Subaru Legacy III (2000-2003 year). Service manual — part 627
MT-76
MANUAL TRANSMISSION AND DIFFERENTIAL
MAIN SHAFT ASSEMBLY FOR DUAL-RANGE
8) Remove the rest of parts.
D: ASSEMBLY
1. 2.0 L
1) Assemble when each sleeve and hub assembly
are disassembled.
NOTE:
Position open ends of spring 120
°
apart.
(A) Sleeve and hub ASSY
(B) High-low baulk ring
(C) Friction damper
(D) Low input gear
(E) Needle bearing
(F) Input low gear spacer
(G) Ball
MT-00216
( A )
( B )
( B )
( F )
( C )
( D )
( G )
( E )
(A) High-low coupling sleeve
(B) Shifting insert
(C) High-low synchronizer spring
(D) High-low synchronizer hub
(E) Sleeve
(F) Insert key
(G) 3rd-4th synchronizer hub
(H) Sleeve
(I) Insert key
(J) 5th-Rev synchronizer hub
(K) High side
(L) Low side
(M) 3rd side
(N) 4th side
(O) 5th side
(P) Rev side
MT-00217
( A )
( B )
( C )
( D )
( K )
( L )
( E )
( F )
( N )
( M )
( P )
( O )
( G )
( H )
( I )
( J )
MT-77
MANUAL TRANSMISSION AND DIFFERENTIAL
MAIN SHAFT ASSEMBLY FOR DUAL-RANGE
2) Install 3rd drive gear, baulk ring, sleeve and hub
assembly for 3rd-4th needle bearing on transmis-
sion main shaft.
NOTE:
Align groove in baulk ring with shifting insert.
3) Install 4th needle bearing race onto transmission
main shaft using ST1, ST2 and a press.
ST1
899714110
REMOVER
ST2
499877000
RACE 4-5 INSTALLER
4) Install baulk ring, needle bearing, 4th drive gear
and 4th gear thrust washer to transmission main
shaft.
NOTE:
Face thrust washer in the correct direction.
5) Drive ball bearing onto the rear section of trans-
mission main shaft using ST1, ST2 and a press.
ST1
899714110
REMOVER
ST2
499877000
RACE 4-5 INSTALLER
6) Using ST1 and ST2, install the 5th gear thrust
washer and 5th needle bearing race onto the rear
section of transmission main shaft.
NOTE:
Face thrust washer in the correct direction.
ST1
899714110
REMOVER
ST2
499877000
RACE 4-5 INSTALLER
7) Install bearing onto synchro cone.
(A) 4th needle bearing race
(A) Groove
(B) 4th gear side
MT-00192
( A )
ST1
ST2
MT-00193
( A )
( B )
(A) Face this surface to 5th gear side.
MT-00194
ST2
ST1
MT-00195
( A )
MT-78
MANUAL TRANSMISSION AND DIFFERENTIAL
MAIN SHAFT ASSEMBLY FOR DUAL-RANGE
8) Install new baulk ring and synchro cone onto
5th-Rev sleeve and hub assembly using ST and a
press.
NOTE:
After press fitting, make sure synchro cone rotates
freely.
ST
499757002
INSTALLER
9) Install synchro cone stopper and snap ring to
5th-Rev sleeve and hub assembly.
10) Install the rest parts to the rear section of trans-
mission main shaft.
NOTE:
Align groove in baulk ring with shifting insert.
11) Tighten lock nuts to the specified torque using
ST1 and ST2.
NOTE:
Secure lock nuts in two places after tightening.
ST1
499987003
SOCKET WRENCH
ST2
498937000
TRANSMISSION HOLDER
Tightening torque:
120 N·m (12.2 kgf-m, 88.2 ft-lb)
12) Install needle bearing on main shaft.
(A) Baulk ring
(B) Synchro cone
(C) Ball bearing
(A) Synchro cone stopper
(B) Snap ring
MT-00196
( A ) ( B )
( C )
ST
MT-00188
( A )
( B )
(A) Needle bearing
(B) 5th drive gear
(C) Baulk ring
(D) 5th-Rev sleeve and hub ASSY
(E) Lock washer
(F) Lock nuts
MT-00198
( A )
( B ) ( C )
( D )
( E )
( F )
MT-79
MANUAL TRANSMISSION AND DIFFERENTIAL
MAIN SHAFT ASSEMBLY FOR DUAL-RANGE
13) Install the parts to the front section of transmis-
sion main shaft.
NOTE:
• Be careful not to damage the graded section of
transmission main shaft when installing needle
bearing.
• Face the grooved side toward input gear.
• Align high-low baulk ring's groove with shifting in-
sert.
14) Install new snap ring to the rod section of trans-
mission main shaft using ST1 and ST2.
NOTE:
Select a suitable outer snap ring so that axial clear-
ance between snap ring and hub is held within
0.060 to 0.100 mm (0.0024 to 0.0039 in).
ST1
499757002
INSTALLER
ST2
499757001
SNAP RING GUIDE
2. EXCEPT 2.0 L
1) Assemble when each sleeve and hub assembly
are disassembled.
NOTE:
Position open ends of spring 120
°
apart.
2) Install 3rd drive gear, inner baulk ring, outer
baulk ring, synchro cone sleeve and hub assembly
for 3rd needle bearing on transmission main shaft.
NOTE:
Align groove in baulk ring with shifting insert.
(A) Ball
(B) Input low gear spacer
(C) Needle bearing
(D) Low input gear
(E) Friction damper
(F) High-low baulk ring
(G) Sleeve and hub ASSY
Snap ring
Part No.
Thickness mm (in)
805025051
2.42 (0.0953)
805025052
2.47 (0.0972)
805025053
2.52 (0.0992)
805025054
2.57 (0.1012)
805025055
2.62 (0.1031)
805025056
2.67 (0.1051)
805025057
2.72 (0.1071)
805025058
2.37 (0.0933)
MT-00225
( A )
( B )
( C )
( D )
( E )
( F )
( F )
( G )
(A) High-low coupling sleeve
(B) Shifting insert
(C) High-low synchronizer spring
(D) High-low synchronizer hub
(E) Sleeve
(F) Insert key
(G) 3rd-4th synchronizer hub
(H) Sleeve
(I) Insert key
(J) 5th-Rev synchronizer hub
(K) High side
(L) Low side
(M) 3rd side
(N) 4th side
(O) 5th side
(P) Rev side
MT-00217
( A )
( B )
( C )
( D )
( K )
( L )
( E )
( F )
( N )
( M )
( P )
( O )
( G )
( H )
( I )
( J )
MT-00200
( A )
( B ) ( C )
( D ) ( E )
( F )
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