Subaru Legacy (2005 year). Manual - part 652

5MT-55

MANUAL TRANSMISSION AND DIFFERENTIAL

Transmission Case

14.Transmission Case

A: REMOVAL

1. SINGLE-RANGE MODEL

1) Remove the manual transmission assembly
from vehicle. <Ref. to 5MT-30, REMOVAL, Manual
Transmission Assembly.>
2) Remove the clutch release lever. <Ref. to CL-
23, REMOVAL, Release Bearing and Lever.>
3) Remove the transfer case with extension case
assembly. <Ref. to 5MT-43, REMOVAL, Transfer
Case and Extension Case Assembly.>
4) Remove the bearing mounting bolts.

5) Remove the main shaft rear plate.

6) Separate the transmission case into the right
and left cases by loosening coupling bolts and nuts.

7) Remove the drive pinion shaft assembly from
the left side of transmission case.

NOTE:
Use a hammer handle, etc. to remove if too tight.

8) Remove the main shaft assembly for single-
range.
9) Remove the differential assembly.

NOTE:
• Be careful not to confuse right and left roller
bearing outer races.
• Be careful not to damage the oil seal of retainer.

2. DUAL-RANGE MODEL

(A) Main shaft rear plate

MT-00158

MT-00159

(A)

MT-00160

(A) Main shaft ASSY for single-range

(B) Drive pinion shaft ASSY

MT-00161

( A )

( B )

MT-00162

5MT-56

MANUAL TRANSMISSION AND DIFFERENTIAL

Transmission Case

4) Remove the input shaft holder.

5) Remove the high-low switch. <Ref. to 5MT-40,
REMOVAL, Switches and Harness.>
6) Using the ST, drive out the straight pin, and re-
move the high-low shifter lever.
ST

398791700

STRAIGHT PIN REMOVER 2

NOTE:
When driving out the straight pin, remove it in the
direction that it does not hit against transmission
case.

7) Remove the main shaft rear plate.

8) Separate the transmission case into right and
left cases by loosening the seventeen coupling
bolts and nuts.

9) Remove the drive pinion shaft assembly from
transmission case LH.

NOTE:
Use a hammer handle, etc. to remove if too tight.

10) Raise the main shaft assembly slightly, and re-
move the high-low shifter fork together with high-
low shifter shaft and washer.

NOTE:
Be careful not to drop the two high-low shifter piec-
es.

(A) Input shaft holder

(B) Input shaft

(A) Straight pin

(B) High-low shifter lever

(A) Main shaft rear plate

MT-00163

(A)

(B)

MT-00164

(A)

(B)

MT-00165

(A)

(A) Main shaft ASSY for dual-range

(B) Drive pinion shaft ASSY

(A) High-low shifter fork

(B) Input shaft ASSY

MT-00160

MT-00161

( A )

( B )

MT-00169

( B )

( A )

5MT-57

MANUAL TRANSMISSION AND DIFFERENTIAL

Transmission Case

11) Remove the main shaft assembly and input
shaft assembly.

NOTE:
Be careful not to drop the input shaft and main shaft
as they are separable.

12) Remove the differential assembly.

NOTE:
• Be careful not to confuse the right and left roller
bearing outer races.
• Be careful not to damage the retainer oil seal.

B: INSTALLATION

1. SINGLE-RANGE MODEL

1) Wipe off grease, oil and dust on the mating sur-
faces of transmission cases with white gasoline.
2) Install the front differential assembly.
3) Install the main shaft assembly for single-range.
Install the transmission case knock pin into needle
bearing knock pin hole.
4) Install the drive pinion shaft assembly.
Install the transmission case knock pin into roller
bearing knock pin hole.
5) Apply liquid gasket, and then put the case RH
and LH together.

Liquid gasket:

THREE BOND 1215 (Part No. 004403007) or
equivalent

6) Tighten seventeen bolts with bracket, clip, etc.
as shown in the figure.

NOTE:
• Insert the bolts from the bottom and tighten nuts
on the top.
• Put the cases together being careful that the
drive pinion shim and input shaft holder shim are
not caught up in between.

