1. General Description
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1 1. General Description A: SPECIFICATION 1. MANUAL TRANSMISSION AND FRONT DIFFERENTIAL Type Transmission gear ratio Front reduction gear Rear reduction gear Front differential Center differential Final Transfer Final 2. TRANSMISSION GEAR OIL Recommended oil 6-forward speeds and 1-reverse 1st nd rd th th th Reverse Type of gear Hypoid Gear ratio Type of gear Helical Gear ratio Type of gear Hypoid Gear ratio Type and number of gear Type and number of gear Transmission gear oil Transmission gear oil capacity AP TRAC Planetary gear (Internal gear: 1, Pinion gear: 6, Sun gear: 1 and Electromagnetic floating variable control multiple clutch) GL (4.3 US qt, 3.6 Imp qt) ( C) ( F) (2) (3) GL-5 (4) W 80W 75W -90 MT Item (2) Transmission gear oil (3) API classification (4) SAE viscosity No. and applicable temperature 6MT-2
2 B: COMPONENT 1. CLUTCH HOUSING (2) (3) (4) (5) (7) (6) T2 (8) (9) (10) (12) (13) (11) T3 T1 T4 MT Oil level gauge (8) Clutch housing Tightening torque: N m (kgf-m, ft-lb) (2) Oil seal (9) Speedometer driven gear T1: 6.4 (0.65, 4.7) (3) Snap ring (10) Snap ring T2: 41 (4.2, 30.2) (4) Washer (11) Gasket T3: 50 (5.1, 36.9) (5) Speedometer gear shaft (12) Oil seal T4: 70 (7.1, 51.6) (6) Pitching stopper bracket (13) Clutch release bearing guide (7) Clip 6MT-3
3 2. ADAPTER PLATE T3 T2 (2) T2 (3) (4) (5) (7) (9) (8) (6) (10) T1 T3 (12) (13) T1 (11) MT Breather hose (7) Plug (13) Oil chamber (2) Transmission harness stay (8) Gasket (3) Plug (9) Spring Tightening torque: N m (kgf-m, ft-lb) (4) Gasket (10) Ball T1: 6.4 (0.65, 4.7) (5) Spring (11) Lubrication pipe T2: 37 (3.8, 27.3) (6) Plunger (12) Adapter plate T3: 50 (5.1, 36.9) 6MT-4
4 3. TRANSMISSION CASE T1 T4 (6) (9) (10) (16) (2) (4) T3 T3 T1 (16) (16) (4) (3) (11) (12) (5) (13) (14) (16) (15) (8) T2 (16) T5 T2 (7) T3 T3 (16) T1 MT Pilot bolt (9) Return spring Tightening torque: N m (kgf-m, ft-lb) (2) Neutral switch (10) Pressure relief valve T1: 13 (1.3, 9.6) (3) Back-up light switch (11) Return spring T2: 16 (1.6, 11.8) (4) O-ring (12) Ball T3: 32 (3.3, 23.6) (5) Adapter plate (13) Plunger T4: 34 (3.5, 25.1) (6) Transmission case (14) Spring T5: 41 (4.2, 30.2) (7) Oil pipe (15) Plug (8) Harness bracket (16) Gasket 6MT-5
5 4. OIL PAN AND OIL PUMP (11) (2) (3) (4) T3 (12) T3 (9) (5) (13) (6) (7) T2 (8) T4 (10) T1 MT Main case (8) Oil pan Tightening torque: N m (kgf-m, ft-lb) (2) Oil pump cover (9) Plate T1: 6.4 (0.65, 4.7) (3) Oil guide (10) Gasket T2: 10 (1.0, 7.4) (4) Oil pump driven gear ASSY (11) Oil guide T3: 25 (2.5, 18.1) (5) Oil pump rotor ASSY (12) Oil pipe T4: 44 (4.5, 32.5) (6) Strainer ASSY (13) O-ring (7) Magnet 6MT-6
6 5. EXTENSION CASE AND CENTER DIFFERENTIAL GENERAL DESCRIPTION (3) (4) (5) (15) (16) (17) (2) (14) T3 (18) (21) (9) (10) (13) (19) (20) (22) (23) (24) (8) (12) (11) (31) (25) (7) T1 (27) (28) (29) T2 (26) (6) (30) MT Taper roller bearing (13) Extension guide (25) Reverse check lever COMPL (2) Transfer driven gear (14) Extension case (26) Straight pin (3) Taper roller bearing (15) Oil seal (27) Reverse check plug (4) Shim (16) Oil seal (28) Spring (5) Oil plate (17) Dust cover (29) Gasket (6) Center differential (18) Snap ring (30) Plug (7) Shim (19) Washer (31) Plunger (8) Needle bearing (20) Bush (9) Needle bearing (21) Spring Tightening torque: N m (kgf-m, ft-lb) (10) Transfer drive gear (22) Reverse check shaft T1: 25 (2.5, 18.1) (11) Ball bearing (with flange) (23) Ball bearing T2: 41 (4.2, 30.2) (12) Snap ring (24) Oil seal T3: 48 (4.9, 35.4) 6MT-7
