Subaru Legacy III (2000-2003 year). Manual - part 634

MT-104

MANUAL TRANSMISSION AND DIFFERENTIAL

REVERSE IDLER GEAR

21.Reverse Idler Gear

A: REMOVAL

1) Remove the manual transmission assembly
from vehicle. <Ref. to MT-32, REMOVAL, Manual
Transmission Assembly.>
2) Remove back-up light switch and neutral posi-
tion switch. <Ref. to MT-42, REMOVAL, Switches
and Harness.>
3) Remove transfer case with extension case as-
sembly. <Ref. to MT-47, REMOVAL, Transfer
Case and Extension Case Assembly.>
4) Remove transmission case. <Ref. to MT-59, RE-
MOVAL, Transmission Case.>
5) Remove drive pinion shaft assembly. <Ref. to
MT-87, REMOVAL, Drive Pinion Shaft Assembly.>
6) Remove main shaft assembly.
Single-range model:
<Ref. to MT-66, REMOVAL, Main Shaft Assembly
for Single-Range.>
Dual-range model:
<Ref. to MT-74, REMOVAL, Main Shaft Assembly
for Dual-Range.>
7) Remove differential assembly. <Ref. to MT-95,
REMOVAL, Front Differential Assembly.>
8) Remove shifter forks and rods. <Ref. to MT-106,
REMOVAL, Shifter Fork and Rod.>
9) Pull out straight pin, and remove idler gear shaft,
reverse idler gear and washer.

10) Remove reverse shifter lever.

B: INSTALLATION

1) Install reverse shifter lever, reverse idler gear
and reverse idler gear shaft, and secure with
straight pin. 

NOTE:
Be sure to install reverse idler shaft from the rear
side. 

2) Inspect and adjust clearance between reverse
idler gear and transmission case wall. <Ref. to MT-
104, INSTALLATION, Reverse Idler Gear.>  and
<Ref. to MT-105, ADJUSTMENT, Reverse Idler
Gear.>
3) Install shifter forks and rods. <Ref. to MT-106,
INSTALLATION, Shifter Fork and Rod.>
4) Install differential assembly. <Ref. to MT-95, IN-
STALLATION, Front Differential Assembly.>
5) Install main shaft assembly.
Single-range model:
<Ref. to MT-66, INSTALLATION, Main Shaft As-
sembly for Single-Range.>
Dual-range:
<Ref. to MT-74, INSTALLATION, Main Shaft As-
sembly for Dual-Range.>
6) Install drive pinion shaft assembly. <Ref. to MT-
87, INSTALLATION, Drive Pinion Shaft Assem-
bly.>
7) Install transmission case. <Ref. to MT-61, IN-
STALLATION, Transmission Case.>
8) Install transfer case with extension case assem-
bly. <Ref. to MT-47, INSTALLATION, Transfer
Case and Extension Case Assembly.>
9) Install back-up light switch and neutral position
switch. <Ref. to MT-43, INSTALLATION, Switches
and Harness.>
10) Install the manual transmission assembly to ve-
hicle. <Ref. to MT-35, INSTALLATION, Manual
Transmission Assembly.>

(A) Straight pin

(B) Idler gear shaft

(C) Idler gear

(D) Washer

MT-00303

( B )

( A )

( C )

( D )

(A) Reverse shifter lever

(B) Reverse idler gear

(C) Reverse idler gear shaft

(D) Straight pin

MT-00304

( B )

( A )

( C )

( D )

MT-105

MANUAL TRANSMISSION AND DIFFERENTIAL

REVERSE IDLER GEAR

C: INSPECTION

1) Move the reverse shifter rod toward the reverse
side. Inspect clearance between reverse idler gear
and transmission case wall.
If out of specification, select the appropriate re-
verse shifter lever and adjust.

Clearance A:

6.0 — 7.5 mm (0.236 — 0.295 in)

2) After installing a suitable reverse shifter lever,
shift into neutral. Inspect clearance between re-
verse idler gear and transmission case wall.
If out of specification, select the appropriate washer
and adjust.

Clearance:

0 — 0.5 mm (0 — 0.020 in)

3) Check the reverse idler gear and shaft for dam-
age. Replace if damaged.

D: ADJUSTMENT

1) Select the appropriate reverse shifter lever from
the table below, and adjust until the gap between
the reverse idler gear and transmission case wall is
within specification.

Clearance A:

6.0 — 7.5 mm (0.236 — 0.295 in)

2) Select the appropriate washer from the table be-
low, and adjust until the gap between the reverse
idler gear and transmission case wall is within
specification.

Clearance:

0 — 0.5 mm (0 — 0.020 in)

MT-00305

A

MT-00306

Reverse shifter lever

Part No.

Mark

Remarks

32820AA070

7

Further from case wall

32820AA080

8

Standard

32820AA090

9

Closer to case wall

Washer

Part No.

