Subaru Legacy IV (2008 year). Service manual - part 816

6MT-77

Main Shaft Assembly

MANUAL TRANSMISSION AND DIFFERENTIAL

E: INSPECTION

Disassembled parts should be washed clean first
with cleaning solvent and then inspected carefully.
1) 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.
• The bearing has other defects.
2) Bushing (each gear)
Replace the bushing in following cases.
• The sliding surface is damaged or abnormally
worn.
3) Gear
Replace gears in the following cases.
• The gear teeth surface is damaged or excessive-
ly worn.
• The contact area of the baulk ring is damaged.
• The inner face of the gear is worn.
4) Baulk ring, synchro cone
Replace the baulk ring and synchro cone in the fol-
lowing cases.
• Wear, rusting or damage of the baulk ring
5) Shifting insert key
Replace the shifting insert key if deformed, exces-
sively worn or defective in any way.

F: ADJUSTMENT

1. MAIN SHAFT SNAP RING & WASHER 
SELECTION

NOTE:
In the following conditions, perform the procedures
below.
• Replacing driven gears 1st through 6th
• Replacing the 1st and 2nd synchro ring assem-
bly
• Replacing the ball bearing
• Replacing the adapter plate
• Replacing the driven shaft
1) Insert the drive pinion assembly into the adapter
plate.

NOTE:
Confirm that the thrust bearing outer race has not
been removed and the drive pinion is not lifted.
2) Set the height gauge to the adapter plate. Lower
the height gauge indicator to the mating surface of
the adapter plate and case, and set to zero points.
ST

18853AA000

HEIGHT GAUGE

NOTE:
• The adapter plate will be the base point for the
measurement. Use a scraper to remove any gasket
material remaining on the end face.
• During measurement, do not place the height
gauge in the shaded area shown in the figure.

MT-00581

MT-00582

ST

MT-00583

6MT-78

Main Shaft Assembly

MANUAL TRANSMISSION AND DIFFERENTIAL

3) Measure the height to the ball bearing end face
(height H).

NOTE:
Set the height gauge indicator near the measure-
ment target, and lock dial (1) as shown in the figure.
Turn dial (2), and set the indicator to the end face of
the bearing.

Turn approximately 120° at a time, and measure
the ball bearing in 5 locations. Round down the 2
highest and 2 lowest measurement values. The re-
maining center value is used as the measurement
value.

4) According to the measurement value, select the
snap ring and washer from the following table.
Snap ring

Washer

(A) Ball bearing

(A)

MT-00955

H

MT-00585

(2)

(1)

H: mm (in)

Part No.

Thickness: mm 

(in)

270.83 — 271.40

(10.66 — 10.69)

805072010

1.65

(0.065)

271.41 — 271.98

(10.69 — 10.71)

805072011

1.95

(0.077)

271.99 — 272.56

(10.71 — 10.73)

805072012

2.25

(0.089)

H: mm (in)

Part No.

Thickness: mm 

(in)

270.83 — 271.40

(10.66 — 10.69)

803067012

1.6

(0.063)

271.41 — 271.98

(10.69 — 10.71)

803067011

1.3

(0.051)

271.99 — 272.56

(10.71 — 10.73)

803067010

1.0

(0.039)

6MT-79

Driven Gear Assembly

MANUAL TRANSMISSION AND DIFFERENTIAL

18.Driven Gear Assembly

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 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 driven gear assembly. <Ref. to
6MT-64, REMOVAL, Main Shaft Assembly.>
9) Remove the 1st needle bearing.

10) Remove the thrust needle bearing.

B: INSTALLATION

1) Adjust the main shaft snap ring. <Ref. to 6MT-
77, ADJUSTMENT, Main Shaft Assembly.>
2) Adjust the 1st-2nd shifter rod. <Ref. to 6MT-115,
ADJUSTMENT, Shifter Fork and Rod.>
3) Install the thrust needle bearing.

NOTE:
Confirm that the thrust needle bearing is installed in
the proper direction.

4) Install the 1st needle bearing.
5) Install the driven gear assembly. <Ref. to 6MT-
65, INSTALLATION, Main Shaft Assembly.>
6) Install the transmission case. <Ref. to 6MT-60,
INSTALLATION, Transmission Case.>
7) Adjust the backlash of the driven gear assembly
in the axial direction. <Ref. to 6MT-87, ADJUST-
MENT, Driven Gear Assembly.>
8) Install the center differential. <Ref. to 6MT-57,
INSTALLATION, Center Differential.>
9) Install the transfer driven gear. <Ref. to 6MT-55,
INSTALLATION, Transfer Driven Gear.>
10) Install the extension case. <Ref. to 6MT-43, IN-
STALLATION, Extension Case.>
11) Install the neutral position switch, back-up light
switch and harness. <Ref. to 6MT-41, INSTALLA-
TION, Neutral Position Switch.> <Ref. to 6MT-39,
INSTALLATION, Back-up Light Switch.>
12) Install the manual transmission assembly to the
vehicle. <Ref. to 6MT-34, INSTALLATION, Manual
Transmission Assembly.>

MT-00586

MT-00587

6MT-80

Driven Gear Assembly

MANUAL TRANSMISSION AND DIFFERENTIAL

C: DISASSEMBLY

NOTE:
Individual sleeves and hubs meet at a specified po-
sition. Before disassembly, mark the meeting posi-
tion of the sleeve and hub.
1) Affix the ST to the work table.
ST

18664AA000

BASE

2) Flatten the tab of the axle nut.
3) Attach ST3 to the lock nut, set the driven gear
assembly to the ST, and remove the lock nut and
washer.
ST1

18666AA000

HOLDER

ST2

18664AA000

BASE

ST3

18620AA000

ADAPTER WRENCH

4) Attach ST1 to the 6th gear, then remove the ball
bearing and 5th-6th driven gear.
ST1

18723AA000

REMOVER

ST2

499877000

RACE 4-5 INSTALLER

5) Attach ST1 to the 4th gear, then remove the 3rd-
4th driven gear.
ST1

18723AA000

REMOVER

ST2

499877000

RACE 4-5 INSTALLER

6) Remove the driven gear key.

7) Remove the 2nd gear.

8) Remove the needle bearing and 1st-2nd sleeve.

(A) Ball bearing

(B) 5th-6th driven gear

MT-00588

ST3

ST2

ST1

MT-01480

(A)

(B)

ST2

ST1

(A) 3rd-4th driven gear

(A) Needle bearing

(B) 1st-2nd sleeve

MT-01481

(A)

ST2

ST1

MT-00590

MT-00591

MT-00592

(A)

(B)