Subaru Legacy III (2000-2003 year). Service manual — part 608
AT-166
AUTOMATIC TRANSMISSION (DIAGNOSTICS)
SYMPTOM RELATED DIAGNOSTIC
MEMO:
MANUAL TRANSMISSION AND DIFFEREN-
TIAL
MT
Page
General Description . . . . . . . . . . . . . . . . . . . . . 2
Transmission Gear Oil . . . . . . . . . . . . . . . . . . . ..31
Manual Transmission Assembly . . . . . . . . . . . . . . . ...32
Transmission Mounting System . . . . . . . . . . . . . . . . 39
Oil Seal. . . . . . . . . . . . . . . . . . . . . . . . . ..41
Switches and Harness . . . . . . . . . . . . . . . . . . . ..42
Vehicle Speed Sensor. . . . . . . . . . . . . . . . . . . ...45
Preparation for Overhaul. . . . . . . . . . . . . . . . . . ...46
Transfer Case and Extension Case Assembly. . . . . . . . . . ..47
Transfer Drive Gear . . . . . . . . . . . . . . . . . . . . ..51
Transfer Driven Gear . . . . . . . . . . . . . . . . . . . . 53
Center Differential . . . . . . . . . . . . . . . . . . . . . .55
Reverse Check Sleeve. . . . . . . . . . . . . . . . . . . ..56
Transmission Case . . . . . . . . . . . . . . . . . . . . ...59
Main Shaft Assembly for Single-Range . . . . . . . . . . . . . 66
Main Shaft Assembly for Dual-Range . . . . . . . . . . . . . ...74
Input Shaft Assembly . . . . . . . . . . . . . . . . . . . . 83
Drive Pinion Shaft Assembly . . . . . . . . . . . . . . . . . .87
Front Differential Assembly . . . . . . . . . . . . . . . . . ...95
Speedometer Gear. . . . . . . . . . . . . . . . . . . . ..103
Reverse Idler Gear. . . . . . . . . . . . . . . . . . . . ..104
Shifter Fork and Rod . . . . . . . . . . . . . . . . . . . ...106
Counter Gear . . . . . . . . . . . . . . . . . . . . . . ..109
General Diagnostic. . . . . . . . . . . . . . . . . . . . ..111
MT-2
MANUAL TRANSMISSION AND DIFFERENTIAL
GENERAL DESCRIPTION
1. General Description
A: SPECIFICATIONS
1. MANUAL TRANSMISSION AND DIFFERENTIAL
*: Dual-range model only
Item
Model
2.0 L
non-TURBO
2.5 L
2.0 L
TURBO
General and Europe
Australia
Except OUTBACK
OUTBACK
Except
OUTBACK
OUTBACK
Type
5-forward speeds and 1-reverse
(5 x 2-forward speeds and 1 x 2-reverse)*
Transmission gear
ratio
1st
3.454
3.166
2nd
2.062
1.882
3rd
1.448
1.296
4th
1.088
0.972
5th
0.825
0.780
0.825
0.738
Reverse
3.333
Auxiliary transmis-
sion gear ratio*
High
1.000
—
Low
1.447
1.196
—
Front
reduction
gear
Final
Type of
gear
Hypoid
Gear ratio
3.900
3.700
3.900
4.111
Rear
reduction
gear
Transfer
Type of
gear
Helical
Gear ratio
1.000
Final
Type of
gear
Hypoid
Gear ratio
3.900
3.700
3.900
4.111
Front dif-
ferential
Type and number of
gear
Straight bevel gear (Bevel pinion: 2, Bevel gear: 2)
Center dif-
ferential
Type and number of
gear
Straight bevel gear
(Bevel pinion: 2, Bevel gear: 2 and viscous coupling)
Transmission gear oil
GL-5
Transmission gear oil
capacity
Single-
range
model
3.5
2
(3.7 US qt, 3.1 Imp qt)
Dual-range
model
4.0
2
(4.2 US qt, 3.5 Imp qt)
—
MT-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
Snap ring to counter washer clearance
0.05 — 0.35 mm (0.0020 — 0.0138 in)
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 bearing clearance
0 — 0.12 mm (0 — 0.0047 in)
(1) ITEM
(2) Transmission gear oil
(3) API Classification
(4) SAE Viscosity No. and Applicable Temperature
Drive pinion shim
Part No.
Thickness
mm (in)
Part No.
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 No.
Mark
4.00 — 4.13
(0.1575 — 0.1626)
32294AA041
1
3.87 — 3.99
(0.1524 — 0.1571)
32294AA051
2
Snap ring (Outer-19)
Part No.
Thickness mm (in)
031319000
1.50 (0.0591)
805019010
1.72 (0.0677)
MT-00001
(1)
(4)
GL-5
(3)
(2)
-30 -26 -15
15
90
85W
80W
75W -90
25
30
-5 0
-22 -15
23 32
86
59
77
5
(˚C)
(˚F)
Dimension “D” mm (in)
Number of shim
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
Adjusting washer No. 1
Part No.
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 No.
Thickness mm (in)
803025059
3.850 (0.1516)
803025054 4.000
(0.1575)
803025058
4.150 (0.1634)
Snap ring (Outer-28)
Part No.
Thickness mm (in)
805028050
2.48 (0.0976)
805028060
2.56 (0.1008)
805028070
2.64 (0.1039)
Snap ring (Inner-68)
Part No.
Thickness mm (in)
805168020
1.84 (0.0724)
805168030
1.92 (0.0756)
805168040
2.00 (0.0787)
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