Transmission Unit Assembly: Inspection

Gear shift head No. 1 check
1. Check the dimension of the gear shift head No. 1 groove.
  Standard value: 15.2 to 15.4 mm {0.59843 to 0.60630 in}
  
  Limit: 15.4 mm {0.60630 in}
  
  NOTE: If the value exceeds the limit, replace the gear shift head No. 1 with a new one.
  
  Fig 1: Measuring Gear Shift Head No. 1 Groove Dimension
  Courtesy of SUBARU OF AMERICA, INC.
Gear shift head No. 2 check
1. Check the dimension of the gear shift head No. 2 groove.
  Standard value: 15.2 to 15.4 mm {0.59843 to 0.60630 in}
  
  Limit: 15.4 mm {0.60630 in}
  
  NOTE: If the value exceeds the limit, replace the gear shift head No. 2 with a new one.
  
  Fig 2: Measuring Gear Shift Head No. 2 Groove Dimension
  Courtesy of SUBARU OF AMERICA, INC.
Gear shift head No. 3 check
1. Check the dimension of the gear shift head No. 3 groove.
  Standard value: 15.2 to 15.4 mm {0.59843 to 0.60630 in}
  
  Limit: 15.4 mm {0.60630 in}
  
  NOTE: If the value exceeds the limit, replace the gear shift head No. 3 with a new one.
  
  Fig 3: Measuring Gear Shift Head No. 3 Groove Dimension
  Courtesy of SUBARU OF AMERICA, INC.
Shift shaft check
1. Check the thickness of the shift shaft claw.
  Standard value: 14.8 to 15.0 mm {0.583 to 0.591 in}
  
  Limit: 14.8 mm {0.583 in}
  
  NOTE: If the value is smaller than the limit, replace the shift shaft with a new one.
  
  Fig 4: Measuring Shift Shaft Claw Thickness
  Courtesy of SUBARU OF AMERICA, INC.
Check of shift inner lock block No. 1.
1. Check the thickness of the shift inner lock block No. 1 claw.
  Standard value: 14.8 to 15.0 mm {0.583 to 0.591 in}
  
  Limit: 14.8 mm {0.583 in}
  
  NOTE: If the value is smaller than the limit, replace the shift inner lock block No. 1 with a new one.
  
  Fig 5: Measuring Shift Inner Lock Block No. 1 Claw Thickness
  Courtesy of SUBARU OF AMERICA, INC.
Gear shift fork No. 4 check
1. Check the dimension of the gear shift fork No. 4 groove.
  Standard value: 15.2 to 15.4 mm {0.59843 to 0.60630 in}
  
  Limit: 15.4 mm {0.60630 in}
  
  NOTE: If the value exceeds the limit, replace the gear shift fork No. 4 with a new one.
  
  Fig 6: Measuring Gear Shift Fork No. 4 Groove Dimension
  Courtesy of SUBARU OF AMERICA, INC.
Check of 5th shift head
1. Check the dimension of the 5th shift head groove.
  Standard value: 15.2 to 15.4 mm {0.59843 to 0.60630 in}
  
  Limit: 15.4 mm {0.60630 in}
  
  NOTE: If the value exceeds the limit, replace the 5th shift head with a new one.
  
  Fig 7: Measuring 5th Shift Head Groove Dimension
  Courtesy of SUBARU OF AMERICA, INC.
Check of synchronizer ring No. 2
1. Apply manual transmission oil to the tapered cone portion of the counter shaft 6th gear. With the synchronizer ring No. 2 pressed by hand, check the clearance between the synchronizer ring No. 2 and the counter shaft 6th gear.
  Standard value: 0.88 to 1.52 mm {0.0346 to 0.0598 in}
  
  Limit: 0.88 mm {0.0346 in}
  
  CAUTION: Check the entire circumference of the gear.
  
  Fig 8: Checking Synchronizer Ring No. 2
  Courtesy of SUBARU OF AMERICA, INC.
  NOTE:
  - If the value is smaller than the limit, replace the synchronizer ring No. 2 and the counter shaft 6th gear with new ones.
  - Be sure to use the recommended product or the substitute product for manual transmission oil. (Refer to MANUAL TRANSMISSION OIL )
2. Apply manual transmission oil to the tapered cone portion of the counter shaft 6th gear, and check that the synchronizer ring No. 2 does not slip in the circumferential direction while pressing it by hand.
  NOTE:
  - If it slips, replace the synchronizer ring No. 2 and the counter shaft 6th gear with new ones.
  - Be sure to use the recommended product or the substitute product for manual transmission oil. (Refer to MANUAL TRANSMISSION OIL )
  Fig 9: Checking Synchronizer Ring No. 2 For Slippage
  Courtesy of SUBARU OF AMERICA, INC.
Check of counter shaft 6th gear
1. Check the inner diameter of the counter shaft 6th gear.
  Standard value: 34.015 to 34.040 mm {1.33917 to 1.34016 in}
  
  Limit: 34.040 mm {1.34016 in}
  
  NOTE: If the value exceeds the limit, replace the counter shaft 6th gear with a new one.
  
  Fig 10: Checking Counter Shaft 6th Gear Inner Diameter
  Courtesy of SUBARU OF AMERICA, INC.
Check of transmission hub sleeve No. 4
1. Check that the end of the spline gear of the transmission hub sleeve No. 4 is not worn.
  NOTE: If it is worn, replace the transmission hub sleeve No. 4 with a new one.
2. Install the transmission hub sleeve No. 4 to the transmission clutch hub No. 4 and check that they slide smoothly.
  NOTE: If they do not slide smoothly, replace the transmission hub sleeve No. 4 and the transmission clutch hub No. 4 with new ones.
  
  Fig 11: Checking Transmission Hub Sleeve No. 4
  Courtesy of SUBARU OF AMERICA, INC.
Check of transmission hub sleeve No. 4 clearance
1. Check the thickness of the gear shift fork No. 4 claw.
  Standard value: 7.9 to 8.0 mm {0.311 to 0.315 in}
  
  Limit: 7.9 mm {0.311 in}
  
  NOTE: If the value is smaller than the limit, replace the gear shift fork No. 4 with a new one.
2. Measure the groove of the transmission hub sleeve No. 4 and calculate the clearance between it and the gear shift fork No. 4.
  Standard value: 0.15 to 0.35 mm {0.00590 to 0.0138 in}
  
  Limit: 0.35 mm {0.0138 in}
  
  NOTE: If the value exceeds the limit, replace the gear shift fork No. 4 and the transmission hub sleeve No. 4 with new ones as a set.
  
  Fig 12: Measuring Transmission Hub Sleeve No. 4 Clearance
  Courtesy of SUBARU OF AMERICA, INC.
Reverse idler gear check
1. Check the inner diameter of the reverse idler gear.
  Standard value: 22.040 to 22.061mm {0.86771 to 0.86854 in}
  
  Limit: 22.061mm {0.86854 in}
  
  NOTE: If the value exceeds the limit, replace the reverse idler gear with a new one.
  
  Fig 13: Checking Reverse Idler Gear Inner Diameter
  Courtesy of SUBARU OF AMERICA, INC.
Reverse idler gear shaft check
1. Check the outer diameter of the reverse idler gear shaft.
  Standard value: 21.979 to 22.000 mm {0.86531 to 0.86614 in}
  
  Limit: 21.979 mm {0.86531 in}
  
  NOTE: If the value is smaller than the limit, replace the reverse idler gear shaft with a new one.
  
  Fig 14: Checking Reverse Idler Gear Outer Diameter
  Courtesy of SUBARU OF AMERICA, INC.