SUBARU LEGACY 1995 Service Repair Manual

G2M0294
6) Install torque converter to drive plate. (AT model)
(1) Tighten bolts which hold torque converter to drive
plate.
(2) Tighten other bolts while rotating the engine by
using ST.
ST 499977000 CRANK PULLEY WRENCH
CAUTION:
Be careful not to drop bolts into torque converter
housing.
Tightening torque:
25±2 N⋅m (2.5±0.2 kg-m, 18.1±1.4 ft-lb)
(3) Clog plug onto service hole.
B2M0017
(4) Install V-belt cover.
G2M0313
7) Remove special tools.
G2M0302
8) Install pitching stopper.
Tightening torque:
T1: 49±5 N⋅m (5.0±0.5 kg-m, 36.2±3.6 ft-lb)
T2: 57±10 N⋅m (5.8±1.0 kg-m, 42±7 ft-lb)
37
2-11SERVICE PROCEDURE
3. Transmission

G2M0325
9) Install front drive shafts into transmission.
(1) Lift-up the vehicle.
(2) Install front drive shaft into transmission.
(3) Drive spring pin into chamfered hole of drive shaft.
CAUTION:
Always use a new spring pin.
G2M0324
(4) Install ball joints of lower arm into knuckle arm of
housing, and tighten installing bolts.
Tightening torque:
49±10 N⋅m (5.0±1.0 kg-m, 36±7 ft-lb)
G2M0323
10) Install stabilizer clamps onto front crossmember.
Tightening torque:
25±4 N⋅m (2.5±0.4 kg-m, 18.1±2.9 ft-lb)
G3M0697
11) Install gear shift rod and stay. (MT model)
(1) Install gear shift rod onto transmission.
(2) Install stay onto transmission.
(3) Install spring.
B2M0033A
12) Install shift selector cable onto selector lever. (AT
model)
(1) Install selector cable into selector lever.
(2) Install cable bracket onto body.
NOTE:
Tighten selector cable adjusting and lock nut after check-
ing selector lever operation [step. 24)].
38
2-11SERVICE PROCEDURE
3. Transmission

G2M0317
13) Install ATF level gauge guide, and ATF cooler hoses
onto pipe. (AT model)
G3M0023
14) Install propeller shaft. (AWD model)
(1) Install propeller shaft into transmission.
(2) Tighten bolts which install propeller shaft onto com-
panion flange of rear differential.
Tightening torque:
31±8 N⋅m (3.2±0.8 kg-m, 23.1±5.8 ft-lb)
G3M0024
(3) Install center bearing bracket on body.
Tightening torque:
52±5 N⋅m (5.3±0.5 kg-m, 38.3±3.6 ft-lb)
G2M0830
15) Install exhaust system.
(1) Install heat shield cover. (AWD model)
G2M0382
(2) Install rear exhaust pipe to muffler. (AWD model)
Tightening torque:
48±9 N⋅m (4.9±0.9 kg-m, 35.4±6.5 ft-lb)
39
2-11SERVICE PROCEDURE
3. Transmission

B2M0032
(3) Install hanger bracket on right side of transmission.
(AWD model)
G2M0290
(4) Install front exhaust pipe onto engine.
Tightening torque:
30±5 N⋅m (3.1±0.5 kg-m, 22.4±3.6 ft-lb)
G2M0291
(5) Install center exhaust pipe to rear exhaust pipe.
Tightening torque:
18±5 N⋅m (1.8±0.5 kg-m, 13.0±3.6 ft-lb)
B2M0313
(6) Tighten bolt which installs center exhaust pipe to
hanger bracket.
Tightening torque:
30±5 N⋅m (3.1±0.5 kg-m, 22.4±3.6 ft-lb)
B2M0335
(7) Connect connector to rear oxygen sensor.
40
2-11SERVICE PROCEDURE
3. Transmission

