5MT-100
MANUAL TRANSMISSION AND DIFFERENTIAL
Front Differential Assembly
E: INSPECTION
Repair or replace the differential gear in the follow-
ing cases:
The hypoid drive gear and drive pinion shaft
tooth surface are damaged, excessively worn, or
seized.
The roller bearing on the drive pinion shaft has a
worn or damaged roller path.
There is damage, wear, or seizure of the differ-
ential bevel pinion, differential bevel gear, washer,
pinion shaft, and straight pin.
The differential case has worn or damaged slid-
ing surfaces.
1. DIFFERENTIAL BEVEL PINION GEAR
BACKLASH
Measure the backlash between differential bevel
gear and pinion. If it is not within specifications, in-
stall a suitable washer to adjust it.
NOTE:
Be sure the pinion gear tooth contacts adjacent
gear teeth during measurement.
ST1 498247001 MAGNET BASE
ST2 498247100 DIAL GAUGE
Standard backlash:
0.13 — 0.18 mm (0.0051 — 0.0071 in)
2. HYPOID GEAR BACKLASH
1) Set the ST1, ST2 and ST3. Insert the needle
through transmission oil drain plug hole so that the
needle comes in contact with the tooth surface at a
right angle.
ST1 498247001 MAGNET BASE
ST2 498247100 DIAL GAUGE
ST3 498255400 PLATE
2) Install the axle shaft (SUBARU Genuine Parts)
to both sides, move it clockwise and counter clock-
wise to contact tooth, and then read the value of
dial gauge runout.
Parts No. 38415AA100 AXEL SHAFT
Backlash:
0.13 — 0.18 mm (0.0051 — 0.0071 in)
3) If the backlash is outside specified range, adjust
it by turning the holder in right side case.
(A) Drive pinion shaft
(B) Hypoid driven gear
(C) Pinion shaft
(D) Straight pin
(E) Washer
(F) Differential bevel gear
(G) Differential bevel pinion
(H) Roller bearing
(I) Differential case
MT-00291
(A)
(B)(C)
(E)
(E)
(F)
(F)
(G)
(G)
(D)
(H) (I)
(H)MT-00285
ST1
ST2
MT-00293ST1
ST2ST3
CL-38
CLUTCH SYSTEM
Clutch Pedal
2) If not as specified, loosen the clutch stopper nut
to adjust it.
Tightening torque (Clutch stopper nut):
8 N
⋅m (0.8 kgf-m, 5.8 ft-lb)
3) Loosen the push rod lock nut.
4) Turn the push rod to adjust.
(1) Ensure that the clutch pedal contacts stop-
per bolt, when releasing the clutch pedal.
(2) Ensure that the clutch pedal contacts clutch
pedal bracket stopper, when fully depressing
the clutch pedal.5) Turn the push rod clockwise to shorten until
clearance is made at stopper bolt or clutch switch.
Model without cruise control
Model with cruise control
6) Turn the push rod counter clockwise to lengthen
until clutch pedal contacts to stopper bolt.
7) Turn the push rod further 270° counterclockwise
to lengthen (arrow direction as shown in the figure).
8) Move the clevis pin in lateral direction to ensure
it moves smoothly.
(A) Clevis pin
(B) Snap pin
(C) Push rod
(D) Push rod lock nut
(A) Clevis hole
(B) Push rod lock nut
(C) Lengthening direction
(D) Shortening direction
(E) Push rod
(F) U shaped bracket
CL-00042
(A)
(B)
(C)(D)
CL-00080
(B)(A)
(C)
(D)(E)(F)
(A) Stopper
(B) Stopper bolt
(A) Clutch switch
(B) Stopper
(C) Clearance
(A) Accelerator pedal
(B) Clevis
(A)
(B)
CL-00131
(A)
(B) (C)
CL-00132
CL-00101
(B)
(A)
CL-40
CLUTCH SYSTEM
Clutch Pedal
6) Turn the push rod clockwise to shorten until
clearance is made at stopper bolt or clutch switch.
7) Turn the push rod counter clockwise to lengthen
until clutch pedal contacts to stopper bolt.
8) Turn the push rod further 270° counterclockwise
to lengthen (arrow direction as shown in the figure).
9) Move the clevis pin in lateral direction to ensure
it moves smoothly.
10) Tighten the push rod lock nut.
Tightening torque :
10 N
⋅m (1.0 kgf-m, 7.2 ft-lb)
11) Measure the full stroke amount of clutch pedal
again.
Specified clutch pedal full stroke: A
125 — 130 mm (4.92 — 5.12 in)
12) Install the clutch switch.
STALLATION, Clutch Switch.>
(A) Stopper bolt
(A) Clutch pedal
(B) Brake pedal
CL-00134
(A)
CL-00085
(A)
(B)
