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Old 03-14-2014, 03:25 PM   #1
H_wells3000
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Default Play in main shaft rear plate&synchro stopper 5mt Video - guru help

Hey there, just getting my transfer case back together after finding a bad transfer roller bearing (just switched to the updated one part # 806322080 now) and also a bad thrust bearing that exploded and little rollers were rattling around. All back together and looking good, but I found some very sketchy looking play in the mainshaft rear plate.

this has been serviced before, that center diff snap ring exploded at one point. All repaired and the transmission was shifting and sounding fine for over a year but just recently starting making odd noises from the bad bearings.

Anybody know if this play is out of wack? Heres a video. Along with the play of the synchro cone stopper up front.

https://www.youtube.com/watch?v=VAgh...ature=youtu.be


Also been looking at this diagram, 3rd page. (5mt-72)

http://ken-gilbert.com/wrx/04impreza..._trans_4-3.pdf

Thanks for the help, just a DIYer here
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Last edited by H_wells3000; 03-14-2014 at 05:38 PM.
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Old 03-14-2014, 05:24 PM   #2
H_wells3000
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if nobody stops me Im about to throw it back together. Main question is if that synchro cone stopper wiggles like that normally.
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Old 03-14-2014, 06:32 PM   #3
H_wells3000
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Backing plate has to be in a certain spot to pull it back together, fiddled with it with a long screwdriver while resting transfer case on the dowels. popped into place solid, no more play, and transfer case slid on smoothly. Along with the synchro stopper, rotates into place. Kindof a PITA but not impossible.

Last edited by H_wells3000; 03-14-2014 at 07:28 PM.
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Old 03-14-2014, 09:00 PM   #4
JarHarms
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The input shaft nut (35mm) is staked like poop from the factory and has worked loose. You need to tighten to spec and re-stake that before reassembly. **Sorry a bit late, work blocks youtube.** I would plan to take that housing back off now rather than a day later.....Sorry 88.5 lbs-ft isn't going to result in a stopper that loose. Stopper position is important when you start tightening that up.
That spacer plate is usually loose but when the transfer housing is bolted up, there is a recessed seat that holds the spacer in place. In your case it is probably looser since the tolerance stack has moved (loose).
35mm socket with an OD that clears the tabs on the stopper assembly. 45mm or so I think, bench grinder helps make the "special" socket cheaper than you can purchase from Subaru Tools (BOSCH).

Last edited by JarHarms; 03-14-2014 at 09:26 PM.
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Old 03-14-2014, 09:16 PM   #5
drewmob
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Everything in the video looks fine to me.
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Old 03-14-2014, 11:27 PM   #6
H_wells3000
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Quote:
Originally Posted by JarHarms View Post
The input shaft nut (35mm) is staked like poop from the factory and has worked loose. You need to tighten to spec and re-stake that before reassembly. **Sorry a bit late, work blocks youtube.** I would plan to take that housing back off now rather than a day later.....Sorry 88.5 lbs-ft isn't going to result in a stopper that loose. Stopper position is important when you start tightening that up.
That spacer plate is usually loose but when the transfer housing is bolted up, there is a recessed seat that holds the spacer in place. In your case it is probably looser since the tolerance stack has moved (loose).
35mm socket with an OD that clears the tabs on the stopper assembly. 45mm or so I think, bench grinder helps make the "special" socket cheaper than you can purchase from Subaru Tools (BOSCH).
Thanks for the input, unfortunately I just slapped it back together already .-. Ill try to work up the courage to crack her open again.

Live and learn, hopefully it hangs in there in the meantime!
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Old 03-14-2014, 11:30 PM   #7
H_wells3000
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Quote:
Originally Posted by drewmob View Post
Everything in the video looks fine to me.
I think it won't kaput on me because everything fell into its place during installation. But I have to agree that it seemed a bit loose! I have to rid myself of this lightweight flywheel sometime soon anyways. Next time it's off ill tighten
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Old 03-15-2014, 10:25 AM   #8
drewmob
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You can see that the but hasn't moved in the first few seconds of the video. You're fine.
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