Subaru Legacy (2005 year). Service manual — part 663
5MT-99
MANUAL TRANSMISSION AND DIFFERENTIAL
General Diagnostic Table
2. DIFFERENTIAL
Symptom
Possible cause
Corrective action
1. Broken differential (case, gear, bear-
ing, etc.)
NOTE:
Noise will be developed and finally it will
become impossible to continue to run due
to broken pieces obstructing the gear rev-
olution.
(a) Insufficient or improper oil
Disassemble differential and replace bro-
ken 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 clutch
Readjust bearing preload and backlash
and face contact of gears.
(c) Improper adjustment of taper roller
bearing
Adjustment.
(d) Improper adjustment of drive pinion
and hypoid driven gear
Adjustment.
(e) Excessive backlash due to worn dif-
ferential side gear, washer or differential
pinion under severe operating conditions
of the vehicle.
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 maladjusted bear-
ings and incorrect shim adjustment.
• Bearing noise when driving or coast-
ing:
Cracked, broken or rusty bearings
• Noise mainly when turning:
Noise occurs form differential side gear,
differential pinion or differential pinion
shaft, etc.
(a) Insufficient oil
Lubricate.
(b) Improper adjustment of hypoid driven
gear and drive pinion
Check tooth contact.
(c) Worn teeth of hypoid driven gear and
drive pinion
Replace as a set.
Readjust bearing preload.
(d) Loose roller bearing
Readjust hypoid driven gear to drive pin-
ion backlash and check tooth contact.
(e) Distorted hypoid driven gear or differ-
ential case
Replace.
(f) Worn washer and differential pinion
shaft
Replace.
5MT-100
MANUAL TRANSMISSION AND DIFFERENTIAL
General Diagnostic Table
MANUAL TRANSMISSION
AND DIFFERENTIAL
6MT
Page
General Description . . . . . . . . . . . . . . . . . . . . . 2
Transmission Gear Oil . . . . . . . . . . . . . . . . . . . ..29
Oil Seal. . . . . . . . . . . . . . . . . . . . . . . . . ..30
Differential Side Retainer Oil Seal. . . . . . . . . . . . . . . .31
Transmission Mounting System . . . . . . . . . . . . . . . . 32
Manual Transmission Assembly . . . . . . . . . . . . . . . ...34
Preparation for Overhaul. . . . . . . . . . . . . . . . . . ...40
Air Breather Hose. . . . . . . . . . . . . . . . . . . . . ..41
Oil Pipe. . . . . . . . . . . . . . . . . . . . . . . . . ..42
Back-up Light Switch. . . . . . . . . . . . . . . . . . . . .43
Neutral Position Switch . . . . . . . . . . . . . . . . . . . .45
Extension Case . . . . . . . . . . . . . . . . . . . . . . .47
Reverse Check System. . . . . . . . . . . . . . . . . . . .53
Transfer Drive Gear . . . . . . . . . . . . . . . . . . . . ..56
Transfer Driven Gear . . . . . . . . . . . . . . . . . . . . 58
Center Differential . . . . . . . . . . . . . . . . . . . . . .60
Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . ...61
Transmission Case . . . . . . . . . . . . . . . . . . . . ...64
Main Shaft Assembly . . . . . . . . . . . . . . . . . . . . 69
Driven Gear Assembly . . . . . . . . . . . . . . . . . . . ..83
Reverse Idler Gear. . . . . . . . . . . . . . . . . . . . . 91
Drive Pinion Shaft Assembly. . . . . . . . . . . . . . . . . .96
Front Differential Assembly . . . . . . . . . . . . . . . . . .102
Shifter Fork and Rod . . . . . . . . . . . . . . . . . . . ...110
Clutch Housing. . . . . . . . . . . . . . . . . . . . . . 124
General Diagnostic Table. . . . . . . . . . . . . . . . . . 126
6MT-2
MANUAL TRANSMISSION AND DIFFERENTIAL
General Description
1. General Description
A: SPECIFICATION
1. MANUAL TRANSMISSION AND FRONT DIFFERENTIAL
2. TRANSMISSION GEAR OIL
Recommended oil:
GL-5 or equivalent
Type
6-forward speeds and 1-reverse
Transmission gear ratio
1st
3.636
2nd
2.375
3rd
1.761
4th
1.346
5th
0.971
6th
0.756
Reverse
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: 2, Bevel gear: 2)
Center Differential
Type and number of gear
Straight bevel gear
(Bevel pinion: 2, Bevel gear: 2 and viscous coupling)
Transmission gear oil
GL-5
Transmission gear oil capacity
4.1
2(4.3 US qt, 3.6 Imp qt)
(1) Item
(2) Transmission gear oil
(3) API standard
(4) SAE viscosity No. and applicable temperature
MT-00001
(1)
(4)
GL-5
(3)
(2)
( C)
( F)
-30 -26 -15
15
90
85W
80W
75W -90
25
30
-5 0
-22 -15
23 32
86
59
77
5
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