Subaru Legacy IV (2008 year). Service manual — part 797
5MT-84
General Diagnostic Table
MANUAL TRANSMISSION AND DIFFERENTIAL
2. DIFFERENTIAL
Symptoms
Possible cause
Corrective action
1. Broken differential (case, gear, bear-
ing, etc.)
NOTE:
Noise will occur, and eventually the differ-
ential will not be able to operate due to
broken pieces obstructing the gear revo-
lution.
(a) Insufficient or improper oil
Disassemble the differential and replace
broken components. At the same time
check other components for any trouble,
and replace if necessary.
(b) Use of vehicle under severe condi-
tions such as excessive load and
improper use of the clutch
Readjust the preload and backlash of the
bearing, and the contact surface of gear.
(c) Improper adjustment of taper roller
bearing
Adjust.
(d) Improper adjustment of the drive pin-
ion and the hypoid driven gear
Adjust.
(e) Excessive backlash of a vehicle under
severe operating conditions due to worn
differential side gear, washer or differen-
tial pinion.
Add recommended oil to the specified
level. Do not use vehicle under severe
operating conditions.
(f) Loose hypoid driven gear tightening
bolts
Tighten.
2. Differential and hypoid gear noises
Troubles of the differential and hypoid
gear always appear as noise problems.
Therefore noise is the first indication of
trouble. However, noises from the engine,
muffler, tire, exhaust gas, bearing, body,
etc. are easily mistaken for the differential
noise. Pay special attention to the hypoid
gear noise because it is easily confused
with other gear noises. There are the fol-
lowing four kinds of noises.
• Gear noise when driving:
If noise increases as the vehicle speed
increases, it may be due to insufficient
gear oil, incorrect gear engagement,
damaged gears, etc.
• Gear noise when coasting:
Damaged gears due to misadjusted bear-
ings and incorrect shim adjustment.
• Bearing noise when driving or coasting:
Cracked, broken or damaged bearings
• Noise mainly when turning:
Noise from differential side gear, differen-
tial pinion or differential pinion shaft, etc.
(a) Insufficient oil
Lubricate.
(b) Improper adjustment of hypoid driven
gear and drive pinion
Check the tooth contact.
(c) Worn teeth of hypoid driven gear and
drive pinion
Replace as a set.
Readjust the bearing preload.
(d) Loose roller bearing
Readjust the backlash of the hypoid
driven gear to drive pinion, and check the
tooth contact.
(e) Distorted hypoid driven gear or differ-
ential case
Replace.
(f) Worn washer and differential pinion
shaft
Replace.
6MT-2
General Description
MANUAL TRANSMISSION AND DIFFERENTIAL
1. General Description
A: SPECIFICATION
1. MANUAL TRANSMISSION AND FRONT DIFFERENTIAL
2. TRANSMISSION GEAR OIL
Recommended oil:
GL-5 (75W-90) or equivalent
Type
6-forward speeds and 1-reverse
Transmission gear ratio
1st
3.636
2nd
2.235
3rd
1.521
4th
1.137
5th
0.891
6th
0.707
Rev.
3.545
Front reduction
gear
Final
Type of gear
Hypoid
Gear ratio
3.900
Rear reduction
gear
Transfer
Type of gear
Helical
Gear ratio
1.100
Final
Type of gear
Hypoid
Gear ratio
3.545
Front differential
Type and number of gear
Straight bevel gear
(Bevel pinion: 4, Bevel gear: 2)
Center differential
Type and number of gear
Straight bevel gear
(Bevel pinion: 2, bevel gear: 2 and viscous LSD)
Transmission gear oil
GL-5
Transmission gear oil capacity
4.1
2 (4.3 US qt, 3.6 Imp qt)
6MT-3
General Description
MANUAL TRANSMISSION AND DIFFERENTIAL
B: COMPONENT
1. CLUTCH HOUSING
(1)
Oil level gauge
(7)
Oil seal
Tightening torque:N·m (kgf-m, ft-lb)
(2)
Plug
(8)
Clutch release bearing guide
T1: 6.4 (0.7, 4.7)
(3)
Pitching stopper bracket
(9)
Return spring bracket
T2: 41 (4.2, 30.2)
(4)
Clip
(10)
O-ring
T3: 50 (5.1, 36.9)
(5)
Clutch housing
(11)
Drain plug
T4: 70 (7.1, 51.6)
(6)
Gasket
MT-01809
(1)
(5)
(6)
(7)
(8)
T3
T4
T1
(4)
(3)
(2)
(9)
T2
(10)
(11)
6MT-4
General Description
MANUAL TRANSMISSION AND DIFFERENTIAL
2. ADAPTER PLATE
(1)
Breather hose
(7)
Check plug
(13)
Adapter plate
(2)
Transmission harness stay
(8)
O-ring
(3)
Check plug
(9)
Check spring
Tightening torque:N·m (kgf-m, ft-lb)
(4)
O-ring
(10)
Check ball
T1: 18 (1.8, 13.3)
(5)
Check spring
(11)
Oil guide A
T2: 25 (2.5, 18.4)
(6)
Plunger
(12)
Oil guide B
T3: 50 (5.1, 36.9)
MT-01609
(2)
(3)
(4)
(1)
(5)
(7)
(6)
(8)
(9)
(10)
(13)
T2
T1
T3
T2
T1
T3
(12)
T1
(11)
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