Output Shaft Assembly: Inspection

Check of output shaft bearing RR
1. Check the output shaft bearing RR.
  Criteria: There is no abnormal response, bind, noise, and play.
  
  NOTE: If defective, replace the output shaft bearing RR with a new one.
  
  Fig 1: Checking Output Shaft Bearing RR
  Courtesy of SUBARU OF AMERICA, INC.

Output shaft check

Check the outer diameter of each part.

Standard value

STANDARD VALUE

Inspection parts	Standard value mm {in}	Limit mm {in}
A	31.984 to 32.000 {1.25921 to 1.25984}	31.984 {1.25984}
B	42.984 to 43.000 {1.69228 to 1.69291}	42.984 {1.69291}
C	40.984 to 41.000 {1.61354 to 1.61417}	40.984 {1.61417}

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

Fig 2: Measuring Output Shaft Outer Diameters

Courtesy of SUBARU OF AMERICA, INC.

Check the runout at 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 output shaft with a new one.

Fig 3: Locating Output Shaft Runout Points
Courtesy of SUBARU OF AMERICA, INC.

Reverse gear check
1. Check the inner diameter of the reverse gear.
  Standard value: 47.015 to 47.040 mm {1.85098 to 1.85197 in}
  
  Limit: 47.040 mm {1.85197 in}
  
  NOTE: If the value exceeds the limit, replace the reverse gear with a new one.
  
  Fig 4: Checking Reverse Gear Inner Diameter
  Courtesy of SUBARU OF AMERICA, INC.
1st gear check
1. Check the inner diameter of the 1st 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 1st gear with a new one.
  
  Fig 5: Checking 1st Gear Inner Diameter
  Courtesy of SUBARU OF AMERICA, INC.
2nd gear check
1. Check the inner diameter of the 2nd gear.
  Standard value: 49.015 to 49.040 mm {1.92972 to 1.93071 in}
  
  Limit: 49.040 mm {1.93071 in}
  
  NOTE: If the value exceeds the limit, replace the 2nd gear with a new one.
  
  Fig 6: Checking 2nd Gear Inner Diameter
  Courtesy of SUBARU OF AMERICA, INC.
Check of 1st gear bearing inner race
1. Check the outer diameter of the 1st gear bearing inner race.
  Standard value: 40.284 to 40.300 mm {1.58598 to 1.58661 in}
  
  Limit: 40.284 mm {1.58598 in}
  
  NOTE: If the value is smaller than the limit, replace the 1st gear bearing inner race with a new one.
  
  Fig 7: Checking 1st Gear Bearing Inner Race
  Courtesy of SUBARU OF AMERICA, INC.
Check of transmission hub sleeve No. 1 clearance
1. Check the thickness of the gear shift fork No. 1 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. 1 with a new one.
2. Measure the groove of the transmission hub sleeve No. 1 and calculate the clearance between it and the gear shift fork No. 1.
  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. 1 and the transmission hub sleeve No. 1 with new ones as a set.
  
  Fig 8: Checking Transmission Hub Sleeve No. 1 Clearance
  Courtesy of SUBARU OF AMERICA, INC.
Check of transmission hub sleeve No. 3 clearance
1. Check the thickness of the gear shift fork No. 3 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. 3 with a new one.
2. Measure the groove of the transmission hub sleeve No. 3 and calculate the clearance between it and the gear shift fork No. 3.
  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. 3 and the transmission hub sleeve No. 3 with new ones as a set.
  
  Fig 9: Checking Transmission Hub Sleeve No. 3 Clearance
  Courtesy of SUBARU OF AMERICA, INC.
Check of transmission hub sleeve No. 1
1. Check that the end of the spline gear of the transmission hub sleeve No. 1 is not worn.
  NOTE: If it is worn, replace the transmission hub sleeve No. 1 with a new one.
2. Install the transmission hub sleeve No. 1 to the transmission clutch hub No. 1 and check that they slide smoothly.
  NOTE: If they do not slide smoothly, replace the transmission hub sleeve No. 1 and the transmission clutch hub No. 1 with new ones.
  
  Fig 10: Checking Transmission Hub Sleeve No. 1
  Courtesy of SUBARU OF AMERICA, INC.
Check of transmission hub sleeve No. 3
1. Check that the end of the spline gear of the transmission hub sleeve No. 3 is not worn.
  NOTE: If it is worn, replace the transmission hub sleeve No. 3 with a new one.
2. Install the transmission hub sleeve No. 3 to the transmission clutch hub No. 3 and check that they slide smoothly.
  NOTE: If they do not slide smoothly, replace the transmission hub sleeve No. 3 and the transmission clutch hub No. 3 with new ones.
  
  Fig 11: Checking Transmission Hub Sleeve No. 3
  Courtesy of SUBARU OF AMERICA, INC.

Check of synchronizer ring set No. 1 (for 1st gear)

Apply manual transmission oil to the tapered cone portion of the 1st gear and the synchronizer ring set No. 1, and check the clearance between the synchronizer ring set No. 1 and the 1st gear while pressing the synchronizer ring set No. 1 by hand.

Fig 12: Checking Synchronizer Ring Set No. 1 (1st Gear)

Courtesy of SUBARU OF AMERICA, INC.

Standard value

STANDARD VALUE

Measured part	Standard value mm {in}
Inner	0.48 to 1.12 {0.0189 to 0.0441}
Middle	0.38 to 1.22 {0.0150 to 0.0480}
Outer	0.8 to 1.8 {0.0315 to 0.0709}

CAUTION: Check the entire circumference of the gear.

NOTE:

If the value is not within the standard value, replace the synchronizer ring set No. 1 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 1st gear, and check that the synchronizer ring set No. 1 does not slip in the circumferential direction while pressing it by hand.
NOTE:
- If it slips, replace the synchronizer ring set No. 1 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 13: Checking Synchronizer Ring Set No. 1 For Slippage
Courtesy of SUBARU OF AMERICA, INC.

Check of synchronizer ring set No. 1 (for 2nd gear)

Apply manual transmission oil to the tapered cone portion of the 2nd gear and the synchronizer ring set No. 1, and check the clearance between the synchronizer ring set No. 1 and the 2nd gear while pressing the synchronizer ring set No. 1 by hand.

Fig 14: Checking Synchronizer Ring Set No. 1 (For 2nd Gear)

Courtesy of SUBARU OF AMERICA, INC.

Standard value

STANDARD VALUE

Measured part	Standard value mm {in}
Inner	0.48 to 1.12 {0.0189 to 0.0441}
Middle	0.38 to 1.22 {0.0150 to 0.0480}
Outer	0.8 to 1.8 {0.0315 to 0.0709}

CAUTION: Check the entire circumference of the gear.

NOTE:

If the value is not within the standard value, replace the synchronizer ring set No. 1 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 2nd gear, and check that the synchronizer ring set No. 1 does not slip in the circumferential direction while pressing it by hand.
NOTE:
- If it slips, replace the synchronizer ring set No. 1 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 15: Checking Synchronizer Ring Set No. 1 For Slippage
Courtesy of SUBARU OF AMERICA, INC.