Tightening torque:

8 mm bolt

25 N

⋅

m (2.5 kgf-m, 18.4 ft-lb)

★

10 mm bolt

39 N

⋅

m (4.0 kgf-m, 28.9 ft-lb)

7) Tighten the ball bearing mounting bolts.

Tightening torque:

30 N

⋅

m (3.1 kgf-m, 22.4 ft-lb)

8) Adjust backlash of hypoid gear and preload of
roller bearing.

NOTE:
Set the ST on drive pinion assembly.
ST

498427100

STOPPER

9) Place the transmission with the left side of case
facing downward, and put ST1 on bearing cup.

(A) Main shaft ASSY

(B) Input shaft ASSY

MT-00170

(A)

(B)

MT-00162

(9)

(7)

(5)

(1)

(2)

(16)

(17)

(11)

(3)

(4)

(12)

(8)

(6)

(10)

(14)

(15)

(13)

MT-00172

MT-00158

MT-00174

5MT-58

MANUAL TRANSMISSION AND DIFFERENTIAL

Transmission Case

10) Screw the retainer assembly into left case from
the bottom with ST2. Fit the ST3 on transmission
main shaft. Shift the gear into 4th or 5th and turn
the shaft several times. Screw in the retainer while
turning ST3 until a slight resistance is felt on ST2.
This is the contact point of hypoid gear and drive
pinion shaft. Repeat the above sequence several
times to ensure the contact point.
ST1

399780104

WEIGHT

ST2

499787000

WRENCH ASSY

ST3

499927100

HANDLE

11) Remove the weight, and screw in the retainer
without O-ring on the upper side and stop at the
point where slight resistance is felt.

NOTE:
At this condition, the backlash between hypoid gear
and drive pinion shaft is zero.
ST

499787000

WRENCH ASSY

12) Loosen the retainer on the lower side by 3
notches, and turn the retainer on the upper side by
the same amount in order to obtain the backlash.
13) Turn in the retainer on the upper side addition-
ally by 1 notch in order to apply preload on taper
roller bearing.
14) Install temporarily both the upper and lower
lock plates and mark both holder and lock plate for
later readjustment.

NOTE:
Install the lock plate upside down if it is hard to in-
stall.
15) Turn the transmission main shaft several times
while tapping around retainer lightly with plastic
hammer.

16) Inspect and adjust the backlash and tooth con-
tact of hypoid gear. <Ref. to 5MT-87, INSPEC-
TION, Front Differential Assembly.>
17) After checking the tooth contact of hypoid
gears, remove the lock plate. Then loosen the re-
tainer until the O-ring groove appears. Fit O-ring
into the groove and tighten the retainer to the orig-
inal position.
Install the lock plate.

NOTE:
• Record how many times the retainer is turned
while loosening.
• Carry out this job on both upper and lower retain-
ers.

Tightening torque:

T: 25 N

⋅

m (2.5 kgf-m, 18.4 ft-lb)

18) Selecting of main shaft rear plate: <Ref. to
5MT-65, ADJUSTMENT, Main Shaft Assembly for
Single-Range.>
19) Install the clutch release lever and bearing.
<Ref. to CL-23, INSTALLATION, Release Bearing
and Lever.>
20) Install the transfer case with extension case as-
sembly. <Ref. to 5MT-43, INSTALLATION, Trans-
fer Case and Extension Case Assembly.>
21) Install the manual transmission assembly into
vehicle. <Ref. to 5MT-32, INSTALLATION, Manual
Transmission Assembly.>

2. DUAL-RANGE MODEL

1) Wipe off grease, oil and dust on the mating sur-
faces of transmission cases with white gasoline.
2) Install the front differential assembly.
3) Install the main shaft assembly for dual-range
and the input shaft assembly.
Connect the main shaft assembly for dual-range
with the input shaft assembly, and install the trans-
mission case knock pin into needle bearing knock
pin hole.
4) Install the drive pinion shaft assembly.
Install the transmission case knock pin into roller
bearing knock pin hole.
5) Apply liquid gasket, and then put the case right
side and left side together.

MT-00175

ST3

ST2

ST1

MT-00176

MT-00177

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