Subaru Legacy IV (2008 year). Manual - part 809

6MT-49

Extension Case

MANUAL TRANSMISSION AND DIFFERENTIAL

2. TRANSFER DRIVE GEAR THRUST 
WASHER SELECTION

1) Measure height “Z” between the transmission
case end area and ST.
ST

398643600

GAUGE

2) Measure depth “Y” between the end of the ST
and the transfer drive gear.
ST

398643600

GAUGE

3) Using the following calculation, calculate the
transfer drive gear thrust washer value “t”.
t = {Y – 15 mm (0.59 in)} – {Z – 15 mm (0.59 in)} –
0.45 — 0.65 mm (0.018 — 0.026 in)

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

Standard clearance between the thrust washer 
and transfer drive gear

0.45 — 0.65 mm (0.018 — 0.026 in)

5) Install the selected thrust washer.

t

mm (in)

Transfer drive gear thrust washer 
thickness

Y

mm (in)

Depth between the end of the ST 
and the transfer drive gear

Z

mm (in)

Height from the end of the trans-
mission case to the end of the ST.

0.45 — 0.65 mm

(0.018 — 0.026 in)

Standard clearance between the 
thrust washer and transfer drive 
gear

15 mm (0.591 in)

Thickness of ST

MT-00492

Z

ST

MT-00493

Y

ST

ST

Thrust washer (36.3 × 52 × t)

Part number

Thickness mm (in)

803036070

0.80 (0.0315)

803036071

0.95 (0.0374)

803036072

1.10 (0.0433)

803036073

1.25 (0.0492)

803036074

1.40 (0.0551)

803036075

0.65 (0.0256)

6MT-50

Reverse Check System

MANUAL TRANSMISSION AND DIFFERENTIAL

12.Reverse Check System

A: REMOVAL

1) Remove the manual transmission assembly
from the vehicle. <Ref. to 6MT-32, REMOVAL,
Manual Transmission Assembly.>
2) Prepare the transmission for overhaul. <Ref. to
6MT-37, Preparation for Overhaul.>
3) Remove the extension case. <Ref. to 6MT-43,
REMOVAL, Extension Case.>
4) Remove the snap ring and washer from the re-
verse check shaft.

5) Remove the reverse check shaft and spring from
the extension case.

6) Remove the spring pin, and remove the reverse
check lever and oil seal from the reverse check
shaft.

NOTE:
Do not reuse the oil seal.

7) Remove the plug from the extension case, and
remove the gasket, spring and plunger.

NOTE:
Do not reuse the gasket.

8) Remove the reverse lock plunger.

(A) Snap ring

(B) Washer

MT-00494

(A)

(B)

MT-00495

(A) Spring pin

(B) Reverse check lever

(C) Oil seal

(A) Plug

(B) Gasket

(C) Spring

(D) Plunger

(A) Reverse lock plunger

MT-00496

(A)

(C)

(B)

MT-01818

(A)

(B)

(C)

(D)

MT-00498

(A)

6MT-51

Reverse Check System

MANUAL TRANSMISSION AND DIFFERENTIAL

B: INSTALLATION

1) Insert the reverse lock plunger.
2) Install the reverse check plug, spring, gasket,
and plug in order.

Tightening torque:

41 N·m (4.2 kgf-m, 30.2 ft-lb)

3) Install the spring and reverse check shaft to the
extension case.

NOTE:
Confirm that the end of the spring matches the hole
of the reverse check shaft and the cut out of the ex-
tension case.

4) Install the washer and snap ring.

5) Attach ST1 to the reverse check shaft. Install the
new oil seal, and push it in using ST2.
ST1

18671AA000

OIL SEAL GUIDE

ST2

18657AA010

INSTALLER

6) Insert the reverse check lever, and turn the re-
verse check shaft until the plunger is pushed in
first.

(A) Plug

(B) Gasket

(C) Spring

(D) Reverse check plug

(A) Reverse check shaft

(B) Spring

(C) Hole

(D) Cut out

MT-01818

(A)

(B)

(C)

(D)

(A)

(A)

(C)

(D)

(B)

(B)

MT-00499

(A) Snap ring

(B) Washer

(A) Oil seal

(A) Plunger

(B) Reverse check shaft

MT-00494

(A)

(B)

MT-00500

(A)

ST2

ST1

MT-00501

(A)

(B)

6MT-52

Reverse Check System

MANUAL TRANSMISSION AND DIFFERENTIAL

7) Match the hole of the reverse check lever and
the reverse check shaft, and attach the spring pin.

8) Check that the reverse check is operating cor-
rectly. <Ref. to 6MT-52, INSPECTION, Reverse
Check System.>
9) Install the extension case. <Ref. to 6MT-43, IN-
STALLATION, Extension Case.>
10) Install the manual transmission assembly to the
vehicle. <Ref. to 6MT-34, INSTALLATION, Manual
Transmission Assembly.>

C: INSPECTION

1) Check that there is no damage on any parts.
2) Check that the reverse check lever is operating
smoothly.
3) Inspect that there is no oil leak at the oil seal sec-
tion of the reverse check shaft. If there is oil leak-
age, replace the oil seal.
4) Check the operation of the reverse check.

(1) When the reverse check lever is in the fol-
lowing position, the plunger is pressed, or the
gear can shift into reverse.

(2) When the reverse check lever is in the fol-
lowing position, the plunger is not pressed, or
the gear cannot shift into reverse.

5) If it is not as specified, reassemble the reverse
check system.

(A) Reverse check shaft

(B) Reverse check lever

(C) Hole

MT-00502

(A)

(B)

(C)

MT-00503

MT-00504