Subaru Crosstrek Service Manual: Inspection
MANUAL TRANSMISSION AND DIFFERENTIAL(5MT) > Main Shaft Assembly
INSPECTION
Disassembled parts should be washed with cleaning solvent first, then inspected carefully.
1. Bearing
Replace the bearings in the following cases.
• When the bearing balls, outer races and inner races are broken or rusty.
• When the bearing is worn.
• When the bearings fail to turn smoothly or emit noise in rotation after transmission gear oil has been applied.
• When bearing has other defects.
2. Bushing (each gear)
Replace the bushing in following cases.
• When the sliding surface is damaged or abnormally worn.
• When the inner wall is abnormally worn.
3. Gear
Replace gears in the following cases.
• Replace the gear with new part if its tooth surfaces are broken, damaged or excessively worn.
• Correct or replace if the cone that contacts the baulk ring is rough or damaged.
• Correct or replace if the inner surface or end face is damaged.
4. Baulk ring, synchro cone
Replace the baulk ring and synchro cone in the following cases.
• When the inner surface and end face are damaged.
• When the baulk ring inner surface is abnormally or partially worn down.
• When the contact surface of the baulk ring insert section is cracked or abnormally worn.
• If the gap between the end faces of the baulk ring and the gear splined part is excessively small, check the clearance (A) while pressing the ring against the cone.
Clearance (A):
0.5 mm (0.020 in) or more
Single cone
Double cone
• Apply transmission gear oil to the cone of the gear and while press-fitting the baulk ring, check there is no rotation in the circumferential direction.
5. Shifting insert
Replace the shifting insert if deformed, excessively worn or defective in any way.
6. Coupling sleeve and synchronizer hub
• Check the slipping condition of the coupling sleeve.
• Check the splines on the coupling sleeve and synchronizer hub for wear.
7. Oil seal
Replace the oil seal if the lip is deformed, hardened, worn or defective in any way.
8. Gearshift mechanism
Repair or replace the gearshift mechanism if excessively worn, bent or defective in any way.
Disassembly
MANUAL TRANSMISSION AND DIFFERENTIAL(5MT) > Main Shaft AssemblyDISASSEMBLY1. Put vinyl tape around main shaft spline to protect the oil seal from damage. Then pull out the oil seal and needle beari ...
Installation
MANUAL TRANSMISSION AND DIFFERENTIAL(5MT) > Main Shaft AssemblyINSTALLATION1. Attach the needle bearing and oil seal to the front of the main shaft assembly.NOTE:• Wrap the clutch splined sec ...
Other materials:
Preparation tool
DIFFERENTIALS > General DescriptionPREPARATION TOOL1. SPECIAL TOOLILLUSTRATIONTOOL NUMBERDESCRIPTIONREMARKS398477701HANDLE• Used for installing the rear bearing race.• Used for installing the front bearing race.398477702DRIFT• Used for installing the front bearing race. (T-type) ...
Location
LIGHTING SYSTEM > Relay and FuseLOCATIONMain fuse boxHeadlight relay (HI)(A)Headlight relay (LO)(B)Fuse 15 A (daytime running light relay)(C)Fuse 30 A (combination light LH/RH)(D)Fuse 20 A (spot map light, room light, ignition switch illumination (immobilizer antenna))(E)Fuse 15 A (tail and illum ...
General diagnostic table Inspection
PARKING BRAKE > General Diagnostic TableINSPECTIONSymptomsPossible causeCorrective actionBrake draggingLever assembly - hand brake is maladjusted.Adjust.Parking brake cable does not move.Repair or replace.Parking brake shoe clearance is maladjusted.Adjust.Spring - shoe return is faulty.Replace.No ...
