Counter Gear Assembly: Disassembly

Thrust clearance check

Check the thrust clearances of the counter shaft 3rd gear and counter shaft 4th gear.

Fig 1: Checking Counter Shaft 3rd Gear And Counter Shaft 4th Gear Thrust Clearances

Courtesy of SUBARU OF AMERICA, INC.

Standard value

STANDARD VALUE

Gear	Standard value mm {in}	Limit mm {in}
Counter shaft 3rd gear	0.10 to 0.35 {0.00394 to 0.0138}	0.35 {0.0138}
Counter shaft 4th gear	0.10 to 0.35 {0.00394 to 0.0138}	0.35 {0.0138}

NOTE: If the value exceeds the limit, adjust with the 4th inner race thrust washer.

Radial clearance check

Check the radial clearances of the counter shaft 3rd gear and counter shaft 4th gear.

Fig 2: Checking Counter Shaft 3rd Gear And Counter Shaft 4th Gear Radial Clearances

Courtesy of SUBARU OF AMERICA, INC.

Standard value

STANDARD VALUE

Gear	Standard value mm {in}	Limit mm {in}
Counter shaft 3rd gear	0.015 to 0.068 {0.000590 to 0.00268}	0.068 {0.00268}
Counter shaft 4th gear	0.065 to 0.115 {0.002559 to 0.00453}	0.115 {0.00453}

NOTE: If the value exceeds the limit, replace the corresponding gear and needle roller bearing or 4th gear bearing inner race with new ones as a set.

Removal of counter gear front bearing
1. Use the SST to remove the shaft snap ring.
  SST 499895400
  
  CAUTION: Verify the direction of the parts.
  
  Fig 3: Removing Counter Gear Front Bearing Snap Ring
  Courtesy of SUBARU OF AMERICA, INC.
2. Use the SST to remove the counter gear front bearing.
  SST 09950-00020, 899864100
  
  Fig 4: Removing Counter Gear Front Bearing
  Courtesy of SUBARU OF AMERICA, INC.
Removal of counter drive gear
1. Use the SST to remove the shaft snap ring.
  SST 499895400
  
  Fig 5: Removing Counter Drive Gear Snap Ring
  Courtesy of SUBARU OF AMERICA, INC.
2. Use the SST to remove the counter drive gear.
  SST 899714110, 899864100
  
  Fig 6: Removing Counter Drive Gear
  Courtesy of SUBARU OF AMERICA, INC.
Removal of counter shaft 4th gear
1. Use the SST to remove the shaft snap ring, then remove the 4th inner race thrust washer after removing the 4th washer retaining ring.
  SST 499895400
  
  CAUTION: Verify the direction of the parts.
  
  Fig 7: Removing Counter Shaft 4th Gear Snap Ring
  Courtesy of SUBARU OF AMERICA, INC.
2. Remove the 4th gear bearing inner race by turning it counterclockwise along the gear while prying with a flat tip screwdriver.
  
  Fig 8: Removing 4th Gear Bearing Inner Race
  Courtesy of SUBARU OF AMERICA, INC.
3. Remove the counter shaft 4th gear and synchronizer ring No. 1.
  
  Fig 9: Removing Counter Shaft 4th Gear And Synchronizer Ring No. 1
  Courtesy of SUBARU OF AMERICA, INC.
Removal of counter shaft 3rd gear
1. Use the SST to remove the transmission clutch hub No. 2, counter shaft 3rd gear, synchronizer ring set No. 3, and needle roller bearing.
  SST 899714110
  
  CAUTION: Verify the direction of the parts.
  
  Fig 10: Removing Counter Shaft 3rd Gear
  Courtesy of SUBARU OF AMERICA, INC.
Removal of transmission hub sleeve No. 2
1. Remove the transmission hub sleeve No. 2, then remove the 3 synchromesh shifting keys No. 1, 3 synchromesh shifting key springs No. 1, and 3 balls from the transmission clutch hub No. 2.
  CAUTION:
  - Keep the synchromesh shifting keys No. 1, synchromesh shifting key springs No. 1, and balls from flying out using a cloth.
  - Be careful not to deform the synchromesh shifting key springs No. 1.
  - Verify the direction of the parts.
  NOTE: Perform the work without displacing the positions of the transmission clutch hub No. 2 and synchromesh shifting keys No. 1.
  
  Fig 11: Keeping Synchromesh Components From Flying Out
  Courtesy of SUBARU OF AMERICA, INC.