Subaru BRZ 2014 User Manual
PREPARATION MATERIALS
DRIVE TRAIN
PREPARATION MATERIALS
MANUAL TRANSMISSION/TRANSAXLE
PP
MT
PREPARATION MATERIALS
PREPARATION MATERIALS
MANUAL TRANSMISSION/TRANSAXLE
SST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PP-2
GENERAL TOOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PP-8
GREASE ⋅ OTHER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PP-8
PP
PP
PP–2
Preparation materialsPreparation materials
Preparation materials - MANUAL TRANSMISSION/TRANSAXLE
MANUAL TRANSMISSION/TRANSAXLE
SST
Illustration Tool number Description Remarks
39852770 Puller ASSY Used for removing the transmission extension
ST-398527700
499277100 Bushing 1-2 installer • Used for installing the transmission clutch hub
housing oil seal.
No. 3.
• Used for installing the transmission clutch hub
No. 1.
• Used for installing the output shaft bearing RR.
• Used for installing the sixth gear.
ST-499277100
ST-899714110
ST-398477703
899714110 Remover • Used for removing the input shaft bearing FR.
• Used for removing the counter drive gear.
• Used for removing the counter shaft third gear.
• Used for removing and installing the
transmission clutch hub No. 3.
• Used for installing the transmission clutch hub
No. 1.
• Used for installing the output shaft bearing RR.
• Used for installing the sixth gear.
398477703 Drift 2 • Used for installing the input shaft bearing FR.
• Used for installing the transmission clutch hub
No. 3.
• Used for installing the transmission clutch hub
No. 1.
• Used for installing the output shaft bearing RR.
• Used for installing the sixth gear.
• Used for installing the transmission clutch hub
No. 2.
• Used for installing the counter drive gear.
Preparation materials - MANUAL TRANSMISSION/TRANSAXLE
Illustration Tool number Description Remarks
499277000 Installer • Used for installing the input shaft bearing FR.
• Used for installing the transmission clutch hub
No. 1.
• Used for installing the output shaft bearing RR.
• Used for installing the sixth gear.
• Used for installing the counter drive gear.
ST-499277000
18654AA000 Installer Used for installing the transmission clutch hub No. 2.
PP–3
PP
ST18654AA000
ST0932520010
ST-498057300
09325-20010 Transmission oil plug • Used for installing the transmission extension
housing oil seal (MTM).
• Used for installing the transmission extension
housing oil seal.
498057300 Installer Used for installing the counter gear front bearing.
PP
PP–4
Preparation materials - MANUAL TRANSMISSION/TRANSAXLE
Illustration Tool number Description Remarks
09350-20015 TOYOTA automatic transmission tool
set
ST0935020015
(09350-06120) Terminal No. 2 measure Used for inspecting the counter shaft 6th gear thrust
Used for inspecting the counter shaft 6th gear thrust
clearance.
clearance.
ST0935006120
ST18657AA040
ST18682AA000
18657AA040 Installer Used for installing the extension housing rear oil seal.
18682AA000 Installer Used for installing the transmission clutch hub No. 4.
Preparation materials - MANUAL TRANSMISSION/TRANSAXLE
Illustration Tool number Description Remarks
499895400 Expander Used for removing and installing the shaft snap ring.
ST-499895400
899864100 Remover • Used for removing the transmission clutch hub
No. 3.
• Used for removing the counter gear front
bearing.
• Used for removing the counter drive gear.
PP–5
PP
ST-899864100
ST0995000020
ST18722AA000
09950-00020 Remover • Used for removing the sixth gear.
• Used for removing the counter gear front
bearing.
18722AA000 Remover Used for removing the first gear.
PP
PP–6
Preparation materials - MANUAL TRANSMISSION/TRANSAXLE
Illustration Tool number Description Remarks
09950-30012 Puller A set Used for removing the transmission clutch hub No. 4.
ST0995030012
(09951-03010) Upper plate Used for removing the transmission clutch hub No. 4.
ST0995103010
ST0995303010
ST0995603010
(09953-03010) Center bolt Used for removing the transmission clutch hub No. 4.
(09956-03010) Adapter 16 Used for removing the transmission clutch hub No. 4.
Preparation materials - MANUAL TRANSMISSION/TRANSAXLE
Illustration Tool number Description Remarks
09950-60010 Replacer set Used for installing the transmission front bearing
retainer oil seal.
ST0995060010
(09951-00420) Replacer 42 Used for installing the transmission front bearing
retainer oil seal.
PP–7
PP
ST0995100420
ST0995060020
ST0995100750
09950-60020 Replacer set No. 2 Used for installing the extension housing dust
deflector.
