Subaru Legacy (2005 year). Manual - part 680

6MT-67

MANUAL TRANSMISSION AND DIFFERENTIAL

Transmission Case

4) Remove the harness bracket.

5) Remove the oil pan.

6) Completely remove the remaining liquid gasket
on transmission case and oil pan.
7) Remove the oil pan magnet, then remove the oil
strainer.

D: ASSEMBLY

1) Install the oil strainer and magnet.

Tightening torque:

10 N

⋅

m (1.0 kgf-m, 7.4 ft-lb)

2) Apply liquid gasket to the oil pan.

Liquid gasket:

THREE BOND 1215 (Part No. 004403007)

3) Install the oil pan.

Tightening torque:

6.4 N

⋅

m (0.65 kgf-m, 4.7 ft-lb)

4) Install the relief valve, relief valve spring and
new seal bolt assembly.

(A) Oil pan magnet

(B) Oil strainer

MT-00538

MT-00539

(A)

(B)

MT-00540

(A) Oil pan magnet

(B) Oil strainer

(A)

(B)

MT-00540

MT-00541

MT-00539

6MT-68

MANUAL TRANSMISSION AND DIFFERENTIAL

Transmission Case

5) Install the ball, valve spring and new seal bolt as-
sembly.

Tightening torque:

T1: 13 N

⋅

m (1.3 kgf-m, 9.6 ft-lb)

T2: 16 N

⋅

m (1.6 kgf-m, 11.8 ft-lb)

E: INSPECTION

1) Completely remove sludge using shop cloth if it
is adhered to the oil pan magnet.
2) Check the oil strainer for clogging. Remove clog-
ging or replace the oil strainer if there is clogging.
3) Check each part for damage. Replace the dam-
aged part with a new one.

(A) Seal bolt assembly

(B) Relief valve spring

(C) Relief valve

(D) Valve spring

(E) Ball

(F) Harness bracket

MT-00542

(A)

(B)

(C)

(A)

(D)

(E)

T2

T1

T1

(F)

6MT-69

MANUAL TRANSMISSION AND DIFFERENTIAL

Main Shaft Assembly

19.Main Shaft Assembly

A: REMOVAL

1) Remove the manual transmission assembly
from vehicle. <Ref. to 6MT-34, REMOVAL, Manual
Transmission Assembly.>
2) Prepare the transmission for overhaul. <Ref. to
6MT-40, Preparation for Overhaul.>
3) Remove the oil pipe, neutral position switch,
back-up light switch and harness. <Ref. to 6MT-42,
REMOVAL, Oil Pipe.> <Ref. to 6MT-45, REMOV-
AL, Neutral Position Switch.> <Ref. to 6MT-43, RE-
MOVAL, Back-up Light Switch.>
4) Remove the extension case. <Ref. to 6MT-47,
REMOVAL, Extension Case.>
5) Remove the transfer driven gear. <Ref. to 6MT-
58, REMOVAL, Transfer Driven Gear.>
6) Remove the center differential. <Ref. to 6MT-60,
REMOVAL, Center Differential.>
7) Remove the oil pump. <Ref. to 6MT-61, RE-
MOVAL, Oil Pump.>
8) Remove the transmission case. <Ref. to 6MT-
64, REMOVAL, Transmission Case.>
9) Remove the striking rod.
10) Shift to 4th gear position using a screwdriver.

11) Remove the reverse idler holder.

12) Remove all of the checking ball plug, gasket,
checking ball spring, plunger and ball from adapter
plate.

NOTE:
Use a new gasket.

13) Remove the bolts and gasket which install the
reverse idler shaft.

14) Push the main shaft assembly, driven gear as-
sembly, reverse idler gear and each shifter fork to
remove them from adapter plate at a time.

NOTE:
A helper is required to perform this work.

(A) 3rd-4th shift rod

(A) Reverse idler holder

(A)

MT-00543

(A)

MT-00544

(A) Checking ball plug

(B) Gasket

(C) Checking ball spring

(D) Plunger

(E) Ball

(D)

(E)

(A)

(A)

(B)

(B)

(C)

(C)

MT-00545

MT-00546

6MT-70

MANUAL TRANSMISSION AND DIFFERENTIAL

Main Shaft Assembly

B: INSTALLATION

1) Adjust the 3rd-4th and 5th-6th shifter fork rod.
<Ref. to 6MT-115, ADJUSTMENT, Shifter Fork
and Rod.>
2) Rotate the sub gear counterclockwise for ap-
prox. three teeth. Insert the ST aligning sub gear
and reverse idler gear hole.
ST

18757AA000

STRAIGHT PIN REMOVER

3) Install the driven gear assembly to 1st-2nd
shifter fork assembly.

4) Install the main shaft assembly to 3rd-4th shifter
fork and assemble them to driven gear assembly.

5) Install the 5th-6th shifter fork assembly to main
shaft assembly.

(A) Sub gear

(B) Reverse idler gear

(A) 1st-2nd shifter fork

(B) Driven gear ASSY

(C) 1st-2nd sleeve

(A)

(B)

ST

MT-00547

MT-00548

(A)

(B)

(C)

(A) 3rd-4th shifter fork

(B) 3rd-4th sleeve

(C) Driven gear ASSY

(D) Main shaft ASSY

(A) 5th-6th shifter fork

(B) 5th-6th sleeve

(C) Main shaft ASSY

MT-00549

(C)

(A)

(B)

(C)

(D)

(D)

(A)

(B)

MT-00550

(B)

(A)

(C)