Subaru BRZ 2013 · Service Manual Drive train

Counter gear ASSY

Components Removal / installation

MANUAL TRANSMISSION / TRANSAXLE
COUNTER GEAR ASSY
EXPLODED VIEW
NOTE:
Be sure to use the recommended product or the substitute product for manual transmission oil. (Refer to )
NOTE:
Be sure to use the recommended product or the substitute product for manual transmission oil. (Refer to )
DISASSEMBLY
3. Removal of counter gear front bearing
(1) Use the SST to remove the shaft snap ring.
SST     499895400
CAUTION:
Verify the direction of the parts.
(2) Use the SST to remove the counter gear front bearing.
SST     899854100  899864100
4. Removal of counter drive gear
(1) Use the SST to remove the shaft snap ring.
SST     499895400
(2) Use the SST to remove the counter drive gear.
SST     899714110  899864100
5. Removal of counter shaft 4th gear
(1) Use the SST to remove the shaft snap ring, then remove the 4th inner race thrust washer after removing the 4th washer retaining ring.
SST     499895400
CAUTION:
Verify the direction of the parts.
(2) Remove the 4th gear bearing inner race by turning it counterclockwise along the gear while prying with a flat tip screwdriver.
(3) Remove the counter shaft 4th gear and synchronizer ring No.1.
6. Removal of counter shaft 3rd gear
(1) Use the SST to remove the transmission clutch hub No.2, counter shaft 3rd gear, synchronizer ring set No.3, and needle roller bearing.
SST     899714110
CAUTION:
Verify the direction of the parts.
7. Removal of transmission hub sleeve No.2
(1) Remove the transmission hub sleeve No.2, then remove the 3 synchromesh shifting keys No.1, 3 synchromesh shifting key springs No.1, and 3 balls from the transmission clutch hub No.2.
CAUTION:
·Keep the synchromesh shifting keys No.1, synchromesh shifting key springs No.1, and balls from flying out using a cloth.
·Be careful not to deform the synchromesh shifting key springs No.1.
·Verify the direction of the parts.
NOTE:
Perform the work without displacing the positions of the transmission clutch hub No.2 and synchromesh shifting keys No.1.
INSPECTION
1. 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.
2. 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 8.0mm {0.311 to 0.315in}
Limit :  7.9mm {0.311in}
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 0.0138in}
Limit :  0.35mm {0.0138in}
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.
4. Check of synchronizer ring No.3
(1) 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.
Captions in illustration
*a
 Inner
 *b
 Middle
*c
 Outer
 -
 -
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 )
(2) 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 )
6. Check of counter shaft 3rd gear
(1) Check the inner diameter of the counter shaft 3rd gear.
Standard value :  43.015 to 43.040mm {1.69350 to 1.69448in}
Limit :  43.040mm {1.69448in}
NOTE:
If the value exceeds the limit, replace the counter shaft 3rd gear with a new one.
7. Counter shaft 4th gear check
(1) Check the inner diameter of the counter shaft 4th gear.
Standard value :  46.315 to 46.340mm {1.82425 to 1.82441in}
Limit :  46.340mm {1.82441in}
NOTE:
If the value exceeds the limit, replace the counter shaft 4th gear with a new one.
8. Check of 4th gear bearing inner race
(1) Check the outer diameter of the 4th gear bearing inner race.
Standard value :  46.225 to 46.25 mm {1.81988 to 1.82087 in}
Limit :  46.225mm {1.81988in}
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.
ASSEMBLY
1. Installation of transmission hub sleeve No.2
(1) Apply manual transmission oil to the sliding area of the transmission clutch hub No.2.
NOTE:
Be sure to use the recommended product or the substitute product for manual transmission oil. (Refer to )
(2) Install the transmission hub sleeve No.2 to the transmission clutch hub No.2, and install the 3 balls after installing the 3 synchromesh shifting keys No.1 and the 3 synchromesh shifting key springs No.1 as a unit.
NOTE:
·Install the shifting key pole while pressing the shifting key spring. Install the balls while pressing the synchromesh shifting key spring No.1.
·After the installation, settle the synchromesh shifting key spring No.1.
2. Installation of counter shaft 3rd gear
(1) Apply manual transmission oil to the counter shaft installation portion, the needle roller bearing, and the inner surface and the tapered cone portion of the counter shaft 3rd gear.
NOTE:
Be sure to use the recommended product or the substitute product for manual transmission oil. (Refer to )
(2) Install the needle roller bearing and the counter shaft 3rd gear.
3. Installation of transmission clutch hub No.2
(1) Install the synchronizer ring set No.3 to the counter shaft 3rd gear.
·Align the middle ring claw with the gear groove.
·Align the inner ring claw with the outer ring claw groove.
(2) Use the SST to install the transmission clutch hub No.2.
SST     18654AA000  398477703
CAUTION:
Check the position of the synchronizer ring set No.3.
NOTE:
·Press-fit the transmission clutch hub No.2 until it contacts the counter shaft.
·After the press-fitting, check that the synchronizer ring set No.3 moves in the thrust direction.
4. Installation of counter shaft 4th gear
(1) Install the synchronizer ring No.1 to the transmission clutch hub No.2.
(2) Apply manual transmission oil to the 4th gear bearing inner race, and the inner surface and the tapered cone portion of the counter shaft 4th gear.
NOTE:
Be sure to use the recommended product or the substitute product for manual transmission oil. (Refer to )
(3) Install the counter shaft 4th gear and 4th gear bearing inner race.
NOTE:
Install the 4th gear bearing inner race by turning it clockwise along the gear.
5. Installation of 4th inner race thrust washer
(1) Select a 4th inner race thrust washer so that the thrust clearance between the 4th gear bearing inner race and the 4th inner race thrust washer is within the standard value.
Standard value :  0 to 0.1mm {0 to 0.00394in}
NOTE:
Select a 4th inner race thrust washer with the maximum thickness that can be installed.
Type of 4th inner race thrust washer
Item number
 Thickness mm {in}
 Identification mark
17002AA090
 3.75 mm {0.14763}
 A
17002AA100
 3.80mm {0.14960}
 B
17002AA110
 3.85mm {0.15157}
 C
17002AA120
 3.90mm {0.15354}
 D
17002AA130
 3.95mm {0.15551}
 E
17002AA140
 4.00mm {0.15748}
 F
17002AA150
 4.05mm {0.15944}
 G
17002AA160
 4.10mm {0.16141}
 H
(2) Use the SST to install a new 4th inner race thrust washer, a new 4th washer retaining ring, and a new shaft snap ring to the counter shaft.
SST     499895400
6. Installation of counter drive gear
(1) Use the SST to install the counter drive gear.
SST     499277000  398477703
8. Installation of counter gear front bearing
(1) Use the SST to install a new counter gear front bearing while holding it by hand.
SST     498057300