Subaru Crosstrek manuals

Subaru Crosstrek Service Manual: General diagnostic table Inspection

MANUAL TRANSMISSION AND DIFFERENTIAL(5MT) > General Diagnostic Table

INSPECTION

1. MANUAL TRANSMISSION

Symptoms

Possible cause

Corrective action

1. Gears are difficult to intermesh.

NOTE:

The cause for difficulty in shifting gears can be classified into two types: One is a defective gear shift system and the other is defective transmission. However, if the operation is heavy and engagement of the gears is difficult, a defective clutch disengagement may also be responsible. Check whether the clutch is correctly functioning, before checking the gear shift system and transmission.

(a) Worn, damaged or burred chamfer at internal spline of the sleeve and reverse driven gear

Replace.

(b) Worn, damaged or burred chamfer of gear spline

Replace.

(c) Worn or scratched bushings

Replace.

(d) Incorrect contact or wear between baulk ring and gear cone

Repair or replace.

2. Gear slip-out

Gear slips out when coasting on rough road.

Gear slips out during acceleration.

(a) Defective pitching stopper adjustment

Replace.

(b) Loose engine mounting bolts

Tighten.

(c) Worn shifter fork or broken shifter check ball spring

Replace.

(d) Worn or damaged ball bearing

Replace.

(e) Excessive clearance between splines of synchronizer hub and synchronizer sleeve

Replace.

(f) Synchronizer hub tooth step wear

Replace.

(g) Worn 1st driven gear and driven shaft

Replace.

(h) Worn 2nd driven gear and bushing

Replace.

(i) Worn 3rd drive gear and needle bearing

Replace.

(j) Worn 4th drive gear and needle bearing

Replace.

(k) Worn 5th drive gear and needle bearing

Replace.

(l) Worn reverse idler gear and bushing

Replace.

3. Noise emitted from transmission

NOTE:

If a noise is heard when the vehicle is parked with its engine idling and if a noise ceases when the clutch is disengaged, it may be considered that the noise is coming from the transmission.

(a) Insufficient or improper lubrication

Lubricate with specified oil or replace.

(b) Worn or damaged gears and bearings

NOTE:

If the trouble is only wear of the gear teeth surfaces, only a high whirring noise will occur at high speeds, but if any part is broken, rhythmical clicking sounds will be heard even at low speeds.

Replace.

2. DIFFERENTIAL

Symptoms

Possible cause

Corrective action

1. Broken differential (case, gear, bearing, etc.)

NOTE:

Noise will occur, and eventually the differential will not be able to operate due to broken pieces obstructing the gear revolution.

(a) Insufficient or improper oil

Disassemble the differential and replace broken components. At the same time check other components for any trouble, and replace if necessary.

(b) Use of vehicle under severe conditions such as excessive load and improper use of the clutch

Readjust the preload and backlash of the bearing, and the contact surface of gear.

(c) Improper adjustment of taper roller bearing

Adjust.

(d) Improper adjustment of the drive pinion and the hypoid driven gear

Adjust.

(e) Excessive backlash of a vehicle under severe operating conditions due to worn differential side gear, adjusting washer or differential pinion

Add recommended oil to the specified level. Do not use vehicle under severe operating conditions.

(f) Loose hypoid driven gear clamping bolts

Tighten.

2. Differential and hypoid gear noises

Troubles of the differential and hypoid gear always appear as noise problems. Therefore noise is the first indication of trouble. However, noises from the engine, muffler, tire, exhaust gas, bearing, body, etc. are easily mistaken for the differential noise. Pay special attention to the hypoid gear noise because it is easily confused with other gear noises. There are the following four kinds of noises.

Gear noise when driving:

If noise increases as the vehicle speed increases, it may be due to insufficient gear oil, incorrect gear engagement, damaged gears, etc.

Gear noise when coasting:

Damaged gears due to misadjusted bearings and incorrect shim adjustment

Bearing noise when driving or coasting:

Cracked, broken or damaged bearings

Noise mainly when turning:

Noise from differential side gear, differential pinion or differential pinion shaft, etc.

(a) Insufficient oil

Replenish or replace with the specified amount of recommended oil.

(b) Improper adjustment of hypoid driven gear and drive pinion

Check the tooth contact.

(c) Worn teeth of hypoid driven gear and drive pinion

Replace as a set.

Readjust the bearing preload.

(d) Loose roller bearing

Readjust the backlash of the hypoid driven gear to drive pinion, and check the tooth contact.

(e) Distorted hypoid driven gear or differential case

Replace.

(f) Worn adjusting washer and differential pinion shaft

Replace.

Installation
MANUAL TRANSMISSION AND DIFFERENTIAL(5MT) > Transmission Mounting SystemINSTALLATION1. PITCHING STOPPER1. Install the pitching stopper.Tightening torque:T1: 50 N·m (5.1 kgf-m, 36.9 ft-lb)T2: ...

Preparation for overhaul Procedure
MANUAL TRANSMISSION AND DIFFERENTIAL(5MT) > Preparation for OverhaulPROCEDURE1. Clean oil, grease, dirt and dust from the transmission.2. When transmission gear oil remains in the transmission, usi ...

Other materials:

Rear wiring harness Location
WIRING SYSTEM > Rear Wiring HarnessLOCATIONConnectorConnecting toNo.PoleColorAreaNo.DescriptionR120C-1B97Bulkhead wiring harnessR320C-3B99R41BlackB-4 Parking brake switchR520C-3B92Bulkhead wiring harnessR93C-5 Front door switch LHR108B-5D22Rear door cord LHR123B-2 Front door switch RHR138B-3D28Re ...

Adjustment
CONTROL SYSTEMS > Select CableADJUSTMENT1. Shift the select lever to “N” range.2. Lift up the vehicle.3. Remove the center exhaust pipe. Center Exhaust Pipe > REMOVAL">4. Remove the center exhaust cover.5. Loosen the adjusting nuts on both sides.(A)Adjusting nut A(B)Adjust ...

Using the voice command system
Steering switch Talk switch Action Function Press Start the voice command system. Press and hold Cancel voice recognition. Microphone Type A Type B It is unnecessary to speak directly into the microphone when giving a command. NOTE Wait ...

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