Subaru Legacy IV (2008 year). Manual — part 793

5MT-68

Drive Pinion Shaft Assembly

MANUAL TRANSMISSION AND DIFFERENTIAL

3) After removing the ST2, measure the starting
torque using torque driver.
ST1

899884100

HOLDER

ST3

899988608

SOCKET WRENCH (27)

Starting torque:

0.3 — 0.8 N·m (0.03 — 0.08 kgf-m, 0.2 — 0.6 ft-lb)

4) If the starting torque is not within the specified
limit, select new adjusting washer No. 1 and re-
check starting torque.

5) If the specified starting torque cannot be ob-
tained by the selection of washer No. 1, select ad-
justing washer No. 2 from the list below. Repeat
steps 1) through 4) to adjust starting torque.

6) Recheck that the starting torque is within the
specified range, then crimp the lock nut at four po-
sitions.

(A) Adjusting washer No. 1

(B) Adjusting washer No. 2

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)

MT-00269

ST1

ST3

MT-00270

( A )

( B )

(A) Adjusting washer No. 1

(B) Adjusting washer No. 2

Starting torque

Dimension H

Adjusting washer No. 2

Low

Small

Select thicker one.

High

Large

Select thinner one.

Adjusting washer No. 2

Part number

Thickness mm (in)

803025059

3.850 (0.1516)

803025054

4.000 (0.1575)

803025058

4.150 (0.1634)

MT-00270

( A )

( B )

5MT-69

Front Differential Assembly

MANUAL TRANSMISSION AND DIFFERENTIAL

17.Front Differential Assembly

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. <Ref. to 5MT-54, REMOVAL, Main Shaft
Assembly for Single-Range.>
6) Remove the front differential assembly.

NOTE:
• Do not confuse the right and left roller bearing
outer races.
• Be careful not to damage the oil seal of retainer.

7) Remove the differential side retainers using ST.
ST

18630AA010

WRENCH COMPL RETAINER

8) Remove the bearing outer race from the trans-
mission case.
ST

398527700

PULLER ASSY

B: INSTALLATION

1) Install the differential side retainers using ST.
ST

18630AA010

WRENCH COMPL RETAINER

2) Install the bearing outer race to the transmission
case.
3) Install the front differential assembly.

NOTE:
Be careful not to fold the sealing lip of oil seal.

4) Install the main shaft assembly for single-range.
<Ref. to 5MT-54, INSTALLATION, Main Shaft As-
sembly for Single-Range.>
5) Install the drive pinion shaft assembly. <Ref. to
5MT-60, INSTALLATION, Drive Pinion Shaft As-
sembly.>
6) Install the transmission case. <Ref. to 5MT-52,
INSTALLATION, Transmission Case.>
7) Install the transfer case together with the exten-
sion case assembly. <Ref. to 5MT-38, INSTALLA-
TION, Transfer Case and Extension Case
Assembly.>
8) Install the manual transmission assembly to the
vehicle. <Ref. to 5MT-27, INSTALLATION, Manual
Transmission Assembly.>

MT-00162

MT-00176

ST

MT-00162

5MT-70

Front Differential Assembly

MANUAL TRANSMISSION AND DIFFERENTIAL

C: DISASSEMBLY

1. DIFFERENTIAL CASE ASSEMBLY

1) Loosen the twelve bolts and remove hypoid driv-
en gear.

2) Drive out the straight pin from differential assem-
bly toward hypoid driven gear side.
ST

899904100

REMOVER

3) Pull out the pinion shaft, and remove the differ-
ential bevel pinion, differential bevel gear and
washer.

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

899524100

PULLER SET

(A) Hypoid driven gear

(A)

MT-00275

MT-00276

ST

(A) Pinion shaft

(B) Differential bevel pinion

(C) Differential bevel gear

(D) Washer

MT-00277

(A)

(D)

(D)

(C)

(C)

(B)

(B)

MT-00278

ST

5MT-71

Front Differential Assembly

MANUAL TRANSMISSION AND DIFFERENTIAL

2. SIDE RETAINER

1) Remove the O-ring.

2) Remove the oil seal.

NOTE:
• Remove it by using flat tip screwdriver.
• Do not reuse the oil seal. Replace the oil seal
with a new part.

D: ASSEMBLY

1. DIFFERENTIAL CASE ASSEMBLY

1) Install the differential bevel gear and differential
bevel pinion together with washer, and insert the
pinion shaft.

NOTE:
Face the chamfered side of washer toward gear.

2) Measure the backlash between the differential
bevel gear and differential bevel pinion. If backlash
is not within specified value, install a suitable wash-
er to adjust. <Ref. to 5MT-73, BEVEL PINION
GEAR BACKLASH, INSPECTION, Front Differen-
tial Assembly.>

NOTE:
Be sure the pinion gear teeth contacts adjacent
gear teeth during measurement.
ST1

498247001

MAGNET BASE

ST2

498247100

DIAL GAUGE

Standard backlash

0.13 — 0.18 mm (0.0051 — 0.0071 in)

MT-00279

MT-01445

(A) Differential bevel pinion

(B) Differential bevel gear

(C) Pinion shaft

MT-00284

(A)

(B)

(C)

MT-00285

ST1

ST2