Subaru Legacy (2005 year). Manual - part 661

5MT-91

MANUAL TRANSMISSION AND DIFFERENTIAL

Reverse Idler Gear

20.Reverse Idler Gear

A: REMOVAL

1) Remove the manual transmission assembly
from vehicle. <Ref. to 5MT-30, REMOVAL, Manual
Transmission Assembly.>
2) Remove the back-up light switch and neutral po-
sition switch. <Ref. to 5MT-40, REMOVAL, Switch-
es and Harness.>
3) Remove the transfer case with extension case
assembly. <Ref. to 5MT-43, REMOVAL, Transfer
Case and Extension Case Assembly.>
4) Remove the transmission case. <Ref. to 5MT-
76, REMOVAL, Drive Pinion Shaft Assembly.>
5) Remove the drive pinion shaft assembly. <Ref.
to 5MT-76, REMOVAL, Drive Pinion Shaft Assem-
bly.>
6) 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.>
7) Remove the differential assembly. <Ref. to 5MT-
84, REMOVAL, Front Differential Assembly.>
8) Remove the shifter forks and rods. <Ref. to 5MT-
93, REMOVAL, Shifter Fork and Rod.>
9) Pull out the straight pin, and remove the idler
gear shaft, reverse idler gear and washer.

10) Remove the reverse shifter lever.

B: INSTALLATION

1) Install the reverse shifter lever, reverse idler
gear and reverse idler gear shaft, and secure them
with straight pin.

NOTE:
Be sure to install the reverse idler shaft from rear
side.

2) Inspect and adjust the clearance between re-
verse idler gear and transmission case wall. <Ref.
to 5MT-91, INSTALLATION, Reverse Idler Gear.>
<Ref. to 5MT-92, ADJUSTMENT, Reverse Idler
Gear.>
3) Install the shifter forks and rods. <Ref. to 5MT-
93, INSTALLATION, Shifter Fork and Rod.>
4) Install the differential assembly. <Ref. to 5MT-
84, INSTALLATION, Front Differential Assembly.>
5) 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.>
6) Install the drive pinion shaft assembly. <Ref. to
5MT-76, INSTALLATION, Drive Pinion Shaft As-
sembly.>
7) Install the transmission case. <Ref. to 5MT-57,
INSTALLATION, Transmission Case.>
8) Install the transfer case with extension case as-
sembly. <Ref. to 5MT-43, INSTALLATION, Trans-
fer Case and Extension Case Assembly.>
9) Install the back-up light switch and neutral posi-
tion switch. <Ref. to 5MT-40, INSTALLATION,
Switches and Harness.>
10) Install the manual transmission assembly into
vehicle. <Ref. to 5MT-32, INSTALLATION, Manual
Transmission Assembly.>

(A) Straight pin

(B) Reverse idler gear shaft

(C) Reverse idler gear

(D) Washer

MT-00303

(A)

(B)

(C)

(D)

(A) Reverse shifter lever

(B) Reverse idler gear

(C) Reverse idler gear shaft

(D) Straight pin

MT-00304

(A)

(B)

(D)

(C)

5MT-92

MANUAL TRANSMISSION AND DIFFERENTIAL

Reverse Idler Gear

C: INSPECTION

1) Move the reverse shifter rod toward reverse
side. Inspect the clearance between reverse idler
gear and transmission case wall.
If out of specification, select an appropriate reverse
shifter lever and adjust.

Clearance A:

6.0 — 7.5 mm (0.236 — 0.295 in)

2) After installing a suitable reverse shifter lever,
shift into neutral. Inspect the clearance between re-
verse idler gear and transmission case wall.
If out of specification, select an appropriate washer
and adjust.

Clearance:

0 — 0.5 mm (0 — 0.020 in)

3) Check the reverse idler gear and shaft for dam-
age. Replace if it is damaged.

D: ADJUSTMENT

1) Select an appropriate reverse shifter lever from
the table below, and adjust until the gap between
reverse idler gear and transmission case wall is
within specification.

Clearance A:

6.0 — 7.5 mm (0.236 — 0.295 in)

2) Select an appropriate washer from the table be-
low, and adjust until the gap between the reverse
idler gear and transmission case wall is within
specification.

Clearance:

0 — 0.5 mm (0 — 0.020 in)

MT-00305

A

MT-00306

Reverse shifter lever

Part Number

Marking

Remarks

32820AA070

7

Further from case wall

32820AA080

8

Standard

32820AA090

9

Closer to case wall

Washer

Part Number

Thickness mm (in)

803020151

0.4 (0.016)

803020152

1.1 (0.043)

803020153

1.5 (0.059)

803020154

1.9 (0.075)

803020155

2.3 (0.091)

MT-00305

A

MT-00306

5MT-93

MANUAL TRANSMISSION AND DIFFERENTIAL

Shifter Fork and Rod

21.Shifter Fork and Rod

A: REMOVAL

1) Remove the manual transmission assembly
from vehicle. <Ref. to 5MT-30, REMOVAL, Manual
Transmission Assembly.>
2) Remove the back-up light switch and neutral po-
sition switch. <Ref. to 5MT-40, REMOVAL, Switch-
es and Harness.>
3) Remove the transfer case with extension case
assembly. <Ref. to 5MT-43, REMOVAL, Transfer
Case and Extension Case Assembly.>
4) Remove transmission case. <Ref. to 5MT-55,
REMOVAL, Transmission Case.>
5) Removes the drive pinion shaft assembly. <Ref.
to 5MT-76, REMOVAL, Drive Pinion Shaft Assem-
bly.>
6) 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.>
7) Remove the differential assembly. <Ref. to 5MT-
84, REMOVAL, Front Differential Assembly.>
8) Drive out the straight pin tapping by ST, and pull
out the 5th shifter fork.
ST

398791700

STRAIGHT PIN REMOVER

9) Remove the plugs, springs and checking balls.
10) Drive out the straight pin tapping by ST, and
pull out the 3-4 fork rod and shifter fork.