(09951-00750) Replacer 75 Used for installing the extension housing dust
deflector.
PP
PP–8
Preparation materials - MANUAL TRANSMISSION/TRANSAXLE
Illustration Tool number Description Remarks
09950-70010 Handle set • Used for installing the transmission front bearing
retainer oil seal.
• Used for installing the extension housing dust
deflector.
ST0995070010
09951-07100 Handle 100 • Used for installing the transmission front bearing
retainer oil seal.
• Used for installing the extension housing dust
deflector.
ST0995107100
GENERAL TOOL
Tool name Remarks
Socket hexagon Used for removing and installing the lock ball pin.
TORX® socket wrench T40 Used for removing and installing the head straight screw plug.
TORX® socket wrench T45 Used for removing and installing the TORX bolt.
Brass bar 16φ • Used for disassembling and assembling the manual transmission ASSY.
Thickness gauge Used for measuring clearance.
Caliper Used for measuring clearance.
Dial gauge (10 mm) Used for measuring clearance.
Micrometer Used for measuring outer diameter.
V-b loc k • Used for inspecting the output shaft runout.
Cylinder gauge Used for measuring inner diameter.
Magnetic base Used for measuring clearance.
• Used for disassembling and assembling the input shaft ASSY.
• Used for disassembling and assembling the output shaft ASSY.
• Used for inspecting the counter shaft runout.
GREASE⋅OTHER
Description Part number Used location
MG Gear Oil Special II – • Manual transmission ASSY
• Input shaft ASSY
• Output shaft ASSY
• Counter gear ASSY
Nichimoly N-130 or equivalent – Input shaft —
Permalub ECN-9 or equivalent – • Floor shift control shaft
• Control shaft
Nigtight LYW No. 2 or equivalent – • Shift lever cap
• Shift lever pin
• Control shift lever retainer
GL-3 or more (75W-90)
<Caution>
• The function or the
performance of the substitute
oil might be inferior to the
genuine transmission gear oil.
• Do not mix different types of oil.
—
—
DRIVE TRAIN
MANUAL TRANSMISSION/TRANSAXLE
MANUAL TRANSMISSION ASSY
EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MT-2
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MT-8
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MT-23
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MT-26
INPUT SHAFT ASSY
EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MT-44
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MT-44
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MT-46
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MT-46
OUTPUT SHAFT ASSY
EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MT-48
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MT-50
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MT-52
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MT-57
COUNTER GEAR ASSY
EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MT-61
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MT-62
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MT-65
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MT-68
MT
MT–2
Drive trainManual transmission/transaxle
Manual transmission/transaxle - MANUAL TRANSMISSION ASSY
MANUAL TRANSMISSION ASSY
EXPLODED VIEW
7.0 {71}{5.2}
Wiring harness clamp bracket
MT
x7
17 {173}{12.5}
16 {163}{11.8}
Clutch release fork support
Transmission front bearing
retainer oil seal
Clutch housing
Reverse idler gear
Reverse idler
gear shaft
Gasket
Bearing retainer FR
Nm {kgfcm}{ftlbf} : Tightening torque
Non-reusable parts
Locking part
Manual transmission oil
<Reference>
Use recommended or substitute products for manual transmission oil. (Refer to PP-8)
28 {286}{20.7}
MT-03050
Manual transmission/transaxle - MANUAL TRANSMISSION ASSY
Shaft snap ring
Gear shift fork No. 1
Gear shift fork No. 3
MT–3
19.5 {198.8}{14.4}
Shaft snap ring
Gear shift fork shaft No. 1
Input shaft
Gear shift fork shaft No. 3
19.5 {198.8}{14.4}
Counter shaft
MT
Shaft snap ring
Output shaft
19.5 {198.8}{14.4}
Shaft snap ring
Nm {kgfcm}{ftlbf} : Tightening torque
Non-reusable parts
Manual transmission oil
NICHIMOLY N-130 or equivalent
Straight pin
Gear shift fork No. 2
Shaft snap ring
Gear shift fork shaft No. 2
Oil receiver pipe
MT-03005
MT
MT–4
<Reference>
Use recommended or substitute products for manual transmission oil. (Refer to PP-8)
