Subaru Legacy (2005 year). Manual - part 662

5MT-95

MANUAL TRANSMISSION AND DIFFERENTIAL

Shifter Fork and Rod

Clearance (a) and (b):

9.3 mm (0.366 in)

5) Inspect the clearance between 5th drive gear
and coupling sleeve. If any clearance is not within
specifications, replace the shifter fork as required.

Clearance (a):

9.3 mm (0.366 in)

6) Inspect the rod end clearances (A) and (B). If
any clearance is not within specifications, replace
the rod or fork as required.

Clearance (A):

3rd-4th — 5th:

0.5 — 1.3 mm (0.020 — 0.051 in)

Clearance (B):

1st-2nd — 3rd-4th

0.4 — 1.4 mm (0.016 — 0.055 in)

(A) 3rd drive gear

(B) Coupling sleeve

3rd-4th shifter fork

Part Number

Marking

Remarks

32810AA061

Approach to 4th gear
by 0.2 mm (0.008 in).

32810AA071

No mark

Standard

32810AA101

Become distant from
3rd gear by 0.2 mm
(0.008 in).

(A) 5th drive gear

(B) Coupling sleeve

5th shifter fork (Non-turbo model)

Part Number

Marking

Remarks

32812AA201

Approach to 5th gear
by 0.2 mm (0.008 in).

32812AA211

No mark

Standard

32812AA221

Become distant from
5th gear by 0.2 mm
(0.008 in).

MT-00940

(A)

(B)

(C)

(a)

(b)

MT-00315

(A)

(B)

(a)

5th shifter fork (Turbo model)

Part No.

Mark

Remarks

32812AA231

Approach to 5th gear
by 0.2 mm (0.008 in)

32812AA241

No mark

Standard

32812AA251

Become distant from
5th gear by 0.2 mm
(0.008 in)

(B)

MT-00316

(A)

5MT-96

MANUAL TRANSMISSION AND DIFFERENTIAL

Counter Gear

22.Counter Gear

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) Move the counter gear shaft until it touches
transmission case, and remove the snap ring with a
suitable tool.

5) Slide the washer to the rear of high-low counter
shaft, and remove the straight pin from counter
shaft.

6) Remove the counter shaft from transmission
case, taking care not to drop the counter gear and
two washers.

NOTE:
• Be careful not to damage the O-ring.
• Be careful not to drop the straight pin on front
side.

• Be careful not to drop the two needle bearings
and collar contained in counter gear.

B: INSTALLATION

1) Install the O-ring and straight pin onto counter
gear shaft.
2) Install the following parts in main case (Right-
side), and push the shaft perfectly into case.
• Counter gear shaft
• Two counter gear washers
• Two needle bearings
• Counter gear collar
• Counter gear
• Straight pin
• Snap ring
3) Install the transmission case. <Ref. to 5MT-57,
INSTALLATION, Transmission Case.>
4) Install the transfer case with extension case as-
sembly. <Ref. to 5MT-43, INSTALLATION, Trans-
fer Case and Extension Case Assembly.>
5) Install the manual transmission assembly on ve-
hicle. <Ref. to 5MT-32, INSTALLATION, Manual
Transmission Assembly.>

NOTE:
• Make sure that the cut-out end surface of counter
gear shaft does not protrude above the end surface
of the case.
• Position the cut-out portion of counter gear shaft.

C: INSPECTION

1) After installing the snap ring, measure the clear-
ance between snap ring and counter washer.

Clearance:

0.05 — 0.35 mm (0.0020 — 0.0138 in)

2) If the clearance is out of specified value, select a
snap ring and install to put clearance within speci-
fied value. <Ref. to 5MT-97, ADJUSTMENT,
Counter Gear.>

(A) Snap ring

(A) Straight pin

(B) Counter gear

MT-00317

(A)

MT-00318

(A)

(B)

(A) Counter shaft

(B) Counter gear

MT-00319

(A)

(B)

(C)

5MT-97

MANUAL TRANSMISSION AND DIFFERENTIAL

Counter Gear

D: ADJUSTMENT

Selection of snap ring:
If the measurement is not within specification, se-
lect a suitable snap ring.

Snap ring

Part No.

Thickness mm (in)

031319000

1.50 (0.0591)

805019010

1.72 (0.0677)

5MT-98

MANUAL TRANSMISSION AND DIFFERENTIAL

General Diagnostic Table

23.General Diagnostic Table

A: INSPECTION

1. MANUAL TRANSMISSION

Symptom

Possible cause

Corrective action

1. Gears are difficult to intermesh.
NOTE:
The cause for difficulty in shifting gears
can be classified into two kinds: one is de-
fective gear shift system and the other is
defective transmission. However, if the
operation is heavy and engagement of the
gears is difficult, defective clutch disen-
gagement may also be responsible.
Check whether the clutch is correctly
functioning, before checking the gear shift
system and transmission.

(a) Worn, damaged or burred chamfer of
internal spline of sleeve and reverse
driven gear

Replace.

(b) Worn, damaged or burred chamfer of
spline of gears

Replace.

(d) Incorrect contact between synchro-
nizer ring and gear cone, or wear

Rectify or replace.

2. Gear slip-out
• Gear slips out when coasting on rough
road.
• Gear slips out during acceleration.

(a) Defective pitching stopper adjustment

Adjust.

(b) Loose engine mounting bolts

Tighten or replace.

Replace.

(d) Worn or damaged ball bearing

Replace.

(e) Excessive clearance between splines
of synchronizer hub and synchronizer
sleeve

Replace.

(f) Worn tooth step of synchronizer hub
(caused by slip-out of 3rd gear)

Replace.

(g) Worn 1st driven gear and driven shaft

Replace.

(h) Worn 2nd driven gear and bushing

Replace.

(i) Worn 3rd drive gear main shaft needle
bearing

Replace.

(j) Worn 4th drive gear bushing needle
bearing

Replace.

(k) Worn 5th drive gear bushing needle
bearing

Replace.

(l) Worn reverse idler gear and bushing

Replace.

3. Noise emit from transmission.
NOTE:
If a noise is heard when the vehicle is
parked with its engine idling and if a noise
ceases when the clutch is disengaged, it
may be considered that the noise comes
from the transmission.

(a) Insufficient or improper lubrication

Lubricate with specified oil or replace.

(b) Worn or damaged gears and bearings
NOTE:
If the trouble is only wear of the tooth sur-
faces, merely a high roaring noise will oc-
cur at high speeds, but if any part is
broken, rhythmical knocking sound will be
heard even at low speeds.

Replace.

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