Subaru Legacy III (2000-2003 year). Service 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)
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