Subaru Legacy (2005 year). Manual - part 654

 

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Subaru Legacy (2005 year). Manual - part 654

 

 

5MT-63

MANUAL TRANSMISSION AND DIFFERENTIAL

Main Shaft Assembly for Single-Range

D: ASSEMBLY

1) When the sleeve & hub assemblies have been
disassembled, reassemble with aligning each en-
gaging point.

NOTE:
Position open ends of spring 120

° apart.

2) Install the 3rd drive gear, outer baulk ring, syn-
chro cone, inner baulk ring, sleeve & hub assembly
for 3rd needle bearing, on the transmission main
shaft.

NOTE:
Align the groove in baulk ring with shifting insert.
3) Install the 4th needle bearing race onto trans-
mission main shaft using ST1, ST2 and a press.

NOTE:
Do not apply pressure in excess of 10 kN (1 ton, 1.1
US ton, 1.0 Imp ton).
ST1

899714110

REMOVER

ST2

499877000

RACE 4-5 INSTALLER

4) Install the baulk ring, needle bearing, 4th drive
gear and 4th gear thrust washer to transmission
main shaft.

NOTE:
Align the baulk ring and gear & hub assembly with
key groove.

5) Press the ball bearing into the rear section of
transmission main shaft using ST1, ST2 and a
press.

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

(A) 3rd-4th hub ASSY

(B) 3rd gear side

(C) 5th-Rev hub ASSY

(D) 5th gear side

(A) 3rd needle bearing

(B) 3rd drive gear

(C) Inner baulk ring

(D) Synchro cone

(E) Outer baulk ring

(F) Sleeve & hub ASSY

MT-00191

(D)

(C)

(B)

(A)

MT-01318

(A)

(B)

(C)

(D)

(E)

(F)

(A) 4th needle bearing race

(A) Groove

(B) 4th gear side

MT-00192

(A)

ST1

ST2

MT-00193

(A)

(B)

5MT-64

MANUAL TRANSMISSION AND DIFFERENTIAL

Main Shaft Assembly for Single-Range

ST1

899714110

REMOVER

ST2

499877000

RACE 4-5 INSTALLER

6) Using the ST1 and ST2, install the 5th gear
thrust washer and 5th needle bearing race onto the
rear section of transmission main shaft.

NOTE:
• Do not apply pressure in excess of 10 kN (1 ton,
1.1 US ton, 1.0 Imp ton).
• Face the thrust washer in the correct direction.
ST1

899714110

REMOVER

ST2

499877000

RACE 4-5 INSTALLER

7) Install the bearing onto synchro cone.
8) Install the baulk ring and synchro cone onto 5th-
Rev sleeve & hub assembly using ST and a press.

NOTE:
• Do not apply pressure in excess of 10 kN (1 ton,
1.1 US ton, 1.0 Imp ton).
• Use new ball bearing.
• Make sure the synchro cone rotates smoothly af-
ter press-fitting.

ST

499757002

INSTALLER

9) Install the synchro cone stopper and snap ring to
5th-Rev sleeve & hub assembly.

10) Install the rest of parts to the rear section of
transmission main shaft.

NOTE:
Align the groove in baulk ring with shifting insert.

(A) Face this surface to 5th gear side.

MT-00194

ST1

ST2

MT-00195

(A)

(A) Baulk ring

(B) Synchro cone

(C) Ball bearing

(A) Synchro cone stopper

(B) Snap ring

(A) Needle bearing

(B) 5th drive gear

(C) Baulk ring

(D) 5th-Rev sleeve & hub ASSY

(E) Lock washer

(F) Lock nuts

MT-00196

(B)

(A)

(C)

ST

MT-00188

(A)

(B)

MT-00198

(A)

(B)

(C)

(D)

(E)

(F)

5MT-65

MANUAL TRANSMISSION AND DIFFERENTIAL

Main Shaft Assembly for Single-Range

11) Tighten the lock nuts to the specified torque us-
ing ST1 and ST2.

NOTE:
Caulk the lock nuts in two places after tightening.
ST1

499987003

SOCKET WRENCH (35)

ST2

498937000

TRANSMISSION HOLDER

Tightening torque:

120 N

⋅

m (12.2 kgf-m, 88.5 ft-lb)

E: INSPECTION

Disassembled parts should be washed with un-
leaded gasoline first and then inspected carefully.
1) Bearings
Replace the bearing in following cases:
• When the bearing balls, outer races and inner
races are broken or rusty.
• When the bearing is worn.
• When the bearings fail to turn smoothly or emit
noise in rotation after gear oil lubrication.
• When bearings have other defects.
2) Bushing (each gear)
Replace the bushings in following cases:
• When the sliding surface is damaged or abnor-
mally worn.
• When the inner wall is abnormally worn.
3) Gears
• Replace gears with new ones if their tooth sur-
faces are broken, damaged or excessively worn.
• Correct or replace if the cone that contacts the
baulk ring is rough or damaged.
• Correct or replace if the inner surface or end face
is damaged.
4) Baulk ring
Replace the ring in following cases:
• When the inner surface and end face is dam-
aged.
• When the ring inner surface is abnormally or par-
tially worn.
• When contact surfaces of the synchronizer ring
insert have cracks or abnormally worn.
5) Shifting insert key
Replace the insert key if deformed, excessively
worn or defective in any way.