G2M0312
16) Install transmission connector holder bracket.
B2M0031
17) Install ATF level gauge. (AT model)
18) Connect connectors and cables.
(1) Connect the following connectors.
Transmission harness connectors
Transmission ground terminal
Front oxygen sensor connector
Vehicle speed sensor 2
Neutral position switch connector (MT model)
Back-up light switch connector (MT model)
(2) Connect the following cables.
Cruise control cable
(With cruise control model)
Clutch cable
G2M0309
19) Install starter.
(1) Install starter onto transmission case, and connect
connectors and terminals.
(2) Tighten bolt and nut which install starter onto trans-
mission.
Tightening torque:
40±4 N⋅m (4.1±0.4 kg-m, 29.7±2.9 ft-lb)
41
2-11SERVICE PROCEDURE
3. Transmission

G2M0266
20) Install air intake duct.
21) Connect battery ground cable.
22) Fill ATF. (AT model)
<Ref. to 3-2 [W2A1].>
23) Check selector lever operation. (AT model)
<Ref. to 3-3 [W2E0].>
24) Take off vehicle from lift arms.
25) Check the vehicle on road tester. (AT model)
<Ref. to 3-2 [W3E0].>
42
2-11SERVICE PROCEDURE
3. Transmission

1. Manual Transmission and
Differential
A: SPECIFICATIONS
ItemModel
FWD AWD
2200 cc 2200 cc
Type 5-forward speeds with synchromesh and 1-reverse
Transmission gear ratio1st 3.545
2nd 2.111
3rd 1.448
4th 1.088
5th 0.825 0.780
Reverse 3.416
Front reduction
gearFinalType of gear Hypoid
Gear ratio 3.454 3.900
Rear reduction
gearTransferType of gear — Helical
Gear ratio — 1.000
FinalType of gear — Hypoid
Gear ratio — 3.900
Front
differentialType and number of gear Straight bevel gear (Bevel pinion: 2, Bevel gear: 2)
Center
differentialType and number of gear —Straight bevel gear
(Bevel pinion: 2, Bevel gear: 2 and
viscous coupling)
Transmission gear oil GL-5
Transmission oil capacity 3.3
(3.5 US qt, 2.9 Imp qt) 4.0
(4.2 US qt, 3.5 Imp qt)
2
3-1SPECIFICATIONS AND SERVICE DATA
1. Manual Transmission and Differential

B: SERVICE DATA
1. EXTENSION (AWD Model)
Snap ring (Inner-72) to ball bearing side clearance
0—0.15 mm (0—0.0059 in)
Snap ring (Inner-72)
Part No. Thickness mm (in)
805172071 1.78 (0.0701)
805172072 1.90 (0.0748)
805172073 2.02 (0.0795)
Snap ring (Outer-30) to ball bearing side clearance
0—0.15 mm (0—0.0059 in)
Snap ring (Outer-30)
Part No. Thickness mm (in)
805030041 1.53 (0.0602)
805030042 1.65 (0.0650)
805030043 1.77 (0.0697)
2. EXTENSION ASSEMBLY (AWD Model)
Thrust washer (52 x 61 x t) to ball bearing side clearance
0.05—0.30 mm (0.0020—0.0118 in)
Thrust washer (52 x 61 x t)
Part No. Thickness mm (in)
803052021 0.50 (0.0197)
803052022 0.75 (0.0295)
803052023 1.00 (0.0394)
3. TRANSFER CASE OR REAR CASE
Neutral position adjustment
Adjustment shim
Part No. Thickness mm (in)
32190AA000 0.15 (0.0059)
32190AA010 0.30 (0.0118)
Reverse accent shaft
Part No. Mark Remarks
32188AA020 ANeutral position is closer to
1st.
32188AA002 No mark or B Standard
32188AA030 CNeutral position is closer to
reverse gear.
Reverse check plate adjustment
Reverse check plate
Part No. Mark AngleθRemarks
32189AA000 0 28°Arm stops closer to
5th gear.
32189AA010 1 31°Arm stops closer to
5th gear.
33189AA020 2 34°Arm stops in the
center.
32189AA030 3 37°Arm stops closer to
reverse gear.
32189AA040 4 40°Arm stops closer to
reverse gear.
4. REVERSE IDLER GEAR
Adjustment of reverse idler gear position
Reverse idler gear to transmission case (LH) wall clearance
6.0—7.5 mm (0.236—0.295 in)
Reverse shifter lever
Part No. Mark Remarks
32820AA000 0 Further from case wall
32820AA010 No mark Standard
32820AA020 2 Closer to the case wall
After installing a suitable reverse shifter lever, adjust reverse idler
gear to transmission case wall clearance to within 0 to 0.5 mm (0
to 0.020 in) using washers.
Washer (20.5 x 26 x t)
Part No.Thickness
mm (in)Part No.Thickness
mm (in)
803020151 0.4 (0.016) 803020154 1.9 (0.075)
803020152 1.1 (0.043) 803020155 2.3 (0.091)
803020153 1.5 (0.059)
3
3-1SPECIFICATIONS AND SERVICE DATA
1. Manual Transmission and Differential

