Repairing the gearbox output flange on a Subaru Impreza STI (both turbo and non-turbo models) requires some understanding of vehicle mechanics, but I’ll explain it in a simple way. Get instant access to the manual—click here for details……
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The output flange is where the driveshaft connects to the gearbox, and it can wear out or become damaged over time. Here’s a step-by-step guide to help you understand the process:
### Tools and Materials Needed:
1. **Basic Tools**: Socket set, wrenches, screwdrivers, pliers, and a torque wrench.
2. **Replacement Parts**: New output flange (if damaged), new seals, and possibly new bolts.
3. **Grease**: For lubrication.
4. **Safety Gear**: Gloves and goggles.
### Step-by-Step Guide:
1. **Safety First**:
– Park the car on a flat surface and turn off the engine.
– Engage the parking brake to prevent the car from rolling.
2. **Prepare the Vehicle**:
– If you can, lift the car using a jack and secure it with jack stands. This gives you more room to work under the vehicle.
3. **Remove the Driveshaft**:
– Locate the driveshaft, which runs from the rear of the gearbox to the rear wheels.
– Use your socket set to remove the bolts that connect the driveshaft to the output flange. make sure to keep these bolts in a safe place as you’ll need them later.
4. **Access the Output Flange**:
– After the driveshaft is removed, you should see the output flange attached to the gearbox.
– Check for any visible damage or wear on the flange and surrounding area.
5. **Remove the Old Flange**:
– depending on the type of flange, you may need to remove bolts or a retaining nut to take it off. Use your socket or wrench to do this.
– Gently pull the flange off the gearbox. If it’s stuck, you may need to tap it lightly with a rubber mallet.
6. **Inspect and Clean**:
– Once removed, inspect the area for any debris or old seal material. Clean the surface where the new flange will sit.
7. **Install the New Flange**:
– Take the new output flange and apply a bit of grease to the seal or mating surface to ensure a good fit and prevent leaks.
– Position the new flange onto the gearbox and secure it with the bolts or retaining nut you removed earlier. make sure it’s tight but don’t over-tighten, as this can cause damage.
8. **Reattach the Driveshaft**:
– Align the driveshaft with the new flange
and secure it using the bolts you saved earlier. Again, ensure they are tight enough to prevent movement but not overly tight.
9. **Final Checks**:
– Double-check all connections to ensure everything is secure. Look for any tools you may have left behind.
– Lower the vehicle if it was raised.
10. **Test Drive**:
– Start the car and take it for a short drive to ensure everything is working properly. Listen for any unusual noises that could indicate an issue.
### Conclusion:
Repairing the gearbox output flange can be a manageable task with the right tools and a bit of patience. If at any point you Feel uncertain, don’t hesitate to consult a professional mechanic. Taking care of your vehicle’s components helps ensure its longevity and performance!
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