Subaru Legacy III (2000-2003 year). Manual - part 623

MT-60

MANUAL TRANSMISSION AND DIFFERENTIAL

TRANSMISSION CASE

2. DUAL-RANGE

1) Remove the manual transmission assembly
from vehicle. <Ref. to MT-32, REMOVAL, Manual
Transmission Assembly.>
2) Remove clutch release lever. <Ref. to CL-22,
REMOVAL, Release Bearing and Lever.>
3) Remove transfer case with extension case as-
sembly. <Ref. to MT-47, REMOVAL, Transfer
Case and Extension Case Assembly.>
4) Remove the input shaft holder.

5) Remove the high-low switch. <Ref. to MT-42,
REMOVAL, Switches and Harness.>
6) Using ST, drive out straight pin, and remove
high-low shifter lever.
ST

398791700

STRAIGHT PIN REMOVER 2

NOTE:
When driving out straight pin, remove it in the direc-
tion that it does not butt against transmission case.

7) Remove main shaft rear plate.

8) Put vinyl tape around splines of right and left
axle drive shafts to prevent damage to oil seals.

9) Separate transmission case into right and left
cases by loosening seventeen coupling bolts and
nuts.

(A) Input shaft holder

(B) Input shaft

(A) Straight pin

(B) High-low shifter lever

MT-00163

( A )

( B )

MT-00164

( A )

( B )

(A) Main shaft rear plate

(A) Vinyl tape

MT-00159

( A )

MT-00362

( A )

MT-00160

MT-61

MANUAL TRANSMISSION AND DIFFERENTIAL

TRANSMISSION CASE

10) Remove drive pinion shaft assembly from left
side transmission case.

NOTE:
Use a hammer handle, etc. to remove if too tight.

11) Removing high-low shifter fork
Raise main shaft assembly slightly, and remove
high-low shifter fork together with high-low shifter
shaft and washer.

NOTE:
Be careful not to drop the two high-low shifter piec-
es.

12) Remove main shaft assembly and input shaft
assembly.

NOTE:
Be careful not to drop input shaft and main shaft as
they are separable.

13) Remove differential assembly.

NOTE:
• Be careful not to confuse right and left roller
bearing outer races.
• Be careful not to damage retainer oil seal.

B: INSTALLATION

1. SINGLE-RANGE

1) Wipe off grease, oil and dust on the mating sur-
faces of transmission cases with white gasoline.
2) Install the front differential assembly.
3) Install the main shaft assembly.
Install needle bearing knock pin hole into transmis-
sion case knock pin.
4) Install the drive pinion shaft assembly.
Install roller bearing knock pin hole into transmis-
sion case knock pin.
5) Apply liquid gasket, and then put case right side
and left side together.

Liquid gasket:

THREE BOND 1215 (Part No. 004403007) or
equivalent

(A) Main shaft assembly

(B) Drive pinion shaft assembly

(A) High-low shifter fork

(B) Input shaft ASSY

MT-00161

( A )

( B )

( A )

( B )

MT-00169

(A) Main shaft ASSY

(B) Input shaft ASSY

MT-00170

(A)

(B)

MT-00162

MT-62

MANUAL TRANSMISSION AND DIFFERENTIAL

TRANSMISSION CASE

6) Tighten 17 bolts with bracket, clip, etc. as shown
in the figure.

NOTE:
• Insert bolts from the bottom and tighten nuts at
the top.
• Put cases together so that drive pinion shim and
input shaft holder shim are not caught up in be-
tween.
• Confirm that speedometer gear is meshed.

Tightening torque:

8 mm bolt

25 N·m (2.5 kgf-m, 18.1 ft-lb)

★

10 mm bolt

39 N·m (4.0 kgf-m, 28.9 ft-lb)

7) Tighten ball bearing attachment bolts.

Tightening torque:

29 N·m (3.0 kgf-m, 21.7 ft-lb)

8) Backlash adjustment of hypoid gear and preload
adjustment of roller bearing

NOTE:
Support drive pinion assembly with ST.
ST

498427100

STOPPER

9) Place the transmission with case left side facing
downward and put ST1 on bearing outer race.
10) Screw retainer assembly into left case from the
bottom with ST2. Fit ST3 on the transmission main
shaft. Shift gear into 4th or 5th and turn the shaft
several times. Screw in the retainer while turning
ST3 until a slight resistance is felt on ST2.
This is the contact point of hypoid gear and drive
pinion shaft. Repeat the above sequence several
times to ensure the contact point.
ST1

399780104

WEIGHT

ST2

499787000

WRENCH ASSY

ST3

499927100

HANDLE

MT-00178

( 8 )

( 6 )

( 3 )

( 4 )

( 7 )

( 5 )

( 9 )

( 2 )

( 1 )

(11)

(17)

(16)

(13)

(15)

(14)

(10)

(12)

MT-00158

MT-00174

MT-00175

ST3

ST1

ST2

MT-63

MANUAL TRANSMISSION AND DIFFERENTIAL

TRANSMISSION CASE

11) Remove weight and screw in retainer without
O-ring on the upper side and stop at the point
where slight resistance is felt.

NOTE:
At this point, the backlash between the hypoid gear
and drive pinion shaft is zero.
ST

499787000

WRENCH ASSY

12) Fit lock plate. Loosen the retainer on the lower
side by 1-1/2 notches of lock plate and turn in the
retainer on the upper side by the same amount in
order to obtain the backlash.

NOTE:
The notch on the lock plate moves by 1/2 notch if
the plate is turned upside down.
13) Turn in the retainer on the upper side addition-
ally by 1 notch in order to apply preload on taper
roller bearing.
14) Tighten temporarily both the upper and lower
lock plates and mark both holder and lock plate for
later readjustment.
15) Turn transmission main shaft several times
while tapping around retainer lightly with plastic
hammer.
16) Inspect and adjust backlash and tooth contact
of hypoid gear. <Ref. to MT-99, INSPECTION,
Front Differential Assembly.>
17) After checking the tooth contact of hypoid
gears, remove the lock plate. Then loosen retainer
until the new O-ring groove appears. Fit new O-ring
into the groove and tighten retainer into the position
where retainer has been tightened in.
Tighten lock plate.

NOTE:
Carry out this job on both upper and lower retain-
ers.

Tightening torque:

T: 25 N·m (2.5 kgf-m, 18.1 ft-lb)

18) Selecting of main shaft rear plate <Ref. to MT-
73, ADJUSTMENT, Main Shaft Assembly for Sin-
gle-Range.>
19) Install clutch release lever and bearing. <Ref.
to CL-22, INSTALLATION, Release Bearing and
Lever.>
20) Install transfer case with extension case as-
sembly. <Ref. to MT-47, INSTALLATION, Transfer
Case and Extension Case Assembly.>
21) Install the manual transmission assembly into
the vehicle. <Ref. to MT-35, INSTALLATION, Man-
ual Transmission Assembly.>

2. DUAL-RANGE

1) Wipe off grease, oil and dust on the mating sur-
faces of transmission cases with white gasoline.
2) Install the front differential assembly.
3) Install the main shaft assembly and input shaft
assembly.
Connect main shaft assembly and input shaft as-
sembly, and install needle bearing knock pin hole
into transmission case knock pin.
4) Install the drive pinion shaft assembly.
Install roller bearing knock pin hole into transmis-
sion case knock pin.
5) Apply liquid gasket, and then put case right side
and left side together.

Liquid gasket:

THREE BOND 1215 (Part No. 004403007) or
equivalent

6) Tighten 17 bolts with bracket, clip, etc. as shown
in the figure.

MT-00176

MT-00177

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