M/T - 2nd Gear Grinds
89subaru01NUMBER: 03-43-89
DATE: 02-10-89
APPLICABILITY 1985 THROUGH 1988 MODEL YEAR SUBARU VEHICLES
WITH MANUAL TRANSMISSION
SUBJECT: 2ND GEAR GRIND
THIS SERVICE BULLETIN IS FOR YOUR INFORMATION ONLY
This service information describes production line improvements as well as field service procedures to be taken when addressing a customer complaint of 2nd gear grind. Improvements have taken place in production starting with transmission number 072334 which is approximately the beginning of 89 MY production.
These improvements consist of changing the angle of the baulk ring and reverse driven gear friction surfaces from 108 degrees to 116 degrees to improve the braking and shifting characteristics of these components.
If a customer complains of a 2nd gear grind:
1. Ensure the customer understands that a higher than normal shifting effort may be required when initially operating a vehicle in very cold ambient temperatures and is considered a normal vehicle characteristic.
2. Follow the diagnosis and service information contained in the applicable Service Manual when performing service work.
3. Confirm the usual in-car checks described in the Service Manual (i.e., fluid level, shifter and clutch adjustment, etc.).
4. If everything checks out o.k., remove the transmission assembly and replace the baulk ring and reverse driven gear with modified parts as well as replace the 2nd driven gear. Select parts from the chart included with this bulletin.
It is important to replace the 2nd driven gear when performing this repair because of the wear patterns these parts have developed with each other and it will prevent the transmission from being repaired a second time for the same condition. A check of the gear dogs and synchronizer sleeve splines for wear as well as a check of other related parts should also be performed at this time.
NOTE: '88 MY AND LATER MODELS USE THE SPRING GEAR TYPE 2ND DRIVEN GEAR, BUT '87 MY AND PRIOR MODELS USE THE CONVENTIONAL TYPE.
Please refer to this Parts Chart for applicability information.