Subaru Legacy IV (2008 year). Manual - part 820

6MT-93

Reverse Idler Gear Assembly

MANUAL TRANSMISSION AND DIFFERENTIAL

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.
• Wear, rusting or damage of the bearings
• The bearing does not rotate smoothly or abnor-
mal noise is emitted when turning.
• The bearing has other defects.
2) Bushing (each gear)
Replace the bushing in following cases.
• The sliding surface is damaged or abnormally
worn.
3) Gear
Replace gears in the following cases.
• The gear teeth surface is damaged or excessive-
ly worn.
• The contact area of the baulk ring is damaged.
• The inner face of the gear is worn.
4) Baulk ring, synchro cone
Replace the baulk ring and synchro cone in the fol-
lowing cases.
• Wear, rusting or damage of the baulk ring
5) Shifting insert key
Replace the shifting insert key if deformed, exces-
sively worn or defective in any way.

6) Check clearance between the snap ring and
washer.

Clearance specification:

0.1 — 0.3 mm (0.0039 — 0.0118 in)

If the clearance is out of the specification, select a
snap ring from the following table and replace it.

After replacing the snap ring, inspect the clearance.

MT-00581

Snap ring

Part No.

Thickness mm (in)

031319000

1.50 (0.059)

805019030

1.60 (0.062)

805019010

1.72 (0.068)

MT-00639

6MT-94

Drive Pinion Shaft Assembly

MANUAL TRANSMISSION AND DIFFERENTIAL

20.Drive Pinion Shaft Assembly

A: REMOVAL

1) Remove the manual transmission assembly
from the vehicle. <Ref. to 6MT-32, REMOVAL,
Manual Transmission Assembly.>
2) Prepare the transmission for overhaul. <Ref. to
6MT-37, Preparation for Overhaul.>
3) Remove the neutral position switch, back-up
light switch and harness. <Ref. to 6MT-41, RE-
MOVAL, Neutral Position Switch.> <Ref. to 6MT-
39, REMOVAL, Back-up Light Switch.>
4) Remove the extension case. <Ref. to 6MT-43,
REMOVAL, Extension Case.>
5) Remove the transfer driven gear. <Ref. to 6MT-
55, REMOVAL, Transfer Driven Gear.>
6) Remove the center differential. <Ref. to 6MT-57,
REMOVAL, Center Differential.>
7) Remove the transmission case. <Ref. to 6MT-
58, REMOVAL, Transmission Case.>
8) Remove the individual gear assemblies. <Ref. to
6MT-64, REMOVAL, Main Shaft Assembly.>
9) Remove the drive pinion shaft assembly. 

B: INSTALLATION

1) Remove any remaining gasket material from the
drive plate and clutch housing.
2) Apply liquid gasket to the clutch housing.

Liquid gasket:

THREE BOND 1215 (Part No. 004403007) or 
equivalent

3) Install the individual gear assemblies. <Ref. to
6MT-65, INSTALLATION, Main Shaft Assembly.>
4) Install the transmission case. <Ref. to 6MT-60,
INSTALLATION, Transmission Case.>
5) Install the center differential. <Ref. to 6MT-57,
INSTALLATION, Center Differential.>
6) Install the transfer driven gear. <Ref. to 6MT-55,
INSTALLATION, Transfer Driven Gear.>
7) Install the extension case. <Ref. to 6MT-43, IN-
STALLATION, Extension Case.>
8) Install the neutral position switch, back-up light
switch and harness. <Ref. to 6MT-41, INSTALLA-
TION, Neutral Position Switch.> <Ref. to 6MT-39,
INSTALLATION, Back-up Light Switch.>
9) Install the manual transmission assembly to the
vehicle. <Ref. to 6MT-34, INSTALLATION, Manual
Transmission Assembly.>

MT-00640

MT-00532

6MT-95

Drive Pinion Shaft Assembly

MANUAL TRANSMISSION AND DIFFERENTIAL

C: DISASSEMBLY

NOTE:
Replace the drive pinion shaft and hypoid driven
gear as a set.
1) Remove the oil guide A.

2) Remove the drive pinion shaft and shim from the
adapter plate.

3) Affix the ST to the work table.
ST

18664AA000

BASE

4) Flatten the tab of the axle nut.
5) Attach ST3 to the lock nut, and set the drive pin-
ion shaft to ST. Remove the lock nut and washer.
ST1

18667AA000

HOLDER

ST2

18664AA000

BASE

ST3

18621AA000

ADAPTER WRENCH

6) Using the ST, remove the taper roller bearing as-
sembly.
ST

18723AA000

REMOVER

(A) Oil guide A

MT-01624

(A)

MT-00642

MT-00643

ST2

ST3

ST1

ST

MT-00644

6MT-96

Drive Pinion Shaft Assembly

MANUAL TRANSMISSION AND DIFFERENTIAL

D: ASSEMBLY

1) Using the ST, measure drive pinion measure-
ment A.

NOTE:
When selecting the drive pinion shim, refer to mea-
surement A.
ST

398643600

GAUGE

2) Using the ST and a press, attach the inner bear-
ing of the taper roller bearing to the drive pinion
shaft.
ST

18723AA000

REMOVER

CAUTION:
Do not apply pressure in excess of 40 kN (4.0
ton, 4.4 US ton, 3.9 Imp ton).

3) Using the ST and a press, attach the outer race
and the taper roller bearing to the drive pinion shaft.
ST

18723AA000

REMOVER

NOTE:
Push in to a position where the bearing rotates
smoothly.

4) Attach the washer and a new lock nut.
5) Set the ST to the drive pinion, and tighten the
lock nut.
ST1

18667AA000

HOLDER

ST2

18664AA000

BASE

ST3

18621AA000

ADAPTER WRENCH

ST4

18852AA000

TORQUE WRENCH

NOTE:
Tighten using the ST and the straight line torque
wrench.

Tightening torque:

265 N·m (27.0 kgf-m, 195.4 ft-lb)

NOTE:
When using a torque wrench other than ST4, use
the calculation below to calculate and tighten the
lock nut.
Tighten using the ST and the straight line torque
wrench.
T = L1 / (0.1 + L1) × 285

6) Measure the starting torque. <Ref. to 6MT-98,
INSPECTION, Drive Pinion Shaft Assembly.>

(A) Outer race

MT-00645

A

ST

MT-00646

ST

MT-00647

(A)

ST

T

N·m(kgf-m, ft-lb) Torque wrench setting

L1

m (in) Torque wrench length

0.1 m (3.94 in)

Length of ST

285 N·m (29.0 kgf-m, 210 ft-lb)

Tightening torque (lock 
nut)

(A) 0.1 m (3.94 in)

MT-00648

ST2

ST4

ST3

ST1

MT-00614

(A)

L1