Subaru Legacy III (2000-2003 year). Manual - part 621

 

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Subaru Legacy III (2000-2003 year). Manual - part 621

 

 

MT-52

MANUAL TRANSMISSION AND DIFFERENTIAL

TRANSFER DRIVE GEAR

E: INSPECTION

1) Bearings
Replace bearings in the following cases: 
• Broken or rusty bearings
• Worn or damaged
• Bearings that fail to turn smoothly or make ab-
normal noise when turned after gear oil lubrication.
2) Drive gear
Replace drive gear in the following cases: 
• If their tooth surfaces and shaft are excessively
broken or damaged.
3) Measure clearance between snap ring and inner
race of ball bearing with a thickness gauge.

Clearance:

0.01 — 0.15 mm (0.0004 — 0.0059 in)

If the measurement is not within the specification,
select suitable snap ring.

Snap ring

Part No.

Thickness mm (in)

805030041

1.53 (0.0602)

805030042

1.65 (0.0650)

805030043

1.77 (0.697)

MT-00138

MT-53

MANUAL TRANSMISSION AND DIFFERENTIAL

TRANSFER DRIVEN GEAR

11.Transfer Driven Gear

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. <Ref. to MT-47, REMOVAL, Transfer
Case and Extension Case Assembly.>
4) Remove extension case assembly.
5) Remove transfer driven gear.

6) Remove bearing outer race from extension case
and transfer case.

B: INSTALLATION

1) Install bearing outer race to extension case and
transfer case.

2) Install transfer driven gear.

3) Install transfer case and extension case assem-
bly. <Ref. to MT-47, INSTALLATION, Transfer
Case and Extension Case Assembly.>
4) Install back-up light switch and neutral position
switch. <Ref. to MT-43, INSTALLATION, Switches
and Harness.>
5) Install the manual transmission assembly to ve-
hicle. <Ref. to MT-35, INSTALLATION, Manual
Transmission Assembly.>

(A) Bearing outer race (transfer case)

(B) Bearing outer race (extension case)

MT-00118

MT-00140

( A )

( B )

(A) Bearing outer race

(B) Bearing outer race

(C) Transfer case

(D) Extension case

(C)

(A)

(D)

(B)

MT-00141

MT-00118

MT-54

MANUAL TRANSMISSION AND DIFFERENTIAL

TRANSFER DRIVEN GEAR

C: DISASSEMBLY

1) Using ST, remove roller bearing (extension case
side).
ST

498077000

REMOVER

2) Using ST1 and ST2, remove roller bearing
(transfer case side).
ST1

498077000

REMOVER

ST2

899864100

REMOVER

D: ASSEMBLY

1) Using ST, install roller bearing (extension case
side). 
ST1

398177700

INSTALLER

ST2

899864100

REMOVER

NOTE:
Do not apply pressure in excess of 10 kN (1 ton, 1.1
US ton, 1.0 Imp ton) 

2) Using ST, install roller bearing (transfer case
side).
ST

499757002

INSTALLER

NOTE:
Do not apply pressure in excess of 10 kN (1 ton, 1.1
US ton, 1.0 Imp ton) 

E: INSPECTION

1) Bearings
Replace bearings in the following cases: 
• Broken or rusty bearings
• Worn or damaged
• Bearings that fail to turn smoothly or make ab-
normal noise when turned after gear oil lubrication.
2) Driven gear
Replace drive gear in the following cases: 
• If their tooth surfaces and shaft are excessively
broken or damaged.

(A) Roller bearing

(A) Roller bearing

MT-00143

( A )

ST

MT-00144

( A )

ST2

ST1

(A) Roller bearing

(A) Roller bearing

MT-00145

( A )

ST1

ST2

MT-00146

( A )

ST

MT-55

MANUAL TRANSMISSION AND DIFFERENTIAL

CENTER DIFFERENTIAL

12.Center Differential

A: REMOVAL

1) Remove the manual transmission assembly
from vehicle. <Ref. to MT-32, REMOVAL, Manual
Transmission Assembly.>
2) Remove the transfer case with extension case
assembly. <Ref. to MT-47, REMOVAL, Transfer
Case and Extension Case Assembly.>
3) Remove the extension case assembly. <Ref. to
MT-47, REMOVAL, Transfer Case and Extension
Case Assembly.>
4) Remove the transfer driven gear. <Ref. to MT-
53, REMOVAL, Transfer Driven Gear.>
5) Remove the center differential.

B: INSTALLATION

1) Install the center differential into transfer case.
2) Install the transfer driven gear. <Ref. to MT-53,
INSTALLATION, Transfer Driven Gear.>
3) Install the extension case assembly. <Ref. to
MT-47, INSTALLATION, Transfer Case and Exten-
sion Case Assembly.>
4) Install the transfer case with extension case as-
sembly. <Ref. to MT-47, REMOVAL, Transfer
Case and Extension Case Assembly.>
5) Install the back-up light switch and neutral posi-
tion switch. <Ref. to MT-42, REMOVAL, Switches
and Harness.>
6) Install the manual transmission assembly to ve-
hicle. <Ref. to MT-35, INSTALLATION, Manual
Transmission Assembly.>

C: DISASSEMBLY

1) Remove ball bearing using ST.

NOTE:
Do not reuse ball bearing.
ST

498077300

CENTER DIFFERENTIAL 
BEARING REMOVER

2) Do not disassemble center differential because it
is a non-disassemble part.

D: ASSEMBLY

Install new ball bearing to center differential assem-
bly.

NOTE:
Do not apply pressure in excess of 10 kN (1 ton, 1.1
US ton, 1.0 Imp ton).

E: INSPECTION

1) Bearings
Replace bearings in the following cases: 
• Broken or rusty bearings
• Worn or damaged
• Bearings that fail to turn smoothly or make ab-
normal noise when turned after gear oil lubrication.
• Bearings having other defects
2) Center differential
Replace center differential assembly in the follow-
ing case: 
• Worn or damaged

MT-00147

ST

(A) Ball bearing

MT-00148

( A )

 

 

 

 

 

 

 

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