Subaru Legacy (2005 year). Service manual — part 639
5MT-3
MANUAL TRANSMISSION AND DIFFERENTIAL
General Description
2. TRANSMISSION GEAR OIL
Recommended oil:
3. TRANSMISSION CASE ASSEMBLY
Drive pinion shim adjustment
Hypoid gear backlash:
0.13 — 0.18 mm (0.0051 — 0.0071 in)
Selection of main shaft rear plate
Input shaft holder adjustment
4. DRIVE PINION ASSEMBLY
Preload adjustment of thrust bearing
Starting torque:
0.3 — 0.8 N
⋅
m (0.03 — 0.08 kgf-m, 0.2 — 0.6 ft-
lb)
5. INPUT SHAFT ASSEMBLY
Snap ring (Outer-28) to ball bearing clearance:
0 — 0.12 mm (0 — 0.0047 in)
Snap ring (Inner-68) to ball bearing clearance:
0 — 0.12 mm (0 — 0.0047 in)
6. MAIN SHAFT
Snap ring (Outer-25) to synchronizer hub clear-
ance:
0.060 — 0.100 mm (0.0024 — 0.0039 in)
(1) Item
(2) Transmission gear oil
(3) API standard
(4) SAE viscosity No. and applicable temperature
Drive pinion shim
Part Number
Thickness
mm (in)
Part Number
Thickness
mm (in)
32295AA031
0.150
(0.0059)
32295AA071
0.250
(0.0098)
32295AA041
0.175
(0.0069)
32295AA081
0.275
(0.0108)
32295AA051
0.200
(0.0079)
32295AA091
0.300
(0.0118)
32295AA061
0.225
(0.0089)
32295AA101
0.500
(0.0197)
Main shaft rear plate
Dimension “A” mm (in)
Part Number
Marking
4.00 — 4.13
(0.1575 — 0.1626)
32294AA041
1
3.87 — 3.99
(0.1524 — 0.1571)
32294AA051
2
Dimension “D” mm (in)
Shim Number
52.50 — 53.11
(2.0669 — 2.0909)
—
52.00 — 52.49
(2.0472 — 2.0665)
1
51.26 — 51.99
(2.0181 — 2.0468)
2
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
Adjusting washer No. 1
Part Number
Thickness mm (in)
803025051
3.925 (0.1545)
803025052
3.950 (0.1555)
803025053
3.975 (0.1565)
803025054
4.000 (0.1575)
803025055
4.025 (0.1585)
803025056
4.050 (0.1594)
803025057
4.075 (0.1604)
Adjusting washer No. 2
Part Number
Thickness mm (in)
803025059
3.850 (0.1516)
803025054
4.000 (0.1575)
803025058
4.150 (0.1634)
Snap ring (Outer-28)
Part Number
Thickness mm (in)
805028050
2.48 (0.0976)
805028060
2.56 (0.1008)
805028070
2.64 (0.1039)
Snap ring (Inner-68)
Part Number
Thickness mm (in)
805168020
1.84 (0.0724)
805168030
1.92 (0.0756)
805168040
2.00 (0.0787)
Snap ring (Outer-25)
Part Number
Thickness
mm (in)
Part Number
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)
5MT-4
MANUAL TRANSMISSION AND DIFFERENTIAL
General Description
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 the clearance using washer.
Reverse idler gear to transmission case wall
clearance:
0 — 0.5 mm (0 — 0.020 in)
8. SHIFTER FORK AND ROD
Select suitable shifter forks so that both the cou-
pling sleeve and reverse driven gear are positioned
in the center of their synchromesh mechanisms.
Rod end clearance:
A: 3rd-4th — 5th
0.5 — 1.3 mm (0.020 — 0.051 in)
B: 1st-2nd — 3rd-4th
0.4 — 1.4 mm (0.016 — 0.055 in)
9. TRANSFER CASE OR REAR CASE
Neutral position adjustment
Reverse check plate adjustment
Reverse shifter lever
Part Number
Marking
Remarks
32820AA070
7
Further from case wall
32820AA080
8
Standard
32820AA090
9
Closer to the case wall
Washer (20.5
× 26 × t)
Part Number
Thickness
mm (in)
Part Number
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 Number
Marking
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 Number
Marking
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)
Adjusting shim
Part Number
Thickness mm (in)
32190AA000
0.15 (0.0059)
32190AA010
0.30 (0.0118)
Reverse accent shaft
Part No.
Mark
Remarks
32188AA130
S
Neutral position is
closer to 1st.
32188AA140
T
Standard
32188AA150
U
Neutral position is
closer to reverse gear.
Reverse check plate
Part Number
Mark-
ing
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 cen-
ter.
32189AA030
3
37
°
Arm stops closer to
reverse gear.
32189AA040
4
40
°
Arm stops closer to
reverse gear.
5MT-5
MANUAL TRANSMISSION AND DIFFERENTIAL
General Description
10.EXTENSION ASSEMBLY
Standard protrusion amount of taper roller
bearing outer race:
0.2 — 0.3 mm (0.0008 — 0.012 in)
NOTE:
Be sure that it is within the standard protrusion
amount.
Thrust washer to center differential side clear-
ance:
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)
12.TRANSFER DRIVE GEAR
Snap ring (Outer-30) to ball bearing clearance:
0.01 — 0.15 mm (0.0004 — 0.0059 in)
Thrust washer (50
× 61 × t)
Part Number
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 Number
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 Number
Thickness
mm (in)
Part Number
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-30)
Part Number
Thickness mm (in)
805030041
1.53 (0.0602)
805030042
1.65 (0.0650)
805030043
1.77 (0.0697)
5MT-6
MANUAL TRANSMISSION AND DIFFERENTIAL
General Description
B: COMPONENT
1. TRANSMISSION CASE
MT-01360
(12)
(10)
(11)
(13)
T1
(3)
(1)
(2)
(4)
(7)
(6)
(5)
(9)
(8)
T2
(14)
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