3RD-4TH Fork Rod Selection

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

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

Main shaft replacement
3rd, and 3rd to 6th drive gear and bushing replacement
3rd, and 3rd to 6th synchro assembly replacement
3rd-4th synchronizer hub and coupling sleeve assembly replacement

Insert the main shaft assembly into the adapter plate.
Set the height gauge to the adapter plate. Lower the height gauge indicator to the top surface of the snap ring groove, and set to the zero point on the upper side of the main rear bearing.
ST 18853AA000 HEIGHT GAUGE

Fig 1: Setting Height Gauge To Adapter Plate
Courtesy of SUBARU OF AMERICA, INC.
NOTE:
- The height gauge will be set on the adapter plate during 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.
Use a height gauge to measure "C1" and "C2" as shown in the figure.

Fig 3: Measuring C1 And C2 Dimensions
Courtesy of SUBARU OF AMERICA, INC.
1. Shift up the 3rd-4th coupling sleeve all the way to the 4th drive gear side, and measure "C2".
  
  Fig 4: Checking 4th Drive Gear
  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 4th side end surface of the coupling 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 5: Turning Ball Bearing End Face
  Courtesy of SUBARU OF AMERICA, INC.
2. Set the height gauge indicator upside down.
  
  Fig 6: Setting Height Gauge Indicator Upside Down
  Courtesy of SUBARU OF AMERICA, INC.
3. Shift down the 3rd-4th coupling sleeve all the way to the 3rd drive gear side, and measure "C1".
  
  Fig 7: Checking 3rd Drive Gear Side
  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 3rd side end surface of the sleeve.
  - Turn approximately 72° at a time, and measure the 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 3rd-4th sleeve. From the following calculation, select a fork rod which matches the calculated value.

Calculation: T = (C1 + C2)/2

T: 3rd-4th sleeve center position

C1: Measured depth from the main shaft rear bearing snap ring groove to the sleeve end, when shifted to 3rd gear: +55 mm (2.17 in)

C2: Measured depth from the main shaft rear bearing snap ring groove to the sleeve end, when shifted to 4th gear

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 "C1", and measure "C1".

Fig 9: Identifying Indicator Dimension

Courtesy of SUBARU OF AMERICA, INC.

T mm (in)	Lot No. (marking)
T mm (in)	M.SFT Snap ring 805072010 [t = 1.65 mm (0.065 in)]	M.SFT Snap ring 805072011 [t = 1.95 mm (0.077 in)]	M.SFT Snap ring 805072012 [t = 2.25 mm (0.089 in)]
137.22 - 137.52 (5.4024 - 5.4142)	32809AA240 (none)	32809AA250 (2)	32809AA260 (4)
137.52 - 137.82 (5.4142 - 5.4260)	32809AA230 (1)	32809AA240 (none)	32809AA250 (2)
137.82 - 138.12 (5.4260 - 5.4379)	32809AA220 (3)	32809AA230 (1)	32809AA240 (none)
T = Thickness