Subaru Legacy III (2000-2003 year). Service manual — part 635
MT-108
MANUAL TRANSMISSION AND DIFFERENTIAL
SHIFTER FORK AND ROD
4) Inspect clearance between 3rd, 4th drive gear
and coupling sleeve. If any clearance is not within
specifications, replace shifter fork as required.
Clearance (a) and (b):
9.3 mm (0.366 in)
5) Inspect clearance between 5th drive gear and
coupling sleeve. If any clearance is not within spec-
ifications, replace shifter fork as required.
Clearance (a):
9.3 mm (0.366 in)
6) Inspect rod end clearances (A) and (B). If any
clearance is not within specifications, replace rod
or fork as required.
Clearance (A):
3rd — 4th to 5th:
0.5 — 1.3 mm (0.020 — 0.051 in)
Clearance (B):
1st — 2nd to 3rd — 4th:
0.4 — 1.4 mm (0.016 — 0.055 in)
(A) 3rd drive gear
(B) Coupling sleeve
(C) 4th drive gear
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
Become distant from
3rd gear by 0.2 mm
(0.008 in).
(A) 5th drive gear
(B) Coupling sleeve
MT-00314
( a )
( b )
( A )
( B )
( C )
MT-00315
( A )
( a )
( B )
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).
MT-00316
( A )
( B )
MT-109
MANUAL TRANSMISSION AND DIFFERENTIAL
COUNTER GEAR
23.Counter Gear
A: REMOVAL
1) Remove the manual transmission assembly
from the vehicle. <Ref. to MT-32, REMOVAL, Man-
ual Transmission Assembly.>
2) Remove the transfer case with extension case
assembly. <Ref. to MT-47, REMOVAL, Transfer
Case and Extension Case Assembly.>
3) Remove transmission case. <Ref. to MT-59, RE-
MOVAL, Transmission Case.>
4) Move counter gear shaft until it touches trans-
mission case, and remove snap ring with a suitable
tool.
5) Slide washer at rear of high-low counter shaft,
and remove straight pin from counter shaft.
6) Remove counter shaft from transmission case,
taking care not to drop counter gear and the two
washers.
NOTE:
• Be careful not to damage O-ring.
• Be careful not to drop straight pin on front side.
• Be careful not to drop two needle bearings and
collar contained in counter gear.
B: INSTALLATION
1) Install new O-ring and straight pin onto counter
gear shaft.
2) Install the following parts in main case (Right-
side), and push the shaft perfectly into case.
• Counter gear shaft
• Two counter gear washers
• Two needle bearings
• Counter gear collar
• Counter gear
• Straight pin
• Snap ring
3) Install the transmission case. <Ref. to MT-61,
INSTALLATION, Transmission Case.>
4) Install the transfer case with extension case as-
sembly. <Ref. to MT-47, INSTALLATION, Transfer
Case and Extension Case Assembly.>
5) Install the manual transmission assembly on ve-
hicle. <Ref. to MT-35, INSTALLATION, Manual
Transmission Assembly.>
NOTE:
• Make sure that cut-out end surface of counter
gear shaft does not protrude above the end surface
of the case.
• Position the cut-out portion of counter gear shaft
as shown in the figure.
C: INSPECTION
1) After installing snap ring, measure clearance be-
tween snap ring and counter washer.
Clearance:
0.05 — 0.35 mm (0.0020 — 0.0138 in)
2) If the clearance is out of measured value, select
a snap ring and install to put clearance within mea-
sured value. <Ref. to MT-110, ADJUSTMENT,
Counter Gear.>
(A) Snap ring
(A) Straight pin
(B) Counter gear
MT-00317
( A )
MT-00318
( A )
( B )
(A) Counter shaft
(B) Counter gear
(C) Washers
MT-00319
( A )
( B )
( C )
MT-110
MANUAL TRANSMISSION AND DIFFERENTIAL
COUNTER GEAR
D: ADJUSTMENT
Selection of snap ring
If the measurement is not with in the specification,
select suitable snap ring.
Snap ring
Part No.
Thickness mm (in)
031319000
1.50 (0.0591)
805019010
1.72 (0.0677)
MT-111
MANUAL TRANSMISSION AND DIFFERENTIAL
GENERAL DIAGNOSTIC
24.General Diagnostic
A: INSPECTION
1. MANUAL TRANSMISSION
Symptom
Possible cause
Remedy
1. Gears are difficult to intermesh.
NOTE:
The cause for difficulty in shifting gears
can be classified into two kinds: one is
malfunction of the gear shift system and
the other is malfunction of the transmis-
sion. However, if the operation is heavy
and engagement of the gears is difficult,
defective clutch disengagement may also
be responsible. Check whether the clutch
is correctly functioning, before checking
the gear shift system and transmission.
(a) Worn, damaged or burred chamfer of
internal spline of sleeve and reverse
driven gear
Replace.
(b) Worn, damaged or burred chamfer of
spline of gears
Replace.
(c) Worn or scratched bushings
Replace.
(d) Incorrect contact between synchro-
nizer ring and gear cone or wear
Correct or replace.
2. Gear slips out.
• Gear slips out when coasting on rough
road.
• Gear slips out during acceleration.
(a) Defective pitching stopper or loose-
ness of installation bolt
Tighten or replace.
(b) Loose engine mounting bolts
Tighten or replace.
(c) Worn fork shifter, broken shifter fork
rail spring
Replace.
(d) Worn or damaged ball bearing
Replace.
(e) Excessive clearance between splines
of synchronizer hub and synchronizer
sleeve
Replace.
(f) Worn tooth step of synchronizer hub
(responsible for slip-out of 3rd gear)
Replace.
(g) Worn 1st driven gear, needle bearing
and race
Replace.
(h) Worn 2nd driven gear, needle bear-
ing and race
Replace.
(i) Worn 3rd drive gear and bushing
Replace.
(j) Worn 4th drive gear and bushing
Replace.
(k) Worn reverse idler gear and bushing
Replace.
3. Unusual noise comes from transmis-
sion.
NOTE:
If an unusual noise is heard when the ve-
hicle is parked with its engine idling and if
the noise ceases when the clutch is disen-
gaged, it may be considered that the
noise comes from the transmission.
(a) Insufficient or improper lubrication
Lubricate or replace with specified oil.
(b) Worn or damaged gears and bear-
ings
NOTE:
If the trouble is only wear of the tooth sur-
faces, merely a high roaring noise will oc-
cur at high speeds, but if any part is
broken, rhythmical knocking sound will be
heard even at low speeds.
Replace.
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