Subaru Legacy IV (2008 year). Service manual — part 827

6MT-121

Shifter Fork and Rod

MANUAL TRANSMISSION AND DIFFERENTIAL

(1) Shift the 5th-6th sleeve to the 6th main gear
side, push up on the stopper, and measure
“D2”.

NOTE:
• Set the height gauge indicator near the measure-
ment target, and lock dial (1) as shown in the figure.
Turn dial (2), and set the indicator to the 6th side
end surface of the sleeve.
• The measurement is to be performed with 2 per-
sons, while holding the sleeve straight.
• Turn approximately 72° at a time, and measure
the sleeve in 5 locations. Round down the 2 highest
and 2 lowest measurement values. The remaining
center value is used as the measurement value.

(2) Set the height gauge indicator upside down.

(3) Shift the 5th-6th sleeve to the 5th main gear
side, push down to the stopper, and measure
“D1”.

NOTE:
• Set the height gauge indicator near the measure-
ment target, and lock dial (1) as shown in the figure.
Turn dial (2), and set the indicator to the 5th side
end surface of the sleeve.
• Turn approximately 72° at a time, and measure
the sleeve in 5 locations. Round down the 2 highest
and 2 lowest measurement values. The remaining
center value is used as the measurement value.

(A) 6th main gear

(A) Indicator

MT-00713

(A)

MT-00585

(2)

(1)

MT-00710

(A)

(A) 5th main gear

MT-00714

(A)

MT-00585

(2)

(1)

6MT-122

Shifter Fork and Rod

MANUAL TRANSMISSION AND DIFFERENTIAL

4) According to both of the measurements, calcu-
late the neutral position of the 5th-6th sleeve. From
the following calculation, select a fork rod which
matches the calculated value.
Calculation: T = (D1 + D2) / 2
T: 5th-6th sleeve center position
D1: Measured length from the shaft rear bearing
snap ring groove to the sleeve groove end, when
shifted to 5th gear [Value: +55 mm (2.17 in)]
D2: Measured length from the main shaft rear bear-
ing snap ring groove to the sleeve groove end,
when shifted to 6th gear

NOTE:
Attach the indicator upside down in comparison to
the setting procedures for the 0 point. Add d1 [Val-
ue: 55 mm (2.17 in)] from the figure below to “D1”,
and measure “D1”.

4. REVERSE FORK ROD SELECTION

NOTE:
In the following conditions, perform the procedures
below.
• Replacing the reverse idler gear
• Replacing the reverse idler gear No. 2
• Replacing the adapter plate
• Replacing the base
1) Insert the reverse idler gear assembly into the
adapter plate.
2) Tighten the base COMPL attachment bolts.

Tightening torque:

25 N·m (2.5 kgf-m, 18.4 ft-lb)

3) Set the height gauge to the adapter plate. Lower
the height gauge indicator to the mating surface of
the adapter plate and case, and set to zero points.
ST

18853AA000

HEIGHT GAUGE

NOTE:
• The adapter plate will be the base point for the
measurement. Use a scraper to remove any gasket
material remaining on the end face.
• During measurement, do not place the height
gauge in the shaded area shown in the figure.

T mm (in)

Lot No. (marking)

M.SFT
Snap ring
805072010
[t = 1.65 mm
(0.065 in)]

M.SFT
Snap ring
805072011
[t = 1.95 mm
(0.077 in)]

M.SFT
Snap ring
805072012
[t = 2.25 mm
(0.089 in)]

64.12 — 64.42

(2.5244 — 2.5362)

32945AA021

(none)

32945AA031

(2)

32945AA041

(4)

64.42 — 64.72

(2.5362 — 2.5480)

32945AA011

(1)

32945AA021

(none)

32945AA031

(2)

64.72 — 65.02

(2.5480 — 2.5598)

32945AA001

(3)

32945AA011

(1)

32945AA021

(none)

T = Thickness

MT-00705

d1

MT-00546

MT-00582

ST

MT-00583

6MT-123

Shifter Fork and Rod

MANUAL TRANSMISSION AND DIFFERENTIAL

4) Press fit the reverse sleeve to the reverse idler
gear No. 2, and measure “T”.

NOTE:
• Set the height gauge indicator near the measure-
ment target, and lock dial (1) as shown in the figure.
Turn dial (2), and set the indicator to the end face of
the reverse sleeve side.
• Turn approximately 72° at a time, and measure
the sleeve in 5 locations. Round down the 2 highest
and 2 lowest measurement values. The remaining
center value is used as the measurement value.

5) Calculate the neutral position of the reverse
sleeve according to the measurement. From the
following calculation, select a fork rod which match-
es the calculated value.
Calculation: T + 4.8 mm (0.189 in)

(A) Reverse idler gear No. 2

(A) Reverse idler gear No. 2

MT-00715

(A)

T

MT-00716

(A)

MT-00585

(2)

(1)

T + 4.8 mm (0.189 in) mm (in)

Lot No. (marking)

33.50 — 33.80

(1.3189 — 1.3307)

32816AA110 (1)

33.80 — 34.10

(1.3307 — 1.3425)

32816AA130 (none)

34.10 — 34.40

(1.3425 — 1.3543)

32816AA140 (2)

T = Thickness

6MT-124

Clutch Housing

MANUAL TRANSMISSION AND DIFFERENTIAL

23.Clutch Housing

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. <Ref.
to 6MT-94, REMOVAL, Drive Pinion Shaft Assem-
bly.>
10) Remove the front differential assembly. <Ref.
to 6MT-100, REMOVAL, Front Differential Assem-
bly.>

B: INSTALLATION

1) Install the pitching stopper bracket.

Tightening torque:

41 N·m (4.2 kgf-m, 30.2 ft-lb)

2) Install the front differential assembly. <Ref. to
6MT-101, INSTALLATION, Front Differential As-
sembly.>
3) Install the drive pinion shaft assembly. <Ref. to
6MT-94, INSTALLATION, Drive Pinion Shaft As-
sembly.>
4) Install the individual gear assemblies all at once.
<Ref. to 6MT-65, INSTALLATION, Main Shaft As-
sembly.>
5) Install the transmission case. <Ref. to 6MT-60,
INSTALLATION, Transmission Case.>
6) Install the center differential. <Ref. to 6MT-57,
INSTALLATION, Center Differential.>
7) Install the transfer driven gear. <Ref. to 6MT-55,
INSTALLATION, Transfer Driven Gear.>
8) Install the extension case. <Ref. to 6MT-43, IN-
STALLATION, Extension Case.>
9) 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.>
10) Install the manual transmission assembly to the
vehicle. <Ref. to 6MT-34, INSTALLATION, Manual
Transmission Assembly.>

C: DISASSEMBLY

1) Remove the clutch release bearing guide.

2) Remove the oil seal.

MT-01383

MT-01381