Subaru Legacy 2004 Service Manual page 2687

12) Tighten the lock nuts to the specified torque us-
ing ST1 and ST2.
NOTE:
Stake the caulking of lock nuts in two places after
tightening.
ST1 499987003 SOCKET WRENCH
ST2 498937000 TRANSMISSION HOLDER
Tightening torque:
!
120 N m (12.2 kgf-m, 88.5 ft-lb)
13) Install the needle bearing on main shaft.
14) Install rest of the parts to the front section of
transmission main shaft.
NOTE:
• Be careful not to damage the graded section of
transmission main shaft when installing the needle
bearing.
• Face the grooved side toward input gear.
• Align the high-low baulk ring's groove with shift-
ing insert.
(F)
(G)
(A) Ball
(B) Input low gear spacer
(C) Needle bearing
(D) Input low gear
(E) Friction damper
(F) High-low baulk ring
(G) Sleeve & hub ASSY
15) Install a new snap ring to the rod section of
transmission main shaft using ST1 and ST2.
NOTE:
Select a suitable outer snap ring so that axial clear-
ance between snap ring and hub is held within
0.060 to 0.100 mm (0.0024 to 0.0039 in).
ST1 499757002 INSTALLER
ST2 499757001 SNAP RING GUIDE
Main Shaft Assembly for Dual-Range
(A)
(B)
(C)
(D)
(E)
(F)
MT-00225
MANUAL TRANSMISSION AND DIFFERENTIAL
Part No.
805025051
805025052
805025053
805025054
805025055
805025056
805025057
805025058
E: INSPECTION
Disassembled parts should be washed with un-
leaded gasoline first and then inspected carefully.
1) Bearings
Replace the bearings in following cases:
• Bearings balls, outer races and inner races are
broken or rusty.
• Worn bearings
• Bearings fail to turn smoothly or emit noise in ro-
tation after gear oil lubrication.
• Bearings having other defects
2) Bushing (each gear)
Replace the bushing in following cases:
• When the sliding surface is damaged or abnor-
mally worn.
• When the inner wall is abnormally worn.
3) Gears
• Replace the gears with new ones if their tooth
surfaces are broken, damaged or excessively
worn.
• Correct or replace if the cone that contacts the
baulk ring is rough or damaged.
• Correct or replace if the inner surface or end face
is damaged.
4) Baulk ring
Replace the ring in following cases:
• When the inner surface and end face are dam-
aged.
• When the ring inner surface is abnormally or par-
tially worn down.
• When the contact surface of the synchronizer
ring insert is scored or abnormally worn down.
5) Shifting insert key
Replace the insert key if deformed, excessively
worn or defective in any way.
6) Oil seal
Replace the oil seal if the lip is deformed, hard-
ened, worn or defective in any way.
7) O-ring
Replace the O-ring if the sealing face is deformed,
hardened, damaged, worn or defective in any way.
8) Gearshift mechanism
Repair or replace the gearshift mechanism if ex-
cessively worn, bent or defective in any way.
5MT-71
Snap ring
Thickness mm (in)
2.42 (0.0953)
2.47 (0.0972)
2.52 (0.0992)
2.57 (0.1012)
2.62 (0.1031)
2.67 (0.1051)
2.72 (0.1071)
2.37 (0.0933)