Content .. 653 654 655 656 ..

Subaru Legacy (2005 year). Manual - part 655

5MT-67

MANUAL TRANSMISSION AND DIFFERENTIAL

Main Shaft Assembly for Dual-Range

ST1

499757002

INSTALLER

ST2

498077400

SYNCHRO CONE REMOV-
ER

6) Using the ST1 and ST2, remove rest of the
parts.

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.
ST1

899864100

REMOVER

ST2

899714110

REMOVER

7) Remove the snap ring from main shaft.
ST

899474100

EXPANDER

8) Remove rest of the parts.

(A) Ball bearing

(B) Synchro cone

(A) Press

MT-00189

(B)

(A)

(C)

ST2

ST1

MT-00190

(A)

ST2

ST1

(A) Snap ring

(A) Sleeve & hub ASSY

(B) High-low baulk ring

(D) Low input gear

(E) Needle bearing

(F) Input low gear spacer

(G) Ball

MT-00215

( A )

S T

MT-00216

(B)

(A)

(E)

(F)

(G)

(D)

(C)

(B)

5MT-68

MANUAL TRANSMISSION AND DIFFERENTIAL

Main Shaft Assembly for Dual-Range

D: ASSEMBLY

1) Assemble with aligning the matching mark if the
sleeve & hub assembly have been disassembled.

NOTE:
Position the 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.
ST1

899714110

REMOVER

ST2

499877000

RACE 4-5 INSTALLER

(A) High-low coupling sleeve

(B) Shifting insert

(D) High-low synchronizer hub

(E) Sleeve

(F) Insert key

(G) 3rd-4th synchronizer hub

(H) Sleeve

(I) Insert key

(J) 5th-Rev synchronizer hub

(K) High side

(L) Low side

(M) 3rd side

(N) 4th side

(O) 5th side

(P) Rev side

MT-00217

( B ) ( A )

( D )

( G )

( F ) ( E )

( I )

( H )

( J )

( K )

( L )

( M ) ( N )

( O ) ( P )

( C )

(A) 3rd needle bearing

(B) 3rd drive gear

(D) Synchro cone

(E) Outer baulk ring

(F) Sleeve & hub ASSY

(A) 4th needle bearing race

MT-01318

(A)

(B)

(C)

(D)

(E)

(F)

MT-00201

(A)

ST1

ST2

5MT-69

MANUAL TRANSMISSION AND DIFFERENTIAL

Main Shaft Assembly for Dual-Range

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

NOTE:
Face the thrust washer in correct direction.

5) Press-fit 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).
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 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 a new ball bearing.
• After press-fitting, make sure the synchro cone
rotates freely.
ST

499757002

INSTALLER

(A) Groove

(B) 4th gear side

MT-00193

(A)

(B)

MT-00194

ST1

ST2

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

(A) Baulk ring

(B) Synchro cone

MT-00195

(A)

MT-00196

(B)

(A)

(C)

5MT-70

MANUAL TRANSMISSION AND DIFFERENTIAL

Main Shaft Assembly for Dual-Range

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

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

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

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

NOTE:
Stake the caulking of 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)

12) Install the needle bearing on main shaft.
13) Install rest of the parts to the front section of
transmission main shaft.

NOTE:
• Be careful not to damage the graded section of
transmission main shaft when installing the needle
bearing.
• Face the grooved side toward input gear.
• Align the high-low baulk ring’s groove with shift-
ing insert.

14) Install a new snap ring to the rod section of
transmission main shaft using ST1 and ST2.

NOTE:
Select a suitable outer snap ring so that axial clear-
ance between snap ring and hub is held within
0.060 to 0.100 mm (0.0024 to 0.0039 in).
ST1

499757002

INSTALLER

ST2

499757001

SNAP RING GUIDE

(A) Synchro cone stopper

(B) Snap ring

(A) Needle bearing

(B) 5th drive gear

(D) 5th-Rev sleeve & hub ASSY

(E) Lock washer

(F) Lock nuts

MT-00188

(A)

(B)

MT-00198

(A)

(B)

(C)

(D)

(E)

(F)

(A) Ball

(B) Input low gear spacer

(D) Input low gear

(E) Friction damper

(F) High-low baulk ring

(G) Sleeve & hub ASSY

Snap ring

Part No.

Thickness mm (in)

805025051

2.42 (0.0953)

805025052

2.47 (0.0972)

805025053

2.52 (0.0992)

805025054

2.57 (0.1012)

805025055

2.62 (0.1031)

805025056

2.67 (0.1051)

805025057

2.72 (0.1071)

805025058

2.37 (0.0933)

MT-00225

(F)

(G)

(C)

(B)

(A)

(D)

(E)

(F)

Content .. 653 654 655 656 ..