Subaru Legacy IV (2008 year). Manual — part 789

5MT-52

Transmission Case

MANUAL TRANSMISSION AND DIFFERENTIAL

B: INSTALLATION

1) Wipe off grease, oil and dust on the mating sur-
faces of transmission cases with cleaning solvent.
2) Install the front differential assembly.
3) Install the main shaft assembly for single-range.
Install the transmission case knock pin into the
knock pin hole of needle bearing.
4) Install the drive pinion shaft assembly.
Install the transmission case knock pin into the roll-
er bearing knock pin hole.
5) Apply liquid gasket, then join the right side and
left side of the case together.

Liquid gasket:

THREE BOND 1215 (Part No. 004403007) or
equivalent

6) With brackets and clips as shown in the figure,
tighten the seventeen bolts.

NOTE:
• Insert the bolts from the bottom and tighten the
nuts at the top.
• Match the cases together so that the drive pinion
shim and input shaft holder shims are not caught
between the case halves.

Tightening torque:

8 mm bolt

25 N·m (2.5 kgf-m, 18.4 ft-lb)

10 mm bolt

39 N·m (4.0 kgf-m, 28.8 ft-lb)

7) Tighten the ball bearing mounting bolts.

Tightening torque:

30 N·m (3.1 kgf-m, 22.1 ft-lb)

8) Perform backlash adjustment of the hypoid gear
and preload measurement of the roller bearing.

NOTE:
Attach the ST on drive pinion assembly.
ST

498427100

STOPPER

9) Place the transmission with the left side of case
facing downward, and put ST1 on bearing cup.
10) Screw the retainer assembly from the bottom
into left case using ST2. Fit the ST3 on transmis-
sion main shaft. Shift the gear into 4th or 5th, and
turn the shaft several times. Screw in the retainer
while rotating the ST3 until a slight resistance is felt
on ST2.
This is the contact point of the hypoid gear and the
drive pinion shaft. Repeat the above sequence sev-
eral times to ensure the contact point.
ST1

399780104

WEIGHT

ST2

18630AA010 WRENCH COMPL RETAINER

ST3

499927100

HANDLE

MT-00172

(9)

(7)

(5)

(1)

(2)

(16)

(17)

(11)

(3)

(4)

(12)

(8)

(6)

(10)

(14)

(15)

(13)

MT-01514

ST

MT-01516

MT-00175

ST3

ST2

ST1

5MT-53

Transmission Case

MANUAL TRANSMISSION AND DIFFERENTIAL

11) Remove the weight, and screw in the retainer
without the O-ring on the upper side, and stop at
the point where a slight resistance is felt.

NOTE:
In this condition, the backlash between the hypoid
gear and drive pinion shaft is zero.
ST

18630AA010

WRENCH COMPL RETAINER

12) Loosen the retainer on the lower side by 3
notches, and turn the retainer on the upper side by
the same amount in order to apply backlash.
13) Rotate the retainer of the upper side additional-
ly by 1 notch in order to apply preload on taper roll-
er bearing.
14) Temporarily attach both the upper and lower
lock plates, and put marks both the retainer and
lock plate for later readjustment.

NOTE:
If it is hard to install the lock plates, reverse the
sides and install them.
15) Turn the transmission main shaft several times
while tapping around the retainer lightly with plastic
hammer.
16) Inspect and adjust backlash and tooth contact
of the hypoid gear. <Ref. to 5MT-73, INSPECTION,
Front Differential Assembly.>

17) After checking the tooth contact of the hypoid
gears, remove the lock plate. Then loosen the re-
tainer until the O-ring groove appears. Fit the O-
ring into the groove and tighten the retainer into the
position where retainer was tightened to.
Install the lock plate.

NOTE:
• When loosening the retainer, record how many
times it was turned to loosen.
• Perform this for both upper and lower retainers.