Manual transmission/transaxle - MANUAL TRANSMISSION ASSY
Manual transmission/transaxle - MANUAL TRANSMISSION ASSY
Shift shaft
Gear shift head No. 2
MT–5
Slotted spring pin
Transmission case
Compression spring
29 {296}{21.4}
Clamp
Slotted spring pin
Gear shift head No. 1
Slotted spring pin
Gear shift head No. 3
x9
Shift inner lock
block No. 1
MT
33.3 {339.5}{24.6}
Shift inner lever FR
Shaft snap ring
Gear shift fork shaft No. 3
Washer
x2
x2
x2
Ball
19 {194}{14}
Head straight
screw plug
Gasket
37 {377}{27.3}
Manual transmission filler plug
Manual transmission oil
Nm {kgfcm}{ftlbf} : Tightening torque
Gear shift fork shaft No. 2
Ball
28 {286}{20.7}
Gasket
19 {194}{14}
Head straight screw plug
Locking part
5th shift head
x2
Ball
Gasket
37 {377}{27.3}
Manual transmission
drain plug
Non-reusable parts
Compression
spring
MT-03006
MT–6
<Reference>
Use recommended or substitute products for manual transmission oil. (Refer to PP-8)
Manual transmission/transaxle - MANUAL TRANSMISSION ASSY
MT
6th gear thrust washer
Needle roller bearing
Counter shaft 6th gear
Shift arm pivot
Shaft snap ring
Bearing retainer RR
Shift arm
x4
30 {306}{22.1}
E-ring
Gear shift fork No. 4
19.5 {198.8}{14.4}
Ball
Synchromesh shifting key spring No. 1
Synchromesh shifting key No. 1
x3
x3
x3
Synchronizer ring No. 2
Transmission clutch hub No.4
Nm {kgfcm}{ftlbf} : Tightening torque
Non-reusable parts
Manual transmission oil
<Reference>
Use recommended or substitute products for manual transmission oil. (Refer to PP-8)
Transmission hub
sleeve No. 4
Hole snap ring
Shaft snap ring
Locking part
MT-03043
Manual transmission/transaxle - MANUAL TRANSMISSION ASSY
Transmission extension housing oil seal
Extension housing dust deflector
Extension housing rear oil seal
MT–7
32.3 {329.4}{23.8}
Back-up light switch ASSY
39.2 {399.7}{28.9}
Holder
Compression spring
Lock ball pin
Extension housing oil
receiver pipe No. 2
Transmission extension
housing SUB-ASSY (MTM)
Gasket
MT
Clamp
x8
29 {296}{21.4}
Lock ball pin
Compression
spring
24.5 {249.8}{18.1}
Head straight
screw plug
Straight pin
8.5 {87}{6.3}
Extension housing oil
receiver pipe No. 1
Nm {kgfcm}{ftlbf} : Tightening torque
Non-reusable parts
Manual transmission oil
Gasket
Stopper plate
32.3 {329.4}{23.8}
Neutral switch
31 {316}{22.9}
MT-03008
MT
MT–8
<Reference>
Use recommended or substitute products for manual transmission oil. (Refer to PP-8)
Manual transmission/transaxle - MANUAL TRANSMISSION ASSY
DISASSEMBLY
1. Remove the manual transmission filler plug.
(1) Remove the manual transmission filler plug and gasket.
C257296
2. Remove the manual transmission drain plug.
(1) Remove the manual transmission drain plug and gasket.
C257297
C258508
MT-02923
3. Remove the clutch release fork support.
(1) Remove the clutch release fork support from the clutch housing.
4. Remove the back-up light switch ASSY.
(1) Release the engagement of the three clamps.
Manual transmission/transaxle - MANUAL TRANSMISSION ASSY
(2) Remove the back-up light switch ASSY and gasket.
C257023
5. Remove the neutral switch.
(1) Release the engagement of the clamp.
C257024
MT–9
MT
C257025
C257298
(2) Remove the neutral switch and gasket.
6. Remove the wiring harness clamp bracket.
(1) Remove the bolt, and remove the wiring harness clamp bracket.
7. Remove the lock ball pin.
(1) Remove the head straight screw plug, compression spring and
lock ball pin.
C257027
MT
MT–10
Manual transmission/transaxle - MANUAL TRANSMISSION ASSY
8. Remove the holder.
(1) Remove the holder, compression spring and lock ball pin.
C257028
9. Remove the transmission extension housing SUB-ASSY (MTM).
(1) Remove the bolt.
C257029
C257030J01
C257031
C257033J01
(2) Remove the eight bolts and clamp.
Captions in illustration
*1 Clamp
(3) Remove the transmission extension housing SUB-ASSY (MTM).
<Caution>
• Be careful not to damage the transmission extension housing
SUB-ASSY (MTM).
• Make sure to remove the transmission extension housing SUBASSY (MTM) with the shift position in neutral.
10. Remove the extension housing rear oil seal.
(1) Remove the extension housing rear oil seal.
Captions in illustration
*1 Protective tape
<Caution>
Be careful not to damage the transmission extension housing SUBASSY (MTM).
