HYPOID GEAR BACKLASH Subaru Outback BS

HYPOID GEAR BACKLASH

Adjust the backlash by turning the side retainers on the left and right side.

ST 18630AA010 WRENCH COMPL RETAINER

Note. Each time the side retainer rotates by one notch (A), the backlash changes by 0.05 mm (0.0020 in).

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1. Adjust until correct teeth contact is obtained.
2. Check tooth contact, and perform the adjustment as follows. Correct tooth contact Check item: Tooth contact surface is slightly shifted toward the toe side under a no-load condition. (When driving, it moves towards the heel side.) Face contact Check item: Backlash is too large. Contact pattern Corrective action: Tighten the side retainer to move the driven gear closer to the drive pinion. Flank contact Check item: Backlash is too small. Contact pattern Corrective action: Loosen the side retainer to move the driven gear away from the drive pinion. Toe contact (inside contact) Check item: Teeth contact area is too small. Contact pattern Corrective action: Increase the thickness of drive pinion shim and tighten the side retainer to move the driven gear closer to the drive pinion shaft according to the procedure for bringing drive pinion shaft away from driven gear. Heel contact (outside end contact) Check item: Teeth contact area is too small. Contact pattern Corrective action: Reduce the thickness of drive pinion shim and loosen the side retainer to move the driven gear away from the drive pinion according to the procedure for moving drive pinion shaft closer to the driven gear.

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1. Remove the manual transmission assembly from the vehicle. Refer to «REMOVAL»(ref-645990-S08806509112014072500000) .
2. Remove the back-up light switch and the neutral position switch. Refer to «REMOVAL»(ref-645990-S23757368862014072500000) .
3. Remove the transfer case together with the extension case assembly. Refer to «REMOVAL»(ref-645990-S23238927522014072500000) .
4. Remove the transmission case. Refer to «REMOVAL»(ref-645990-S18989512262014072500000) .
5. Remove the drive pinion shaft assembly. Refer to «REMOVAL»(ref-645990-S30839780312014072500000) .
6. Remove the main shaft assembly for single-range. Refer to «REMOVAL»(ref-645990-S35195793452014072500000) .
7. Remove the front differential assembly. Refer to «REMOVAL»(ref-645990-S22209550112014072500000) .
8. Shift into 4th.
9. Remove the snap ring.
10. Remove the reverse idler gear shaft securing bolt.
11. Press out the reverse idler gear shaft from the backside of the transmission to remove. NOTE: Support the reverse idler gear assembly with hands to avoid collapsing.
12. Remove the reverse idler gear.
13. Remove the reverse idler gear bushing.

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1. Install the reverse idler gear bushing with the cutout portion of the reverse idler gear bushing facing the front of the transmission.
2. Assembling reverse idler gear assembly Install the reverse coupling sleeve to the reverse idler gear No. 2. NOTE: Install the reverse coupling sleeve in the correct direction. Make sure that the oval-shaped cutout portion inside the reverse coupling sleeve matches the center of the reverse idler gear No. 2 groove. Install the shifting insert. NOTE: Press in the ball part to install. Install the baulk ring and reverse idler gear. Install the needle bearing and reverse idler gear collar. Install the thrust bearing and washer. NOTE: Install the thrust bearing in the correct direction.
3. Install the assembled reverse idler gear assembly to the transmission case and hold it with hands.
4. Install the reverse idler gear shaft. NOTE: Install with the cutout portion of the reverse idler gear shaft facing the RH side of the transmission case. Make sure that the groove of the reverse idler gear shaft comes out of the reverse idler gear bushing.
5. Install the reverse idler gear shaft securing bolt. Tightening torque: 25 N.m (2.5 kgf-m, 18.4 ft-lb)
6. Install the snap ring.
7. Select the reverse idler gear bushing. Refer to «ADJUSTMENT»(ref-645990-S41774161602014072500000) .
8. Remove the reverse idler gear assembly and replace with the selected bushing. Refer to «REMOVAL»(ref-645990-S06019959512014072500000) .
9. Install the reverse idler gear assembly, oil case guide and reverse idler gear shaft. NOTE: Install with the cutout portion of the reverse idler gear shaft facing the RH side of the transmission case. Make sure that the groove of the reverse idler gear shaft comes out of the reverse idler gear bushing. Insert the cutout portion of the reverse idler gear bushing into the oil case guide.
10. Install the reverse idler gear shaft securing bolt. NOTE: Use a new gasket. Tightening torque: 25 N.m (2.5 kgf-m, 18.4 ft-lb)
11. Install the snap ring.
12. Check the reverse shifter fork. Refer to «INSPECTION»(ref-645990-S18121991872014072500000) .
13. Install the front differential assembly. Refer to «INSTALLATION»(ref-645990-S21480220742014072500000) .
14. Install the main shaft assembly for single-range. Refer to «INSTALLATION»(ref-645990-S21072091912014072500000) .
15. Install the drive pinion shaft assembly. Refer to «INSTALLATION»(ref-645990-S13236806022014072500000) .
16. Install the transmission case. Refer to «INSTALLATION»(ref-645990-S26418187792014072500000) .
17. Install the transfer case together with the extension case assembly. Refer to «INSTALLATION»(ref-645990-S12292030082014072500000) .
18. Install the back-up light switch and the neutral position switch. Refer to «INSTALLATION»(ref-645990-S16936247582014072500000) .
19. Install the manual transmission assembly to the vehicle. Refer to «INSTALLATION»(ref-645990-S24838663312014072500000) .

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1. Remove the snap ring and friction plate from reverse gear.
2. Remove the sub gear and spring.

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1. Attach the sub gear and spring. NOTE: Point the stamp (marking A) towards the outside, and install the sub gear.
2. Install the friction plate and snap ring. NOTE: Make sure the friction plate is installed in the proper direction.

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1. Check the clearance between the reverse idler gear bushing and reverse idler gear washer. If out of specification, select the appropriate reverse idler gear bushing and adjust. Clearance (a): 0.1 - 0.3 mm (0.004 - 0.012 in)
2. Check the reverse idler gear and shaft for damage. Replace if it is damaged.
3. Apply gear oil to the cone of the gear and while press-fitting the synchronizer ring, check there is no rotation in the circumferential direction.
4. Coupling sleeve and synchronizer hub Check the slipping condition of the coupling sleeve. Check the splines on the coupling sleeve and reverse idler gear for wear.
5. Shifting insert Replace the shifting insert if there is deformation, excessive wear on the ball section or any defectiveness.