Subaru Legacy III (2000-2003 year). Manual - part 628

MT-80

MANUAL TRANSMISSION AND DIFFERENTIAL

MAIN SHAFT ASSEMBLY FOR DUAL-RANGE

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.
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

(A) 4th needle bearing race

(A) Groove

(B) 4th gear side

MT-00192

( A )

ST1

ST2

MT-00193

( A )

( B )

MT-00194

ST2

ST1

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

(A) Baulk ring

(B) Synchro cone

(C) Ball bearing

MT-00195

( A )

MT-00196

( A ) ( B )

( C )

ST

MT-81

MANUAL TRANSMISSION AND DIFFERENTIAL

MAIN SHAFT ASSEMBLY FOR DUAL-RANGE

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.

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

(A) Synchro cone stopper

(B) Snap ring

(A) Needle bearing 

(B) 5th drive gear

(C) Baulk ring

(D) 5th-Rev sleeve and hub ASSY

(E) Lock washer

(F) Lock nuts 

MT-00188

( A )

( B )

MT-00198

( A )

( B ) ( C )

( D )

( E )

( F )

(A) Sleeve and hub ASSY 

(B) High-low baulk ring

(C) Friction dampe

(D) Low input gear

(E) Needle bearing

(F) Input low gear spacer

(G) Ball

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-00216

( A )

( B )

( B )

( F )

( C )

( D )

( G )

( E )

MT-82

MANUAL TRANSMISSION AND DIFFERENTIAL

MAIN SHAFT ASSEMBLY FOR DUAL-RANGE

E: INSPECTION

Disassembled parts should be washed clean first
and then inspected  carefully.
1) Bearings
Replace bearings in the following cases: 
• Bearings whose balls, outer races and inner rac-
es are broken or  rusty.
• Worn bearings
• Bearings that fail to turn smoothly or make ab-
normal noise when  turned after gear oil lubrication.
• Bearings having other defects
2) Bushing (each gear)
Replace the bushing in the following cases: 
• When the sliding surface is damaged or abnor-
mally worn. 
• When the inner wall is abnormally worn.
3) Gears
• Replace gears with new ones if their tooth sur-
faces are  broken, damaged, or excessively worn.
• Correct or replace if the cone that contacts the
baulk ring is  rough or damaged.
• Correct or replace if the inner surface or end face
is damaged.
4) Baulk ring
Replace the ring in the following cases:
• When the inner surface and end face are dam-
aged.
• When the ring inner surface is abnormally or par-
tially worn  down.
• When the contact surface of the synchronizer
ring insert is scored or abnormally worn down.
5) Shifting insert key
Replace the insert if deformed, excessively worn,
or defective in any  way.
6) Oil seal
Replace the oil seal if the lip is deformed, hard-
ened, damaged, worn,  or defective in any way.
7) O-ring 
Replace the O-ring if the sealing face is deformed,
hardened, damaged,  worn, or defective in any
way.
8) Gearshift mechanism
Repair or replace the gearshift mechanism if ex-
cessively worn, bent, or  defective in any way.

F: ADJUSTMENT

Choose main shaft rear plate. <Ref. to MT-73, AD-
JUSTMENT, Main Shaft Assembly for Single-
Range.>

MT-83

MANUAL TRANSMISSION AND DIFFERENTIAL

INPUT SHAFT ASSEMBLY

17.Input Shaft Assembly

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 transmission case. <Ref. to MT-59, RE-
MOVAL, Transmission Case.>
4) Remove drive pinion shaft assembly. <Ref. to
MT-87, REMOVAL, Drive Pinion Shaft Assembly.>
5) Remove main shaft assembly and input shaft as-
sembly.

B: INSTALLATION

1) Install the needle bearing onto the front of the
transmission main shaft assembly.
2) Connect main shaft assembly and input shaft as-
sembly.
3) Install needle bearing outer race knock pin hole
into transmission case knock pin.
4) Install the drive pinion assembly. <Ref. to MT-
87, INSTALLATION, Drive Pinion Shaft Assem-
bly.>
5) Install the transmission case. <Ref. to MT-61,
INSTALLATION, Transmission Case.>
6) Install the transfer case with extension case as-
sembly. <Ref. to MT-47, INSTALLATION, Transfer
Case and Extension Case Assembly.>
7) Install manual transmission assembly on vehi-
cle. <Ref. to MT-35, INSTALLATION, Manual
Transmission Assembly.>

C: DISASSEMBLY

1) Remove O-ring from input shaft holder. Also, re-
move input shaft holder shim.

NOTE:
Sometimes, shim may not be available.

2) Put vinyl tape around input shaft splines to pro-
tect oil seal from damage.
3) Remove inner snap ring.
ST

398663600

PLIERS

4) Hold input shaft holder stationary and remove in-
put shaft by tapping its end with a plastic hammer.

5) Remove outer snap ring. Then remove oil
squeeze plate and straight pin.

(A) Input shaft holder

(B) O-ring

(C) Input shaft holder shim

MT-00226

( A )

( B )

( C )

(A) Input shaft holder

(B) Input shaft

(A) Snap ring

(B) Oil squeeze plate

MT-00227

ST

MT-00228

( A )

( B )

MT-00229

( A )

( B )