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Subaru Legacy (2005 year). Manual - part 646

5MT-31

MANUAL TRANSMISSION AND DIFFERENTIAL

Manual Transmission Assembly

12) Set the ST.
ST

41099AA000

ENGINE SUPPORT ASSY

13) Remove the bolts which hold upper side of
transmission to engine.

14) Lift-up the vehicle.
15) Remove the front and center exhaust pipes.
<Ref. to EX(H4SO 2.0)-6, REMOVAL, Front Ex-
haust Pipe.>
16) Remove the rear exhaust pipe and muffler.
<Ref. to EX(H4SO 2.0)-10, REMOVAL, Rear Ex-
haust Pipe.> <Ref. to EX(H4SO 2.0)-12, REMOV-
AL, Muffler.>

CAUTION:
When removing the exhaust pipes, be careful
each exhaust pipe does not drop out.
17) Remove the heat shield cover. (if equipped)
18) Remove the hanger bracket from the right side
of transmission.

19) Remove the propeller shaft. <Ref. to DS-10,
REMOVAL, Propeller Shaft.>

20) Remove the gear shift rod and the stay from
transmission.

(1) Disconnect the stay from transmission.
(2) Remove the rod from transmission.

21) Remove the stabilizer link from front arm.

22) Remove the ball joint of front arm from housing.

MT-00070

S T

MT-00073

MT-00074

(A) Stay

(B) Rod

(A) Front arm

(B) Ball joint

MT-00075

(A)

(B)

MT-00988

MT-00987

(A)

(C)

(B)

5MT-32

MANUAL TRANSMISSION AND DIFFERENTIAL

Manual Transmission Assembly

23) Using the pinch bar, remove the left and right
front drive shaft from transmission.

24) Remove the nuts which hold lower side of
transmission to engine.

25) Place the transmission jack under transmis-
sion.

CAUTION:
Always support transmission case with a trans-
mission jack.

26) Remove the transmission rear crossmember
from vehicle.

27) Remove the transmission.

NOTE:
Move the transmission jack toward rear until main
shaft is withdrawn from clutch disc.
28) Separate the transmission assembly from rear
cushion rubber.

B: INSTALLATION

1) Install the rear cushion rubber to transmission
assembly.

Tightening torque:

35 N

⋅

m (3.6 kgf-m, 26 ft-lb)

2) Install the transmission onto engine.

(1) Gradually raise the transmission with trans-
mission jack.
(2) Engage them at splines.

NOTE:
Be careful not to strike the main shaft against clutch
housing cover.
3) Install the transmission rear crossmember.

Tightening torque:

T1: 70 N

⋅

m (7.1 kgf-m, 51.6 ft-lb)

T2: 140 N

⋅

m (14.3 kgf-m, 103 ft-lb)

4) Take out the transmission jack.

(A) Pinch bar

MT-01017

(A)

MT-00077

MT-00078

MT-00079

MT-00081

T 2

T 1

5MT-33

MANUAL TRANSMISSION AND DIFFERENTIAL

Manual Transmission Assembly

5) Tighten the nuts which hold lower side of trans-
mission to engine.

Tightening torque:

50 N

⋅

m (5.1 kgf-m, 36.9 ft-lb)

6) Connect the transmission to engine.

(1) Install the starter.
<Ref. to SC(H4SO 2.0)-6, INSTALLATION,
Starter.>
(2) Tighten the bolts that hold upper side of
transmission to engine.

Tightening torque:

50 N

⋅

m (5.1 kgf-m, 36.9 ft-lb)

7) Remove the ST.

8) Install the pitching stopper.

Tightening torque:

T1: 50 N

⋅

m (5.1 kgf-m, 36.9 ft-lb)

T2: 58 N

⋅

m (5.9 kgf-m, 42.8 ft-lb)

9) Lift-up the vehicle.
10) Install the front drive shaft into transmission.
11) Replace the differential side retainer oil seal.
<Ref. to 5MT-39, REPLACEMENT, Differential
Side Retainer Oil Seal.>
ST

186755AA000 DIFFERENTIAL SIDE OIL

SEAL INSTALLER

NOTE:
Be sure to replace the differential side retainer oil
seal after the procedure of removing the front drive
shaft.

12) Install the front drive shaft into transmission.
ST

28399SA010

FRONT DRIVE SHAFT OIL
SEAL PROTECTOR

MT-00077

MT-00073

MT-00070

S T

MT-00085

MT-00103

AT-00110

5MT-34

MANUAL TRANSMISSION AND DIFFERENTIAL

Manual Transmission Assembly

13) Install the ball joint of front arm.

Tightening torque:

50 N

⋅

m (5.1 kgf-m, 36.9 ft-lb)

14) Install the stabilizer link into front arm.

Tightening torque:

45 N

⋅

m (4.6 kgf-m, 33.2 ft-lb)

15) Install the gear shift rod and the stay.

(1) Install the gear shift rod into transmission.

(2) Install the stay onto transmission.

16) Install the propeller shaft. <Ref. to DS-11, IN-
STALLATION, Propeller Shaft.>
17) Install the heat shield cover. (if equipped)

18) Install the hanger bracket on the right side of
transmission.

19) Install the front, center and rear exhaust pipe,
and muffler. <Ref. to EX(H4SO 2.0)-7, INSTALLA-
TION, Front Exhaust Pipe.> <Ref. to EX(H4SO
2.0)-10, INSTALLATION, Rear Exhaust Pipe.>
<Ref. to EX(H4SO 2.0)-12, INSTALLATION, Muf-
fler.>
20) Install the operating cylinder.

Tightening torque:

37 N

⋅

m (3.8 kgf-m, 27.5 ft-lb)

21) Install the drive select cable on transmission
side. (Dual-range model)

(A) Front arm

(B) Ball joint

(A) Stay

(B) Rod

MT-00987

(A)

(C)

(B)

MT-00988

MT-00089

(A)

(B)

(A) Snap pin

(B) Clevis pin

MT-00074

CL-00253

MT-00066

( A )

( B )

( C )

Content .. 644 645 646 647 ..