7 6. SHIFTER FORK AND FORK ROD (8) (9) (10) (7) (15) (6) (18) (14) (5) (2) (3) (4) (17) (22) (13) (12) (16) (20) (21) (11) (19) (23) (24) MT Spring pin (9) Support (17) 5th-6th shifter arm (2) Interlock arm (10) Snap ring (18) 5th-6th fork COMPL (3) Interlock block (11) Reverse fork COMPL (19) 3rd-4th fork rod (4) Reverse interlock block (12) Reverse shifter arm (20) 3rd-4th shifter arm (5) Interlock arm (13) Reverse fork rod (21) 1st-2nd shifter arm (6) Striking rod (14) Selector arm COMPL (22) 3rd-4th fork COMPL (7) Selector arm No. 2 (15) Shifter arm shaft (23) 1st-2nd fork rod (8) Neutral set spring (16) 5th-6th fork rod (24) 1st-2nd fork COMPL 6MT-8
8 7. MAIN SHAFT ASSY (13) (9) (12) (11) (10) (8) (7) (6) (5) (4) (3) (2) (22) (20) (28) (29) (21) (26) (27) (14) (15) (17) (18) (19) (23) (24) (25) (16) MT Main shaft (12) 4th bush (23) Needle bearing (2) Needle bearing (13) Needle bearing (24) 6th bush (3) 3rd drive gear (14) 5th bush (25) Taper roller bearing (4) Inner baulk ring (15) Needle bearing (26) Snap ring (5) Synchro cone (16) 5th drive gear (27) Washer (6) Outer baulk ring (17) 5th baulk ring (28) Washer (7) 3rd-4th sleeve (18) 5th-6th sleeve (29) Lock nut (8) 3rd-4th hub (19) 5th-6th hub (9) Shifting insert (20) Shifting sleeve Tightening torque: N m (kgf-m, ft-lb) (10) 4th baulk ring (21) 6th baulk ring T: 392 (40.0, 289) (11) 4th gear (22) 6th drive gear 6MT-9
9 8. DRIVE PINION AND DRIVEN SHAFT ASSY (6) (7) (3) (4) (5) (2) T3 T1 (13) (14) (15) (24) (12) (23) (11) (22) (10) (9) (21) (20) (8) (18) (19) (25) T2 (26) (27) (17) (16) MT Drive pinion shaft (13) 1st-2nd sleeve (25) Lock nut (2) Taper roller bearing (14) Shifting insert (26) Shim (3) Shim (15) 1st-2nd hub (27) Collar (4) Washer (16) Outer baulk ring (5) Lock nut (17) Synchro cone Tightening torque: N m (kgf-m, ft-lb) (6) Thrust bearing (18) Inner baulk ring T1: 285 (29.1, 210) (7) Needle bearing (19) 2nd driven gear * 265 (27.0, 195) (8) Driven shaft (20) Needle bearing T2: 570 (58.1, 420) (9) Key (21) 2nd bush * 530 (54.0, 391) (10) Needle bearing (22) 3rd-4th driven gear T3: 54 (5.5, 39.8) (11) 1st driven gear (23) 5th-6th driven gear * Tightening torque when using ST. (12) 1st synchro ring ASSY (24) Ball bearing 6MT-10
10 9. REVERSE IDLER GEAR ASSY GENERAL DESCRIPTION T (7) (5) (6) T (3) (4) (16) (17) (2) (15) (14) (13) (8) (12) (18) (11) (19) (10) (9) MT Base (9) Reverse coupling sleeve (17) Reverse idler holder (2) Washer (10) Reverse idler gear (18) Spring pin (3) Reverse idler gear No. 2 (11) Spring (19) Knock pin (4) Needle bearing (12) Sub gear (5) Reverse idler synchro set (13) Friction plate Tightening torque: N m (kgf-m, ft-lb) (6) Reverse idler gear bush (14) Snap ring T: 25 (2.5, 18.1) (7) Needle bearing (15) Washer (8) Shifting insert (16) Snap ring 6MT-11
11 10.FRONT DIFFERENTIAL (3) (11) (2) (4) T2 (10) (7) (6) (8) (7) (8) (3) (5) (6) (10) (9) T1 (9) (5) T1 MT Drive pinion shaft (6) Differential side retainer (11) Speedometer drive gear (2) Hypoid driven gear (7) O-ring (3) Roller bearing (8) Axle drive shaft Tightening torque: N m (kgf-m, ft-lb) (4) Differential ASSY (9) Retainer lock plate T1: 25 (2.5, 18.1) (5) Oil seal (10) Circlip T2: 69 (7.0, 50.9) 6MT-12
12 11.TRANSMISSION MOUNTING GENERAL DESCRIPTION (4) (6) (3) T4 (5) (2) T3 T2 T5 T1 (7) (8) (3) (2) (7) T2 (9) (11) (10) T5 T5 T6 MT Pitching stopper (7) Cushion D Tightening torque: N m (kgf-m, ft-lb) (2) Spacer (8) Center crossmember T1: 7.5 (0.76, 5.5) (3) Cushion C (9) Rear plate T2: 35 (3.6, 25.8) (4) Front plate (10) Front crossmember T3: 50 (5.1, 36.9) (5) Rear cushion rubber (11) Dynamic dumper T4: 58 (5.9, 42.8) (6) Rear crossmember T5: 70 (7.1, 51.6) T6: 140 (14.3, 103) 6MT-13
