#O2j 5th gear replacement install
#O2j 5th gear replacement full

With the gears back in hand, the reassembly process can start.ДЄ quick note on the gear sets. Nearly reassembled driven gears (pinion side).RA 3rd Gear has ~40% thicker teeth than the 03 WRX.

#O2j 5th gear replacement full

The hub/synchro design changed in 2004 and didnвЂ™t allow full engagement of the selector.

#O2j 5th gear replacement install

Unfortunately, I didnвЂ™t order the install kit at the same time so after I got the transmission reassembled, 3rd gear would pop out of gear with any load put on it. If you have any seals you need to replace, this would be a good time to do that as well.ДЄfter the RA gears arrived, a friend picked them up to swap out 3rd and 4th gear. Broken 3rd GearДЄt this point, I would clean up all of the mating surfaces, and clean out the case if you had a gear failure as well. Once the cases are split, the gears can be pull from the case. One is below the speedo gear and the other is in the bellhousing. There are a couple of pins that are holding the cases together. Then remove the remaining bolts that have corresponding nut on the opposite side of the case. Now we need to lay the transmission down on its side speedo sensor exposed. The 5th gear spacer is missing in this photo. Four bolts are holding the driven gears onto the case. There is a spacer for 5th gear that is more or less just resting in place. The center housing is more of the same, only the selector shaft comes out as well. Transfer gear attached to the tailshaft housing. Take note of the washer on the center differential. Once the tailshaft housing is off, you can remove the transfer gear and output shaft along with the center differential, which is pretty heavy and covered in gear oil. I sacrificed a couple of plastic trim removal tools as wedges throughout this process as well. Mine was basically seized in place and would not release the tailshaft. While you still have the punch handy, I would hit both of the alignment pins on the tailshaft until they move. Next, I would go ahead and remove the wiring harness and any associated brackets. It was almost impossible for it to pivot and I needed to use a lot of force to pry them apart. Whoever installed this wedged some shifter bushings from a different year into this joint. I planned on cleaning my case so I removed it. I am not certain if the shifter linkage bracket needs to be removed as well. The First thing is to remove the pin that holds the shifter linkage u-joint to the selector shaft with a hammer and punch. Most of the little brackets have an obvious home, some others are less so. I would also recommend taking a photo of your trans before taking it apart. I found the best way to work on the transmission is to stand it up on two blocks of wood to keep the input shaft off of the ground.