Subaru Legacy III (2000-2003 year). Manual - part 630

MT-88

MANUAL TRANSMISSION AND DIFFERENTIAL

DRIVE PINION SHAFT ASSEMBLY

8) Select one to three shims from the next table for
the value determined as described above and take
a shim thickness which is closest to the said value.

9) Install differential assembly. <Ref. to MT-95, IN-
STALLATION, Front Differential Assembly.>
10) Set transmission main shaft assembly and
drive pinion assembly in position. (So there is no
clearance between the two when moved all the way
to the front). Inspect suitable 1st — 2nd, 3rd — 4th
and 5th shifter fork so that coupling sleeve and re-
verse driven gear are positioned in the center of
their synchronizing mechanisms. <Ref. to MT-92,
INSPECTION, Drive Pinion Shaft Assembly.>
11) Install transmission case. <Ref. to MT-61, IN-
STALLATION, Transmission Case.>
12) Install transfer case with extension case as-
sembly. <Ref. to MT-47, INSTALLATION, Transfer
Case and Extension Case Assembly.>
13) Install the manual transmission assembly to ve-
hicle. <Ref. to MT-35, INSTALLATION, Manual
Transmission Assembly.>

C: DISASSEMBLY

NOTE:
Attach a cloth to the end of driven shaft (on the fric-
tional side of thrust needle bearing) during disas-
sembly or reassembly to prevent damage.
1) Straighten lock nut at staked portion. Remove
the lock nut using ST1, ST2 and ST3.
ST1

899884100

HOLDER

ST2

498427100

STOPPER

ST3

899988608

SOCKET WRENCH

2) Withdraw drive pinion from driven shaft.
Remove differential bevel gear sleeve, adjusting
washer No. 1, adjusting washer No. 2, thrust bear-
ing, needle bearing, drive pinion collar, needle
bearing and thrust bearing.

3) Remove roller bearing and washer using ST and
press.

NOTE:
Do not reuse roller bearing.
ST

498077000

REMOVER

Drive pinion shim

Part No.

Thickness mm (in)

32295AA031

0.150 (0.0059)

32295AA041

0.175 (0.0069)

32295AA051

0.200 (0.0079)

32295AA061

0.225 (0.0089)

32295AA071

0.250 (0.0098)

32295AA081

0.275 (0.0108)

32295AA091

0.300 (0.0118)

32295AA101

0.500 (0.0197)

MT-00244

ST2

ST3

ST1

(A) Differential bevel gear sleeve

(B) Washer No. 1 (25

37.5

(D) Washer No. 2 (25

37.5

(E) Needle bearing (25

20)

(F) Drive pinion collar

(G) Needle bearing (30

23)

(H) Thrust bearing (33

MT-00245

( H )

( G )

( F )

( E )

( D )

( C )

( B )

( A )

MT-00246

MT-89

MANUAL TRANSMISSION AND DIFFERENTIAL

DRIVE PINION SHAFT ASSEMBLY

4) Straighten lock nut at staked portion. Remove
the lock nut using ST1 and ST2.
ST1

499987300

SOCKET WRENCH (50)

ST2

899884100

HOLDER

5) Remove 5th driven gear using ST.
ST

499857000

5TH DRIVEN GEAR REMOV-
ER

6) Remove woodruff key.
7) Remove roller bearing, 3rd-4th driven gear using
ST1 and ST2.
ST1

499757002

INSTALLER

ST2

899714110

REMOVER

8) Remove the key.

9) Remove 2nd driven gear, inner baulk ring, syn-
chro cone and outer baulk ring.

10) Remove 1st driven gear, 2nd gear bushing,
gear and hub using ST1 and ST2.

NOTE:
Replace gear and hub if necessary. Do not attempt
to disassemble if at all possible because they must
engage at a specified point. If they have to be dis-
assembled, mark the engaging point beforehand.
ST1

499757002

INSTALLER

ST2

899714110

REMOVER

11) Remove sub gear for 1st driven gear.

MT-00247

ST2

ST1

MT-00248

MT-00249

ST1

ST2

(A) 2nd driven gear

(B) Inner baulk ring

(D) Outer baulk ring

MT-00250

( A )

( D )

( B )

( C )

MT-00251

ST1

ST2

MT-90

MANUAL TRANSMISSION AND DIFFERENTIAL

DRIVE PINION SHAFT ASSEMBLY

D: ASSEMBLY

1) Install sleeve and assembly by matching align-
ment marks.

NOTE:
• Use new gear and hub assembly, if gear or hub
have been replaced.

2) Install washer, snap ring and sub gear (except
for Europe model) to 1st driven gear.
3) Install 1st driven gear, 1st baulk ring, gear and
hub assembly onto driven shaft.

NOTE:
• Take care to install gear and hub assembly in
proper direction.
• Align baulk ring and gear & hub assembly with
key groove.
4) Install 2nd driven gear bushing onto driven shaft
using ST1, ST2 and press.

NOTE:
• Do not apply pressure in excess of 10 kN (1 ton,
1.1 US ton, 1.0 Imp ton).
• Attach a cloth to the end of driven shaft to pre-
vent damage.
• When press fitting, align oil holes of shaft and
bush.
ST1

499277200

INSTALLER

ST2

499587000

INSTALLER

5) Install 2nd driven gear, inner baulk ring, synchro
cone, outer baulk ring and insert onto driven shaft.

6) After installing key on driven shaft, install 3rd-4th
driven gear using ST and press.

NOTE:
• Do not apply pressure in excess of 10 kN (1 ton,
1.1 US ton, 1.0 Imp ton).
• Align groove in baulk ring with insert.
ST

499277200

INSTALLER

7) Install a set of roller bearings onto the driven
shaft using ST and press.

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

499277200

INSTALLER

(A) 1st gear side

(B) 2nd gear side

(D) Stepped surface

MT-00252

( B )

( A )

( C )

( D )

MT-00253

ST1

ST2

(A) 2nd driven gear

(B) Inner baulk ring

(D) Outer baulk ring

MT-00254

( A )

( D )

( B )

( C )

MT-00255

MT-00256

MT-91

MANUAL TRANSMISSION AND DIFFERENTIAL

DRIVE PINION SHAFT ASSEMBLY

8) Position woodruff key in groove on the rear of
driven shaft. Install 5th driven gear onto drive shaft
using ST and press.

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

499277200

INSTALLER

9) Install lock washer. Install lock nut and tighten to
the specified torque using ST.
ST

499987300

SOCKET WRENCH (50)

Tightening torque:

260 N·m (26.5 kgf-m, 192 ft-lb)

10) Stake lock nut at two points.
11) Using spring balancer, check that starting
torque of roller bearing is 0.1 to 1.5 N (0.01 to 0.15
kgf, 0.02 to 0.33ft).

12) Install roller bearing onto drive pinion.

NOTE:
When installing roller bearing, note its directions
(front and rear) because knock pin hole in outer
race is offset.

13) Install washer using ST1, ST2 and press.

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

499277100

BUSHING 1-2 INSTALLER

ST2

499277200

INSTALLER

14) Install thrust bearing and needle bearing. Install
driven shaft assembly.

MT-00257

MT-00258

MT-00259

(A) Roller bearing

(B) Knock pin hole

(A) Washer

MT-00260

( A )

( B )

( A )

ST2

ST1

MT-00261

MT-00262

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