Subaru Impreza 2004 Manuel utilisateur

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

5MT

Page

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

2. Transmission Gear Oil ..............................................................................37

3. Manual Transmission Assembly ...............................................................38

4. Transmission Mounting System ................................................................45

5. Oil Seal......................................................................................................47

6. Switches and Harness ..............................................................................48

7. Vehicle Speed Sensor...............................................................................51

8. Preparation for Overhaul...........................................................................52

9. Transfer Case and Extension Case Assembly..........................................53

10. Rear Case .................................................................................................57

11. Transfer Drive Gear ..................................................................................58

12. Transfer Driven Gear ................................................................................60

13. Center Differential .....................................................................................62

14. Reverse Check Sleeve..............................................................................63

15. Transmission Case ...................................................................................66

16. Main Shaft Assembly for Single-Range ....................................................72

17. Main Shaft Assembly for Dual-Range.......................................................82

18. Input Shaft Assembly ................................................................................87

19. Drive Pinion Shaft Assembly.....................................................................91

20. Front Differential Assembly .....................................................................102

21. Speedometer Gear..................................................................................109

22. Reverse Idler Gear..................................................................................110

23. Shifter Fork and Rod ...............................................................................112

24. Counter Gear ..........................................................................................115

25. General Diagnostic..................................................................................117

5MT-72

MANUAL TRANSMISSION AND DIFFERENTIAL

Main Shaft Assembly for Single-Range

16.Main Shaft Assembly for Sin-

gle-Range

A: REMOVAL

1) Remove the manual transmission assembly

from vehicle. <Ref. to 5MT-38, REMOVAL, Manual

Transmission Assembly.>

2) Remove the transfer case with extension case

assembly. <Ref. to 5MT-53, REMOVAL, Transfer

Case and Extension Case Assembly.>

3) Remove the transmission case. <Ref. to 5MT-

53, REMOVAL, Transfer Case and Extension Case

Assembly.>

4) Remove the drive pinion shaft assembly. <Ref.

to 5MT-91, REMOVAL, Drive Pinion Shaft Assem-

bly.>

5) Remove the main shaft assembly.

B: INSTALLATION

1) Install the needle bearing and oil seal onto the

front of transmission main shaft assembly.

NOTE:

•Wrap the clutch splined section with vinyl tape to

prevent damage to oil seal.

•Apply grease (Unilube #2 or equivalent) to the

sealing lip of oil seal.

•Use a new one.

2) Install the needle bearing outer race knock pin

hole into transmission case knock pin.

NOTE:

Align the end face of seal with surface (A) when in-

stalling oil seal.

3) Install the drive pinion assembly. <Ref. to 5MT-

91, INSTALLATION, Drive Pinion Shaft Assem-

bly.>

4) Install the transmission case. <Ref. to 5MT-68,

INSTALLATION, Transmission Case.>

5) Install the transfer case with extension case as-

sembly. <Ref. to 5MT-53, INSTALLATION, Trans-

fer Case and Extension Case Assembly.>

6) Install the manual transmission assembly to ve-

hicle. <Ref. to 5MT-41, INSTALLATION, Manual

Transmission Assembly.>

C: DISASSEMBLY

1. AWD MODEL

1) Put vinyl tape around the main shaft splines to

protect oil seal from damage. Then pull out the oil

seal and needle bearing by hand.

2) Remove the lock nut from transmission main

shaft assembly.

NOTE:

Remove the caulking before removing lock nut.

ST1 499987000 TRANSMISSION HOLDER

ST2 498937003 SOCKET WRENCH (35)

3) Remove the 5th-Rev sleeve and hub assembly,

baulk ring, 5th drive gear and needle bearing.

MT-00185

(A)

(A) 5th-Rev sleeve and hub ASSY

(B) Baulk ring

MT-00186

ST2 ST1

MT-00187

(A)

(B)

(C)

5MT-73

MANUAL TRANSMISSION AND DIFFERENTIAL

Main Shaft Assembly for Single-Range

4) Remove the snap ring and synchro cone stopper

from 5th-Rev sleeve and hub assembly.

