Subaru Legacy IV (2008 year). Manual - part 796

5MT-80

Shifter Fork and Rod

MANUAL TRANSMISSION AND DIFFERENTIAL

B: INSTALLATION

1) Install the reverse arm fork spring, ball and inter-
lock plunger to the reverse fork rod arm. Insert the
reverse fork rod into the hole of the reverse fork rod
arm, and hold it with snap ring (outer) using ST.

NOTE:
Apply grease to plunger to prevent it from falling.
ST

399411700

ACCENT BALL INSTALLER

2) Position the ball, spring and new gasket in the
reverse fork rod hole on the left side of transmis-
sion case, and tighten the checking ball plug.
3) Install the 1st-2nd fork rod into 1st-2nd shifter
fork through the hole on the rear of transmission
case.
4) Align the holes in the rod and the fork, and drive
the new straight pin into these holes using the ST.

NOTE:
• Set other rods to neutral.
• Make sure the interlock plunger is on the 3rd-4th
fork rod side.
ST

398791700

STRAIGHT PIN REMOVER 2

5) Attach the interlock plunger on 3rd – 4th fork rod.

NOTE:
Apply grease to plunger to prevent it from falling.
6) Attach the 3rd – 4th fork rod into 3rd – 4th shifter
fork through the hole on the rear of transmission
case.
7) Align the holes in the rod and the fork, and drive
the new straight pin into these holes.

NOTE:
• Set the reverse fork rod to neutral.
• Make sure the interlock plunger (before installa-
tion) is on the reverse fork rod side.
ST

398791700

STRAIGHT PIN REMOVER 2

8) Install the 5th shifter fork onto the rear of reverse
fork rod. Align the holes in the two parts and drive
new straight pin into the specified place.
ST

398791700

STRAIGHT PIN REMOVER 2

9) Position the balls, check ball springs and new
gaskets into holes of the 3rd – 4th fork rods and 1st
– 2nd fork rods, and install the plugs.

Tightening torque:

20 N·m (2.0 kgf-m, 14.8 ft-lb)

10) Install the front differential assembly. <Ref. to
5MT-69, INSTALLATION, Front Differential As-
sembly.>
11) Install the main shaft assembly for single-
range. <Ref. to 5MT-54, INSTALLATION, Main
Shaft Assembly for Single-Range.>
12) Install the drive pinion shaft assembly. <Ref. to
5MT-60, INSTALLATION, Drive Pinion Shaft As-
sembly.>
13) Install the transmission case. <Ref. to 5MT-52,
INSTALLATION, Transmission Case.>
14) Install the transfer case together with the exten-
sion case assembly. <Ref. to 5MT-38, INSTALLA-
TION, Transfer Case and Extension Case
Assembly.>
15) Install the back-up light switch neutral position
switch. <Ref. to 5MT-35, INSTALLATION, Switch-
es and Harness.>
16) Install the manual transmission assembly to the
vehicle. <Ref. to 5MT-27, INSTALLATION, Manual
Transmission Assembly.>

(A) 5th shifter fork

(B) Reverse fork rod

(C) Straight pin

MT-00311

( C )

( A )

( B )

MT-00366

5MT-81

Shifter Fork and Rod

MANUAL TRANSMISSION AND DIFFERENTIAL

C: INSPECTION

1) Check the fork and 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 the clearance between 1st, 2nd driven
gear and reverse driven gear. If any clearance is
not within specifications, replace the shifter fork as
required.

Clearance (a) and (b):

9.5 mm (0.374 in)

4) Inspect the clearance between the 3rd, 4th drive
gear and the coupling sleeve. If any clearance is
not within specifications, replace the shifter fork as
required.

Clearance (a) and (b):

9.3 mm (0.366 in)

(a), (b) Measured value

(A) 1st driven gear

(B) Reverse driven gear

(C) 2nd driven gear

1st-2nd shifter fork

Part number

Mark

Remarks

32804AA060

1

Approaches 1st gear by 0.2 mm 
(0.008 in).

32804AA070

 — 

Standard

32804AA080

3

Approaches 2nd gear by 0.2 mm 
(0.008 in).

