Subaru Legacy (2005 year). Manual - part 681

6MT-71

MANUAL TRANSMISSION AND DIFFERENTIAL

Main Shaft Assembly

6) Install the reverse shifter fork assembly to re-
verse idler gear assembly.

7) Install the reverse idler gear assembly.

8) Install the thrust bearing of driven gear assem-
bly.
9) Push each shifter fork, main shaft assembly,
driven gear assembly and reverse idler gear as-
sembly to install them to adapter plate at a time.

NOTE:
A helper is required to perform this work.
10) Install the plunger, checking ball spring, new
gasket and checking ball plug.

Tightening torque:

37 N

⋅

m (3.8 kgf-m, 27.3 ft-lb)

(A) Reverse idler gear ASSY

(B) Reverse shifter fork

(C) Reverse sleeve

(A) Reverse idler gear ASSY

(B) 1st drive gear

(C) Reverse gear

MT-00551

(A)

(B)

(C)

MT-00552

(B)

(A)

(C)

(A) Checking ball plug

(B) Gasket

(C) Checking ball spring

(D) Plunger

MT-00553

(D)

(A)

(B)

(C)

6MT-72

MANUAL TRANSMISSION AND DIFFERENTIAL

Main Shaft Assembly

11) Install the ball, checking ball spring, gasket and
checking ball plug.

NOTE:
Use a new gasket and checking ball plug.

Tightening torque:

37 N

⋅

m (3.8 kgf-m, 27.3 ft-lb)

12) Install the bolt and gasket.

NOTE:
Use a new gasket.

Tightening torque:

25 N

⋅

m (2.5 kgf-m, 18.4 ft-lb)

13) Shift to 4th gear position using a screwdriver.

14) Install the reverse idler holder.

15) Install the striking rod.
16) Install the transmission case. <Ref. to 6MT-65,
INSTALLATION, Transmission Case.>
17) Install the snap ring and washer of selected
main shaft.
18) Install the oil pump. <Ref. to 6MT-62, INSTAL-
LATION, Oil Pump.>
19) Install the center differential. <Ref. to 6MT-60,
INSTALLATION, Center Differential.>
20) Install the transfer driven gear. <Ref. to 6MT-
58, INSTALLATION, Transfer Driven Gear.>
21) Install the extension case. <Ref. to 6MT-47, IN-
STALLATION, Extension Case.>
22) Install the oil pipe, neutral position switch,
back-up light switch and harness. <Ref. to 6MT-42,
INSTALLATION, Oil Pipe.> <Ref. to 6MT-45, IN-
STALLATION, Neutral Position Switch.> <Ref. to
6MT-43, INSTALLATION, Back-up Light Switch.>
23) Install the manual transmission assembly to ve-
hicle. <Ref. to 6MT-36, INSTALLATION, Manual
Transmission Assembly.>

C: DISASSEMBLY

NOTE:
Each sleeve and hub engage at specified position.
Before disassembly, put marks on the engagement
position of sleeve and hub.
1) Secure the ST on workbench.
ST

18664AA000

BASE

2) Unlock the caulking of lock nut.

(A) Checking ball plug

(B) Gasket

(C) Checking ball spring

(D) Ball

MT-00554

(D)

(A)

(B)

(C)

MT-00546

(A) Reverse idler holder

(A)

MT-00544

6MT-73

MANUAL TRANSMISSION AND DIFFERENTIAL

Main Shaft Assembly

3) Set the main shaft assembly to ST and remove
the lock nut and washer.
ST1

18665AA000 HOLDER

ST2

18664AA000 BASE

NOTE:
Use 38 mm socket wrench.

4) Remove the main shaft assembly from ST.
5) Set the ST1 to 6th drive gear and remove the
taper roller bearing, bushing and 6th drive gear us-
ing a press.
ST1

18722AA010 REMOVER

ST2

 899864100 REMOVER

6) Remove the 5th-6th sleeve, 6th needle bearing
and 6th baulk ring.

7) Set the ST to 3rd drive gear and remove each
part using a press.
ST

18720AA000

REMOVER

(A) Taper roller bearing

(B) Bushing

(C) 6th drive gear

MT-00556

ST2

ST1

MT-00557

(A)

(B)

(C)

ST1

ST2

ST1

(A) Needle bearing

(B) 6th baulk ring

(C) 5th-6th sleeve

(A) 3rd drive gear

(B) 3rd-4th sleeve

(A)

(B)

(C)

MT-00558

MT-00559

(A)

ST

(B)

(B)

ST

6MT-74

MANUAL TRANSMISSION AND DIFFERENTIAL

Main Shaft Assembly

D: ASSEMBLY

NOTE:
When replacing the following part, replace them as
a set.
• Sleeve and hub
• Outer baulk ring, 3rd synchro cone and inner
baulk ring
• Taper roller bearing
1) Apply sufficient amount of gear oil to the main
shaft, and the inside of 3rd needle bearing and 3rd
drive gear.
2) Install the 3rd needle bearing and 3rd drive gear
to main shaft.

3) Install the inner baulk ring, 3rd synchro cone and
outer baulk ring.

NOTE:
Install the 3rd synchro cone with aligning the pro-
trusion of 3rd synchro cone to hole portion of 3rd
drive gear.

4) Install the 3rd-4th hub and 4th bushing. 

(1) Set the 3rd-4th hub to main shaft paying at-
tention to the installing direction.

(A) 3rd drive gear

(B) 3rd needle bearing

(A) Inner baulk ring

(B) Outer baulk ring

(A)

(B)

MT-00560

(A)

(B)

MT-00561

(A) Main shaft

(B) 3rd-4th hub

(C) 3rd drive gear

MT-00562

MT-00884

(A)

(B)

(C)