Subaru Legacy (2005 year). Manual - part 693

6MT-119

MANUAL TRANSMISSION AND DIFFERENTIAL

Shifter Fork and Rod

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 3rd 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.

4) According to both measurements, calculate the
3rd-4th sleeve neutral position. Select the fork rod,
which applies to the calculated value from following
calculation formula.
Calculation formula: T = (C1 + C2) / 2
T: 3th-4th sleeve center position
C1: Depth measurement from main shaft rear bear-
ing snap ring groove to sleeve edge when shifted to
3rd gear: +55 mm (2.17 in)
C2: Depth from main shaft rear bearing snap ring
groove to sleeve edge when shifted to 4th gear

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
“C1”, to obtain measurement value of “C1”.

T = Thickness

(2)

(1)

MT-00585

mm (in)

Lot No. (Mark)

M.SFT
Snap ring
805072010
[t = 1.65 mm
(0.065 in)]

M.SFT
Snap ring
805072011
[t = 1.95 mm
(0.077 in)]

M.SFT
Snap ring
805072012
[t = 2.25 mm
(0.089 in)]

137.22 —

137.52

(5.4024 —

5.4142)

32809AA171

(None)

32809AA181

(2)

32809AA191

(4)

137.52 —

137.82

(5.4142 —

5.4260)

32809AA161

(1)

32809AA171

(None)

32809AA181

(2)

137.82 —

138.12

(5.4260 —

5.4378)

32809AA141

(3)

32809AA161

(1)

32809AA171

(None)

MT-00705

6MT-120

MANUAL TRANSMISSION AND DIFFERENTIAL

Shifter Fork and Rod

3. SELECTION OF 5TH-6TH FORK ROD

NOTE:
Perform the procedures below in the following cas-
es.
• When replacing the main shaft.
• When replacing the 3rd to 6th drive gear and
bushing.
• When replacing the 3rd to 6th synchro ring as-
sembly.
• When replacing the 3rd-4th hub and sleeve as-
sembly.
• When replacing the 5th-6th 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, or the upper side of main rear bearing.
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.

3) Using the height gauge, measure “D1” and “D2”
shown in the figure.

(1) Shift the 5th-6th sleeve to 6th main gear
side, then press down to the stopper and mea-
sure “D2”.

(A) Ball bearing

(A)

MT-00706

MT-00583

(A) 5th main gear

(B) 6th main gear

(A) 6th main gear

MT-00712

(A)

(B)

(A)

MT-00713

6MT-121

MANUAL TRANSMISSION AND DIFFERENTIAL

Shifter Fork and Rod

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 6th 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 5th-6th sleeve to 5th main gear
side, then press down to the stopper and mea-
sure “D1”.

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 5th 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.

(A) Indicator

(A) 5th main gear

(2)

(1)

MT-00585

MT-00710

(A)

MT-00714

(2)

(1)

MT-00585

6MT-122

MANUAL TRANSMISSION AND DIFFERENTIAL

Shifter Fork and Rod

4) According to both measurements, calculate the
5th-6th sleeve neutral position. Select the fork rod,
which applies to the calculated value from following
calculation formula.
Calculation formula: T = (D1 + D2) / 2
T: 5th-6th sleeve center position
D1: Length from the shaft rear bearing snap ring
groove to sleeve groove edge when shifted to 5th
gear [Measurement +55 mm (2.17 in)]
D2: Length from main shaft rear bearing snap ring
groove to sleeve groove edge when shifted to 6th
gear

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
“D1”, to obtain measurement value of “D1”.

T = Thickness

4. SELECTION OF REVERSE FORK ROD

NOTE:
Perform the procedures below in the following cas-
es.
• When replacing the reverse idler gear.
• When replacing the reverse idler gear No. 2.
• When replacing the adapter plate.
• When replacing the base.
1) Insert the reverse idler gear assembly in adapter
plate.
2) Tighten the base COMPL fixing bolt.

Tightening torque:

25 N

⋅

m (2.5 kgf-m, 18.4 ft-lb)

3) 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

mm (in)

Lot No. (Mark)

M.SFT
Snap ring
805072010
[t = 1.65 mm
(0.065 in)]

M.SFT
Snap ring
805072011
[t = 1.95 mm
(0.077 in)]

M.SFT
Snap ring
805072012
[t = 2.25 mm
(0.089 in)]

64.12 —

64.42

(2.5244 —

2.5362)

32945AA021

(None)

32945AA031

(2)

32945AA041

(4)

64.42 —

64.72

(2.5362 —

2.5480)

32945AA011

(1)

32945AA021

(None)

32945AA031

(2)

64.72 —

65.02

(2.5480 —

2.5598)

32945AA001

(3)

32945AA011

(1)

32945AA021

(None)

MT-00705

MT-00546

MT-00582

Content .. 691 692 693 694 ..