Subaru Legacy III (2000-2003 year). Manual - part 624

MT-64

MANUAL TRANSMISSION AND DIFFERENTIAL

TRANSMISSION CASE

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) Tighten input shaft holder attaching bolts.

Tightening torque:

20 N·m (2.0 kgf-m, 14.5 ft-lb) 

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

NOTE:
Support drive pinion assembly with ST.
ST

498427100

STOPPER

10) Place the transmission with case left side fac-
ing downward and put ST1 on bearing outer race.
11) 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

(A) Input shaft holder

(B) Input shaft

MT-00178

( 8 )

( 6 )

( 3 )

( 4 )

( 7 )

( 5 )

( 9 )

( 2 )

( 1 )

(11)

(17)

(16)

(13)

(15)

(14)

(10)

(12)

MT-00158

MT-00163

( A )

( B )

MT-00174

ST

MT-00175

ST3

ST1

ST2

MT-65

MANUAL TRANSMISSION AND DIFFERENTIAL

TRANSMISSION CASE

12) 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

13) 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.
14) Turn in the retainer on the upper side addition-
ally by 1 notch in order to apply preload on taper
roller bearing.
15) Tighten temporarily both the upper and lower
lock plates and mark both holder and lock plate for
later readjustment.
16) Turn transmission main shaft several times
while tapping around retainer lightly with plastic
hammer.
17) Inspect and adjust backlash and tooth contact
of hypoid gear. <Ref. to MT-99, INSPECTION,
Front Differential Assembly.>  

18) After checking the tooth contact of hypoid
gears, remove the lock plate. Then loosen retainer
until the 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)

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

C: INSPECTION

Check the transmission case for cracks, damage,
and oil leaks.

MT-00176

ST

MT-00177

T

MT-66

MANUAL TRANSMISSION AND DIFFERENTIAL

MAIN SHAFT ASSEMBLY FOR SINGLE-RANGE

15.Main Shaft Assembly for Sin-

gle-Range

A: REMOVAL

1) Remove the manual transmission assembly
from vehicle. <Ref. to MT-32, REMOVAL, Manual
Transmission Assembly.>  
2) Remove transfer case with extension case as-
sembly. <Ref. to MT-47, REMOVAL, Transfer
Case and Extension Case Assembly.>  
3) Remove transmission case. <Ref. to MT-47, RE-
MOVAL, Transfer Case and Extension Case As-
sembly.>
4) Removes drive pinion shaft assembly. <Ref. to
MT-87, REMOVAL, Drive Pinion Shaft Assembly.>  
5) Remove main shaft assembly.

B: INSTALLATION

1) Install the needle bearing and oil seal onto the
front of transmission main shaft assembly.

NOTE:
• Wrap clutch splined section with vinyl tape to
prevent damage to oil seal.
• Apply grease (Unilube #2 or equivalent) to the
sealing lip of oil seal.
• Use a new one.
2) Install needle bearing outer race knock pin hole
into transmission case knock pin.

NOTE:
Align the end face of seal with surface (A) when in-
stalling oil seal.

3) Install the drive pinion assembly. <Ref. to MT-
87, INSTALLATION, Drive Pinion Shaft Assem-
bly.>
4) Install transmission case. <Ref. to MT-61, IN-
STALLATION, Transmission Case.>
5) Install transfer case with extension case assem-
bly. <Ref. to MT-47, INSTALLATION, Transfer
Case and Extension Case Assembly.>  
6) Install the manual transmission assembly to ve-
hicle. <Ref. to MT-35, INSTALLATION, Manual
Transmission Assembly.>  

C: DISASSEMBLY

1) Put vinyl tape around main shaft splines to pro-
tect oil seal  from damage. Then pull out oil seal
and needle bearing by hand.
2) Remove lock nut from transmission main shaft
assembly.

NOTE:
Remove caulking before taking off lock nut.
ST1

498937000

TRANSMISSION HOLDER

ST2

499987003

SOCKET WRENCH (35)

3) Remove 5th-Rev sleeve and hub assembly,
baulk ring, 5th drive gear and needle bearing.

4) Remove snap ring and synchro cone stopper
from 5th-Rev sleeve and hub assembly.

MT-00185

( A )

(A) 5th-Rev sleeve and hub ASSY

(B) Baulk ring

(C) 5th drive gear

(A) Synchro cone stopper

(B) Snap ring

MT-00186

ST2

ST1

MT-00187

( A )

( B )

( C )

MT-00188

( A )

( B )

MT-67

MANUAL TRANSMISSION AND DIFFERENTIAL

MAIN SHAFT ASSEMBLY FOR SINGLE-RANGE

5) Using ST1, ST2 and a press, remove ball bear-
ing, synchro cone and baulk ring (Rev).

NOTE:
• Replace sleeve and hub with new ones. Do not
attempt to disassemble because they must engage
at a specified point. If they should be disassem-
bled, mark engagement point on splines before-
hand.
• Do not reuse ball bearing.
ST1

499757002

INSTALLER

ST2

498077400

SYNCHRO CONE REMOV-
ER

6) Using ST1 and ST2, remove the rest of parts.

NOTE:
Replace sleeve and hub with new ones. Do not at-
tempt to disassemble because they must engage
at a specified point. If they should be disassem-
bled, marking engagement point on splines before-
hand.
ST1

899864100

REMOVER

ST2

899714110

REMOVER

(A) Ball bearing

(B) Synchro cone

(C) Baulk ring

MT-00189

( A )

( B )

( C )

ST1

ST2

(A) Press

MT-00190

ST1

ST2

( A )