Subaru Legacy IV (2008 year). Manual - part 785

5MT-36

Switches and Harness

MANUAL TRANSMISSION AND DIFFERENTIAL

C: INSPECTION

1. BACK-UP LIGHT SWITCH

Check the back-up light switch. <Ref. to LI-8, IN-
SPECTION, Back-up Light System.>

2. NEUTRAL POSITION SWITCH

1) Turn the ignition switch to OFF.
2) Disconnect the connector of neutral position
switch.
3) Measure the resistance between neutral posi-
tion switch terminals.
• Non-turbo model

• Turbo model

4) Replace faulty parts.

Gear shift position

Terminal No.

Specified resistance

Neutral position

1 and 2

Less than 1 

:

Other positions

1 M

: or more

Gear shift position

Terminal No.

Specified resistance

Neutral position

1 and 3

Less than 1 

:

Other positions

1 M

: or more

MT-00110

1

2

MT-00111

1

2

3

4

5MT-37

Preparation for Overhaul

MANUAL TRANSMISSION AND DIFFERENTIAL

8. Preparation for Overhaul

A: PROCEDURE

1) Clean oil, grease, dirt and dust from the trans-
mission.
2) Using the TORX

®

 bit T70, remove the drain plug

of the transmission gear oil, and drain the transmis-
sion gear oil completely.
3) Using the TORX

®

 bit T70, tighten the transmis-

sion gear oil drain plug.

NOTE:
Use a new gasket.

Tightening torque:

44 N·m (4.5 kgf-m, 32.5 ft-lb) (Aluminum gas-
ket)
70 N·m (7.1 kgf-m, 51.6 ft-lb) (Copper gasket)

4) Attach the transmission to ST.
ST

499937100

TRANSMISSION STAND

5) Apply oil to rotating parts before assembly.
6) All disassembled parts, if to be reused, should
be reinstalled in the original positions and direc-
tions.
7) Gaskets, lock washers and lock nuts must be re-
placed with new ones.
8) Apply liquid gasket to the specified areas to pre-
vent leakage.

MT-01548

MT-00115

S T

5MT-38

Transfer Case and Extension Case Assembly

MANUAL TRANSMISSION AND DIFFERENTIAL

9. Transfer Case and Extension 

Case Assembly

A: REMOVAL

1) Remove the manual transmission assembly
from the vehicle. <Ref. to 5MT-24, REMOVAL,
Manual Transmission Assembly.>
2) Remove the back-up light switch neutral position
switch. <Ref. to 5MT-35, REMOVAL, Switches and
Harness.>
3) Remove the transfer case together with the ex-
tension case assembly.

4) Remove the shifter arm.
5) Remove the extension case assembly.

B: INSTALLATION

1) Install the center differential and transfer driven
gear into the transfer case.

2) Remove the bearing outer race from the exten-
sion case.

3) While holding the bearing outer race horizontal-
ly, rotate the driven shaft for ten turns.
4) Measure the height “W” between transfer case
and taper roller bearing on the transfer driven gear.

MT-00116

MT-00117

(A) Bearing outer race

(B) Extension Case

W Measured value

MT-00118

MT-00119

(B)

(A)

MT-00120

W

5MT-39

Transfer Case and Extension Case Assembly

MANUAL TRANSMISSION AND DIFFERENTIAL

5) Measure depth “X” on bearing insertion part of
the extension case.

NOTE:
Measure with bearing outer race and thrust washer
removed.

6) Calculate the thrust washer thickness “t” using
the following calculation.
t = X – W + (0.15 — 0.25 mm (0.006 — 0.010 in))
7) Select the washer with the nearest value in the
following table.

Preload (standard protrusion) of the taper roller 
bearing:

0.15 — 0.25 mm (0.006 — 0.010 in)

NOTE:
Be sure that the preload is always within the stan-
dard.

8) Fit the thrust washers on the transfer drive shaft.
9) Install the bearing outer race into the extension
case.
10) Measure the depth “S” between transfer case
and center differential.
ST

398643600

GAUGE

11) Measure the height “T” between the extension
case and transfer drive gear.
ST

398643600

GAUGE

NOTE:
Thickness of ST: 15 mm (0.59 in)
12) Calculate the thrust washer thickness “U” using
the following calculation.
U = S + T – 30 mm (1.18 in) [Thickness of ST]

X Measured value

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)

MT-00121

X

S Measured value

T Measured value

MT-00122

ST

S

MT-00123

T

ST