13 C: CAUTION Wear working clothing, including a cap, protective goggles, and protective shoes during operation. Remove contamination including dirt and corrosion before removal, installation, and disassembly. Keep the disassembled parts in order and protect them from dust or dirt. Before removal, installation or disassembly, be sure to clarify the failure. Avoid unnecessary removal, installation, disassembly and replacement. When disassembling the case and other light alloy parts, use a plastic hammer to force it apart. Do not pry it apart with a screwdriver or other tool. Be careful not to burn your hands, because each part on the vehicle is hot after running. Use SUBARU genuine gear oil, grease etc. or the equivalent. Do not mix gear oil, grease etc. with that of another grade or from other manufacturers. D: PREPARATION TOOL 1. SPECIAL TOOLS Be sure to tighten fasteners including bolts and nuts to the specified torque. Place shop jacks or safety stands at the specified points. Apply gear oil onto sliding or revolution surfaces before installation. Replace deformed or otherwise damaged snap rings with new ones. Before installing O-rings or oil seals, apply sufficient amount of gear oil to avoid damage and deformation. Be careful not to incorrectly install or fail to install O-rings, snap rings and other such parts. Before securing a part on a vise, place cushioning material such as wood blocks, aluminum plate, or shop cloth between the part and the vise. Avoid damaging the mating surface of the case. Before applying sealant, completely remove the old seal REMOVER Used for removing and installing spring pin (6 mm). ST PULLER SET Used for removing and installing roller bearing (Differential). BOLT (2) PULLER (3) HOLDER (4) ADAPTER (5) BOLT (6) NUT ST MT-14
14 REMOVER Used for removing roller bearing of drive pinion shaft. ST DEPTH GAUGE Used for adjusting main shaft axial end play. ST MAGNET BASE Used for measuring backlash between side gear and pinion, and hypoid gear. Used with DIAL GAUGE ( ). ST DIAL GAUGE Used for measuring backlash between side gear and pinion, and hypoid gear. Used with MAGNET BASE ( ). ST MT-15
15 REMOVER Used for removing differential taper roller bearing. ST REMOVER Used for removing roller bearing. ST INSTALLER Used for installing oil seal. ST INSTALLER Used for installing bearing cone of transfer driven gear (extension core side). ST MT-16
16 WRENCH ASSY Used for removing and installing differential side retainer. ST PRESS Used for installing speedometer oil seal when installing speedometer cable to transmission. ST RACE 4-5 INSTALLER Used for disassembling driven shaft and transfer driven gear. ST REMOVER Used for removing parts on transmission main shaft and drive pinion. ST MT-17
17 REMOVER Used for removing and installing straight pin. ST PRESS Used for installing speedometer shaft oil seal. ST INSTALLER Used for installing extension oil seal. ST PLATE Used for measuring backlash. ST MT-18
18 41099AA000 ENGINE SUPPORT BRACKET Used for supporting engine. ENGINE SUPPORT BRACKET (41099AA010) (2) ENGINE SUPPORT (41099AA020) (2) ST41099AA PULLER ASSY Used for removing extension case oil seal and clutch housing oil seal. ST GAUGE Used for measuring total end play, extension end play and drive pinion height. ST INSTALLER Used for assembling main shaft. ST MT-19
