Subaru Legacy IV (2008 year). Manual - part 821

6MT-97

Drive Pinion Shaft Assembly

MANUAL TRANSMISSION AND DIFFERENTIAL

7) Using the ST, crimp the lock nut in 2 locations,
with dimensions within A 37

r0.5 mm (1.46r0.02

in).
ST

18670AA000

PUNCH

NOTE:
Do not damage the crimp area of the lock nut.

8) Using the ST, measure drive pinion measure-
ment B.
ST

398643600

GAUGE

9) Calculate from the calculation below to select 1
or 2 drive pinion shims from the following table.
6.5

r0.0625 mm – (B – A) [0.26r0.0025 in – (B – A)]

NOTE:
A: Measurement value in step 1)
B: Measurement value in step 8)

10) Apply transmission gear oil to the side face of
the taper roller bearing, and attach the drive pinion
shaft and the selected shims to the adapter plate.

Tightening torque:

54 N·m (5.5 kgf-m, 40 ft-lb)

11) Install the oil guide A.

Tightening torque:

18 N·m (1.8 kgf-m, 13.3 ft-lb)

MT-00649

A

ST

MT-00650

B

ST

Drive pinion shim

Part No.

Thickness mm (in)

32295AA270

0.15 (0.0059)

32295AA280

0.175 (0.0069)

32295AA290

0.20 (0.0079)

32295AA300

0.225 (0.0089)

32295AA310

0.25 (0.0098)

32295AA320

0.275 (0.0108)

(A) Oil guide A

MT-00642

MT-01624

(A)

6MT-98

Drive Pinion Shaft Assembly

MANUAL TRANSMISSION AND DIFFERENTIAL

E: INSPECTION

1) Using a spring scale, measure the starting
torque. If the starting torque is outside the specifi-
cation range, replace the taper roller bearing.

Starting torque:

0 — 0.95 N (0 — 0.097 kgf, 0 — 0.21 lb)

2) Gear
Replace gears in the following cases.
• The gear teeth surface is damaged or excessive-
ly worn.
3) Bearing
Replace the bearings in the following cases.
• Wear, rusting or damage of the bearings
• The bearing does not rotate smoothly or an ab-
normal noise is emitted when turning.
4) Adapter plate
Replace the adapter plate in the following cases:
• Wear, rusting or damage of the bearings
• Damage of the adapter plate
5) Check that the pipes and pipe chambers are not
damaged or clogged. Repair or replace if damaged
or clogged.

F: ADJUSTMENT

1) Inspect and adjust the hypoid driven gear-to-
drive pinion backlash. <Ref. to 6MT-108, HYPOID
GEAR BACKLASH, ADJUSTMENT, Front Differ-
ential Assembly.>
2) Apply a thin uniform coat of lead-free red dye on
the surfaces of 3 or 4 hypoid driven gear teeth.

3) Install the drive pinion shaft assembly to the
clutch housing, and tighten at least 4 bolts.

NOTE:
Install with the remaining liquid gasket, so that the
clutch housing and the adapter plate will not be
damaged.

Tightening torque:

50 N·m (5.1 kgf-m, 36.9 ft-lb)

4) Turn a few times using the ST.
ST

18631AA000

HANDLE

5) Remove the drive pinion shaft assembly, and in-
spect the mating condition of the teeth. If the mat-
ing is not correct, change shim thickness to adjust
backlash.
• Correct tooth contact
Check item: Tooth contact surface is slightly
shifted toward the toe side under a no-load con-
dition. (When driving, it moves towards the heel
side.)

MT-00651

MT-00652

(A) Toe side

(B) Heel side

MT-00653

ST

(A)

(B)

MT-01401

6MT-99

Drive Pinion Shaft Assembly

MANUAL TRANSMISSION AND DIFFERENTIAL

• Face contact
Check item: Backlash is too large.
Contact pattern

Corrective action: Reconfirm and adjust backlash.

• Flank contact
Check item: Backlash is too small.
Contact pattern

Corrective action: Reconfirm and adjust backlash.

• Toe contact (inside contact)
Check item: Teeth contact area is too small.
Contact pattern

Corrective action: Reduce the thickness of the
drive pinion shim according to the procedure for
moving the drive pinion away from the driven gear.

• Heel contact (outside end contact)
Check item: Teeth contact area is too small.
Contact pattern

Corrective action: Increase thickness of the drive
pinion shim according to the procedures for moving
the drive pinion closer to the driven gear.

AT-00208

AT-01253

AT-00209

AT-01254

AT-00210

AT-00213

AT-00211

AT-00212

6MT-100

Front Differential Assembly

MANUAL TRANSMISSION AND DIFFERENTIAL

21.Front Differential Assembly

A: REMOVAL

1) Remove the manual transmission assembly.
<Ref. to 6MT-32, REMOVAL, Manual Transmis-
sion Assembly.>
2) Prepare the transmission for overhaul. <Ref. to
6MT-37, Preparation for Overhaul.>
3) Remove the neutral position switch, back-up
light switch and harness. <Ref. to 6MT-41, RE-
MOVAL, Neutral Position Switch.> <Ref. to 6MT-
39, REMOVAL, Back-up Light Switch.>
4) Remove the extension case. <Ref. to 6MT-43,
REMOVAL, Extension Case.>
5) Remove the transfer driven gear. <Ref. to 6MT-
55, REMOVAL, Transfer Driven Gear.>
6) Remove the center differential. <Ref. to 6MT-57,
REMOVAL, Center Differential.>
7) Remove the transmission case. <Ref. to 6MT-
58, REMOVAL, Transmission Case.>
8) Remove the individual gear assemblies. <Ref. to
6MT-64, REMOVAL, Main Shaft Assembly.>
9) Remove the drive pinion shaft assembly. <Ref.
to 6MT-94, REMOVAL, Drive Pinion Shaft Assem-
bly.>
10) Remove the lock plates on both sides.

11) Remove the differential side retainers on both
sides using the ST.
ST1

18630AA010

WRENCH COMPL 
RETAINER (RH SIDE)

ST2

18630AA000

WRENCH ASSEMBLY 
(LH SIDE)

NOTE:
Be careful not to damage the section where the
clutch case retainer will be attached.

12) Remove the front differential.

(A) Lock plate

MT-01022

(A)

(A) LH side

(B) RH side

(A)

(B)

MT-00657

ST1

ST2