MT-01635

(A)

(B)

(a)

(b)

(C)

(a), (b) Measured value

(A) 3rd drive gear

(B) Coupling sleeve

(C) 4th drive gear

3rd-4th shifter fork

Part number

Mark

Remarks

32810AA061

1

Approaches 4th gear by 0.2 mm 
(0.008 in).

32810AA071

 — 

Standard

32810AA101

3

Approaches 3rd gear by 0.2 mm 
(0.008 in).

MT-00940

(A)

(B)

(C)

(a)

(b)

5MT-82

Shifter Fork and Rod

MANUAL TRANSMISSION AND DIFFERENTIAL

5) Inspect the clearance between 5th drive gear
and coupling sleeve. If any clearance is not within
specifications, replace the shifter fork as required.

Clearance (a):

9.3 mm (0.366 in)

6) Inspect the rod end clearances (A) and (B). If
any clearance is not within specifications, replace
the rod or fork as required.

Clearance (A):

3rd-4th — 5th

0.5 — 1.3 mm (0.020 — 0.051 in)

Clearance (B):

1st-2nd — 3rd-4th

0.4 — 1.4 mm (0.016 — 0.055 in)

(a) Measured value

(A) 5th drive gear

(B) Coupling sleeve

5th shifter fork

Part number

Mark

Remarks

32812AA201

7

Approaches 5th gear by 0.2 mm 
(0.008 in).

32812AA211

No mark

Standard

32812AA221

9

Moves away from 5th gear by 
0.2 mm (0.008 in).

(A), (B) Measured value

MT-01512

(A)

(B)

(a)

MT-00316

(B)

(A)

5MT-83

General Diagnostic Table

MANUAL TRANSMISSION AND DIFFERENTIAL

20.General Diagnostic Table

A: INSPECTION

1. MANUAL TRANSMISSION

Symptom

Possible cause

Corrective action

1. Gears are difficult to intermesh.

NOTE:
The causes for difficulty in shifting gears 
can be classified into two kinds: One is a 
abnormal gear shift system and the other 
is abnormal transmission. However, if the 
operation is heavy and engagement of the 
gears is difficult, a defective clutch disen-
gagement may also be responsible. 
Check whether the clutch is correctly 
functioning, before checking the gear shift 
system and transmission.

(a) Worn, damaged or burred chamfer at 
internal spline of sleeve and reverse 
driven gear

Replace.

(b) Worn, damaged or burred chamfer of 
gear spline

Replace.

(c) Worn or scratched bushings

Replace.

(d) Incorrect contact or wear between 
synchronizer ring and gear cone

Repair or replace.

2. Gear slip-out
• Gear slips out when coasting on rough 
road.
• Gear slips out during acceleration.

(a) Abnormal pitching stopper adjustment

Adjust.

(b) Loose engine mounting bolts

Tighten or replace.

(c) Worn fork shifter, broken shifter fork 
rail spring

Replace.

(d) Worn or damaged ball bearing

Replace.

(e) Excessive clearance between splines 
of synchronizer hub and synchronizer 
sleeve

Replace.

(f) Synchronizer hub tooth step wear

Replace.

(g) Worn 1st driven gear and driven shaft

Replace.

(h) Worn 2nd driven gear and bushing

Replace.

(i) Worn 3rd drive gear and needle bear-
ing

Replace.

(j) Worn 4th drive gear and needle bear-
ing

Replace.

(k) Worn reverse idler gear and bushing

Replace.

3. Noise emitted from transmission

NOTE:
If a noise is heard when the vehicle is 
parked with its engine idling and if a noise 
ceases when the clutch is disengaged, it 
may be considered that the noise is com-
ing from the transmission.

(a) Insufficient or improper lubrication

Lubricate with specified oil or replace.

(b) Worn or damaged gears and bearings

NOTE:
If the trouble is only wear of the tooth sur-
faces, merely a high roaring noise will oc-
cur at high speeds, but if any part is 
broken, rhythmical knocking sound will be 
heard even at low speeds.

Replace.