Subaru Legacy III (2000-2003 year). Manual - part 627

MT-76

MANUAL TRANSMISSION AND DIFFERENTIAL

MAIN SHAFT ASSEMBLY FOR DUAL-RANGE

8) Remove the rest of parts.

D: ASSEMBLY

1. 2.0 L

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

NOTE:
Position open ends of spring 120

°

 apart.

(A) Sleeve and hub ASSY

(B) High-low baulk ring

(C) Friction damper

(D) Low input gear

(E) Needle bearing 

(F) Input low gear spacer

(G) Ball

MT-00216

( A )

( B )

( B )

( F )

( C )

( D )

( G )

( E )

(A) High-low coupling sleeve

(B) Shifting insert

(C) High-low synchronizer spring

(D) High-low synchronizer hub

(E) Sleeve

(F) Insert key

(G) 3rd-4th synchronizer hub

(H) Sleeve

(I) Insert key

(J) 5th-Rev synchronizer hub

(K) High side

(L) Low side

(M) 3rd side

(N) 4th side

(O) 5th side

(P) Rev side

MT-00217

( A )

( B )

( C )

( D )

( K )

( L )

( E )

( F )

( N )

( M )

( P )

( O )

( G )

( H )

( I )

( J )

MT-77

MANUAL TRANSMISSION AND DIFFERENTIAL

MAIN SHAFT ASSEMBLY FOR DUAL-RANGE

2) Install 3rd drive gear, baulk ring, sleeve and hub
assembly for 3rd-4th needle bearing on transmis-
sion 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.
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:
Face thrust washer in the correct direction.

5) Drive ball bearing onto the rear section of trans-
mission main shaft using ST1, ST2 and a press.
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:
Face thrust washer in the correct direction.
ST1

899714110

REMOVER

ST2

499877000

RACE 4-5 INSTALLER

7) Install bearing onto synchro cone.

(A) 4th needle bearing race

(A) Groove

(B) 4th gear side

MT-00192

( A )

ST1

ST2

MT-00193

( A )

( B )

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

MT-00194

ST2

ST1

MT-00195

( A )

MT-78

MANUAL TRANSMISSION AND DIFFERENTIAL

MAIN SHAFT ASSEMBLY FOR DUAL-RANGE

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

NOTE:
After press fitting, make sure synchro cone rotates
freely.
ST

499757002

INSTALLER

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

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:

120 N·m (12.2 kgf-m, 88.2 ft-lb)

12) Install needle bearing on main shaft.

(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 )

(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 )

MT-79

MANUAL TRANSMISSION AND DIFFERENTIAL

MAIN SHAFT ASSEMBLY FOR DUAL-RANGE

13) Install the parts to the front section of transmis-
sion main shaft.

NOTE:
• Be careful not to damage the graded section of
transmission main shaft when installing needle
bearing.
• Face the grooved side toward input gear.
• Align high-low baulk ring's groove with shifting in-
sert.

14) Install new snap ring to the rod section of trans-
mission main shaft using ST1 and ST2.

NOTE:
Select a suitable outer snap ring so that axial clear-
ance between snap ring and hub is held within
0.060 to 0.100 mm (0.0024 to 0.0039 in).
ST1

499757002

INSTALLER

ST2

499757001

SNAP RING GUIDE

2. EXCEPT 2.0 L

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

NOTE:
Position open ends of spring 120

°

 apart.

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

NOTE:
Align groove in baulk ring with shifting insert.

(A) Ball 

(B) Input low gear spacer

(C) Needle bearing 

(D) Low input gear

(E) Friction damper

(F) High-low baulk ring

(G) Sleeve and hub ASSY

Snap ring

Part No.

Thickness mm (in)

805025051

2.42 (0.0953)

805025052

2.47 (0.0972)

805025053

2.52 (0.0992)

805025054

2.57 (0.1012)

805025055

2.62 (0.1031)

805025056

2.67 (0.1051)

805025057

2.72 (0.1071)

805025058

2.37 (0.0933)

MT-00225

( A )

( B )

( C )

( D )

( E )

( F )

( F )

( G )

(A) High-low coupling sleeve

(B) Shifting insert

(C) High-low synchronizer spring

(D) High-low synchronizer hub

(E) Sleeve

(F) Insert key

(G) 3rd-4th synchronizer hub

(H) Sleeve

(I) Insert key

(J) 5th-Rev synchronizer hub

(K) High side

(L) Low side

(M) 3rd side

(N) 4th side

(O) 5th side

(P) Rev side

MT-00217

( A )

( B )

( C )

( D )

( K )

( L )

( E )

( F )

( N )

( M )

( P )

( O )

( G )

( H )

( I )

( J )

MT-00200

( A )

( B ) ( C )

( D ) ( E )

( F )