Subaru Outback manuals

Subaru Outback: Reverse Idler Gear

REMOVAL

1) Remove the manual transmission assembly from the vehicle. <Ref. to 6MT-25, REMOVAL, Manual Transmission Assembly.>

2) Remove the back-up light switch neutral position switch. <Ref. to 6MT-37, REMOVAL, Switches and Harness.>

3) Remove the transfer case together with the extension case assembly. <Ref. to 6MT-40, REMOVAL, Transfer Case and Extension Case Assembly.>

4) Remove the transmission case. <Ref. to 6MT- 57, REMOVAL, Transmission Case.>

5) Remove the drive pinion shaft assembly. <Ref. to 6MT-67, REMOVAL, Drive Pinion Shaft Assembly.>

6) Remove the main shaft assembly for single-range. <Ref. to 6MT-60, REMOVAL, Main Shaft Assembly for Single-Range.>

7) Remove the front differential assembly. <Ref. to 6MT-77, REMOVAL, Front Differential Assembly.>

8) Remove the shifter forks and rods. <Ref. to 6MT- 90, REMOVAL, Shifter Fork and Rod.>

9) Remove the snap ring and bolt. Remove the reverse idler gear bushing and drive out the spring pin by tapping it.

NOTE: When driving out the spring pin, rotate the reverse idler gear shaft to prevent it from contacting the case and remove the spring pin into the case inside.

Subaru Outback. Manual Transmission and Differential

  1. Spring pin
  2. Snap ring
  3. Reverse idler gear bushing
  4. Bolt

10) Pull out the reverse idler gear shaft toward the rear side and remove all parts.

NOTE: When pulling out the reverse idler gear shaft, remove the reverse idler gear assembly as a unit while supporting it from the bottom by hand to prevent the parts to scatter in the transmission case.

Subaru Outback. Manual Transmission and Differential

  1. Oil case guide
  2. Washer
  3. Reverse idler gear ASSY
  4. Reverse idler gear shaft

B: INSTALLATION

NOTE: Rotate the reverse idler sub gear by two teeth from free status in the direction of the arrow to make it engage with the reverse gear of the main shaft and install the main shaft assembly.

Subaru Outback. Manual Transmission and Differential

1) Insert the reverse idler gear shaft into the transmission case, then install the oil case guide, washer and reverse idler gear assembly as a single unit.

NOTE:

Subaru Outback. Manual Transmission and Differential

  1. Oil case guide
  2. Washer
  3. Reverse idler gear ASSY
  4. Reverse idler gear shaft

2) Insert the reverse idler gear bushing into reverse idler gear shaft, install the snap ring, and then drive in the spring pin to fix.

NOTE:

Subaru Outback. Manual Transmission and Differential

  1. Spring pin
  2. Snap ring
  3. Reverse idler gear bushing

Subaru Outback. Manual Transmission and Differential

  1. Snap ring

3) Install the reverse idler gear shaft securing bolt.

NOTE: Use a new gasket.

Tightening torque: 25 N*m (2.5 kgf-m, 18.4 ft-lb)

Subaru Outback. Manual Transmission and Differential

4) Check and adjust clearance between the reverse idler gear No. 2 and transmission case wall, and the reverse idler gear and reverse idler gear washer. <Ref. to 6MT-88, INSPECTION, Reverse Idler Gear.> <Ref. to 6MT-89, ADJUSTMENT, Reverse Idler Gear.>

5) Install the shifter forks and rods. <Ref. to 6MT- 91, INSTALLATION, Shifter Fork and Rod.>

6) Install the front differential assembly. <Ref. to 6MT-77, INSTALLATION, Front Differential Assembly.>

7) Install the main shaft assembly for single-range. <Ref. to 6MT-60, INSTALLATION, Main Shaft Assembly for Single-Range.>

8) Install the drive pinion shaft assembly. <Ref. to 6MT-67, INSTALLATION, Drive Pinion Shaft Assembly.>

9) Install the transmission case. <Ref. to 6MT-58, INSTALLATION, Transmission Case.>

10) Install the transfer case together with the extension case assembly. <Ref. to 6MT-40, INSTALLATION, Transfer Case and Extension Case Assembly.>

11) Install the back-up light switch and the neutral position switch. <Ref. to 6MT-37, INSTALLATION, Switches and Harness.>

12) Install the manual transmission assembly to the vehicle. <Ref. to 6MT-29, INSTALLATION, Manual Transmission Assembly.>

C: DISASSEMBLY

1) Remove the snap ring from the reverse idler gear assembly.

Subaru Outback. Manual Transmission and Differential

2) Remove the friction plate, reverse idler sub gear and reverse idler spring.

Subaru Outback. Manual Transmission and Differential

  1. Reverse idler gear
  2. Reverse idler sub gear
  3. Reverse idler spring
  4. Friction plate

D: ASSEMBLY

1) Insert the reverse idler spring into the holes on reverse idler gear and reverse idler sub gear to install.

NOTE: Install the reverse idler sub gear with the side with the mark on it facing outside.

Subaru Outback. Manual Transmission and Differential

  1. Side with the mark facing outside

Subaru Outback. Manual Transmission and Differential

  1. Reverse idler spring
  2. Reverse idler gear
  3. Reverse idler sub gear

2) Install the friction plate, and then secure with the snap ring.

Subaru Outback. Manual Transmission and Differential

E: INSPECTION

1) Move the reverse shifter rod toward the reverse side. Check the clearance between the reverse idler gear and reverse coupling sleeve. If out of specification, select the appropriate reverse shifter fork and adjust.

Clearance (a): 0.50 - 0.85 mm (0.020 - 0.033 in)

Subaru Outback. Manual Transmission and Differential

  1. Reverse idler gear
  2. Reverse coupling sleeve

2) After installing a suitable reverse shifter fork, shift into neutral. Check the clearance between the reverse idler gear and reverse idler gear washer. If out of specification, select the appropriate reverse idler gear bushing and adjust.

NOTE: In clearance check, be sure to insert a thickness gauge vertically.

Clearance (a): 0.1 - 0.3 mm (0.004 - 0.012 in)

Subaru Outback. Manual Transmission and Differential

  1. Reverse idler gear
  2. Reverse idler gear washer

Subaru Outback. Manual Transmission and Differential

3) Check the reverse idler gear and shaft for damage.

Replace if it is damaged.

F: ADJUSTMENT

1) Select the appropriate reverse shifter fork from the table below, and adjust until the clearance between the reverse idler gear and reverse coupling sleeve is within specification.

Clearance (a): 0.50 - 0.85 mm (0.020 - 0.033 in)

Subaru Outback. Manual Transmission and Differential

  1. Reverse idler gear
  2. Reverse coupling sleeve

Subaru Outback. Manual Transmission and Differential

2) Select the appropriate reverse idler gear bushing from the table below, and adjust until the clearance between the reverse idler gear and reverse idler gear washer is within specification.

NOTE: In clearance check, be sure to insert a thickness gauge vertically.

Clearance (a): 0.1 - 0.3 mm (0.004 - 0.012 in)

Subaru Outback. Manual Transmission and Differential

  1. Reverse idler gear
  2. Reverse idler gear washer

Subaru Outback. Manual Transmission and Differential

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