5) Using the ST1, ST2 and a press, remove the ball

bearing, synchro cone and baulk ring (Rev).

NOTE:

•Replace the sleeve and hub with new ones. Do

not attempt to disassemble because they must en-

gage at a specified point. If they should be disas-

sembled, mark engagement point on splines

beforehand.

•Do not reuse the ball bearing.

ST1 499757002 INSTALLER

ST2 498077400 SYNCHRO CONE REMOV-

6) Using the ST1 and ST2, remove rest of the

parts.

NOTE:

Replace the sleeve and hub with new ones. Do not

attempt to disassemble because they must engage

at a specified point. If they should be disassem-

bled, mark engagement point on splines before-

hand.

ST1 899864100 REMOVER

ST2 899714110 REMOVER

2. FWD MODEL

1) Put vinyl tape around main shaft splines to pro-

tect oil seal from damage. Then pull out oil seal and

needle bearing by hand.

2) Remove lock nut.

NOTE:

Remove caulking before taking off lock nut.

ST1 498937000 TRANSMISSION HOLDER

ST2 499987003 SOCKET WRENCH (35)

(A) Synchro cone stopper

(B) Snap ring

(A) Ball bearing

(B) Synchro cone

MT-00188

(A)

(B)

MT-00189

(B)

(A)

(C)

ST2

ST1

(A) Press

MT-00190

(A)

ST2

ST1

ST2

ST1

MT-00818

5MT-74

MANUAL TRANSMISSION AND DIFFERENTIAL

Main Shaft Assembly for Single-Range

3) Remove the insert stopper plate, sleeve and hub

assembly No. 2, baulk ring, 5th drive gear and nee-

dle bearing.

4) Using ST1, ST2 and a press, remove the rest of

parts.

NOTE:

Replace sleeve and hub with ones. Do not attempt

to disassemble because they must engage at a

specified point. If they should be disassembled,

mark engagement point on splines before hand.

ST1 899864100 REMOVER

ST2 899714110 REMOVER

D: ASSEMBLY

1. AWD NON-TURBO MODEL

1) Assemble when each sleeve and hub assembly

are disassembled.

NOTE:

Position the open ends of spring 120°apart.

2) Install the 3rd drive gear, baulk ring, sleeve and

hub assembly for 3rd needle bearing on transmis-

sion main shaft.

NOTE:

Align the groove in baulk ring with shifting insert.

3) Install the 4th needle bearing race onto trans-

mission main shaft using ST1, ST2 and a press.

NOTE:

Do not apply pressure in excess of 10 kN (1 ton, 1.1

US ton, 1.0 Imp ton).

(A) Insert stopper plate

(B) Sleeve and hub ASSY No. 2

(D) 5th drive gear

(E) Needle bearing

(A) Press

(E)

(D)

(C)

(B)

(A)

MT-00819

MT-00820

(A)

ST2

ST1

(A) 3rd-4th hub ASSY

(B) 3rd gear side

(D) 5th gear side

MT-00191

(D)

(C)

(B)

(A)

5MT-75

MANUAL TRANSMISSION AND DIFFERENTIAL

Main Shaft Assembly for Single-Range

ST1 899714110 REMOVER

ST2 499877000 RACE 4-5 INSTALLER

4) Install the baulk ring, needle bearing, 4th drive

gear and 4th gear thrust washer to transmission

main shaft.

NOTE:

Align the baulk ring and gear & hub assembly with

key groove.

5) Drive the ball bearing onto the rear section of

transmission main shaft using ST1, ST2 and a

press.

NOTE:

Do not apply pressure in excess of 10 kN (1 ton, 1.1

US ton, 1.0 Imp ton).

