Subaru Legacy 2005 Service Manual page 2656

MANUAL TRANSMISSION AND DIFFERENTIAL
6) Install the 3-4 fork rod into 3-4 shifter fork
through the hole on the rear of transmission case.
7) Align the holes in rod and fork, and drive new
straight pin into these holes.
NOTE:
• Set the reverse fork rod to neutral.
• Make sure the interlock plunger (before installa-
tion) is on the reverse fork rod side.
ST 398791700 STRAIGHT PIN REMOVER
8) Install the 5th shifter fork onto the rear of reverse
fork rod. Align the holes in the two parts and drive
new straight pin into the specified place.
ST 398791700 STRAIGHT PIN REMOVER
( B )
( A )
( C )
(A) 5th shifter fork
(B) Reverse fork rod
(C) Straight pin
9) Position the balls, checking ball springs and new
gaskets into 3-4 and 1-2 rod holes, and install
plugs.
10) Install the differential assembly. <Ref. to 5MT-
84, INSTALLATION, Front Differential Assembly.>
11) Install the main shaft assembly.
• Single-range model
<Ref. to 5MT-61, INSTALLATION, Main Shaft As-
sembly for Single-Range.>
• Dual-range model
<Ref. to 5MT-66, INSTALLATION, Main Shaft As-
sembly for Dual-Range.>
12) Install the drive pinion shaft assembly. <Ref. to
5MT-76, INSTALLATION, Drive Pinion Shaft As-
sembly.>
Shifter Fork and Rod
13) Install the transmission case. <Ref. to 5MT-57,
INSTALLATION, Transmission Case.>
14) Install the transfer case with extension case as-
sembly. <Ref. to 5MT-43, INSTALLATION, Trans-
fer Case and Extension Case Assembly.>
15) Install the back-up light switch and neutral po-
sition switch. <Ref. to 5MT-40, INSTALLATION,
Switches and Harness.>
16) Install the manual transmission assembly into
vehicle. <Ref. to 5MT-32, INSTALLATION, Manual
Transmission Assembly.>
C: INSPECTION
1) Inspect the fork and rod for damage. Replace if it
is damaged.
2) Gearshift mechanism
Repair or replace the gearshift mechanism if ex-
cessively worn, bent, or defective in any way.
3) Inspect the clearance between 1st, 2nd driven
gear and reverse driven gear. If any clearance is
not within specifications, replace the shifter fork as
required.
Clearance (a) and (b):
9.5 mm (0.374 in)
MT-00311
Part Number
MT-00366
32804AA060
32804AA070
32804AA080
4) Inspect the clearance between 3rd, 4th drive
gear and coupling sleeve. If any clearance is not
within specifications, replace the shifter fork as re-
quired.
5MT-94
(a)
(A) (B)
(A) 1st driven gear
(B) Reverse driven gear
(C) 2nd driven gear
1st-2nd shifter fork
Marking
1
No mark
3
(b)
(C)
MT-00999
Remarks
Approach to 1st gear
by 0.2 mm (0.008 in).
Standard
Become distant from
2nd gear by 0.2 mm
(0.008 in).