Subaru Legacy (2005 year). Manual - part 692

6MT-115

MANUAL TRANSMISSION AND DIFFERENTIAL

Shifter Fork and Rod

2) Install the reverse interlock block and interlock
block to striking rod.

NOTE:
Be sure the reverse interlock block and interlock
block are installed in proper direction.

E: INSPECTION

1) Check the shift shaft and shift rod for damage.
Replace if damaged.
2) Repair or replace the gear shift mechanism if ex-
cessively worn, bent or defective in any way.

F: ADJUSTMENT

1. SELECTION OF 1ST-2ND FORK ROD

NOTE:
Perform the procedures below in the following cas-
es.
• When replacing the 1st and 2nd driven gear.
• When replacing the 1st and 2nd synchro ring as-
sembly.
• When replacing the adapter plate.
• When replacing the driven shaft.
• When replacing the 1st-2nd hub and sleeve as-
sembly.
1) Insert the drive pinion assembly in adapter plate.

NOTE:
Make sure the thrust bearing outer race is not re-
moved and drive pinion is not lifted-up.

2) Set the height gauge to adapter plate. Lower the
indicator of height gauge to mating surface of
adapter plate and case, then set to zero point.
ST

18853AA000

HEIGHT GAUGE

NOTE:
• Remove the remaining gasket on edge surface
with scraper, since the adapter plate is base point
of measurement.
• Do not place the height gauge on shaded area in
the figure during the measurement.

3) Select the main shaft snap ring. <Ref. to 6MT-
81, ADJUSTMENT, Main Shaft Assembly.>
4) Measure “B1” and “B2” as shown in the figure.

(A) Reverse interlock block

(B) Interlock block

(A)

(B)

MT-00688

MT-00582

ST

MT-00583

MT-00979

B1

B2

6MT-116

MANUAL TRANSMISSION AND DIFFERENTIAL

Shifter Fork and Rod

(1) Shift the 1st-2nd sleeve to 1st driven gear
side, then press down to the stopper and mea-
sure “B1”.

NOTE:
• Set the indicator of height gauge near measuring
object, then lock the dial (1) as shown in the figure.
Turn dial (2) to set the indicator to edge surface of
sleeve 1st side.
• Measure five points of the sleeve turning every
approx. 72

°. Round off each two upper and lower

measurement value. Use the remaining middle val-
ue as measurement value.

(2) Set the height gauge indicator upside down.

(3) Shift the 1st-2nd sleeve to 2nd driven gear
side, then press down to the stopper and mea-
sure “B2”.

NOTE:
• Set the indicator of height gauge near measuring
object, then lock the dial (1) as shown in the figure.
Turn dial (2) to set the indicator to edge surface of
sleeve 2nd side.
• Perform the measuring procedure with two peo-
ple, and measure the sleeve lifted up straight.
• Measure five points of the sleeve turning every
approx. 72

°. Round off each two upper and lower

measurement value. Use the remaining middle val-
ue as measurement value.

(A) 1st driven gear

(B) 1st-2nd sleeve

(A) Indicator

MT-00702

(A)

(B)

(2)

(1)

MT-00585

MT-00703

(A)

(A) 2nd driven gear

(B) 1st-2nd sleeve

MT-00704

(A)

(B)

(2)

(1)

MT-00585

6MT-117

MANUAL TRANSMISSION AND DIFFERENTIAL

Shifter Fork and Rod

(4) According to both measurements, calculate
the 1st-2nd sleeve neutral position. Select the
fork rod, which applies to the calculated value
from following calculation formula.
Calculation formula: T = (B1 + B2) / 2
T: 1st-2nd sleeve center position
B1: Height from adapter plate edge to sleeve
edge when shifted to 1st gear
B2: Height measurement from adapter plate
edge to sleeve edge when shifted to 2nd gear:
+55 mm (2.17 in)

NOTE:
The indicator is installed upside down compared to
the setting procedure of zero point. Add d1 [fixing
value: 55 mm (2.17 in)] from the following figure to
“B2”, to obtain measurement value of “B2”.

2. SELECTION OF 3RD-4TH FORK ROD

NOTE:
Perform the procedures below in the following cas-
es.
• When replacing the main shaft.
• When replacing the 3rd, 3rd to 6th drive gear and
bushing.
• When replacing the 3rd, 3rd to 6th synchro as-
sembly and bushing.
• When replacing the 3rd-4th hub and sleeve as-
sembly.
1) Insert the main shaft assembly in adapter plate.
2) Set the height gauge to adapter plate. Lower the
indicator of height gauge to upper surface of snap
ring groove, on the upper side of main rear bearing,
then set to zero point.
ST

18853AA000

HEIGHT GAUGE

NOTE:
• Remove the remaining gasket on edge surface
with scraper, since the height gauge is set on
adapter plate during measurement.
• Do not place the height gauge on shaded area in
the figure during the measurement.

T      mm (in)

Lot No. (Mark)

62.93 — 63.23

(2.4776 — 2.4894)

32801AA111 (1)

63.23 — 63.53

(2.4894 — 2.5012)

32801AA131 (None)

63.53 — 63.83

(2.5012 — 2.5130)

32801AA141 (2)

d1

MT-00705

(A) Loller bearing

(A)

MT-00706

MT-00583

6MT-118

MANUAL TRANSMISSION AND DIFFERENTIAL

Shifter Fork and Rod

3) Using the height gauge, measure “C1” and “C2”
shown in the figure.

(1) Shift the 3rd-4th sleeve to 4th gear side,
then press down to the stopper and measure
“C2”.

NOTE:
• Set the indicator of height gauge near measuring
object, then lock the dial (1) as shown in the figure.
• Turn dial (2) to set the indicator to edge surface
of sleeve 4th side.
• Perform the measuring procedure with two peo-
ple, and measure the sleeve lifted up straight.
• Measure five points of the sleeve turning every
approx. 72

°. Round off each two upper and lower

measurement value. Use the remaining middle val-
ue as measurement value.

(2) Set the height gauge indicator upside down.

(3) Shift the 3rd-4th sleeve to 3rd drive gear
side, then press down to the stopper and mea-
sure “C1”.

(A) 3rd drive gear

(B) 4th drive gear

(A) 4th drive gear

MT-00707

C1

C2

(A)

(B)

(A)

MT-00708

(A) Indicator

(A) 3rd drive gear

(2)

(1)

MT-00585

MT-00710

(A)

(A)

MT-00711