<Reference>
When removing the part, apply a cloth to avoid damaging the
transmission extension housing SUB-ASSY (MTM).
Manual transmission/transaxle - MANUAL TRANSMISSION ASSY
11. Remove the extension housing dust deflector.
(1) Remove the extension housing dust deflector.
C257039
MT–11
MT
C257299J01
C257034
12. Remove the transmission extension housing oil seal.
(1) Remove the transmission extension housing oil seal.
Captions in illustration
*1 Protective tape
<Caution>
Be careful not to damage the transmission extension housing SUBASSY (MTM).
<Reference>
When removing the part, apply a cloth to avoid damaging the
transmission extension housing SUB-ASSY (MTM).
13. Remove the extension housing oil receiver pipe No. 2.
(1) Remove the extension housing oil receiver pipe No. 2.
14. Remove the extension housing oil receiver pipe No. 1.
(1) Remove the bolt, and remove the extension housing oil receiver
pipe No. 1 and stopper plate.
C257036
MT
MT–12
Manual transmission/transaxle - MANUAL TRANSMISSION ASSY
(2) Remove the straight pin.
C257037
15. Remove the shift shaft.
(1) Slide the shift shaft and shift inner lock block No. 1 to remove.
C257328
C262543
C257329
16. Remove the shift inner lock block No. 1.
(1) Remove the shift inner lock block No. 1 from the shift shaft.
17. Remove the shift inner lever FR.
(1) Remove the bolt, and remove the shift inner lever FR from the shift
shaft.
<Caution>
Check the direction of the part.
18. Remove the head straight screw plug.
(1) Remove the three head straight screw plugs.
C257294
Manual transmission/transaxle - MANUAL TRANSMISSION ASSY
(2) Remove the two compression springs and two balls.
C257295
19. Remove the shift arm.
(1) Remove the E-ring.
<Caution>
Hold with a cloth to prevent the E-ring from flying out.
C257330
MT–13
MT
C257331
MT-02895
(2) Remove the shift arm.
20. Remove the gear shift fork shaft No. 3.
(1) Remove the gear shift fork shaft No. 3.
<Caution>
• Be careful that the ball may fall off from the 5th shift head portion.
• The ball in the transmission case portion may fall into the
transmission case. In this case, remove the ball when the
transmission case is detached.
(2) Remove the ball from the 5th shift head portion.
(3) Remove the ball.
C257335
MT
MT–14
Manual transmission/transaxle - MANUAL TRANSMISSION ASSY
21. Remove the 5th shift head.
(1) Remove the shaft snap ring.
<Caution>
Hold with a cloth to prevent the shaft snap ring from flying out.
C257332
(2) Remove the washer.
C257333
(3) Remove the 5th shift head, and remove the ball and compression
spring.
<Caution>
Be careful that sliding the 5th shift head may cause fall of the ball and
compression spring.
C257336
556
C257300J01
22. Check the counter shaft 6th gear thrust clearance.
(1) Using the SST, check the thrust clearance.
SST 09350-20015 (09350-06120), 498255400
Standard value: 0.10 to 0.40 mm {0.00394 to 0.0157 in}
Limit: 0.40 mm {0.0157 in}
<Reference>
When the result exceeds the limit, replace the counter shaft 6th
gear, transmission clutch hub No. 4, 6th gear thrust washer, needle
roller bearing, and counter shaft.
Manual transmission/transaxle - MANUAL TRANSMISSION ASSY
23. Check the counter shaft 6th gear radial clearance.
(1) Check the radial clearance.
Standard value: 0.015 to 0.068 mm {0.000590 to 0.00268 in}
Limit: 0.068 mm {0.00268 in}
<Reference>
When the result exceeds the limit, replace the counter shaft 6th
gear, needle roller bearing, and counter shaft.
C257301
24. Remove the transmission clutch hub No. 4.
(1) Remove the shaft snap ring.
<Caution>
Hold with a cloth to prevent the shaft snap ring from flying out.
C257337
MT–15
MT
C
D
556
C257338J01
MT-03025
(2) Using the SST, remove the transmission clutch hub No. 4 with the
transmission hub sleeve No. 4, gear shift fork No. 4 and gear shift
fork shaft No. 2 as a unit.
Captions in illustration
*a Hold
*b Rotate
SST 09950-30012 (09951-03010, 09953-03010,
09956-03010)
<Caution>
Check the direction of the part.
25. Remove the gear shift fork No. 4.
(1) Remove a bolt, and remove the gear shift fork No.4 from the gear
shift fork shaft No.2.
26. Remove the transmission hub sleeve No. 4.
(1) Remove the hole snap ring.
C257340
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