Subaru Legacy IV (2008 year). Service manual — part 787
5MT-44
Transfer Driven Gear
MANUAL TRANSMISSION AND DIFFERENTIAL
11.Transfer Driven Gear
A: REMOVAL
1) Remove the manual transmission assembly
from the vehicle. <Ref. to 5MT-24, REMOVAL,
Manual Transmission Assembly.>
2) Remove the back-up light switch neutral position
switch. <Ref. to 5MT-35, REMOVAL, Switches and
Harness.>
3) Remove the transfer case together with the ex-
tension case assembly. <Ref. to 5MT-38, REMOV-
AL, Transfer Case and Extension Case
Assembly.>
4) Remove the extension case assembly.
5) Remove the transfer driven gear.
6) Remove bearing outer races from the extension
case and transfer case.
B: INSTALLATION
1) Install the bearing outer races to extension case
and transfer case.
2) Install the transfer driven gear.
3) Install the transfer case and the extension case
assembly. <Ref. to 5MT-38, INSTALLATION,
Transfer Case and Extension Case Assembly.>
4) Install the back-up light switch neutral position
switch. <Ref. to 5MT-35, INSTALLATION, Switch-
es and Harness.>
5) Install the manual transmission assembly to the
vehicle. <Ref. to 5MT-27, INSTALLATION, Manual
Transmission Assembly.>
(A) Bearing outer race (Transfer case side)
(B) Bearing outer race (Extension case side)
MT-00118
MT-00140
(B)
(A)
(A) Bearing outer race
(B) Bearing outer race
(C) Transfer case
(D) Extension Case
MT-00141
(C)
(A)
(D)
(B)
MT-00118
5MT-45
Transfer Driven Gear
MANUAL TRANSMISSION AND DIFFERENTIAL
C: DISASSEMBLY
1) Using the ST, remove the roller bearing (exten-
sion case side).
ST
498077000
REMOVER
2) Using ST1 and ST2, remove the roller bearing
(transfer case side).
ST1
498077000
REMOVER
ST2
899864100
REMOVER
D: ASSEMBLY
1) Using the ST, install the roller bearing (extension
case side).
ST1
398177700
INSTALLER
ST2
899864100
REMOVER
CAUTION:
Do not apply a load in excess of 10 kN (1 ton, 1.1
US ton, 1.0 Imp ton).
2) Using ST, install the roller bearing (transfer case
side).
ST
499757002
INSTALLER
CAUTION:
Do not apply a load in excess of 10 kN (1 ton, 1.1
US ton, 1.0 Imp ton).
E: INSPECTION
1) Bearing
Replace the bearings in the following cases.
• In case of broken or rusty bearings
• In case of worn or damaged bearings
• When the bearings fail to turn smoothly or emit
noise in rotation after gear oil lubrication.
2) Driven gear
If the driven gear tooth surface and shaft are exces-
sively broken or damaged, replace the driven gear.
(A) Roller bearing
(A) Roller bearing
MT-00143
(A)
ST
MT-00144
(A)
ST1
ST2
(A) Roller bearing
(A) Roller bearing
MT-00145
(A)
ST1
ST2
MT-00146
(A)
ST
5MT-46
Center Differential
MANUAL TRANSMISSION AND DIFFERENTIAL
12.Center Differential
A: REMOVAL
1) Remove the manual transmission assembly
from the vehicle. <Ref. to 5MT-24, REMOVAL,
Manual Transmission Assembly.>
2) Remove the back-up light switch neutral position
switch. <Ref. to 5MT-35, REMOVAL, Switches and
Harness.>
3) Remove the transfer case together with the ex-
tension case assembly. <Ref. to 5MT-38, REMOV-
AL, Transfer Case and Extension Case
Assembly.>
4) Remove the extension case assembly. <Ref. to
5MT-38, REMOVAL, Transfer Case and Extension
Case Assembly.>
5) Remove the transfer driven gear. <Ref. to 5MT-
44, REMOVAL, Transfer Driven Gear.>
6) Remove the center differential.
B: INSTALLATION
1) Install the center differential into transfer case.
2) Install the transfer driven gear. <Ref. to 5MT-44,
INSTALLATION, Transfer Driven Gear.>
3) Install the extension case assembly. <Ref. to
5MT-38, INSTALLATION, Transfer Case and Ex-
tension Case Assembly.>
4) Install the transfer case together with the exten-
sion case assembly. <Ref. to 5MT-38, INSTALLA-
TION, Transfer Case and Extension Case
Assembly.>
5) Install the back-up light switch neutral position
switch. <Ref. to 5MT-35, INSTALLATION, Switch-
es and Harness.>
6) Install the manual transmission assembly to the
vehicle. <Ref. to 5MT-27, INSTALLATION, Manual
Transmission Assembly.>
C: DISASSEMBLY
NOTE:
Center differential is a non-disassembled part
which should not be disassembled.
Remove the ball bearing using ST.
NOTE:
Do not reuse the ball bearing.
ST
498077300
CENTER DIFFERENTIAL
BEARING REMOVER
D: ASSEMBLY
Install the ball bearing into the center differential
assembly.
CAUTION:
Do not apply a load in excess of 10 kN (1 ton, 1.1
US ton, 1.0 Imp ton).
E: INSPECTION
1) Bearing
Replace the bearings in the following cases.
• In case of broken or rusty bearings
• In case of worn or damaged bearings
• When the bearings fail to turn smoothly or emit
noise in rotation after gear oil lubrication.
• When bearing has other defects.
2) Center differential
Replace the center differential case assembly if
worn or damaged.
(A) Ball bearing
MT-00147
ST
MT-00148
(A)
5MT-47
Reverse Check Sleeve
MANUAL TRANSMISSION AND DIFFERENTIAL
13.Reverse Check Sleeve
A: REMOVAL
1) Remove the manual transmission assembly
from the vehicle. <Ref. to 5MT-24, REMOVAL,
Manual Transmission Assembly.>
2) Remove the transfer case together with the ex-
tension case assembly. <Ref. to 5MT-38, REMOV-
AL, Transfer Case and Extension Case
Assembly.>
3) Remove the shifter arm.
4) Remove the plug, gasket, reverse accent spring,
and reverse check ball.
5) Remove the reverse check sleeve.
B: INSTALLATION
1) Install the reverse check sleeve.
Tightening torque:
6.4 N·m (0.7 kgf-m, 4.7 ft-lb)
2) Install the reverse check ball, reverse accent
spring, gasket, and plug to the transfer case.
Tightening torque:
9.75 N·m (1.0 kgf-m, 7.2 ft-lb)
3) Attach the shifter arm to the transfer case as-
sembly.
4) Install the transfer case together with the exten-
sion case assembly. <Ref. to 5MT-38, INSTALLA-
TION, Transfer Case and Extension Case
Assembly.>
5) Install the manual transmission assembly to the
vehicle. <Ref. to 5MT-27, INSTALLATION, Manual
Transmission Assembly.>
MT-00149
MT-00150
MT-00150
MT-00149
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