Subaru Legacy (2005 year). Manual - part 658

5MT-79

MANUAL TRANSMISSION AND DIFFERENTIAL

Drive Pinion Shaft Assembly

NOTE:
Use the new gear and hub assembly, when replac-
ing the gear or hub.

2) Install the washer to 1st driven gear. (EC, EK
and KA model)
3) Install the washer, snap ring and sub gear onto
1st driven gear. (Except for EC, EK and KA model)
4) Install the 1st driven gear, 1st baulk ring, gear
and hub assembly onto driven shaft.

NOTE:
• Take care to install the gear and hub assembly in
proper direction.
• Align the baulk ring and gear and hub assembly
with key groove.
5) Install the 2nd driven gear bushing onto driven
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).
• Attach a cloth to the end of driven shaft to pre-
vent damage.

• When press-fitting, align the oil holes of shaft and
bushing.
ST1

499277200

INSTALLER

ST2

499587000

INSTALLER

6) Install the 2nd driven gear, inner baulk ring, syn-
chro cone and outer baulk ring, and insert onto driv-
en shaft.

7) After installing the key on driven shaft, install the
3rd-4th driven gear using ST and press.

NOTE:
• Do not apply pressure in excess of 10 kN (1 ton,
1.1 US ton, 1.0 Imp ton).
• Align the groove in baulk ring with insert.
ST

499277200

INSTALLER

8) Install a set of roller bearings onto the driven
shaft using ST and press.

(A) 1st gear side

(B) 2nd gear side

(C) Flush surface

(D) Stepped surface

(A) 1st driven gear

(B) 1st baulk ring

(C) Gear and hub ASSY

(D) 2nd gear bushing

MT-00252

( B )

( A )

( C )

( D )

MT-00991

(A)

(D)

(C)

(B)

(A) 2nd driven gear

(B) Inner baulk ring

(C) Synchro cone

(D) Outer baulk ring

MT-00253

ST1

ST2

MT-00997

(A)

(B)

(D)

(C)

MT-00255

ST

5MT-80

MANUAL TRANSMISSION AND DIFFERENTIAL

Drive Pinion Shaft Assembly

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

499277200

INSTALLER

9) Position the woodruff key in groove on the rear
of driven shaft. Install the 5th driven gear onto driv-
en shaft using ST and press.

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

499277200

INSTALLER

10) Install the lock washer. Install the lock nut and
tighten to the specified torque using ST.
ST

499987300

SOCKET WRENCH (50)

Tightening torque:

260 N

⋅

m (26.5 kgf-m, 191.7 ft-lb)

NOTE:
• Stake the caulking of lock nut at two points.

• Using a spring balancer, check that starting
torque of roller bearing is 0.1 to 1.5 N (0.01 to 0.15
kgf, 0.02 to 0.33 lbf).

11) Install the roller bearing onto drive pinion.

NOTE:
When installing roller bearing, note its directions
(front and rear) because the knock pin hole in outer
race is offset.

12) Install the washer 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

499277100

BUSHING 1-2 INSTALLER

ST2

499277200

INSTALLER

MT-00256

ST

MT-00257

ST

MT-00258

ST

(A) Roller bearing

(B) Knock pin hole

(A) Washer

MT-00259

MT-00260

(A)

(B)

MT-00261

(A)

ST1

ST2

5MT-81

MANUAL TRANSMISSION AND DIFFERENTIAL

Drive Pinion Shaft Assembly

13) Install the thrust bearing and needle bearing.
Install the driven shaft assembly.

14) Install the drive pinion collar, needle bearing,
adjusting washer No. 2, thrust bearing, adjusting
washer No. 1 and differential bevel gear sleeve in
this order.

NOTE:
Be careful because the spacer must be installed in
proper direction.

15) Adjust the thrust bearing preload. <Ref. to
5MT-82, THRUST BEARING PRELOAD, AD-
JUSTMENT, Drive Pinion Shaft Assembly.>

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.

• The ball bearing on the rear side of the drive pin-
ion shaft should be checked for smooth rotation be-
fore the drive pinion assembly is disassembled. In
this case, because a preload is working on the
bearing, its rotation feels like it is slightly dragging
unlike other bearings.

• 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 are dam-
aged.
• When the ring inner surface is abnormally or par-
tially worn.
• If the gap between the end faces of ring and the
gear splined part is excessively small, check the
clearance (A) while pressing the ring against the
cone.

(A) Driven shaft

(B) Drive shaft

(C) Drive pinion collar

(D) Needle bearing (25 

× 30 × 20)

(E) Washer No. 2 (25 

× 36 × 4)

(F) Thrust bearing (25 

× 37.5 × 3)

(G) Washer No. 1 (25 

× 36 × t)

(H) Differential bevel gear sleeve

MT-00262

MT-00263

(A) (B)

(C) (D) (E) (F) (G)

(H)

(A) Drive pinion shaft

(B) Ball bearing

MT-00264

(A)

(B)

5MT-82

MANUAL TRANSMISSION AND DIFFERENTIAL

Drive Pinion Shaft Assembly

Clearance (A):

0.5 — 1.0 mm (0.020 — 0.040 in)

• When the contact surface of synchronizer ring in-
sert is scratched 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.

F: ADJUSTMENT

1. THRUST BEARING PRELOAD

1) Select a suitable adjusting washer No. 1 to ad-
just dimension (H) to zero through visual check.
Position the washer (18.3 

× 30 × 4) and lock washer

(18 

× 30 × 2) and install the lock nut (18 × 13.5).

2) Using the ST1, ST2 and ST3, tighten new lock
nut to the specified torque.
ST1

899884100

HOLDER

ST2

498427100

STOPPER

ST3

899988608

SOCKET WRENCH (27)

Tightening torque:

120 N

⋅

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

3) After removing the ST2, measure the starting
torque using torque driver.
ST1

899884100

HOLDER

ST3

899988608

SOCKET WRENCH (27)

(A) Insert key

MT-00265

(A)

MT-00989

(A)

MT-00267

(H)

MT-00268

ST1

ST2

ST3