Subaru Legacy III (2000-2003 year). Manual - part 619

MT-44

MANUAL TRANSMISSION AND DIFFERENTIAL

SWITCHES AND HARNESS

3. HIGH-LOW SWITCH

1) Turn ignition switch to OFF.
2) Disconnect connector high-low switch.
3) Measure resistance between HIGH-LOW switch
terminals.

4) Replace defective parts if outside the standard
value.

Gear shift position

Terminal No.

Specified resis-

tance

Lo position

1 and 2

Less than 1

Ω

Hi position

More than 1 M

Ω

MT-00112

MT-45

MANUAL TRANSMISSION AND DIFFERENTIAL

VEHICLE SPEED SENSOR

7. Vehicle Speed Sensor

A: REMOVAL

1) Disconnect battery ground cable.
2) Lift-up the vehicle.
3) Remove front, center exhaust pipes. (Non-TUR-
BO model)
Without OBD
<Ref. to EX(H4SOw/oOBD)-9, REMOVAL, Front
Exhaust Pipe.>
With OBD
<Ref. to EX-<Ref. to EX(H4SO)-5, REMOVAL,
Front Exhaust Pipe.>
4) Remove center exhaust pipes. (TURBO model)
<Ref. to EX(H4DOSTC)-7, REMOVAL, Center Ex-
haust Pipe.>
5) Disconnect connector from vehicle speed sen-
sor.
6) Turn and remove vehicle speed sensor.

B: INSTALLATION

NOTE:
• Discard vehicle speed sensor and after removal,
replace with a new one.
• Ensure sensor mounting hole is clean and free of
foreign matter.
• Align tip end of key with key groove on end of
speedometer shaft during installation.
1) Hand tighten vehicle speed sensor.
2) Tighten vehicle speed sensor using suitable tool.

Tightening torque:

5.9 N·m (0.6 kgf-m, 4.3 ft-lb)

3) Connect connector to vehicle speed sensor.
4) Install front, center exhaust pipes. (Non-TURBO
model)
Without OBD
<Ref. to EX(H4SOw/oOBD)-10, INSTALLATION,
Front Exhaust Pipe.>
With OBD
<Ref. to EX(H4SO)-6, INSTALLATION, Front Ex-
haust Pipe.>
5) Install center exhaust pipes. (TURBO model)
<Ref. to EX(H4DOSTC)-8, INSTALLATION, Cen-
ter Exhaust Pipe.>

6) Lower the vehicle.
7) Connect battery ground cable.

C: INSPECTION

Inspect the vehicle speed sensor. <Ref. to IDI-18,
INSPECTION, Speedometer.>

MT-00113

MT-46

MANUAL TRANSMISSION AND DIFFERENTIAL

PREPARATION FOR OVERHAUL

8. Preparation for Overhaul

A: PROCEDURE

1) Clean oil, grease, dirt and dust from transmis-
sion.
2) Remove drain plug to drain oil. After draining, re-
tighten it as before.

NOTE:
Replace gasket with a new one.

Tightening torque:

44 N·m (4.5 kgf-m, 32.5 ft-lb)

3) Attach transmission to ST.
ST

499937100

TRANSMISSION STAND
SET

4) Rotating parts should be coated with oil prior to
assembly.
5) All disassembled parts, if to be reused, should
be reinstalled in the original positions and direc-
tions.
6) Gaskets, lock washers and lock nut must be re-
placed with new ones.
7) Liquid gasket should be used where specified to
prevent leakage.

MT-00097

MT-00115

MT-47

MANUAL TRANSMISSION AND DIFFERENTIAL

TRANSFER CASE AND EXTENSION CASE ASSEMBLY

9. Transfer Case and Extension

Case Assembly

A: REMOVAL

1) Remove the manual transmission assembly
from vehicle. <Ref. to MT-32, REMOVAL, Manual
Transmission Assembly.>
2) Remove back-up light switch and neutral posi-
tion switch. <Ref. to MT-42, REMOVAL, Switches
and Harness.>
3) Remove transfer case with extension case as-
sembly.

4) Remove shifter arm.
5) Remove extension case assembly.

B: INSTALLATION

1) Install center differential and transfer driven gear
into transfer case.

2) Remove bearing cone from the extension case
assembly, and install to taper roller bearing of the
transfer driven gear.

3) While pressing the bearing cone horizontally,
turn the driven shaft ten rotations.
4) Measure height “W” between transfer case and
taper roller bearing on the transfer driven gear.

5) Measure depth “X”.

NOTE:
Measure with bearing cone and thrust washer re-
moved.

6) Calculate space “t” using the following equation:
t = X

−

W + 0.2 to 0.3 mm (0.008 to 0.012 in)

MT-00116

MT-00117

MT-00118

(A) Bearing cone (Extension case)

(B) Extension case

MT-00119

( A )

( B )

MT-00120

MT-00121

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