Subaru Legacy III (2000-2003 year). Manual - part 625

MT-68

MANUAL TRANSMISSION AND DIFFERENTIAL

MAIN SHAFT ASSEMBLY FOR SINGLE-RANGE

D: ASSEMBLY

1. 2.0 L SOHC

1) Assemble when each sleeve and hub assembly
are disassembled.

NOTE:
Position open ends of spring 120

°

 apart. 

2) Install 3rd drive gear, baulk ring, sleeve and hub
assembly for 3rd needle bearing on transmission
main shaft. 

NOTE:
Align groove in baulk ring with shifting insert.

3) Install 4th needle bearing race onto transmission
main shaft using ST1, ST2 and a press.

NOTE:
Do not apply pressure in excess of 10 kN (1 ton, 1.1
US ton, 1.0 Imp ton).
ST1

899714110

REMOVER

ST2

499877000

RACE 4-5 INSTALLER

4) Install baulk ring, needle bearing, 4th drive  gear
and 4th gear thrust washer to transmission main
shaft.

NOTE:
Align baulk ring and gear & hub assembly with key
groove.

(A) 3rd-4th hub ASSY

(B) 3rd gear side

(C) 5th-Rev hub ASSY

(D) 5th gear side

MT-00191

( A )

( B )

( C )

( D )

(A) 4th needle bearing race

(A) Groove

(B) 4th gear side

MT-00192

( A )

ST1

ST2

MT-00193

( A )

( B )

MT-69

MANUAL TRANSMISSION AND DIFFERENTIAL

MAIN SHAFT ASSEMBLY FOR SINGLE-RANGE

5) Drive ball bearing onto the rear section of trans-
mission  main shaft using ST1, ST2 and a press.

NOTE:
Do not apply pressure in excess of 10 kN (1 ton, 1.1
US ton, 1.0 Imp ton).
ST1

899714110

REMOVER

ST2

499877000

RACE 4-5 INSTALLER

6) Using ST1 and ST2, install the 5th gear thrust
washer and 5th needle bearing race onto the rear
section of transmission main shaft.

NOTE:
• Do not apply pressure in excess of 10 kN (1 ton,
1.1 US ton, 1.0 Imp ton).
• Face thrust washer in the correct direction.
ST1

899714110

REMOVER

ST2

499877000

RACE 4-5 INSTALLER

7) Install bearing onto synchro cone.

8) Install baulk ring and synchro cone onto 5th-Rev
sleeve and hub assembly using ST and a press.

NOTE:
• Do not apply pressure in excess of 10 kN (1 ton,
1.1 US ton, 1.0 Imp ton).
• Use new ball bearing.
• After press fitting, make sure synchro cone ro-
tates freely.
ST

499757002

INSTALLER

9) Install synchro cone stopper and snap ring to
5th-Rev sleeve and hub assembly.

(A) Face this surface to 5th gear side.

MT-00194

ST2

ST1

MT-00195

( A )

(A) Baulk ring

(B) Synchro cone

(C) Ball bearing

(A) Synchro cone stopper

(B) Snap ring

MT-00196

( A ) ( B )

( C )

ST

MT-00188

( A )

( B )

MT-70

MANUAL TRANSMISSION AND DIFFERENTIAL

MAIN SHAFT ASSEMBLY FOR SINGLE-RANGE

10) Install the rest parts to the rear section of trans-
mission main shaft.

NOTE:
Align groove in baulk ring with shifting insert.

11) Tighten lock nuts to the specified torque using
ST1 and ST2.

NOTE:
Secure lock nuts in two places after tightening.
ST1

499987003

SOCKET WRENCH

ST2

498937000

TRANSMISSION HOLDER

Tightening torque:

118 N·m (12.0 kgf-m, 86.8 ft-lb) 

2. EXCEPT 2.0 L SOHC

1) Assemble each sleeve and hub assembly. 

NOTE:
Position open ends of spring 120

°

 apart. 

(A) Needle bearing 

(B) 5th drive gear

(C) Baulk ring

(D) 5th-Rev sleeve and hub ASSY

(E) Lock washer

(F) Lock nuts

MT-00198

( A )

( B ) ( C )

( D )

( E )

( F )

(A) 3rd-4th hub ASSY

(B) 3rd gear side

(C) 5th-Rev hub ASSY

(D) 5th gear side

MT-00191

( A )

( B )

( C )

( D )

MT-71

MANUAL TRANSMISSION AND DIFFERENTIAL

MAIN SHAFT ASSEMBLY FOR SINGLE-RANGE

2) Install 3rd drive gear, outer baulk ring, synchro
cone, inner baulk ring, sleeve and hub assembly for
3rd needle bearing on transmission main shaft. 

NOTE:
Align groove in baulk ring with shifting insert.

3) Install 4th needle bearing race onto transmission
main shaft using ST1, ST2 and a press.

NOTE:
Do not apply pressure in excess of 10 kN (1 ton, 1.1
US ton, 1.0 Imp ton).
ST1

899714110

REMOVER

ST2

499877000

RACE 4-5 INSTALLER

4) Install baulk ring, needle bearing, 4th drive  gear
and 4th gear thrust washer to transmission main
shaft.

NOTE:
Align baulk ring and gear & hub assembly with key
groove.

5) Drive ball bearing onto the rear section of trans-
mission  main shaft using ST1, ST2 and a press.

NOTE:
Do not apply pressure in excess of 10 kN (1 ton, 1.1
US ton, 1.0 Imp ton).
ST1

899714110

REMOVER

ST2

499877000

RACE 4-5 INSTALLER

(A) 3rd needle bearing 

(B) 3rd drive gear

(C) Inner baulk ring

(D) Synchro cone

(E) Outer baulk ring

(F) Sleeve and hub ASSY

(A) 4th needle bearing race

MT-00200

( A )

( B ) ( C )

( D ) ( E )

( F )

MT-00192

( A )

ST1

ST2

(A) Groove

(B) 4th gear side

MT-00193

( A )

( B )

MT-00194

ST2

ST1