Subaru Legacy (2005 year). Manual - part 650

 

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Subaru Legacy (2005 year). Manual - part 650

 

 

5MT-47

MANUAL TRANSMISSION AND DIFFERENTIAL

Transfer Drive Gear

10.Transfer Drive Gear

A: REMOVAL

1) Remove the manual transmission assembly
from vehicle. <Ref. to 5MT-30, REMOVAL, Manual
Transmission Assembly.>
2) Remove the back-up light switch and neutral po-
sition switch. <Ref. to 5MT-40, REMOVAL, Switch-
es and Harness.>
3) Remove the transfer case with extension case
assembly. <Ref. to 5MT-43, REMOVAL, Transfer
Case and Extension Case Assembly.>
4) Remove the extension case assembly.
5) Remove the transfer driven gear.
6) Remove the transfer drive gear.

B: INSTALLATION

1) Install the transfer drive gear.

Tightening torque:

26 N

⋅

m (2.7 kgf-m, 20 ft-lb)

2) Install the transfer driven gear.
3) Install the extension case assembly.
4) Install the transfer case and extension case as-
sembly. <Ref. to 5MT-43, INSTALLATION, Trans-
fer Case and Extension Case Assembly.>
5) Install the back-up light switch and neutral posi-
tion switch. <Ref. to 5MT-40, INSTALLATION,
Switches and Harness.>
6) Install the manual transmission assembly into
vehicle. <Ref. to 5MT-32, INSTALLATION, Manual
Transmission Assembly.>

C: DISASSEMBLY

1) Remove the snap ring.

2) Remove the ball bearing.

D: ASSEMBLY

1) Set the ST applying to the inner race of bearing
to install the drive shaft.
ST

398177700

INSTALLER

NOTE:
Do not apply pressure in excess of 10 kN (1 ton, 1.1
US ton, 1.0 Imp ton).

2) Install the snap ring on transfer drive shaft.
3) Inspect the clearance between snap ring and
ball bearing. <Ref. to 5MT-48, INSPECTION,
Transfer Drive Gear.>

MT-00133

MT-00133

MT-00135

MT-00136

MT-00137

ST

5MT-48

MANUAL TRANSMISSION AND DIFFERENTIAL

Transfer Drive Gear

E: INSPECTION

1) Bearings
Replace the bearing in following cases:
• In case of broken or rusty bearings
• In case of worn or damaged bearings
• When the bearings fail to turn smoothly or emit
noise in rotation after gear oil lubrication.
2) Drive gear
Replace the drive gear when their tooth surface
and shaft are excessively broken or damaged.
3) Measure the clearance between snap ring and
inner race of ball bearing with a thickness gauge.

Clearance:

0.01 — 0.15 mm (0.0004 — 0.0059 in)

If the measurement is not within specification, se-
lect a suitable snap ring and replace it.

Snap ring (Outer-30)

Part Number

Thickness mm (in)

805030041

1.53 (0.0602)

805030042

1.65 (0.0650)

805030043

1.77 (0.0697)

MT-00138

5MT-49

MANUAL TRANSMISSION AND DIFFERENTIAL

Transfer Driven Gear

11.Transfer Driven Gear

A: REMOVAL

1) Remove the manual transmission assembly
from vehicle. <Ref. to 5MT-30, REMOVAL, Manual
Transmission Assembly.>
2) Remove the back-up light switch and neutral po-
sition switch. <Ref. to 5MT-40, REMOVAL, Switch-
es and Harness.>
3) Remove the transfer case with extension case
assembly. <Ref. to 5MT-43, REMOVAL, Transfer
Case and Extension Case Assembly.>
4) Remove the extension case assembly.
5) Remove the transfer driven gear.

6) Remove the bearing outer races from the exten-
sion case and transfer case.

B: INSTALLATION

1) Install the bearing outer races to the extension
case and transfer case.

2) Install the transfer driven gear.

3) Install the transfer case and extension case as-
sembly. <Ref. to 5MT-43, INSTALLATION, Trans-
fer Case and Extension Case Assembly.>
4) Install the back-up light switch and neutral posi-
tion switch. <Ref. to 5MT-40, INSTALLATION,
Switches and Harness.>
5) Install the manual transmission assembly into
vehicle. <Ref. to 5MT-32, INSTALLATION, Manual
Transmission Assembly.>

(A) Bearing outer race (Transfer case side)

(B) Bearing outer race (Extension case side)

MT-00118

MT-00140

(B)

(A)

(A) Bearing outer race

(B) Bearing outer race

(C) Transfer case

(D) Extension case

MT-00141

(C)

(A)

(D)

(B)

MT-00118

5MT-50

MANUAL TRANSMISSION AND DIFFERENTIAL

Transfer Driven Gear

C: DISASSEMBLY

1) Using the ST, remove the roller bearing (exten-
sion case side).
ST

498077000

REMOVER

2) Using the ST1 and ST2, remove the roller bear-
ing (transfer case side).
ST1

498077000

REMOVER

ST2

899864100

REMOVER

D: ASSEMBLY

1) Using the ST, install the roller bearing (extension
case side).
ST1

398177700

INSTALLER

ST2

899864100

REMOVER

NOTE:
Do not apply pressure in excess of 10 kN (1 ton, 1.1
US ton, 1.0 Imp ton).

2) Using the ST, install the roller bearing (transfer
case side).
ST

499757002

INSTALLER

NOTE:
Do not apply pressure in excess of 10 kN (1 ton, 1.1
US ton, 1.0 Imp ton).

E: INSPECTION

1) Bearings
Replace the bearing in following cases:
• In case of broken or rusty bearings
• In case of worn or damaged bearings
• When the bearings fail to turn smoothly or emit
noise in rotation after gear oil lubrication.
2) Driven gear
Replace the driven gear when their tooth surface
and shaft are excessively broken or damaged.

(A) Roller bearing

(A) Roller bearing

(A) Roller bearing

MT-00143

(A)

ST

MT-00144

(A)

ST1

ST2

MT-00145

(A)

ST1

ST2

(A) Roller bearing

(A)

MT-00146

ST

 

 

 

 

 

 

 

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