Subaru Legacy IV (2008 year). Manual - part 790

5MT-56

Main Shaft Assembly for Single-Range

MANUAL TRANSMISSION AND DIFFERENTIAL

2) Install the 3rd drive gear, outer baulk ring, syn-
chro cone, inner baulk ring, sleeve & hub assembly
for the 3rd needle bearing, on the transmission
main shaft.

NOTE:
Align the groove in baulk ring with the shifting in-
sert.

3) Install the 4th needle bearing race onto trans-
mission main shaft using ST1, ST2 and press.

CAUTION:
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 the baulk ring, needle bearing, 4th drive
gear and 4th gear thrust washer to the transmission
main shaft.

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

5) Press-fit the ball bearing into the rear section of
transmission main shaft using ST1, ST2 and a
press.

CAUTION:
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

(D) Synchro cone

(E) Outer baulk ring

(F) Sleeve & hub ASSY

(A) 4th needle bearing race

MT-01318

(A)

(B)

(C)

(D)

(E)

(F)

MT-00192

(A)

ST1

ST2

(A) Groove

(B) Face this surface to the 4th gear side.

MT-00193

(A)

(B)

MT-00194

ST1

ST2

5MT-57

Main Shaft Assembly for Single-Range

MANUAL TRANSMISSION AND DIFFERENTIAL

6) Using the ST1 and ST2, install the 5th needle
bearing race onto the rear section of the transmis-
sion main shaft.

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

NOTE:
Make sure the thrust washer is facing the correct
direction.
ST1

899714110

REMOVER

ST2

499877000

RACE 4-5 INSTALLER

7) Install rest of the parts to the rear section of the
transmission main shaft.

CAUTION:
• Attach the baulk lever with the narrower side
facing the 5th hub side.

• Align the protruded section of baulk ring be-
tween the baulk levers.

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

MT-00195

(A)

(A) Baulk lever

(B) 5th hub

(A) Baulk ring

(B) Baulk lever

(A) Needle bearing

(B) 5th drive gear

(D) 5th hub & sleeve No. 2

(E) Lock washer

(F) Lock nut

(G) Baulk lever

(A)

(B)

MT-01522

MT-01531

(A)

(B)

(C)

(B)

MT-01627

(D)

(A) (B) (C)

(E)

(F)

(G)

5MT-58

Main Shaft Assembly for Single-Range

MANUAL TRANSMISSION AND DIFFERENTIAL

8) Tighten the lock nuts to the specified torque us-
ing ST1 and ST2.
9) Crimp lock nuts in two locations after tightening.
ST1

499987003

SOCKET WRENCH (35)

ST2

498937000

TRANSMISSION HOLDER

Tightening torque:

120 N·m (12.2 kgf-m, 88.5 ft-lb)

E: INSPECTION

Disassembled parts should be washed clean first
with cleaning solvent and then inspected carefully.
1) Bearing
Replace the bearings in the following cases.
• When the bearing balls, outer races and inner
races are broken or rusty.
• When the bearing is worn.
• When the bearings fail to turn smoothly or emit
noise in rotation after gear oil lubrication.
• When the bearing has other problems.
2) Bushing (each gear)
Replace the bushing in following cases.
• When the sliding surface is damaged or abnor-
mally worn.
• When the inner wall is abnormally worn.
3) Gear
Replace gears in the following cases.
• Replace the gear with new part if its tooth surfac-
es 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 baulk rings 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 section is cracked or abnormally worn.
• If the gap between the end faces of the ring and
the gear splined part is excessively small, check
the clearance (A) while pressing the ring against
the cone.

Clearance (A):

0.5 mm (0.020 in) or more

5) Shifting insert key
Replace the insert key if deformed, excessively
worn or defective in any way.

6) Oil seal
Replace the oil seal if the lip is deformed, hard-
ened, 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.

(A) Measured value

(A)

MT-01674

MT-01213

5MT-59

Main Shaft Assembly for Single-Range

MANUAL TRANSMISSION AND DIFFERENTIAL

F: ADJUSTMENT

Selection of main shaft rear plate:
Using the ST, measure the protrusion amount (A)
of ball bearing from transmission main case sur-
face, and select a suitable plate in the following ta-
ble.

NOTE:
Before measuring, tap the end of main shaft with a
plastic hammer lightly in order to make the clear-
ance zero between the main case surface and
moving flange of bearing.
ST

498147001

DEPTH GAUGE

• Turbo model

• Non-turbo model

Dimension (A)

mm (in)

Part number

Mark

4.00 — 4.13

(0.1575 — 0.1626)

32294AA041

3.87 — 4.00

(0.1524 — 0.1575)

32294AA051

(A) Measured value

MT-01807

(A)

MT-00209

(A)

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