Subaru Legacy III (2000-2003 year). Manual — part 609

MT-4

MANUAL TRANSMISSION AND DIFFERENTIAL

GENERAL DESCRIPTION

6. MAIN SHAFT

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

0.060 — 0.100 mm (0.0024 — 0.0039 in)

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 reverse idler gear to transmission case wall
clearance to within 0 to 0.5 mm (0 to 0.020 in) using
washers.

8. SHIFTER FORK AND ROD

Select suitable shifter forks so that both coupling
sleeve and reverse driven gear are positioned in
the center of their synchromesh mechanisms.
Rod end clearance

A: 1st-2nd — 3rd-4th

0.4 — 1.4 mm (0.016 — 0.055 in)

B: 3rd-4th — 5th

0.5 — 1.3 mm (0.020 — 0.051 in)

9. TRANSFER CASE

Neutral position adjustment

Reverse check plate adjustment

Snap ring (Outer-25)

Part No.

Thickness

mm (in)

Part No.

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)

Reverse shifter lever

Part No.

Mark

Remarks

32820AA070

7

Further from case wall

32820AA080

8

Standard

32820AA090

9

Closer to the case wall

Washer (20.5

×

26

×

t)

Part No.

Thickness

mm (in)

Part No.

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 No.

Mark

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 No.

Mark

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)

Adjustment shim

Part No.

Thickness mm (in)

32190AA000

0.15 (0.0059)

32190AA010 0.30

(0.0118)

Reverse accent shaft

Part No.

Mark

Remarks

32188AA090

3

Neutral position is closer to 1st.

32188AA100

0

Standard

32188AA110

1

Neutral position is closer to
reverse gear.

Reverse check plate

Part No.

Mark

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 center.

32189AA030

3

37

°

Arm stops closer to
reverse gear.

32189AA040

4

40

°

Arm stops closer to
reverse gear.

MT-5

MANUAL TRANSMISSION AND DIFFERENTIAL

GENERAL DESCRIPTION

10.EXTENSION ASSEMBLY

Thrust washer (50

×

61

×

t) to taper roller bearing

table outer race side clearance

0.2 — 0.3 mm T (0.0008 — 0.012 in T)

NOTE:
Clearance should be within the specified value.

Thrust washer to center differential side clearance

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)

Pinion shaft to axle drive shaft clearance

0 — 0.2 mm (0 — 0.008 in)

12.TRANSFER DRIVE GEAR

Snap ring (Outer-30) to ball bearing clearance

0.01 — 0.15 mm (0.004 — 0.0050 in)

Thrust washer (50

×

61

×

t)

Part No.

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 No.

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 No.

Thickness

mm (in)

Part No.

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-28)

Part No.

Thickness

mm (in)

Part No.

Thickness

mm (in)

805028011

1.05 (0.0413)

805028012

1.20 (0.0472)

Snap ring (Outer-30)

Part No.

Thickness

mm (in)

805030041

1.53 (0.0602)

805030042

1.65 (0.0650)

805030043

1.77 (0.0697)

MT-6

MANUAL TRANSMISSION AND DIFFERENTIAL

GENERAL DESCRIPTION

B: COMPONENT

1. TRANSMISSION CASE

MT-00002

T

(3)

(1)

(2)

(4)

(5)

(12)

(10)

(11)

(18)

(13)

(9)

(8)

(7)

(6)

(16)

(14)

(15)

(17)

MT-7

MANUAL TRANSMISSION AND DIFFERENTIAL

GENERAL DESCRIPTION

• Transmission case tightening torque

(1) Transmission case ASSY

(11) Pitching stopper bracket

(17) High-low cable bracket B (Dual-

range)

(2) Gasket

(12) Clip (Dual-range)

(3) Drain plug

(13) Oil level gauge (Non-TURBO

model)

(18) Oil level gauge (TURBO model)

(4) Snap ring (Outer)

(5) Speedometer driven gear

(14) Oil seal (Dual-range)

Tightening torque: N·m (kgf-m, ft-lb)

(6) Washer

(15) Transmission case ASSY (Dual-

range)

T: 44 (4.5, 32.5)

(7) Speedometer shaft

(8) Snap ring (Outer)

(16) High-low cable bracket A (Dual-

range)

(9) Oil seal

(10) Clamp

Bolt No.

Bolt size

Tightening torque: N·m (kgf-m,

ft-lb)

<5> to <15>

8 mm

25 (2.5, 18.1)

<1> to <4>

<16>, <17>

10 mm

39 (4.0, 28.9)

MT-00003

( 9 ) ( 5 ) ( 7 )

(16)

(17)

( 3 )

( 4 )

(11)

( 1 )

( 2 )

( 6 ) ( 8 )

(10)

(12)

(14)

(13)

(15)