Thickness mm (in)

803020151

0.4 (0.016)

803020152

1.1 (0.043)

803020153

1.5 (0.059)

803020154

1.9 (0.075)

803020155

2.3 (0.091)

MT-00305

A

MT-00306

MT-106

MANUAL TRANSMISSION AND DIFFERENTIAL

SHIFTER FORK AND ROD

22.Shifter Fork and Rod

A: REMOVAL

1) Remove the manual transmission assembly
from vehicle. <Ref. to MT-32, REMOVAL, Manual
Transmission Assembly.>
2) Remove back-up light switch and neutral posi-
tion switch. <Ref. to MT-42, REMOVAL, Switches
and Harness.>
3) Remove transfer case with extension case as-
sembly. <Ref. to MT-47, REMOVAL, Transfer
Case and Extension Case Assembly.>
4) Remove transmission case. <Ref. to MT-59, RE-
MOVAL, Transmission Case.>
5) Removes drive pinion shaft assembly. <Ref. to
MT-87, REMOVAL, Drive Pinion Shaft Assembly.>
6) Remove main shaft assembly.
Single-range model:
<Ref. to MT-66, REMOVAL, Main Shaft Assembly
for Single-Range.>
Dual-range model:
<Ref. to MT-74, REMOVAL, Main Shaft Assembly
for Dual-Range.>
7) Remove differential assembly. <Ref. to MT-95,
REMOVAL, Front Differential Assembly.>
8) Drive out straight pin with ST, and 5th shifter
fork.
ST

398791700

STRAIGHT PIN REMOVER

9) Remove plugs, springs and checking balls.

10) Drive out straight pin, and pull out 3-4 fork rod
and shifter fork.

NOTE:
When removing rod, keep other rods in neutral. Al-
so, when pulling out straight pin, remove it toward
the inside of the case so that it does not hit against
the case.

11) Drive out straight pin, and pull out 1-2 fork rod
and shifter fork.
12) Remove outer snap ring, and pull out reverse
shifter rod arm from reverse fork rod. Then take out
ball, spring and interlock plunger from rod.
And then remove rod.

NOTE:
When pulling out reverse shifter rod arm, be careful
not to let ball pop out of arm.
13) Remove reverse shifter lever.

B: INSTALLATION

1) Install reverse arm fork spring, ball and interlock
plunger to reverse fork rod arm. Insert reverse fork
rod into hole in reverse fork rod arm, and hold it with
outer snap ring using ST.

NOTE:
Apply grease to plunger to prevent it from falling.
ST

399411700

ACCENT BALL INSTALLER

2) Position ball, spring and new gasket in reverse
shifter rod hole, on left side transmission case, and
tighten checking ball plug.
3) Install 1-2 fork rod into 1-2 shifter fork via the
hole on the rear of the transmission case.
4) Align the holes in rod and fork, and new drive
straight pin into these holes using ST.

NOTE:
• Set other rods to neutral.
• Make sure interlock plunger is on the 3-4 fork rod
side.
ST

398791700

STRAIGHT PIN REMOVER

(A) Straight pin

(B) 5th shifter fork

MT-00309

( B )

( A )

(A) Straight pin

(B) 3-4 fork rod

(C) Shifter fork

MT-00310

( A )

( B )

( C )

MT-107

MANUAL TRANSMISSION AND DIFFERENTIAL

SHIFTER FORK AND ROD

5) Install interlock plunger onto 3-4 fork rod.

NOTE:
Apply a coat of grease to plunger to prevent it from
falling. 
6) Install 3-4 fork rod into 3-4 shifter fork via the
hole on the rear of transmission case.
7) Align the holes in rod and fork, and drive new
straight pin into these holes.

NOTE:
• Set reverse fork rod to neutral.
• Make sure interlock plunger (installing before) is
on the reverse fork rod side.
ST

398791700

STRAIGHT PIN REMOVER

8) Install 5th shifter fork onto the rear of reverse
fork rod. Align holes in the two parts and drive new
straight pin into place.
ST

398791700

STRAIGHT PIN REMOVER

9) Position balls, checking ball springs and new
gaskets into 3-4 and 1-2 rod holes, and install
plugs.

10) Install differential assembly. <Ref. to MT-95,
INSTALLATION, Front Differential Assembly.>
11) Install main shaft assembly.
12) Install drive pinion shaft assembly. <Ref. to
MT-87, INSTALLATION, Drive Pinion Shaft As-
sembly.>
13) Install transmission case. <Ref. to MT-61, IN-
STALLATION, Transmission Case.>

14) Install transfer case with extension case as-
sembly. <Ref. to MT-47, INSTALLATION, Transfer
Case and Extension Case Assembly.>
15) Install back-up light switch and neutral position
switch. <Ref. to MT-43, INSTALLATION, Switches
and Harness.>
16) Install the manual transmission assembly to ve-
hicle. <Ref. to MT-35, INSTALLATION, Manual
Transmission Assembly.>

C: INSPECTION

1) Check the shift shaft and shift rod for damage.
Replace if damaged.
2) Gearshift mechanism
Repair or replace the gearshift mechanism if ex-
cessively worn, bent, or defective in any way.
3) Inspect clearance between 1st, 2nd driven gear
and reverse driven gear. If any clearance is not
within specifications, replace shifter fork as re-
quired.

Clearance (a) and (b):

9.5 mm (0.374 in) 

(A) 5th shifter fork

(B) Reverse fork rod

(C) Straight pin

MT-00311

( B )

( A ) ( C )

MT-00366

(A) 1st driven gear

(B) Reverse driven gear

(C) 2nd driven gear

1st-2nd shifter fork

Part No.

Mark

Remarks

32804AA060

1

Approach to 1st gear 
by 0.2 mm (0.008 in).

32804AA070

No mark

Standard

32804AA080

3

Become distant from 
2nd gear by 0.2 mm 
(0.008 in).

MT-00313

( a )

( b )

( A )

( B )

( C )