Manual Transmission/Transaxle
The content of this article/image reflects the changes Identified inTSB # 18-100-06
as of 02/06/2006
and applies to 2003 Forester & Impreza Models
SPECIFICATIONS
MANUAL TRANSMISSION AND DIFFERENTIAL
TRANSMISSION CASE ASSEMBLY
Drive pinion shim adjustment Hypoid gear backlash 0.13 - 0.18 mm (0.0051 - 0.0071 inch)
Selection of main shaft rear plate
DRIVE PINION ASSEMBLY
Preload adjustment of thrust bearing
Starting torque 0.3 - 0.8 Nm (0.03 - 0.08 kgf-m, 0.2 - 0.6 ft. lbs.)
MAIN SHAFT
Snap ring (Outer-25) to synchronizer hub clearance 0.060 - 0.100 mm (0.0024 - 0.0039 inch)
REVERSE IDLER GEAR
Adjustment of reverse idler gear position Reverse idler gear to transmission case (LH) wall clearance 6.0 - 7.5 mm (0.236 - 0.295 inch)
After installing a suitable reverse shifter lever, adjust reverse idler gear to transmission case wall clearance to within 0 to 0.5 mm (0 to 0.020 inch) using washers.
SHIFTER FORK AND ROD
Select suitable shifter forks so that both coupling sleeve and reverse driven gear are positioned in the center of their synchromesh mechanisms.
Rod end clearance
A: 1 et-2nd-3rd-4th 0.4 - 1.4 mm (0.016 - 0.055 inch)
B: 3rd-4th-5th 0.5 - 1.3 mm (0.020 - 0.051 inch)
TRANSFER CASE
Neutral position adjustment
Reverse check plate adjustment
EXTENSION ASSEMBLY
FRONT DIFFERENTIAL
Bevel gear to pinion backlash 0.13 - 0.18 mm (0.0051 - 0.0071 inch)
Pinion shaft to axle drive shaft clearance 0 - 0.2 mm (0 - 0.008 inch)
TRANSFER DRIVE GEAR
Snap ring (Outer-30) to ball bearing clearance 0.01 - 0.15 mm (0.0004 - 0.0059 inch)