within specifications, replace the shifter fork as required. Clearance (a), (b): 7.5 mm (0.295 in) 5th-6th shifter fork Part No. Mark Contents 32940AA050 1 Approaches 5th gear by 0.2 mm (0.008 in). 32940AA060 No mark Standard 32940AA070 2 Approaches 6th gear by 0.2 mm (0.008 in).
6. Check the clearance between the reverse idler gear and reverse coupling sleeve. If any clearance is not within specifications, replace the shifter fork as required. Clearance (a): 0.50 mm (0.020 in) or less Reverse shifter fork Part No. Mark Contents 32941AA070 2 Approaches reverse idler gear by 0.3 mm (0.012 in). 32941AA060 No mark Standard 32941AA050 1 Approaches reverse idler gear No. 2 by 0.3 mm (0.012 in).
7. Inspect the rod end clearances (A) and (B). If any clearance is not within specifications, replace the rod or fork as required. Clearance (A): 1st-2nd - 3rd-4th 0.1 - 0.9 mm (0.004 - 0.035 in) Clearance (B): 3rd-4th - 5th-6th 0.2 - 1.0 mm (0.008 - 0.039 in)