Subaru Legacy 2004 Service Manual page 2691

7) Wind a vinyl tape around the shaft splines and
insert the input shaft into holder by lightly tapping it
by hand.
(A) Vinyl tape
(B) Input shaft
8) Install the snap ring to input shaft holder.
NOTE:
Select a suitable snap ring so that clearance be-
tween snap ring and bearing is held within 0 to 0.12
mm (0 to 0.0047 in).
ST 398663600 PLIERS
S T
Snap ring
Part No.
805168020
805168030
805168040
9) Install the O-ring to input shaft holder.
(B)
(A) O-ring
(B) Input shaft holder
Input Shaft Assembly
(B)
(A)
MT-00236
MT-00227
Thickness mm (in)
1.84 (0.0724)
1.92 (0.0756)
2.00 (0.0787)
(A)
MT-00238
MANUAL TRANSMISSION AND DIFFERENTIAL
E: INSPECTION
Disassembled parts should be washed clean first
with unleaded gasoline and then inspected careful-
ly.
1) Bearings
Replace the bearings in following cases:
• Bearing 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.
9) Measure the clearance between snap ring and
ball bearing using thickness gauge.
5MT-75