6) Oil seal
Replace the oil seal if the lip is deformed, hard-
ened, worn or defective in any way.
7) O-ring
Replace the O-ring if the sealing face is deformed,
hardened, damaged, worn or defective in any way.
8) Gearshift mechanism
Repair or replace the gearshift mechanism if ex-
cessively worn, bent or defective in any way.

F: ADJUSTMENT

Selection of main shaft rear plate:
Using the ST, measure the amount (A) of ball bear-
ing protrusion from transmission main case sur-
face, and select a suitable plate in the following
table.

NOTE:
Before measuring, tap the end of main shaft with a
plastic hammer lightly in order to make the clear-
ance zero between the main case surface and
moving flange of bearing.
ST

498147001

DEPTH GAUGE

(A) Insert key

MT-00989

(A)

Dimension (A)

mm (in)

Part Number

Marking

4.00 — 4.13

(0.1575 — 

0.1626)

32294AA041

1

3.87 — 3.99

(0.1524 — 

0.1571)

32294AA051

2

MT-00209

(A)

5MT-66

MANUAL TRANSMISSION AND DIFFERENTIAL

Main Shaft Assembly for Dual-Range

16.Main Shaft Assembly for 

Dual-Range

A: REMOVAL

1) Remove the manual transmission assembly
from vehicle. <Ref. to 5MT-30, REMOVAL, Manual
Transmission Assembly.>
2) Remove the transfer case with extension case
assembly. <Ref. to 5MT-43, REMOVAL, Transfer
Case and Extension Case Assembly.>
3) Remove the transmission case. <Ref. to 5MT-
55, REMOVAL, Transmission Case.>
4) Remove the drive pinion shaft assembly. <Ref.
to 5MT-76, REMOVAL, Drive Pinion Shaft Assem-
bly.>
5) Remove the main shaft assembly and input shaft
assembly.

B: INSTALLATION

1) Install the needle bearing onto the front of trans-
mission main shaft assembly.
2) Connect the main shaft assembly and input shaft
assembly.
3) Install the transmission case knock pin into nee-
dle bearing outer race knock pin hole.
4) Install the drive pinion assembly. <Ref. to 5MT-
76, INSTALLATION, Drive Pinion Shaft Assem-
bly.>
5) Install the transmission case. <Ref. to 5MT-57,
INSTALLATION, Transmission Case.>
6) Install the transfer case with extension case as-
sembly. <Ref. to 5MT-43, INSTALLATION, Trans-
fer Case and Extension Case Assembly.>
7) Install the manual transmission assembly to ve-
hicle. <Ref. to 5MT-32, INSTALLATION, Manual
Transmission Assembly.>

C: DISASSEMBLY

1) Put a vinyl tape around the main shaft splines to
protect oil seal from damage. Then pull out the oil
seal and needle bearing by hand.
2) Remove the lock nut from transmission main
shaft assembly.

NOTE:
Straighten the caulking before taking off lock nut.
ST1

498937000

TRANSMISSION HOLDER

ST2

499987003

SOCKET WRENCH (35)

3) Remove the 5th-Rev sleeve & hub assembly,
baulk ring, 5th drive gear and needle bearing.

4) Remove the snap ring and synchro cone stopper
from 5th-Rev sleeve & hub assembly.

5) Using the ST1, ST2 and a press, remove the ball
bearing, synchro cone and baulk ring (Rev).

NOTE:
• When replacing the sleeve and hub with new
ones, replace them as a set.
• Do not disassemble the sleeve and hub, be-
cause the aligning position is specified.
• If it is necessary to disassemble, mark the en-
gaging points on the splines beforehand.
• Do not reuse the ball bearing.

(A) 5th-Rev sleeve & hub ASSY

(B) Baulk ring

(C) 5th drive gear

(A) Synchro cone stopper

(B) Snap ring

MT-00186

ST2

ST1

MT-00187

( A )

( B )

( C )

MT-00188

(A)

(B)

 

 

 

 

 

 

 

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