Subaru Legacy (2005 year). Service manual — part 639

5MT-3

MANUAL TRANSMISSION AND DIFFERENTIAL

General Description

2. TRANSMISSION GEAR OIL

Recommended oil:

3. TRANSMISSION CASE ASSEMBLY

Drive pinion shim adjustment

Hypoid gear backlash:

0.13 — 0.18 mm (0.0051 — 0.0071 in)

Selection of main shaft rear plate

Input shaft holder adjustment

4. DRIVE PINION ASSEMBLY

Preload adjustment of thrust bearing

Starting torque:

0.3 — 0.8 N

⋅

m (0.03 — 0.08 kgf-m, 0.2 — 0.6 ft-

lb)

5. INPUT SHAFT ASSEMBLY

Snap ring (Outer-28) to ball bearing clearance:

0 — 0.12 mm (0 — 0.0047 in)

Snap ring (Inner-68) to ball bearing clearance:

0 — 0.12 mm (0 — 0.0047 in)

6. MAIN SHAFT

Snap ring (Outer-25) to synchronizer hub clear-
ance:

0.060 — 0.100 mm (0.0024 — 0.0039 in)

(1) Item

(2) Transmission gear oil

(3) API standard

(4) SAE viscosity No. and applicable temperature

Drive pinion shim

Part Number

Thickness

mm (in)

Part Number

Thickness

mm (in)

32295AA031

0.150

(0.0059)

32295AA071

0.250

(0.0098)

32295AA041

0.175

(0.0069)

32295AA081

0.275

(0.0108)

32295AA051

0.200

(0.0079)

32295AA091

0.300

(0.0118)

32295AA061

0.225

(0.0089)

32295AA101

0.500

(0.0197)

Main shaft rear plate

Dimension “A” mm (in)

Part Number

Marking

4.00 — 4.13

(0.1575 — 0.1626)

32294AA041

1

3.87 — 3.99

(0.1524 — 0.1571)

32294AA051

2

Dimension “D” mm (in)

Shim Number

52.50 — 53.11

(2.0669 — 2.0909)

—

52.00 — 52.49

(2.0472 — 2.0665)

1

51.26 — 51.99

(2.0181 — 2.0468)

2

MT-00001

(1)

(4)

GL-5

(3)

(2)

( C)
( F)

-30 -26 -15

15

90

85W

80W

75W -90

25

30

-5 0

-22 -15

23 32

86

59

77

5

Adjusting washer No. 1

Part Number

Thickness mm (in)

803025051

3.925 (0.1545)

803025052

3.950 (0.1555)

803025053

3.975 (0.1565)

803025054

4.000 (0.1575)

803025055

4.025 (0.1585)

803025056

4.050 (0.1594)

803025057

4.075 (0.1604)

Adjusting washer No. 2

Part Number

Thickness mm (in)

803025059

3.850 (0.1516)

803025054

4.000 (0.1575)

803025058

4.150 (0.1634)

Snap ring (Outer-28)

Part Number

Thickness mm (in)

805028050

2.48 (0.0976)

805028060

2.56 (0.1008)

805028070

2.64 (0.1039)

Snap ring (Inner-68)

Part Number

Thickness mm (in)

805168020

1.84 (0.0724)

805168030

1.92 (0.0756)

805168040

2.00 (0.0787)

Snap ring (Outer-25)

Part Number

Thickness

mm (in)

Part Number

Thickness

mm (in)

805025051

2.42 (0.0953)

805025055

2.62 (0.1031)

805025052

2.47 (0.0972)

805025056

2.67 (0.1051)

805025053

2.52 (0.0992)

805025057

2.72 (0.1071)

805025054

2.57 (0.1012)

805025058

2.37 (0.0933)

5MT-4

MANUAL TRANSMISSION AND DIFFERENTIAL

General Description

7. REVERSE IDLER GEAR

Adjustment of reverse idler gear position

Reverse idler gear to transmission case (LH)
wall clearance:

6.0 — 7.5 mm (0.236 — 0.295 in)

After installing a suitable reverse shifter lever, ad-
just the clearance using washer.

Reverse idler gear to transmission case wall
clearance:

0 — 0.5 mm (0 — 0.020 in)

8. SHIFTER FORK AND ROD

Select suitable shifter forks so that both the cou-
pling sleeve and reverse driven gear are positioned
in the center of their synchromesh mechanisms.

