1ST-2ND Fork Rod Selection

WARNING: This page is about a different variant/trim than selected.

NOTE: In the following conditions, perform the procedures below.

Replacement of the 1st and 2nd driven gear
1st and 2nd synchro ring assembly replacement
Adapter plate replacement
Driven shaft replacement
1st-2nd synchronizer hub and coupling sleeve assembly replacement.

Insert the drive pinion assembly into the adapter plate.
NOTE: Confirm that the thrust bearing outer race has not been removed and the drive pinion is not lifted.
Set the height gauge to the adapter plate. Lower the height gauge indicator to the mating surface of the adapter plate and case, and set to zero points.
ST 18853AA000 HEIGHT GAUGE

Fig 1: Setting Height Gauge To Adapter Plate
Courtesy of SUBARU OF AMERICA, INC.
NOTE:
- The adapter plate will be the base point for the measurement. Use a scraper to remove any gasket material remaining on the end face.
- During measurement, do not place the height gauge in the shaded area shown in the figure.
Fig 2: Identifying Adapter Plate
Courtesy of SUBARU OF AMERICA, INC.
Select the main shaft snap ring. <Ref. to ADJUSTMENT , Main Shaft Assembly.>
Measure "B1" and "B2" as shown in the figure.

Fig 3: Measuring B1 And B2 Dimensions
Courtesy of SUBARU OF AMERICA, INC.
Shift down the 1st-2nd coupling sleeve all the way to the 1st driven gear side, and measure "B1".

Fig 4: Checking 1st Driven Gear And 1st-2nd Coupling Sleeve
Courtesy of SUBARU OF AMERICA, INC.
NOTE:
- Set the height gauge indicator near the measurement target, and lock dial (1) as shown in the figure. Turn dial (2), and set the indicator to the 1st side end surface of the coupling sleeve.
- Turn approximately 72° at a time, and measure the coupling sleeve in 5 locations. Round down the 2 highest and 2 lowest measurement values. The remaining center value is used as the measurement value.
Fig 5: Turning Ball Bearing End Face
Courtesy of SUBARU OF AMERICA, INC.
Set the height gauge indicator upside down.

Fig 6: Setting Height Gauge Indicator Upside Down
Courtesy of SUBARU OF AMERICA, INC.
Shift up the 1st-2nd coupling sleeve all the way to the 2nd driven gear side, and measure "B2".

Fig 7: Checking 2nd Driven Gear And 1st-2nd Coupling Sleeve
Courtesy of SUBARU OF AMERICA, INC.
NOTE:
- Set the height gauge indicator near the measurement target, and lock dial (1) as shown in the figure. Turn dial (2), and set the indicator to the 2nd side end surface of the sleeve.
- The measurement is to be performed with two persons, while holding the coupling sleeve straight.
- Turn approximately 72° at a time, and measure the coupling sleeve in 5 locations. Round down the 2 highest and 2 lowest measurement values. The remaining center value is used as the measurement value.
Fig 8: Turning Ball Bearing End Face
Courtesy of SUBARU OF AMERICA, INC.

According to both of the measurements, calculate the neutral position of the 1st-2nd coupling sleeve. From the following calculation, select a fork rod which matches the calculated value.

Calculation: T = (B1 + B2)/2

T: 1st-2nd coupling sleeve center position

B1: Height from the adapter plate end to the coupling sleeve end, when shifted to 1st gear

B2: Measured height from the adapter plate end to the sleeve end, when shifted to 2nd gear: +55 mm (2.17 in)

NOTE: Attach the indicator upside down in comparison to the setting procedures for the zero point. Add "d1" [Value: 55 mm (2.17 in)] from the figure below to "B2", and measure "B2".

Fig 9: Identifying Indicator Dimension

Courtesy of SUBARU OF AMERICA, INC.

T mm (in)	Lot No. (marking)
62.58 - 62.78 (2.4638 - 2.4717)	32801AA370 (5)
62.78 - 62.98 (2.4717 - 2.4795)	32801AA380 (4)
62.98 - 63.18 (2.4795 - 2.4874)	32801AA390 (2)
63.18 - 63.38 (2.4874 - 2.4953)	32801AA400 (1)
63.38 - 63.58 (2.4953 - 2.5031)	32801AA410 (3)