Counter Gear Assembly: Inspection

Check of transmission hub sleeve No. 2
1. Check that the end of the spline gear of the transmission hub sleeve No. 2 is not worn.
  NOTE: If it is worn, replace the transmission hub sleeve No. 2 with a new one.
2. Install the transmission hub sleeve No. 2 to the transmission clutch hub No. 2 and check that they slide smoothly.
  NOTE: If they do not slide smoothly, replace the transmission hub sleeve No. 2 and the transmission clutch hub No. 2 with new ones.
  
  Fig 1: Checking Transmission Hub Sleeve No. 2
  Courtesy of SUBARU OF AMERICA, INC.
Check of transmission hub sleeve No. 2 clearance
1. Check the thickness of the gear shift fork No. 2 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. 2 with a new one.
2. Measure the groove of the transmission hub sleeve No. 2 and calculate the clearance between it and the gear shift fork No. 2.
  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. 2 and the transmission hub sleeve No. 2 with new ones as a set.
  
  Fig 2: Checking Transmission Hub Sleeve No. 2 Clearance
  Courtesy of SUBARU OF AMERICA, INC.
Check of synchronizer ring No. 1
1. Apply manual transmission oil to the tapered cone portion of the counter shaft 4th gear, and check the clearance between the synchronizer ring No. 1 and the counter shaft 4th gear while pressing the synchronizer ring No. 1 by hand.
  Standard value: 0.8 to 1.6 mm {0.0314 to 0.0629 in}
  
  Limit: 0.8 mm {0.0314 in}
  
  CAUTION: Check the entire circumference of the gear.
  NOTE:
  - If the value is smaller than the limit, replace the synchronizer ring No. 1 and counter shaft 4th 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 3: Checking Synchronizer Ring No. 1
  Courtesy of SUBARU OF AMERICA, INC.
2. Apply manual transmission oil to the tapered cone portion of the counter shaft 4th gear, and check that the synchronizer ring No. 1 does not slip in the circumferential direction while pressing it by hand.
  NOTE:
  - If it slips, replace the synchronizer ring No. 1 and counter shaft 4th 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 4: Checking Synchronizer Ring No. 3 For Slippage
  Courtesy of SUBARU OF AMERICA, INC.

Check of synchronizer ring No. 3

Apply manual transmission oil to the tapered cone portion of the counter shaft 3rd gear and the synchronizer ring set No. 3, and check the clearance between the synchronizer ring set No. 3 and the counter shaft 3rd gear while pressing the synchronizer ring set No. 3 by hand.

Fig 5: Checking Synchronizer Ring No. 3

Courtesy of SUBARU OF AMERICA, INC.

Standard value

STANDARD VALUE

Measured part	Standard value mm {in}
Inner	0.4 to 1.2 {0.0157 to 0.0472}
Middle	0.3 to 1.3 {0.0118 to 0.0512}
Outer	0.8 to 1.8 {0.0315 to 0.0709}

CAUTION: Check the entire circumference of the gear.

NOTE:

If the value exceeds the limit, replace the synchronizer ring set No. 3 with a new one.
Be sure to use the recommended product or the substitute product for manual transmission oil. (Refer to MANUAL TRANSMISSION OIL )

Apply manual transmission oil to the tapered cone portion of the counter shaft 3rd gear, and check that the synchronizer ring set No. 3 does not slip in the circumferential direction while pressing it by hand.
NOTE:
- If it slips, replace the synchronizer ring set No. 3 with a new one.
- Be sure to use the recommended product or the substitute product for manual transmission oil. (Refer to MANUAL TRANSMISSION OIL )
Fig 6: Checking Synchronizer Ring Set No. 3 For Slippage
Courtesy of SUBARU OF AMERICA, INC.

Counter shaft check

Check the outer diameter of each part.

Standard value

STANDARD VALUE

Inspection parts	Standard value mm {in}	Limit mm {in}
A	39.284 to 39.300 {1.54661 to 1.54721}	39.284 {1.54661}
B	37.984 to 38.000 {1.49543 to 1.49606}	37.984 {1.49543}
C	24.987 to 25.000 {0.98374 to 0.98425}	24.987 {0.98374}

Fig 7: Measuring Counter Shaft Outer Diameter

Courtesy of SUBARU OF AMERICA, INC.

NOTE: If the value is smaller than the limit, replace the counter shaft with a new one.

Check the runout of the points shown in the figure.
Standard value: 0.03 mm {0.00118 in} or less

NOTE: If the value is not within the limit, replace the counter shaft with a new one.

Fig 8: Checking Counter Shaft Runout
Courtesy of SUBARU OF AMERICA, INC.

Check of counter shaft 3rd gear
1. Check the inner diameter of the counter shaft 3rd gear.
  Standard value: 43.015 to 43.040 mm {1.69350 to 1.69448 in}
  
  Limit: 43.040 mm {1.69448 in}
  
  NOTE: If the value exceeds the limit, replace the counter shaft 3rd gear with a new one.
  
  Fig 9: Checking Counter Shaft 3rd Gear Inner Diameter
  Courtesy of SUBARU OF AMERICA, INC.
Counter shaft 4th gear check
1. Check the inner diameter of the counter shaft 4th gear.
  Standard value: 46.315 to 46.340 mm {1.82425 to 1.82441 in}
  
  Limit: 46.340 mm {1.82441 in}
  
  NOTE: If the value exceeds the limit, replace the counter shaft 4th gear with a new one.
  
  Fig 10: Checking Counter Shaft 4th Gear Inner Diameter
  Courtesy of SUBARU OF AMERICA, INC.
Check of 4th gear bearing inner race
1. Check the outer diameter of the 4th gear bearing inner race.
  Standard value: 46.225 to 46.250 mm {1.81988 to 1.82087 in}
  
  Limit: 46.225 mm {1.81988 in}
  
  CAUTION: Do not measure the oil groove.
  
  NOTE: If the value is smaller than the limit, replace the 4th gear bearing inner race with a new one.
  
  Fig 11: Checking Bearing Inner Race Outer Diameter (4th Gear)
  Courtesy of SUBARU OF AMERICA, INC.