Subaru Legacy III (2000-2003 year). Service manual — part 629

MT-84

MANUAL TRANSMISSION AND DIFFERENTIAL

INPUT SHAFT ASSEMBLY

6) Remove snap ring.

7) Remove inner snap ring.
8) Using a press and ST, remove ball bearing.
ST

498077000

RETAINER

9) Remove oil seal from input shaft holder.

D: ASSEMBLY

1) Install ball bearing onto input shaft.

NOTE:
Place snap ring between input shaft gear and ball
bearing beforehand. Use the table at 8) as a guide
in selecting a suitable snap ring.
ST1

899580100

INSTALLER

ST2

399513600

INSTALLER

2) Install snap ring on input shaft.

3) Inspect clearance between ball bearing and
snap ring. <Ref. to MT-85, INSPECTION, Input
Shaft Assembly.>
4) Install straight pin and oil squeeze plate to input
shaft.

5) Install snap ring.
6) Drive oil seal into input shaft holder.

NOTE:
Apply a coat of grease to sealing lips before install-
ing oil seal.
ST

398507703

DUMMY COLLAR

(A) Snap ring

MT-00230

( A )

ST

MT-00231

ST1

ST2

MT-00232

(A) Snap ring

(A) Straight pin

(B) Oil squeeze plate

MT-00230

( A )

MT-00234

( A )

( B )

ST

MT-00235

MT-85

MANUAL TRANSMISSION AND DIFFERENTIAL

INPUT SHAFT ASSEMBLY

7) Wind vinyl tape around shaft splines and insert
input shaft into holder by lightly tapping it by hand.

8) Install snap ring to input shaft holder.

NOTE:
Select a suitable snap ring so that clearance be-
tween snap ring and bearing is held within 0 to 0.12
mm (0 to 0.0047 in).
ST

398663600

PLIERS

9) Install new O-ring on input shaft holder.

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.

(A) Vinyl tape

(B) Input shaft

Snap ring

Part No.

Thickness mm (in)

805168020

1.84 (0.0724)

805168030

1.92 (0.0756)

805168040

2.00 (0.0787)

(A) O-ring

(B) Input shaft holder

MT-00236

( A )

( B )

MT-00227

ST

MT-00238

( A )

( B )

MT-86

MANUAL TRANSMISSION AND DIFFERENTIAL

INPUT SHAFT ASSEMBLY

9) Measure clearance between snap ring and ball
bearing.

Clearance:

0 — 0.12 mm (0 — 0.0047 in)

If the measurement is not within specifications, se-
lect suitable snap ring.

(A) Snap ring

Snap ring

Part No.

Thickness mm (in)

805028050

2.48 (0.0976)

805028060

2.56 (0.1008)

805028070

2.64 (0.1039)

MT-00239

( A )

MT-87

MANUAL TRANSMISSION AND DIFFERENTIAL

DRIVE PINION SHAFT ASSEMBLY

18.Drive Pinion Shaft Assembly

A: REMOVAL

1) Remove the manual transmission assembly
from vehicle. <Ref. to MT-32, REMOVAL, Manual
Transmission Assembly.>
2) Remove transfer case with extension case as-
sembly. <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.

NOTE:
Use a hammer handle, etc. to remove if too tight.

B: INSTALLATION

1) Remove differential assembly.
2) Alignment marks/numbers on hypoid gear set
The upper number on driven pinion is the match
number for combining it with hypoid driven gear.
The lower number is for shim adjustment. If no low-
er number is shown, the value is zero. The number
on hypoid driven gear indicates a number for com-
bination with drive pinion.

3) Place drive pinion shaft assembly on right hand
transmission main case without shim and tighten
bearing mounting bolts.

4) Inspection and adjustment of ST

NOTE:
• Loosen the two bolts and adjust so that the scale
indicates 0.5 correctly when the plate end and the
scale end are on the same level.
• Tighten the two bolts.
ST

499917500

DRIVE PINION GAUGE
ASSY

5) Position the ST by inserting the knock pin of ST
into the knock hole in the transmission case.
ST

499917500

DRIVE PINION GAUGE
ASSY

6) Slide the drive pinion gauge scale with finger tip
and read the value at the point where it matches
with the end face of drive pinion.
ST

499917500

DRIVE PINION GAUGE
ASSY

7) The thickness of shim shall be determined by
adding the value indicated on drive pinion to the
value indicated on the ST. (Add if the number on
drive pinion is prefixed by + and subtract if the num-
ber is prefixed by

−

.)

ST

499917500

DRIVE PINION GAUGE
ASSY

(A) Main shaft assembly

(B) Drive pinion shaft assembly

(1) Match number

(2) Shim adjustment number

MT-00161

( A )

( B )

MT-00241

246

246

+0.1

( 1 )

( 2 )

( 1 )

(A) Plate

(B) Scale

(A) Adjust clearance to zero without shim.

MT-00242

( B )

( A )

ST

MT-00243

( A )

ST