19 PLIERS Used for removing and installing neutral set spring. Used with CLAW (18756AA000). ST INSTALLER Used for removing axle shaft. Used with REMOVER ASSY ( ). ST REMOVER ASSY Used for removing axle shaft. Used with INSTALLER ( ). ST INSTALLER Used for installing transfer drive gear ball bearing. ST MT-20
20 OIL SEAL INSTALLER Used for installing differential side retainer oil seal. ST SEAT Used for installing transfer drive gear ball bearing. ST INSTALLER Used for installing front differential side bearing. ST AA000 STAND ASSY Used for disassembling and assembling transmission. ST18632AA000 6MT-21
21 OIL SEAL GUIDE 18671AA000 Used for installing oil seal to reverse check. Used with INSTALLER (18657AA010). ST18671AA AA010 INSTALLER Used for installing oil seal to reverse check. Used with OIL SEAL GUIDE (18671AA000). ST18657AA AA000 INSTALLER Used for installing oil seal to shift rod. ST18657AA AA000 PULLER Used for removing extension taper roller bearing outer race. ST18758AA000 6MT-22
22 GAUGE 18831AA000 Used for measuring extension taper roller bearing. ST18831AA AA000 HANDLE Used for measuring front differential backlash. ST18631AA AA000 CLAW Used for installing and removing neutral set spring. Used with PLIERS ( ). ST18756AA AA000 REMOVER Used for removing each parts of driven gear. ST18754AA000 6MT-23
23 Used for installing reverse idler gear AA000 STRAIGHT PIN REMOVER ST18757AA AA000 HOLDER Used for installing and removing main shaft lock nut. Used with BASE (18664AA000). ST18665AA AA000 HOLDER Used for installing and removing driven shaft lock nut. Used with BASE (18664AA000). ST18666AA AA000 HOLDER Used for installing and removing drive pinion shaft lock nut. Used with BASE (18664AA000). ST18667AA000 6MT-24
24 BASE 18664AA000 Used for installing and removing main shaft lock nut. Used for installing and removing drive pinion shaft lock nut. Used for installing and removing driven shaft lock nut. ST18664AA AA010 REMOVER Used for disassembling main shaft. ST18722AA AA000 INSTALLER Used for assembling main shaft. ST18651AA AA000 TORQUE WRENCH Used for tightening main shaft lock nut. Used for tightening drive pinion shaft lock nut. Used for tightening driven shaft lock nut. ST18852AA000 6MT-25
25 18668AA000 PUNCH Used for caulking main shaft lock nut. ST18668AA AA000 PUNCH Used for caulking driven shaft lock nut. ST18669AA AA000 PUNCH Used for caulking drive pinion shaft lock nut. ST18670AA AA000 ADAPTER WRENCH Used for installing and removing driven gear shaft lock nut. ST18620AA000 6MT-26
26 18621AA000 ADAPTER WRENCH Used for installing and removing drive pinion shaft lock nut. ST18621AA AA000 REMOVER Used for disassembling the driven shaft. ST18723AA AA000 WRENCH ASSY Used for removing and installing differential side retainer (left side). ST18630AA AA000 GUIDE CLIP Used for installing reverse idler gear snap ring. ST18672AA000 6MT-27
27 18720AA000 REMOVER Used for disassembling main shaft. ST18720AA AA000 INSTALLER Used for assembling driven shaft. ST18654AA AA000 SOCKET Used for installing and removing oil pump cover. ST18663AA AA000 HEIGHT GAUGE Used for selecting shift rod. ST18853AA000 6MT-28
28 CLAW 18760AA000 Used for removing front side retainer bearing outer race. Used with PULLER ASSEMBLY ( ). ST18760AA GENERAL PURPOSE TOOLS Circuit Tester TOOL NAME REMARKS Used for measuring resistance, voltage and ampere. 6MT-29
1. General Description
1. General Description A: SPECIFICATIONS 1. Type Transmission gear ratio Front reduction gear Rear reduction gear 2. TRANSMISSION GEAR OIL Recommended oil Final Transfer 5-forward speeds with synchromesh
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