Subaru BRZ 2013 · Service Manual Drive train

Output shaft ASSY

Components Removal / installation

MANUAL TRANSMISSION / TRANSAXLE
OUTPUT SHAFT 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 reverse gear
(1) Use the SST to remove the shaft snap ring.
SST     499895400
(2) Use the SST to remove the transmission clutch hub No.3, transmission hub sleeve No.3, reverse gear, synchronizer ring No.3, and reverse gear bearing from the output shaft.
SST     899714110  899864100
CAUTION:
Verify the direction of the parts.
4. Removal of transmission hub sleeve No.3
(1) Remove the transmission hub sleeve No.3, 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.3.
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.
NOTE:
Perform the work without displacing the positions of the transmission clutch hub No.3 and synchromesh shifting keys No.1.
5. Removal of 6th gear
(1) Remove the shaft snap ring.
CAUTION:
Keep the shaft snap ring from flying out with a cloth, etc.
(2) Use the SST to remove the 6th gear.
SST     899854100
6. Removal of 1st gear
(1) Use the SST to remove the output shaft bearing RR, 1st gear, 1st bearing inner race, 1st gear needle roller bearing, and 1st shift restrict ball.
SST     18722AA000
CAUTION:
Verify the direction of the parts.
7. Removal of 2nd gear
(1) Use the SST to remove the 2nd gear, transmission clutch hub No.1, transmission hub sleeve No.1, and 2nd gear needle roller bearing from the output shaft.
SST     18753AA000
CAUTION:
Verify the direction of the parts.
8. Removal of synchronizer ring set No.1
(1) Remove the 2 synchronizer ring No.1 sets.
9. Removal of transmission hub sleeve No.1
(1) Remove the transmission hub sleeve No.1, 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.1.
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.
NOTE:
Perform the work without displacing the positions of the transmission clutch hub No.1 and synchromesh shifting keys No.1.
INSPECTION
1. 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.
3. Reverse gear check
(1) Check the inner diameter of the reverse gear.
Standard value :  47.015 to 47.040mm {1.85098 to 1.85197in}
Limit :  47.040mm {1.85197in}
NOTE:
If the value exceeds the limit, replace the reverse gear with a new one.
4. 1st gear check
(1) Check the inner diameter of the 1st gear.
Standard value :  46.315 to 46.340 mm {1.82343 to 1.82441 in}
Limit :  46.340mm {1.82441in}
NOTE:
If the value exceeds the limit, replace the 1st gear with a new one.
5. 2nd gear check
(1) Check the inner diameter of the 2nd gear.
Standard value :  49.015 to 49.040mm {1.92972 to 1.93071in}
Limit :  49.040mm {1.93071in}
NOTE:
If the value exceeds the limit, replace the 2nd gear with a new one.
6. Check of 1st gear bearing inner race
(1) Check the outer diameter of the 1st gear bearing inner race.
Standard value :  40.284 to 40.300mm {1.58598 to 1.58661in}
Limit :  40.284mm {1.58598in}
NOTE:
If the value is smaller than the limit, replace the 1st gear bearing inner race with a new one.
7. 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 8.0mm {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.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 0.0138in}
Limit :  0.35mm {0.0138in}
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.
8. 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 8.0mm {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.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 0.0138in}
Limit :  0.35mm {0.0138in}
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.
9. 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.
10. 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.
12. Check of synchronizer ring set No.1 (for 2nd gear)
(1) 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.
Captions in illustration
*a
 Inner
 *b
 Middle
*c
 Outer
 -
 -
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 )
(2) 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 )
ASSEMBLY
1. Installation of transmission hub sleeve No.1
(1) Apply manual transmission oil to the sliding area of the transmission clutch hub No.1.
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.1 to the transmission clutch hub No.1, 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 balls while pressing the synchromesh shifting key spring No.1.
·After the installation, settle the synchromesh shifting key spring No.1.
2. Installation of transmission hub sleeve No.3
(1) Apply manual transmission oil to the sliding area of the transmission clutch hub No.3.
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.3 to the transmission clutch hub No.3, 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 balls while pressing the synchromesh shifting key spring No.1.
·After the installation, settle the synchromesh shifting key spring No.1.
3. Reverse gear installation
(1) Apply manual transmission oil to the output shaft installation portion, the reverse gear bearing, and the inner surface and the tapered cone portion of the reverse gear.
NOTE:
Be sure to use the recommended product or the substitute product for manual transmission oil. (Refer to )
(2) Install the reverse gear bearing and the reverse gear to the output shaft.
4. Installation of transmission clutch hub No.3
(1) Install the synchronizer ring No.3 to the reverse gear.
(2) Use the SST to install the transmission clutch hub No.3.
SST     499277100  398477703  899714110
NOTE:
·After installing the transmission clutch hub No.3, check that the synchronizer ring moves in the thrust direction.
·Press-fit the transmission clutch hub No.3 until it contacts the output shaft.
·Match the phases of the transmission clutch hub No.3 and the synchronizer ring No.3.
5. Installation of shaft snap ring (transmission clutch hub No.3)
(1) Select a shaft snap ring so that the thrust clearance between the transmission clutch hub No.3 and the shaft snap ring is within the standard value.
Standard value :  0 to 0.1mm {0 to 0.00394in}
NOTE:
Select a shaft snap ring with the maximum thickness that can be installed.
Shaft snap ring type
Item number
 Thickness mm {in}
 Identification mark
17005AA520
 1.80 {0.07086}
 A
17005AA530
 1.85 {0.07283}
 B
17005AA540
 1.90 {0.07480}
 C
17005AA550
 1.95 {0.07677}
 D
17005AA560
 2.00 {0.07874}
 E
17005AA570
 2.05 {0.08070}
 F
(2) Use the SST to install a new shaft snap ring to the output shaft.
SST     499895400
7. Installation of transmission clutch hub No.1
(1) Align the synchronizer ring set No.1 (for 2nd gear) to the position shown in the figure and install it.
CAUTION:
·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.1.
SST     499277100  899714110  398477703   499277000
NOTE:
·After installing the transmission clutch hub No.1, check that the synchronizer ring set No.1 (for 2nd gear) moves in the thrust direction.
·Press-fit the transmission clutch hub No.1 until it contacts the output shaft.
(3) Align the synchronizer ring set No.1 (for 1st gear) to the position shown in the figure and install it.
CAUTION:
·Align the protruded section of the outer ring with the hub groove.
·Align the inner ring claw with the outer ring claw groove.
8. 1st gear installation
(1) Apply manual transmission oil to the output shaft installation portion, the needle roller bearing inner race, and the inner surface and the tapered cone portion of the 1st gear.
NOTE:
Be sure to use the recommended product or the substitute product for manual transmission oil. (Refer to )
(2) Install the 1st shift restrict ball, 1st gear, 1st gear needle roller bearing, and 1st gear bearing inner race to the output shaft.
CAUTION:
Align the middle ring claw with the gear groove.
Captions in illustration
*1
 1st shift restrict ball
9. Installation of output shaft bearing RR
(1) Use the SST to install the output shaft bearing RR.
SST     499277100  899714110  398477703   499277000
NOTE:
Press-fit the output shaft bearing RR until it contacts the 1st gear bearing inner race.
10. 6th gear installation
(1) Use the SST to install the 6th gear.
SST     499277100  899714110  398477703   499277000
NOTE:
Press-fit the 6th gear until it contacts the output shaft bearing RR.