Subaru Legacy 2003 Service Manual page 2548

5) Install interlock plunger onto 3-4 fork rod.
NOTE:
Apply a coat of grease to plunger to prevent it from
falling.
6) Install 3-4 fork rod into 3-4 shifter fork via 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 reverse fork rod to neutral.
• Make sure interlock plunger (installing before) is
on the reverse fork rod side.
ST 398791700 STRAIGHT PIN REMOVER
8) Install 5th shifter fork onto the rear of reverse
fork rod. Align holes in the two parts and drive new
straight pin into place.
ST 398791700 STRAIGHT PIN REMOVER
( B )
( A ) ( C )
(A) 5th shifter fork
(B) Reverse fork rod
(C) Straight pin
9) Position balls, checking ball springs and new
gaskets into 3-4 and 1-2 rod holes, and install
plugs.
10) Install differential assembly. <Ref. to MT-95,
INSTALLATION, Front Differential Assembly.>
11) Install main shaft assembly.
12) Install drive pinion shaft assembly. <Ref. to
MT-87, INSTALLATION, Drive Pinion Shaft As-
sembly.>
13) Install transmission case. <Ref. to MT-61, IN-
STALLATION, Transmission Case.>
SHIFTER FORK AND ROD
14) Install transfer case with extension case as-
sembly. <Ref. to MT-47, INSTALLATION, Transfer
Case and Extension Case Assembly.>
15) Install back-up light switch and neutral position
switch. <Ref. to MT-43, INSTALLATION, Switches
and Harness.>
16) Install the manual transmission assembly to ve-
hicle. <Ref. to MT-35, INSTALLATION, Manual
Transmission Assembly.>
C: INSPECTION
1) Check the shift shaft and shift rod for damage.
Replace if damaged.
2) Gearshift mechanism
Repair or replace the gearshift mechanism if ex-
cessively worn, bent, or defective in any way.
3) Inspect clearance between 1st, 2nd driven gear
and reverse driven gear. If any clearance is not
within specifications, replace shifter fork as re-
quired.
Clearance (a) and (b):
MT-00311
MT-00366
MT-107
MANUAL TRANSMISSION AND DIFFERENTIAL
9.5 mm (0.374 in)
( a )
( A ) ( B )
(A) 1st driven gear
(B) Reverse driven gear
(C) 2nd driven gear
1st-2nd shifter fork
Part No. Mark
32804AA060 1
32804AA070 No mark
32804AA080 3
( b )
( C )
MT-00313
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).