NOTE:
When removing a rod, keep other rods in neutral.
Also, when pulling out the straight pin, remove it to-
ward the inside of case so that it does not hit
against the case.

ST

398791700

STRAIGHT PIN REMOVER

11) Drive out the straight pin tapping by ST, and
pull out the 1-2 fork rod and shifter fork.
ST

398791700

STRAIGHT PIN REMOVER

12) Remove the outer snap ring, and pull out re-
verse fork rod from reverse shifter rod arm. Then
take out the ball, spring and interlock plunger from
rod.
And then remove the rod.

NOTE:
When pulling out reverse shifter rod arm, be careful
not to let ball pop out of arm.
13) Remove the reverse shifter lever.

B: INSTALLATION

1) Install the reverse arm fork spring, ball and inter-
lock plunger to reverse fork rod arm. Insert the re-
verse fork rod into the hole in reverse fork rod arm,
and hold it with outer snap ring using ST.

NOTE:
Apply a coat of grease to plunger to prevent it from
falling.
ST

399411700

ACCENT BALL INSTALLER

2) Position the ball, spring and new gasket in the
reverse shifter rod hole on the left side of transmis-
sion case, and tighten the checking ball plug.
3) Install the 1-2 fork rod into 1-2 shifter fork
through the hole on the rear of transmission case.
4) Align the holes in rod and fork, and drive new
straight pin into these holes using ST.

NOTE:
• Set other rods to neutral.
• Make sure the interlock plunger is on the 3-4 fork
rod side.
ST

398791700

STRAIGHT PIN REMOVER

5) Install the interlock plunger onto 3-4 fork rod.

NOTE:
Apply a coat of grease to plunger to prevent it from
falling.

(A) Straight pin

(B) 5th shifter fork

MT-00309

( A )

( B )

(A) Straight pin

(B) 3-4 fork rod

(C) Shifter fork

MT-00994

(A)

(B)

(C)

5MT-94

MANUAL TRANSMISSION AND DIFFERENTIAL

Shifter Fork and Rod

6) Install the 3-4 fork rod into 3-4 shifter fork
through the hole on the rear of transmission case.
7) Align the holes in rod and fork, and drive new
straight pin into these holes.

NOTE:
• Set the reverse fork rod to neutral.
• Make sure the interlock plunger (before installa-
tion) is on the reverse fork rod side.
ST

398791700

STRAIGHT PIN REMOVER

8) Install the 5th shifter fork onto the rear of reverse
fork rod. Align the holes in the two parts and drive
new straight pin into the specified place.
ST

398791700

STRAIGHT PIN REMOVER

9) Position the balls, checking ball springs and new
gaskets into 3-4 and 1-2 rod holes, and install
plugs.

10) Install the differential assembly. <Ref. to 5MT-
84, INSTALLATION, Front Differential Assembly.>
11) 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.>
12) Install the drive pinion shaft assembly. <Ref. to
5MT-76, INSTALLATION, Drive Pinion Shaft As-
sembly.>

13) Install the transmission case. <Ref. to 5MT-57,
INSTALLATION, Transmission Case.>
14) Install the transfer case with extension case as-
sembly. <Ref. to 5MT-43, INSTALLATION, Trans-
fer Case and Extension Case Assembly.>
15) Install the back-up light switch and neutral po-
sition switch. <Ref. to 5MT-40, INSTALLATION,
Switches and Harness.>
16) Install the manual transmission assembly into
vehicle. <Ref. to 5MT-32, INSTALLATION, Manual
Transmission Assembly.>

C: INSPECTION

1) Inspect the fork and rod for damage. Replace if it
is damaged.
2) Gearshift mechanism
Repair or replace the gearshift mechanism if ex-
cessively worn, bent, or defective in any way.
3) Inspect the clearance between 1st, 2nd driven
gear and reverse driven gear. If any clearance is
not within specifications, replace the shifter fork as
required.

Clearance (a) and (b):

9.5 mm (0.374 in)

4) Inspect the clearance between 3rd, 4th drive
gear and coupling sleeve. If any clearance is not
within specifications, replace the shifter fork as re-
quired.

(A) 5th shifter fork

(B) Reverse fork rod

(C) Straight pin

MT-00311

( C )

( A )

( B )

MT-00366

(A) 1st driven gear

(B) Reverse driven gear

(C) 2nd driven gear

1st-2nd shifter fork

Part Number

Marking

Remarks

32804AA060

1

Approach to 1st gear 
by 0.2 mm (0.008 in).

32804AA070

No mark

Standard

32804AA080

3

Become distant from 
2nd gear by 0.2 mm 
(0.008 in).

MT-00999

(A)

(a)

(b)

(B)

(C)