Subaru Legacy III (2000-2003 year). Manual - part 608

AT-166

AUTOMATIC TRANSMISSION (DIAGNOSTICS)

SYMPTOM RELATED DIAGNOSTIC

MEMO:

MANUAL TRANSMISSION AND DIFFEREN-
TIAL

MT

Page

1.

General Description ....................................................................................2

2.

Transmission Gear Oil ..............................................................................31

3.

Manual Transmission Assembly ...............................................................32

4.

Transmission Mounting System ................................................................39

5.

Oil Seal......................................................................................................41

6.

Switches and Harness ..............................................................................42

7.

Vehicle Speed Sensor...............................................................................45

8.

Preparation for Overhaul...........................................................................46

9.

Transfer Case and Extension Case Assembly..........................................47

10.

Transfer Drive Gear ..................................................................................51

11.

Transfer Driven Gear ................................................................................53

12.

Center Differential .....................................................................................55

13.

Reverse Check Sleeve..............................................................................56

14.

Transmission Case ...................................................................................59

15.

Main Shaft Assembly for Single-Range ....................................................66

16.

Main Shaft Assembly for Dual-Range .......................................................74

17.

Input Shaft Assembly ................................................................................83

18.

Drive Pinion Shaft Assembly .....................................................................87

19.

Front Differential Assembly .......................................................................95

20.

Speedometer Gear..................................................................................103

21.

Reverse Idler Gear..................................................................................104

22.

Shifter Fork and Rod ...............................................................................106

23.

Counter Gear ..........................................................................................109

24.

General Diagnostic..................................................................................111

MT-2

MANUAL TRANSMISSION AND DIFFERENTIAL

GENERAL DESCRIPTION

1. General Description

A: SPECIFICATIONS

1. MANUAL TRANSMISSION AND DIFFERENTIAL

*: Dual-range model only

Item

Model

2.0 L

non-TURBO

2.5 L

2.0 L

TURBO

General and Europe

Australia

Except OUTBACK

OUTBACK

Except

OUTBACK

OUTBACK

Type

5-forward speeds and 1-reverse

(5 x 2-forward speeds and 1 x 2-reverse)*

Transmission gear 
ratio

1st

3.454

3.166

2nd

2.062

1.882

3rd

1.448

1.296

4th

1.088

0.972

5th

0.825

0.780

0.825

0.738

Reverse

3.333

Auxiliary transmis-
sion gear ratio*

High

1.000

—

Low

1.447

1.196

—

Front 
reduction 
gear

Final

Type of 
gear

Hypoid

Gear ratio

3.900

3.700

3.900

4.111

Rear 
reduction 
gear

Transfer

Type of 
gear

Helical

Gear ratio

1.000

Final

Type of 
gear

Hypoid

Gear ratio

3.900

3.700

3.900

4.111

Front dif-
ferential

Type and number of 
gear

Straight bevel gear (Bevel pinion: 2, Bevel gear: 2)

Center dif-
ferential

Type and number of 
gear

Straight bevel gear

(Bevel pinion: 2, Bevel gear: 2 and viscous coupling)

Transmission gear oil

GL-5

Transmission gear oil 
capacity

Single-
range 
model

3.5 

2

 (3.7 US qt, 3.1 Imp qt)

Dual-range 
model

4.0 

2

 (4.2 US qt, 3.5 Imp qt)

—

MT-3

MANUAL TRANSMISSION AND DIFFERENTIAL

GENERAL DESCRIPTION

2. TRANSMISSION GEAR OIL

Recommended oil

3. TRANSMISSION CASE ASSEMBLY

Drive pinion shim adjustment
Hypoid gear backlash

0.13 — 0.18 mm (0.0051 — 0.0071 in)

Selection of main shaft rear plate

Snap ring to counter washer clearance

0.05 — 0.35 mm (0.0020 — 0.0138 in)

Input shaft holder adjustment

4. DRIVE PINION ASSEMBLY

Preload adjustment of thrust bearing

Starting torque
0.3 — 0.8 N·m (0.03 — 0.08 kgf-m, 0.2 — 0.6 ft-

lb)

5. INPUT SHAFT ASSEMBLY

Snap ring (Outer-28) to ball bearing clearance

0 — 0.12 mm (0 — 0.0047 in)

Snap ring (Inner-68) to bearing clearance

0 — 0.12 mm (0 — 0.0047 in)

(1) ITEM

(2) Transmission gear oil

(3) API Classification

(4) SAE Viscosity No. and Applicable Temperature

Drive pinion shim

Part No.

Thickness

 mm (in)

Part No. 

Thickness

 mm (in)

32295AA031

0.150 

(0.0059) 

32295AA071

0.250 

(0.0098)

32295AA041

0.175 

(0.0069) 

32295AA081

0.275 

(0.0108)

32295AA051

0.200 

(0.0079) 

32295AA091

0.300 

(0.0118)

32295AA061

0.225 

(0.0089) 

32295AA101

0.500 

(0.0197)

Main shaft rear plate

Dimension “A” mm (in) 

Part No.

Mark

4.00 — 4.13

(0.1575 — 0.1626) 

32294AA041

1

3.87 — 3.99

(0.1524 — 0.1571) 

32294AA051

2

Snap ring (Outer-19)

Part No.

Thickness mm (in)

031319000

1.50 (0.0591)

805019010

1.72 (0.0677)

MT-00001

(1)

(4)

GL-5

(3)

(2)

-30 -26 -15

15

90

85W

80W

75W -90

25      

30 

-5 0

-22 -15

23 32

86

59

77

5

(˚C)
(˚F)

Dimension “D” mm (in)

Number of shim

52.50 — 53.11

(2.0669 — 2.0909)

—

52.00 — 52.49

(2.0472 — 2.0665)

1

51.26 — 51.99

(2.0181 — 2.0468)

2

Adjusting washer No. 1

Part No. 

Thickness mm (in)

803025051

3.925 (0.1545)

803025052 3.950 

(0.1555)

803025053

3.975 (0.1565)

803025054 4.000 

(0.1575)

803025055

4.025 (0.1585)

803025056 4.050 

(0.1594)

803025057

4.075 (0.1604)

Adjusting washer No. 2

Part No. 

Thickness mm (in)

803025059

3.850 (0.1516)

803025054 4.000 

(0.1575)

803025058

4.150 (0.1634)

Snap ring (Outer-28)

Part No.

Thickness mm (in)

805028050

2.48 (0.0976)

805028060

2.56 (0.1008)

805028070

2.64 (0.1039)

Snap ring (Inner-68)

Part No.

Thickness mm (in)

805168020

1.84 (0.0724)

805168030

1.92 (0.0756)

805168040

2.00 (0.0787)