Rod end clearance:

A: 3rd-4th — 5th

0.5 — 1.3 mm (0.020 — 0.051 in)

B: 1st-2nd — 3rd-4th

0.4 — 1.4 mm (0.016 — 0.055 in)

9. TRANSFER CASE OR REAR CASE

Neutral position adjustment

Reverse check plate adjustment

Reverse shifter lever

Part Number

Marking

Remarks

32820AA070

7

Further from case wall

32820AA080

8

Standard

32820AA090

9

Closer to the case wall

Washer (20.5

× 26 × t)

Part Number

Thickness

mm (in)

Part Number

Thickness

mm (in)

803020151

0.4 (0.016)

803020154

1.9 (0.075)

803020152

1.1 (0.043)

803020155

2.3 (0.091)

803020153

1.5 (0.059)

—

—

1st-2nd shifter fork

Part Number

Marking

Remarks

32804AA060

1

Approach to 1st gear
by 0.2 mm (0.008 in)

32804AA070

No mark

Standard

32804AA080

3

Approach to 2nd gear
by 0.2 mm (0.008 in)

3rd-4th shifter fork

Part Number

Marking

Remarks

32810AA061

1

Approach to 4th gear
by 0.2 mm (0.008 in)

32810AA071

No mark

Standard

32810AA101

3

Approach to 3rd gear
by 0.2 mm (0.008 in)

5th shifter fork (Non-turbo model)

Part No.

Mark

Remarks

32812AA201

7

Approach to 5th gear
by 0.2 mm (0.008 in)

32812AA211

No mark

Standard

32812AA221

9

Become distant from
5th gear by 0.2 mm
(0.008 in)

5th shifter fork (Turbo model)

Part No.

Mark

Remarks

32812AA231

7

Approach to 5th gear
by 0.2 mm (0.008 in)

32812AA241

No mark

Standard

32812AA251

9

Become distant from
5th gear by 0.2 mm
(0.008 in)

Adjusting shim

Part Number

Thickness mm (in)

32190AA000

0.15 (0.0059)

32190AA010

0.30 (0.0118)

Reverse accent shaft

Part No.

Mark

Remarks

32188AA130

S

Neutral position is
closer to 1st.

32188AA140

T

Standard

32188AA150

U

Neutral position is
closer to reverse gear.

Reverse check plate

Part Number

Mark-

ing

Angle

θ

Remarks

32189AA000

0

28

°

Arm stops closer to
5th gear.

32189AA010

1

31

°

Arm stops closer to
5th gear.

33189AA020

2

34

°

Arm stops in the cen-
ter.

32189AA030

3

37

°

Arm stops closer to
reverse gear.

32189AA040

4

40

°

Arm stops closer to
reverse gear.

5MT-5

MANUAL TRANSMISSION AND DIFFERENTIAL

General Description

10.EXTENSION ASSEMBLY

Standard protrusion amount of taper roller
bearing outer race:

0.2 — 0.3 mm (0.0008 — 0.012 in)

NOTE:
Be sure that it is within the standard protrusion
amount.

Thrust washer to center differential side clear-
ance:

0.15 — 0.35 mm (0.0059 — 0.0138 in)

11.FRONT DIFFERENTIAL

Bevel gear to pinion backlash:

0.13 — 0.18 mm (0.0051 — 0.0071 in)

12.TRANSFER DRIVE GEAR

Snap ring (Outer-30) to ball bearing clearance:

0.01 — 0.15 mm (0.0004 — 0.0059 in)

Thrust washer (50

× 61 × t)

Part Number

Thickness mm (in)

803050060

0.50 (0.0197)

803050061

0.55 (0.0217)

803050062

0.60 (0.0236)

803050063

0.65 (0.0256)

803050064

0.70 (0.0276)

803050065

0.75 (0.0295)

803050066

0.80 (0.0315)

803050067

0.85 (0.0335)

803050068

0.90 (0.0354)

803050069

0.95 (0.0374)

803050070

1.00 (0.0394)

803050071

1.05 (0.0413)

803050072

1.10 (0.0433)

803050073

1.15 (0.0453)

803050074

1.20 (0.0472)

803050075

1.25 (0.0492)

803050076

1.30 (0.0512)

803050077

1.35 (0.0531)

803050078

1.40 (0.0551)

803050079

1.45 (0.0571)

Thrust washer

Part Number

Thickness mm (in)

803036050

0.9 (0.035)

803036054

1.0 (0.039)

803036051

1.1 (0.043)

803036055

1.2 (0.047)

803036052

1.3 (0.051)

803036056

1.4 (0.055)

803036053

1.5 (0.059)

803036057

1.6 (0.063)

803036058

1.7 (0.067)

Washer (38.1

× 50 × t)

Part Number

Thickness

mm (in)

Part Number

Thickness

mm (in)

803038021

0.925 —

0.950

(0.0364 —

0.0374)

803038023

1.025 —

1.050

(0.0404 —

0.0413)

803038022

0.975 —

1.000

(0.0384 —

0.0394)

—

—

Snap ring (Outer-30)

Part Number

Thickness mm (in)

805030041

1.53 (0.0602)

805030042

1.65 (0.0650)

805030043

1.77 (0.0697)

5MT-6

MANUAL TRANSMISSION AND DIFFERENTIAL

General Description

B: COMPONENT

1. TRANSMISSION CASE

MT-01360

(12)

(10)

(11)

(13)

T1

(3)

(1)

(2)

(4)

(7)

(6)

(5)

(9)

(8)

T2

(14)