Subaru Legacy (2005 year). Manual - part 659

5MT-83

MANUAL TRANSMISSION AND DIFFERENTIAL

Drive Pinion Shaft Assembly

Starting torque:

0.3 — 0.8 N

⋅

m (0.03 — 0.08 kgf-m, 0.2 — 0.6 ft-

lb)

4) If the starting torque is not within specified limit,
select new adjusting washer No. 1 and recheck
starting torque.

5) When the specified starting torque cannot be ob-
tained by the adjusting washer No. 1, select the ad-
justing washer No. 2 from following table. Repeat
steps 1) through 4) to adjust starting torque.

6) Recheck that the starting torque is within speci-
fied range, then clinch the lock nut at four positions.

(A) Adjusting washer No. 1

(B) Adjusting washer No. 2

Adjusting washer No. 1

Part Number

Thickness mm (in)

803025051

3.925 (0.1545)

803025052

3.950 (0.1555)

803025053

3.975 (0.1565)

803025054

4.000 (0.1575)

803025055

4.025 (0.1585)

803025056

4.050 (0.1594)

803025057

4.075 (0.1604)

MT-00269

ST1

ST3

MT-00270

( A )

( B )

(A) Adjusting washer No. 1

(B) Adjusting washer No. 2

Starting torque

Dimension H

Washer No. 2

Low

Small

Select thicker one.

High

Large

Select thinner one.

Adjusting washer No. 2

Part Number

Thickness mm (in)

803025059

3.850 (0.1516)

803025054

4.000 (0.1575)

803025058

4.150 (0.1634)

MT-00270

( A )

( B )

5MT-84

MANUAL TRANSMISSION AND DIFFERENTIAL

Front Differential Assembly

19.Front Differential Assembly

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) Removes the drive pinion shaft assembly. <Ref.
to 5MT-76, REMOVAL, Drive Pinion Shaft Assem-
bly.>
5) Remove the main shaft assembly.
• Single-range model
<Ref. to 5MT-61, REMOVAL, Main Shaft Assembly
for Single-Range.>
• Dual-range model
<Ref. to 5MT-66, REMOVAL, Main Shaft Assembly
for Dual-Range.>
6) 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.

7) Remove the differential side retainers using ST.
ST

499787000

WRENCH ASSY

B: INSTALLATION

1) Install the differential side retainers using ST.
ST

499787000

WRENCH ASSY

2) Install the bearing outer race on transmission
case.
3) Install the differential assembly.

NOTE:
Be careful not to fold the sealing lip of oil seal.

4) Install the main shaft assembly.
• Single-range model
<Ref. to 5MT-61, INSTALLATION, Main Shaft As-
sembly for Single-Range.>
• Dual-range model
<Ref. to 5MT-66, INSTALLATION, Main Shaft As-
sembly for Dual-Range.>
5) Install the drive pinion assembly. <Ref. to 5MT-
76, INSTALLATION, Drive Pinion Shaft Assem-
bly.>
6) Install the transmission case. <Ref. to 5MT-57,
INSTALLATION, Transmission Case.>
7) Install the transfer case with extension case as-
sembly. <Ref. to 5MT-43, INSTALLATION, Trans-
fer Case and Extension Case Assembly.>
8) Install the manual transmission assembly into
vehicle. <Ref. to 5MT-32, INSTALLATION, Manual
Transmission Assembly.>

MT-00162

MT-00176

ST

MT-00162

5MT-85

MANUAL TRANSMISSION AND DIFFERENTIAL

Front Differential Assembly

C: DISASSEMBLY

1. DIFFERENTIAL CASE ASSEMBLY

1) Loosen the twelve bolts and remove hypoid driv-
en gear.

2) Drive out the straight pin from differential assem-
bly toward hypoid driven gear side.
ST

899904100

REMOVER

3) Pull out the pinion shaft, and remove the differ-
ential bevel pinion, bevel gear and washer.

4) Using the ST, remove the roller bearing.
ST

899524100

PULLER SET

2. SIDE RETAINER

1) Remove the O-ring.

(A) Hypoid driven gear

(A)

MT-00275

MT-00276

ST

(A) Pinion shaft

(B) Bevel pinion

(C) Bevel gear

(D) Washer

MT-00277

(A)

(D)

(D)

(C)

(C)

(B)

(B)

MT-00278

ST

MT-00279

5MT-86

MANUAL TRANSMISSION AND DIFFERENTIAL

Front Differential Assembly

2) Remove the oil seal.

NOTE:
Do not reuse the oil seal. Replace with a new oil
seal.

D: ASSEMBLY

1. DIFFERENTIAL CASE ASSEMBLY

1) Install the bevel gear and bevel pinion together
with washers, and insert the pinion shaft.

NOTE:
Face the chamfered side of washer toward gear.

2) Measure the backlash between bevel gear and
pinion. If it is not within specifications, install a suit-
able washer to adjust. <Ref. to 5MT-88, ADJUST-
MENT, Front Differential Assembly.>

NOTE:
Be sure the pinion gear teeth contacts adjacent
gear teeth during measurement.
ST1

498247001

MAGNET BASE

ST2

498247100

DIAL GAUGE

Standard backlash:

0.13 — 0.18 mm (0.0051 — 0.0071 in)

3) Align the pinion shaft and differential case at
their holes, and drive the straight pin into holes
from the hypoid driven gear side, using ST.

NOTE:
Lock the straight pin after installing.
ST

899904100

REMOVER

4) Install the roller bearing to differential case.

NOTE:
• Do not apply pressure in excess of 10 kN (1 ton,
1.1 US ton, 1.0 Imp ton).
• Be careful because the roller bearing outer races
are used as a set.
ST1

499277100

BUSHING 1-2 INSTALLER

ST2

398497701

ADAPTER

(A) Bevel pinion

(B) Bevel gear

(C) Pinion shaft

MT-00363

MT-00284

(A)

(B)

(C)

(A) Pinion shaft

(B) Differential case

(C) Straight pin

MT-00285

ST1

ST2

MT-00286

(A)

(C)

(B)

MT-00287

ST1

ST2