Tightening torque:

T: 25 N·m (2.5 kgf-m, 18.4 ft-lb)

18) Select the main shaft rear plate. <Ref. to 5MT-
59, ADJUSTMENT, Main Shaft Assembly for Sin-
gle-Range.>
19) Install the clutch release lever and bearing.
<Ref. to CL-19, INSTALLATION, Release Bearing
and Lever.>
20) Install the transfer case together with the exten-
sion case assembly. <Ref. to 5MT-38, INSTALLA-
TION, Transfer Case and Extension Case
Assembly.>
21) Install the manual transmission assembly to the
vehicle. <Ref. to 5MT-27, INSTALLATION, Manual
Transmission Assembly.>

C: INSPECTION

Check the transmission case for cracks, damage,
or oil leaks.

MT-00176

ST

MT-00177

T

5MT-54

Main Shaft Assembly for Single-Range

MANUAL TRANSMISSION AND DIFFERENTIAL

15.Main Shaft Assembly for

Single-Range

A: REMOVAL

1) Remove the manual transmission assembly
from the vehicle. <Ref. to 5MT-24, REMOVAL,
Manual Transmission Assembly.>
2) Remove the transfer case together with the ex-
tension case assembly. <Ref. to 5MT-38, REMOV-
AL, Transfer Case and Extension Case
Assembly.>
3) Remove the transmission case. <Ref. to 5MT-
51, REMOVAL, Transmission Case.>
4) Remove the drive pinion shaft assembly. <Ref.
to 5MT-60, REMOVAL, Drive Pinion Shaft Assem-
bly.>
5) Remove the main shaft assembly for single-
range.

B: INSTALLATION

1) Install the needle bearing and oil seal to the front
of the transmission single-range main shaft assem-
bly.

NOTE:
• Wrap the clutch splined section with vinyl tape to
prevent damage to the oil seal.
• Apply KOPR-KOTE (or equivalent) to the sealing
lip of the oil seal.
• Use a new oil seal.
2) Install the transmission case knock pin into the
knock pin hole of the needle bearing outer race.

NOTE:
Align the end face of the seal with surface (A) when
installing the oil seal.

3) Install the drive pinion shaft assembly. <Ref. to
5MT-60, INSTALLATION, Drive Pinion Shaft As-
sembly.>
4) Install the transmission case. <Ref. to 5MT-52,
INSTALLATION, Transmission Case.>
5) Install the transfer case together with the exten-
sion case assembly. <Ref. to 5MT-38, INSTALLA-
TION, Transfer Case and Extension Case
Assembly.>

6) Install the manual transmission assembly to the
vehicle. <Ref. to 5MT-27, INSTALLATION, Manual
Transmission Assembly.>

C: DISASSEMBLY

1) Apply vinyl tape around the main shaft splines to
protect the oil seal from damage. Then pull out the
oil seal and needle bearing by hand.
2) Remove the lock nut from transmission main
shaft assembly for single range.

NOTE:
Flatten the lock nut tab before removing the lock
nut.
ST1

498937000

TRANSMISSION HOLDER

ST2

499987003

SOCKET WRENCH (35)

3) Remove the 5th hub & sleeve No. 2, baulk lever,
baulk ring, and the 5th drive gear & needle bearing.

MT-00185

(A)

(A) 5th hub & sleeve No. 2

(B) Baulk ring

(C) 5th drive gear

ST2

ST1

MT-01517

( A )

( B )

( C )

MT-01518

5MT-55

Main Shaft Assembly for Single-Range

MANUAL TRANSMISSION AND DIFFERENTIAL

4) Using ST1 and ST2, remove the rest of the
parts.

NOTE:
• When replacing the sleeve & hub, replace them
as a set.
• Do not disassemble the sleeve & hub; the align-
ing position is pre-matched.
• If it is necessary to disassemble, mark the en-
gaging points on the splines beforehand.
ST1

899864100

REMOVER

ST2

899714110

REMOVER

D: ASSEMBLY

1) When the sleeve & hub assemblies have been
disassembled, reassemble by aligning the align-
ment marks.

NOTE:
Position the spring opening at a position spaced
apart by 120°.

(A) Press

MT-01806

(A)

ST2

ST1

(A) 3rd-4th hub ASSY

(B) 3rd gear side

(C) 5th hub & sleeve No. 2

(D) 5th gear side

(D)

(C)

(B)

(A)

MT-01523