Transmission Subaru 2.5

3-1

[S100] SPECIFICATIONS 1. Manual Transmission and Differential

AND SERVICE DATA

1. Manual Transmission and Differential
Item Type 1st 2nd 3rd Transmission gear ratio 4th 5th Reverse Type of gear Front reduction Final gear Gear ratio Type of gear Transfer Gear ratio Rear reduction gear Type of gear Final Gear ratio Front differential Type and number of gear Center differenType andnumber of gear tial Transmission gear oil Transmission oil capacity Model AWD 2200 cc 2500 cc 5-forward speeds with synchromesh and 1-reverse 3.545 2.111 1.448 1.088 0.780 3.333 Hypoid 3.900 4.111 Helical 1.000 Hypoid 3.900 4.111 Straight bevel gear (Bevel pinion: 2, Bevel gear: 2) Straight bevel gear (Bevel pinion: 2, Bevel gear: 2 and viscous coupling) GL-5 3.5 (3.7 US qt, 3.1 Imp qt)

2.Transmission Gear Oil
Recommended oil

3. Transmission Case Assembly
Drive pinion shim adjustment
Drive pinion shim Thickness Part No. mm (in) 0.150 32295AA071 (0.0059) 0.175 32295AA081 (0.0069) 0.200 32295AA091 (0.0079) 0.225 32295AA101 (0.0089) Thickness mm (in) 0.250 (0.0098) 0.275 (0.0108) 0.300 (0.0118) 0.500 (0.0197)

Part No. 32295AA031 32295AA041 32295AA051 32295AA061

B1H0024

Hypoidgear backlash 0.13 — 0.18 mm (0.0051 — 0.0071 in) Selection of main shaft rear plate
Main shaft rear plate Dimension “A” mm (in) Part No. Mark 4.00 — 4.13 (0.1575 — 0.1626) 32294AA041 1 3.87 — 3.99 (0.1524 — 0.1571) 32294AA051 2

2

SPECIFICATIONS AND SERVICE DATA

[S500] 3-1 5. Reverse Idler Gear

4. Drive Pinion Assembly
Preload adjustment of thrust bearing Starting torque 0.3 — 0.8N·m (0.03 — 0.08 kg-m, 0.2 — 0.6 ft-lb)
Adjusting washer No. 1 Part No. Thickness mm (in) 803025051 3.925 (0.1545) 803025052 3.950 (0.1555) 803025053 3.975 (0.1565) 803025054 4.000 (0.1575) 803025055 4.025 (0.1585) 803025056 4.050 (0.1594) 803025057 4.075 (0.1604) Adjusting washer No. 2 Part No. Thickness mm (in) 803025059 3.850 (0.1516) 803025054 4.000 (0.1575) 803025058 4.150 (0.1634)

5.Reverse Idler Gear
Adjustment of reverse idler gear position Reverse idler gear to transmission case (LH) wall clearance 6.0 — 7.5 mm (0.236 — 0.295 in)
Part No. 32820AA070 32820AA080 32820AA090 Reverse shifter lever Mark Remarks 7 Further from case wall 8 Standard 9 Closer to the case wall

After installing a suitable reverse shifter lever, adjust reverse idler gear to transmission case wallclearance to within 0 to 0.5 mm (0 to 0.020 in) using washers.
Washer (20.5 × 26 × t) Thickness Part No. mm (in) 0.4 (0.016) 803020154 1.1 (0.043) 803020155 1.5 (0.059) Thickness mm (in) 1.9 (0.075) 2.3 (0.091)

Part No. 803020151 803020152 803020153

3

3-1

[S600] 6. Shifter Fork and Rod

SPECIFICATIONS AND SERVICE DATA

6. Shifter Fork and Rod
Select suitable shifter forks so thatboth coupling sleeve and reverse driven gear are positioned in the center of their synchromesh mechanisms.
Part No. 32804AA060 32804AA070 32804AA080 1st-2nd shifter fork Mark Remarks Approach to 1st gear by 0.2 1 mm (0.008 in) No mark Standard Approach to 2nd gear by 3 0.2 mm (0.008 in) 3rd-4th shifter fork Mark Remarks Approach to 4th gear by 0.2 1 mm (0.008 in) No mark Standard Approach to 3rdgear by 0.2 3 mm (0.008 in) 5th shifter fork Mark Remarks Approach to 5th gear by 0.2 7 mm (0.008 in) No mark Standard Become distant from 5th 9 gear by 0.2 mm (0.008 in)

7. Transfer Case
Neutral position adjustment
Part No. 32190AA000 32190AA010 Adjustment shim Thickness mm (in) 0.15 (0.0059) 0.30 (0.0118)

Part No. 32188AA090 32188AA100

Part No. 32810AA061 32810AA071 32810AA10132188AA110

Reverse accent shaft Mark Remarks Neutral position is closer to X 1st gear. Y Standard Neutral position is closer to Z reverse gear.

Reverse check plate adjustment
Part No. 32189AA000 Reverse check plate Mark Angle θ 0 28° Remarks Arm stops closer to 5th gear. Arm stops closer to 5th gear. Arm stops in the center. Arm stops closer to reverse gear. Arm stops closer to reverse gear....