Subaru Legacy (2005 year). Service manual — part 675

6MT-47

MANUAL TRANSMISSION AND DIFFERENTIAL

Extension Case

12.Extension Case

A: REMOVAL

1) Remove the manual transmission assembly
from vehicle. <Ref. to 6MT-34, REMOVAL, Manual
Transmission Assembly.>
2) Prepare the transmission for overhaul. <Ref. to
6MT-40, Preparation for Overhaul.>
3) Remove the extension case.

4) Completely remove the remaining liquid gasket
from the extension case and transmission case.

B: INSTALLATION

1) Select the transfer driven gear thrust washer,
and then install to extension case. <Ref. to 6MT-49,
ADJUSTMENT, Extension Case.>
2) Apply oil lightly to the outer periphery of bearing
cone, and then install to extension case.
3) Select the thrust washer of transfer drive gear,
and then install to center differential.
4) Apply liquid gasket to the transmission case.

Liquid gasket:

THREE BOND 1215 (Part No. 004403007)

5) Install the extension case.

Tightening torque:

48 N

⋅

m (4.9 kgf-m, 35.4 ft-lb)

NOTE:
Insert the stopper portion of center differential be-
tween extension guides.

6) Install the manual transmission assembly into
vehicle. <Ref. to 6MT-36, INSTALLATION, Manual
Transmission Assembly.>

MT-00475

MT-00476

(A) Extension guide

(B) Stopper

(C) Center Differential

(D) Extension case

MT-00475

MT-00973

(A)

(B)

(C)

(D)

6MT-48

MANUAL TRANSMISSION AND DIFFERENTIAL

Extension Case

C: DISASSEMBLY

1) Remove the transfer drive gear. <Ref. to 6MT-
56, REMOVAL, Transfer Drive Gear.>
2) Remove the extension guide.

3) Remove the shift bracket.

4) Using the ST, remove the bearing cone.
ST

18758AA000

PULLER

5) Remove the thrust washer and oil plate.

6) Remove the shifter arm oil seal.

7) Remove the reverse check system. <Ref. to
6MT-53, REMOVAL, Reverse Check System.>
8) Remove the extension case oil seal. <Ref. to
6MT-30, REPLACEMENT, Oil Seal.>

D: ASSEMBLY

1) Install the reverse check system. <Ref. to 6MT-
54, INSTALLATION, Reverse Check System.>
2) Install the extension case oil seal. <Ref. to 6MT-
30, REPLACEMENT, Oil Seal.>
3) Using the ST, install the shifter arm oil seal.
ST1

18657AA000 INSTALLER

ST2

18671AA000 OIL SEAL GUIDE

(A) Bearing cone

MT-00477

MT-00478

MT-00479

(A)

ST

(A) Thrust washer

(B) Oil plate

(A) Oil seal

(A) Oil seal

(A)

(B)

MT-00480

MT-00481

(A)

MT-00482

(A)

ST1

ST2

6MT-49

MANUAL TRANSMISSION AND DIFFERENTIAL

Extension Case

4) Install the oil plate.

5) Select the bearing thrust washer, and then install
to extension case. <Ref. to 6MT-49, ADJUST-
MENT, Extension Case.>
6) Apply oil lightly to the outer periphery of bearing
cone, and then install to extension case.
7) Install the shift bracket.

Tightening torque:

25 N

⋅

m (2.5 kgf-m, 18.4 ft-lb)

8) Install the extension guide, and then install the
transfer driven gear. <Ref. to 6MT-56, INSTALLA-
TION, Transfer Drive Gear.>

E: INSPECTION

1) Check there is no damage or crack on extension
case. If there is damage or crack, replace the ex-
tension case.
2) Check the oil seal and the mating surface of ex-
tension case and transmission case for oil leakage.
If there is oil leakage, replace the oil seal and liquid
gasket.

F: ADJUSTMENT

1. TRANSFER DRIVEN GEAR BEARING
THRUST WASHER ADJUSTMENT

1) Using the ST, remove the bearing cone from ex-
tension case.
ST

18758AA000

PULLER

2) Remove the thrust washer.
3) Measure the depth “Z” between end of extension
case and contact point of bearing cone.
ST

499575500

GAUGE

NOTE:
To measure the depth “Z”, subtract the thickness of
ST [15 mm (0.59 in)] from the measured value.

4) Remove the transfer driven gear. <Ref. to 6MT-
58, REMOVAL, Transfer Driven Gear.>
5) Remove the center differential. <Ref. to 6MT-60,
REMOVAL, Center Differential.>

MT-00483

MT-00478

(A) Bearing cone

(A) 15 mm (0.59 in)

MT-00479

(A)

ST

MT-00484

(A)

Z

ST

ST

6MT-50

MANUAL TRANSMISSION AND DIFFERENTIAL

Extension Case

6) Remove the snap ring and flat washer from se-
lector arm part.

7) Using the ST, remove the neutral set spring and
the support.
ST1

18756AA000 CLAW

ST2

399893600

PLIERS

8) Raise the striking rod up, then remove the spring
pin.

9) Remove the selector arm No. 2 and shifter arm.

10) Install the bearing cone to transfer driven gear.
11) Set the ST.
ST

18831AA000

GAUGE

12) Rotate the transfer driven gear approx. ten
times to get the bearing accustomed.
13) Measure the depth “Y” between end of ST and
bearing cone.
ST

18831AA000

GAUGE

(A) Snap ring

(B) Flat washer

(A) Striking rod

(B) Spring pin

MT-01306

(B)

(A)

MT-01092

ST2

ST2

ST1

(A)

(B)

MT-01307

(A) Selector arm No. 2

(B) Shifter arm

(B)

(A)

MT-01308

MT-00489

ST

MT-00490

Y

ST