Subaru Legacy IV (2008 year). Manual - part 808

 

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Subaru Legacy IV (2008 year). Manual - part 808

 

 

6MT-45

Extension Case

MANUAL TRANSMISSION AND DIFFERENTIAL

D: ASSEMBLY

1) Install the reverse check system. <Ref. to 6MT-
51, INSTALLATION, Reverse Check System.>
2) Install the extension case oil seal. <Ref. to 6MT-
28, REPLACEMENT, Oil Seal.>
3) Install a shifter arm oil seal using the ST.
ST1

18657AA000

INSTALLER

ST2

18671AA000

OIL SEAL GUIDE

4) Install the oil plate.

5) Select the thrust washer of the bearing, and at-
tach to the extension case. <Ref. to 6MT-46, AD-
JUSTMENT, Extension Case.>
6) Apply a thin coat of oil to the outer surface of the
bearing cone, and attach to the extension case.
7) Install the shift bracket.

Tightening torque:

25 N·m (2.5 kgf-m, 18.4 ft-lb)

8) Attach the oil guide and the transfer driven gear.
<Ref. to 6MT-53, INSTALLATION, Transfer Drive
Gear.>

E: INSPECTION

1) Check to make sure there is no damage or
cracks on the extension case. If damage or crack-
ing is found, replace the extension case.
2) Inspect for oil leaks at the extension case and
transmission case oil seals and mating surfaces. If
there are oil leaks, replace the oil seal and liquid
gasket.

(A) Oil seal

MT-00482

(A)

ST1

ST2

MT-00483

MT-00478

6MT-46

Extension Case

MANUAL TRANSMISSION AND DIFFERENTIAL

F: ADJUSTMENT

1. TRANSFER DRIVEN GEAR BEARING 
THRUST WASHER ADJUSTMENT

1) Remove the bearing cone from the extension
case using the ST.
ST

18758AA000

PULLER

2) Remove the thrust washer.
3) Measure depth “Z” between the extension case
end area and bearing cone contact area.
ST

398643600

GAUGE

NOTE:
When measuring depth “Z”, subtract the thickness
of the ST [15 mm (0.59 in)] from the measured val-
ue.

4) Remove the transfer driven gear. <Ref. to 6MT-
55, REMOVAL, Transfer Driven Gear.>

5) Remove the center differential. <Ref. to 6MT-57,
REMOVAL, Center Differential.>
6) Remove the oil guides G and H.

7) Remove the snap ring and flat washer from the
selector arm area.

8) Using an ST, remove the neutral set spring and
support.
ST1

18756AA000

CLAW

ST2

399893600

PLIER

(A) Bearing cone

(A) 15 mm (0.59 in)

MT-00479

(A)

ST

MT-00484

(A)

Z

ST

ST

(A) Oil guide G

(B) Oil guide H

(A) Snap ring

(B) Flat washer

MT-01728

(A)

(B)

MT-01616

(B)

(A)

MT-01092

ST2

ST1

6MT-47

Extension Case

MANUAL TRANSMISSION AND DIFFERENTIAL

9) Lift the striking rod, and remove the spring pin.

10) Remove the selector arm No. 2 and the shifter
arm.

11) Attach the bearing cone to the transfer driven
gear.
12) Set the ST.
ST

18831AA000

GAUGE

13) Turn the transfer driven gear 10 or more times
to seat the bearing properly.

14) Measure depth “Y” between the end of the ST
and the bearing cone.
ST

18831AA000

GAUGE

15) Using the following calculation, calculate the
transfer driven gear bearing thrust washer value “t”.
t = Z – (100 – Y) – {0.02 — 0.11 mm (0.0008 —
0.0043 in)}

(A) Striking rod

(B) Spring pin

(A) Selector arm No. 2

(B) Shifter arm

MT-01307

(A)

(B)

(B)

(A)

MT-01618

MT-00489

ST

t

mm (in)

Transfer driven gear bearing thrust 
washer thickness

Y

mm (in)

Depth between the end of the ST 
and the bearing cone.

Z

mm (in)

Depth between the end of the 
extension case and the bearing 
cone contact area.

0.02 — 0.11 mm

(0.0008 — 0.0043 in)

Standard clearance between the 
thrust washer and taper roller bear-
ing

100 mm

(3.94 in)

Height of ST

MT-00490

Y

ST

6MT-48

Extension Case

MANUAL TRANSMISSION AND DIFFERENTIAL

16) Refer to the calculated value “t” to select the
closest thrust washer from the following table.

Standard clearance between the thrust washer 
and taper roller bearing

0.02 — 0.11 mm (0.0008 — 0.0043 in)

17) Install the selector arm No. 2 and the shifter
arm.

18) Install a new spring pin.

19) Using the ST, install the neutral set spring and
support.
ST1

18756AA000

CLAW

ST2

399893600

PLIER

20) Install the flat washer and snap ring to the se-
lector arm area.

21) Install the center differential. <Ref. to 6MT-57,
INSTALLATION, Center Differential.>

Thrust washer (50 × 61 × t)

Part number

Thickness t 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 (0.0570)

(A) Selector arm No. 2

(B) Shifter arm

(B)

(A)

MT-01618

(A) Snap ring

(B) Flat washer

MT-01092

ST2

ST1

MT-01616

(B)

(A)

 

 

 

 

 

 

 

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