Subaru Legacy (2005 year). Manual - part 685

6MT-87

MANUAL TRANSMISSION AND DIFFERENTIAL

Driven Gear Assembly

11) Install the 1st-2nd sleeve to 1st-2nd hub.

NOTE:
Be sure the 1st-2nd sleeve is installed in proper di-
rection.

12) Install the outer baulk ring.

13) Install the 2nd synchro cone.

14) Install the inner baulk ring.

15) Apply sufficient amount of gear oil to the bush-
ing, 2nd needle bearing and inner periphery of 2nd
drive gear.
16) Install the 2nd needle bearing and 2nd driven
gear.

NOTE:
Align the protrusion portion of 2nd synchro cone
with 2nd driven gear hole, then install.

17) Install the key.

(A) 1st driven gear

(B) 1st-2nd sleeve

(C) 1st driven gear side

MT-00603

(B)

(A)

(C)

(B)

MT-00604

MT-00605

(A) 2nd needle bearing

(B) 2nd driven gear

(C) Protrusion portion of 2nd synchro cone

MT-00606

(A)

(C)

(B)

MT-00607

MT-00608

6MT-88

MANUAL TRANSMISSION AND DIFFERENTIAL

Driven Gear Assembly

18) Using the ST, install the 3rd-4th driven gear.
ST

18654AA000

INSTALLER

CAUTION:
Do not apply pressure in excess of 40 kN (4.0 
ton, 4.4 US ton, 3.9 Imp ton).

NOTE:
• Be sure the 3rd-4th driven gear is installed in
proper direction.
• Align the groove of 3rd-4th driven gear with key.

19) Make sure the 2nd driven gear is smoothly
turned by hand. If it is not rotated smoothly, reas-
semble it.
20) Install the key.

21) Using the ST, install the 5th-6th driven gear.
ST

18654AA000

INSTALLER

CAUTION:
Do not apply pressure in excess of 40 kN (4.0 
ton, 4.4 US ton, 3.9 Imp ton).

NOTE:
• Be sure the 5th-6th driven gear is installed in
proper direction.
• Align the groove of 5th-6th driven gear with key.

22) Using the ST, install the ball bearing.
ST

18654AA000

INSTALLER

CAUTION:
Do not apply pressure in excess of 40 kN (4.0 
ton, 4.4 US ton, 3.9 Imp ton).

NOTE:
Be sure the ball bearing is installed in proper direc-
tion.

23) Make sure the ball bearing is smoothly turned
by hand. If it is not rotated smoothly, reassemble it.
24) Install a new lock nut.

(A) 4th gear

(B) 3rd gear

(C) 2nd gear

(A)

(C)

(B)

ST

MT-00609

MT-00610

(A) 6th gear

(B) 5th gear

(C) 4th gear

(B)

ST

(A)

(C)

MT-00611

ST

MT-00612

6MT-89

MANUAL TRANSMISSION AND DIFFERENTIAL

Driven Gear Assembly

25) Install the ST3 to lock nut, then install the ST1
and ST2 to the driven gear assembly and tighten
the lock nut.
ST1

18666AA000 HOLDER

ST2

18664AA000 BASE

ST3

18620AA000 ADAPTER WRENCH

ST4

18852AA000 TORQUE WRENCH

Tightening torque:

530 N

⋅

m (54.0 kgf-m, 391 ft-lb)

NOTE:
If torque wrench except ST4 is used, calculate the
following calculation formula, then tighten the lock
nut.
T = L1 / (0.1 + L1) 

× 570

26) Using the ST, caulk the lock nut at four points at
dimension A of 44

±0.5 mm (1.73±0.02 in).

ST

18669AA000

PUNCH

NOTE:
Do not damage the caulking portion of lock nut.

T

N

⋅m (kgf-m, ft-lb) Setting value of torque 

wrench

L1

m (in) Torque wrench length

0.1 m (3.94 in)

ST length

570 N

⋅m (58.1 kgf-m, 420 ft-lb) Tightening torque of lock 

nut:

(A) 0.1 m (3.94 in)

MT-00613

ST1

ST2

ST4

ST3

(A)

L1

MT-00614

MT-00615

A

A

ST

6MT-90

MANUAL TRANSMISSION AND DIFFERENTIAL

Driven Gear Assembly

E: INSPECTION

Disassembled parts should be washed with un-
leaded gasoline first and then inspected carefully.
1) Bearing
Replace the bearings in the following cases.
• When there are wear, rust and damage on the
bearing.
• When bearing that fails to turn smoothly or
makes noise when turned.
• When bearings have other defects.
2) Bushing (each gear)
Replace the bushing in following cases.
• When the sliding surface is damaged or abnor-
mally worn.
3) Gear
Replace the gear in the following cases.
• When the gear teeth surfaces are broken or ex-
cessively worn.
• When the parts that contact the baulk ring is
damaged.
• When the inner surface of gear is damaged.
4) Baulk ring, synchro cone
Replace the baulk ring and synchro cone in the fol-
lowing case.
• When there are wear, rust and damage on the
baulk ring.
5) Shifting insert key
Replace the shifting insert key if deformed, exces-
sively worn or defective in any way.

F: ADJUSTMENT

1) Measure length “H”, which is from transmission
case and oil pump cover mating surface to ball
bearing edge.

2) Using the following calculation formula, calcu-
late the washer thickness of driven gear assembly.
T = H 

− {5.8±0.05 mm (0.23±0.002 in)} − {0.1 — 0.3

mm (0.0039 — 0.0118 in)}

3) Select 0 to 3 washers from the following table to
adjust backlash closest to specification.

Backlash specification at axial direction of driv-
en gear assembly: 

0.1 — 0.3 mm (0.0039 — 0.0118 in)

MT-00581

(A) Transmission case

(B) Ball bearing

(C) Driven gear ASSY

t

Thickness of washer

H

Length from transmission case and 
oil pump cover mating surface to ball 
bearing edge

5.8

±0.05 mm

(0.23

±0.002 in)

Thickness of collar

0.1 to 0.3 mm

(0.0039 to 0.0118 in)

Backlash specification at axial direc-
tion of driven gear assembly

Washer

Part No.

Thickness     t     mm (in)

803072030

0.15 (0.0059)

803072031

0.30 (0.0118)

803072032

0.45 (0.0177)

803072033

0.60 (0.0236)

MT-00616

(A)

H

(C)

(B)