ST1 899714110 REMOVER

ST2 499877000 RACE 4-5 INSTALLER

6) Using the ST1 and ST2, install the 5th gear

thrust washer and 5th needle bearing race onto the

rear section of transmission main shaft.

NOTE:

•Do not apply pressure in excess of 10 kN (1 ton,

1.1 US ton, 1.0 Imp ton).

•Face the thrust washer in correct direction.

ST1 899714110 REMOVER

ST2 499877000 RACE 4-5 INSTALLER

7) Install the bearing onto synchro cone.

8) Install the baulk ring and synchro cone onto 5th-

Rev sleeve and hub assembly using ST and a

press.

NOTE:

•Do not apply pressure in excess of 10 kN (1 ton,

1.1 US ton, 1.0 Imp ton).

•Use a new ball bearing.

•After press fitting, make sure the synchro cone

rotates freely.

ST 499757002 INSTALLER

(A) 4th needle bearing race

(A) Groove

(B) 4th gear side

MT-00192

(A)

ST1

ST2

MT-00193

(A)

(B)

MT-00194

ST1

ST2

(A) Face this surface to 5th gear side.

(A) Baulk ring

(B) Synchro cone

MT-00195

(A)

MT-00196

(B)

(A) (C)

5MT-76

MANUAL TRANSMISSION AND DIFFERENTIAL

Main Shaft Assembly for Single-Range

9) Install the synchro cone stopper and snap ring to

5th-Rev sleeve and hub assembly.

10) Install rest of the parts to the rear section of

transmission main shaft.

NOTE:

Align the groove in baulk ring with shifting insert.

11) Tighten the lock nuts to the specified torque us-

ing ST1 and ST2.

NOTE:

Secure the lock nuts in two places after tightening.

ST1 499987003 SOCKET WRENCH

ST2 498937000 TRANSMISSION HOLDER

Tightening torque:

120 N·m (12.2 kgf-m, 88.5 ft-lb)

2. AWD TURBO MODEL

1) Assemble each sleeve and hub assembly.

NOTE:

Position the open ends of spring 120°apart.

(A) Synchro cone stopper

(B) Snap ring

(A) Needle bearing

(B) 5th drive gear

(D) 5th-Rev sleeve and hub ASSY

(E) Lock washer

(F) Lock nuts

MT-00188

(A)

(B)

MT-00198

(A) (B) (C) (D)

(E)

(F)

(A) 3rd-4th hub ASSY

(B) 3rd gear side

(D) 5th gear side

MT-00191

(D)

(C)

(B)

(A)

5MT-77

MANUAL TRANSMISSION AND DIFFERENTIAL

Main Shaft Assembly for Single-Range

2) Install the 3rd drive gear, outer baulk ring, syn-

chro cone, inner baulk ring, sleeve and hub assem-

bly for 3rd needle bearing on transmission main

shaft.

NOTE:

Align the groove in baulk ring with shifting insert.

3) Install the 4th needle bearing race onto trans-

mission main shaft using ST1, ST2 and a press.

NOTE:

Do not apply pressure in excess of 10 kN (1 ton, 1.1

US ton, 1.0 Imp ton).

ST1 899714110 REMOVER

ST2 499877000 RACE 4-5 INSTALLER

4) Install the baulk ring, needle bearing, 4th drive

gear and 4th gear thrust washer to transmission

main shaft.

NOTE:

Align the baulk ring and gear & hub assembly with

key groove.

5) Drive the ball bearing onto the rear section of

transmission main shaft using ST1, ST2 and a

press.

NOTE:

Do not apply pressure in excess of 10 kN (1 ton, 1.1

US ton, 1.0 Imp ton).

