Subaru Legacy IV (2008 year). Manual - part 787

5MT-44

Transfer Driven Gear

MANUAL TRANSMISSION AND DIFFERENTIAL

11.Transfer Driven Gear

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. <Ref. to 5MT-38, REMOV-
AL, Transfer Case and Extension Case
Assembly.>
4) Remove the extension case assembly.
5) Remove the transfer driven gear. 

6) Remove bearing outer races from the extension
case and transfer case.

B: INSTALLATION

1) Install the bearing outer races to extension case
and transfer case.

2) Install the transfer driven gear. 

3) Install the transfer case and the extension case
assembly. <Ref. to 5MT-38, INSTALLATION,
Transfer Case and Extension Case Assembly.>
4) Install the back-up light switch neutral position
switch. <Ref. to 5MT-35, INSTALLATION, Switch-
es and Harness.>
5) Install the manual transmission assembly to the
vehicle. <Ref. to 5MT-27, INSTALLATION, Manual
Transmission Assembly.>

(A) Bearing outer race (Transfer case side)

(B) Bearing outer race (Extension case side)

MT-00118

MT-00140

(B)

(A)

(A) Bearing outer race

(B) Bearing outer race

(C) Transfer case

(D) Extension Case

MT-00141

(C)

(A)

(D)

(B)

MT-00118

5MT-45

Transfer Driven Gear

MANUAL TRANSMISSION AND DIFFERENTIAL

C: DISASSEMBLY

1) Using the ST, remove the roller bearing (exten-
sion case side).
ST

498077000

REMOVER

2) Using ST1 and ST2, remove the roller bearing
(transfer case side).
ST1

498077000

REMOVER

ST2

899864100

REMOVER

D: ASSEMBLY

1) Using the ST, install the roller bearing (extension
case side).
ST1

398177700

INSTALLER

ST2

899864100

REMOVER

CAUTION:
Do not apply a load in excess of 10 kN (1 ton, 1.1
US ton, 1.0 Imp ton).

2) Using ST, install the roller bearing (transfer case
side).
ST

499757002

INSTALLER

CAUTION:
Do not apply a load in excess of 10 kN (1 ton, 1.1
US ton, 1.0 Imp ton).

E: INSPECTION

1) Bearing
Replace the bearings in the following cases.
• In case of broken or rusty bearings
• In case of worn or damaged bearings
• When the bearings fail to turn smoothly or emit
noise in rotation after gear oil lubrication.
2) Driven gear
If the driven gear tooth surface and shaft are exces-
sively broken or damaged, replace the driven gear.

(A) Roller bearing

(A) Roller bearing

MT-00143

(A)

ST

MT-00144

(A)

ST1

ST2

(A) Roller bearing

(A) Roller bearing

MT-00145

(A)

ST1

ST2

MT-00146

(A)

ST

5MT-46

Center Differential

MANUAL TRANSMISSION AND DIFFERENTIAL

12.Center Differential

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. <Ref. to 5MT-38, REMOV-
AL, Transfer Case and Extension Case
Assembly.>
4) Remove the extension case assembly. <Ref. to
5MT-38, REMOVAL, Transfer Case and Extension
Case Assembly.>
5) Remove the transfer driven gear. <Ref. to 5MT-
44, REMOVAL, Transfer Driven Gear.>
6) Remove the center differential. 

B: INSTALLATION

1) Install the center differential into transfer case.
2) Install the transfer driven gear. <Ref. to 5MT-44,
INSTALLATION, Transfer Driven Gear.>
3) Install the extension case assembly. <Ref. to
5MT-38, INSTALLATION, Transfer Case and Ex-
tension Case Assembly.>
4) Install the transfer case together with the exten-
sion case assembly. <Ref. to 5MT-38, INSTALLA-
TION, Transfer Case and Extension Case
Assembly.>
5) Install the back-up light switch neutral position
switch. <Ref. to 5MT-35, INSTALLATION, Switch-
es and Harness.>
6) Install the manual transmission assembly to the
vehicle. <Ref. to 5MT-27, INSTALLATION, Manual
Transmission Assembly.>

C: DISASSEMBLY

NOTE:
Center differential is a non-disassembled part
which should not be disassembled.
Remove the ball bearing using ST.

NOTE:
Do not reuse the ball bearing.
ST

498077300

CENTER DIFFERENTIAL 
BEARING REMOVER

D: ASSEMBLY

Install the ball bearing into the center differential
assembly.

CAUTION:
Do not apply a load in excess of 10 kN (1 ton, 1.1
US ton, 1.0 Imp ton).

E: INSPECTION

1) Bearing
Replace the bearings in the following cases.
• In case of broken or rusty bearings
• In case of worn or damaged bearings
• When the bearings fail to turn smoothly or emit
noise in rotation after gear oil lubrication.
• When bearing has other defects.
2) Center differential
Replace the center differential case assembly if
worn or damaged.

(A) Ball bearing

MT-00147

ST

MT-00148

(A)

5MT-47

Reverse Check Sleeve

MANUAL TRANSMISSION AND DIFFERENTIAL

13.Reverse Check Sleeve

A: REMOVAL

1) Remove the manual transmission assembly
from the vehicle. <Ref. to 5MT-24, REMOVAL,
Manual Transmission Assembly.>
2) Remove the transfer case together with the ex-
tension case assembly. <Ref. to 5MT-38, REMOV-
AL, Transfer Case and Extension Case
Assembly.>
3) Remove the shifter arm.
4) Remove the plug, gasket, reverse accent spring,
and reverse check ball.

5) Remove the reverse check sleeve.

B: INSTALLATION

1) Install the reverse check sleeve.

Tightening torque:

6.4 N·m (0.7 kgf-m, 4.7 ft-lb)

2) Install the reverse check ball, reverse accent
spring, gasket, and plug to the transfer case.

Tightening torque:

9.75 N·m (1.0 kgf-m, 7.2 ft-lb)

3) Attach the shifter arm to the transfer case as-
sembly.
4) Install the transfer case together with the exten-
sion case assembly. <Ref. to 5MT-38, INSTALLA-
TION, Transfer Case and Extension Case
Assembly.>
5) Install the manual transmission assembly to the
vehicle. <Ref. to 5MT-27, INSTALLATION, Manual
Transmission Assembly.>

MT-00149

MT-00150

MT-00150

MT-00149