ST1 899714110 REMOVER

ST2 499877000 RACE 4-5 INSTALLER

(A) 3rd needle bearing

(B) 3rd drive gear

(D) Synchro cone

(E) Outer baulk ring

(F) Sleeve and hub ASSY

(A) 4th needle bearing race

MT-00200

(A)

(B) (C)

(D) (E)

(F)

MT-00192

(A)

ST1

ST2

(A) Groove

(B) 4th gear side

MT-00193

(A)

(B)

MT-00194

ST1

ST2

5MT-78

MANUAL TRANSMISSION AND DIFFERENTIAL

Main Shaft Assembly for Single-Range

6) Using the ST1 and ST2, install the 5th gear

thrust washer and 5th needle bearing race onto the

rear section of transmission main shaft.

NOTE:

•Do not apply pressure in excess of 10 kN (1 ton,

1.1 US ton, 1.0 Imp ton).

•Face the thrust washer in correct direction.

ST1 899714110 REMOVER

ST2 499877000 RACE 4-5 INSTALLER

7) Install the bearing onto synchro cone.

8) Install the baulk ring and synchro cone onto 5th-

Rev sleeve and hub assembly using ST and a

press.

NOTE:

•Do not apply pressure in excess of 10 kN (1 ton,

1.1 US ton, 1.0 Imp ton).

•Use a new ball bearing.

•After press fitting, make sure the synchro cone

rotates freely.

ST 499757002 INSTALLER

9) Install the synchro cone stopper and snap ring to

5th-Rev sleeve and hub assembly.

10) Install the rest parts to the rear section of trans-

mission main shaft.

NOTE:

Align the groove in baulk ring with shifting insert.

11) Tighten the lock nuts to the specified torque us-

ing ST1 and ST2.

NOTE:

Secure the lock nuts in two places after tightening.

ST1 499987003 SOCKET WRENCH

ST2 498937000 TRANSMISSION HOLDER

Tightening torque:

120 N·m (12.2 kgf-m, 88.5 ft-lb)

(A) Face this surface to 5th gear side.

(A) Baulk ring

(B) Synchro cone

MT-00195

(A)

MT-00196

(B)

(A) (C)

(A) Synchro cone stopper

(B) Snap ring

(A) Needle bearing

(B) 5th drive gear

(D) 5th-Rev sleeve and hub ASSY

(E) Lock washer

(F) Lock nuts

MT-00188

(A)

(B)

MT-00198

(A) (B) (C) (D)

(E)

(F)

5MT-79

MANUAL TRANSMISSION AND DIFFERENTIAL

Main Shaft Assembly for Single-Range

3. FWD MODEL

1) Assemble sleeve and hub assembly for 3rd-4th

and 5th-Rev.

NOTE:

Position open ends of spring 120°apart.

2) Install 3rd drive gear, baulk ring and sleeve and

hub assembly for 3rd-4th needle bearing (32 ×36 ×

25.7) on transmission main shaft.

NOTE:

Align groove in baulk ring with shifting insert.

3) Install 4th needle bearing race onto transmission

main shaft using ST1, ST2 and a press.

ST1 899714110 REMOVER

ST2 499877000 RACE 4-5 INSTALLER

4) Install baulk ring, needle bearing (32 ×30 ×

25.7), 4th drive gear and 4th gear thrust washer to

transmission main shaft.

NOTE:

Face thrust washer in the correct direction.

5) Drive ball bearing onto the rear section of trans-

mission main shaft using ST1, ST2 and a press.

ST1 899714110 REMOVER

ST2 499877000 RACE 4-5 INSTALLER

6) Using the same tools as in step 5) above, install

the following parts onto the rear section of trans-

mission main shaft.

NOTE:

Face thrust washer in the correct direction.

ST1 899714110 REMOVER

ST2 499877000 RACE 4-5 INSTALLER

(A) 3rd-4th hub ASSY

(B) 3rd gear side

(D) 5th gear side

(A) 4th needle bearing

MT-00191

(D)

(C)

(B)

(A)

MT-00192

(A)

ST1

ST2

(A) Groove

(B) 4th gear side

(A) Face this surface to 5th gear side.

MT-00193

(A)

(B)

MT-00194

ST1

ST2

MT-00195

(A)

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