5. SHIFTER FORK AND ROD
Select suitable shifter forks so that both coupling sleeve and
reverse driven gear are positioned in the center of their synchro-
mesh mechanisms.
1st-2nd shifter fork
Part No. Mark Remarks
32804AA060 1Approach to 1st gear by
0.2 mm (0.008 in)
32804AA070 No mark Standard
32804AA080 3Approach to 2nd gear by
0.2 mm (0.008 in)
3rd-4th shifter fork
Part No. Mark Remarks
32810AA060 1Approach to 4th gear by
0.2 mm (0.008 in)
32810AA070 No mark Standard
32810AA100 3Approach to 3rd gear by
0.2 mm (0.008 in)
5th shifter fork
Part No. Mark Remarks
32812AA060 1Approach to 5th gear by
0.2 mm (0.008 in)
32812AA070 No mark Standard
32812AA100 3Become distant from 5th
gear by 0.2 mm (0.008 in)
Rod end clearance
A: 1st-2nd—3rd-4th
0.5—1.5 mm (0.020—0.059 in)
B: 3rd-4th—5th
0.6—1.4 mm (0.024—0.055 in)
6. TRANSMISSION CASE ASSEMBLY
Drive pinion shim adjustment
Drive pinion shim
Part No.Thickness
mm (in)Part No.Thickness
mm (in)
32295AA0310.150
(0.0059)32295AA0710.250
(0.0098)
32295AA0410.175
(0.0069)32295AA0810.275
(0.0108)
32295AA0510.200
(0.0079)32295AA0910.300
(0.0118)
32295AA0610.225
(0.0089)32295AA1010.500
(0.0197)
Hypoid gear backlash
0.13—0.18 mm (0.0051—0.0071 in)Selection of main shaft rear plate
Main shaft rear plate
Dimension“A”mm (in) Part No. Mark
4.00—4.13 (0.1575—0.1626) 32294AA040 1
3.87—3.99 (0.1524—0.1571) 32294AA050 2
7. DRIVE PINION ASSEMBLY
Preload adjustment of thrust bearing
Starting torque
0.3—0.8 N⋅m(3—8 kg-cm, 2.6—6.9 in-lb)
Adjusting washer No. 1
Part No. Thickness mm (in)
803025051 3.925 (0.1545)
803025052 3.950 (0.1555)
803025053 3.975 (0.1565)
803025054 4.000 (0.1575)
803025055 4.025 (0.1585)
803025056 4.050 (0.1594)
803025057 4.075 (0.1604)
Adjusting washer No. 2
Part No. Thickness mm (in)
803025059 3.850 (0.1516)
803025054 4.000 (0.1575)
803025058 4.150 (0.1634)
Assemble a driven shaft and 1st driven gear that are selected for
the proper radial clearance adjustment.
Driven shaft 1st driven gear
Part No.Diameter A
mm (in)Part No.
32229AA13049.959—49.966
(1.9669—
1.9672)32231AA270
32229AA12049.967—49.975
(1.9672—
1.9675)32231AA260
8. DRIVE PINION ASSEMBLY (FWD Model)
Selection of 1st driven gear:
1st driven gear
Outer diameter of bushing mm (in) Part No.
41.983—41.996 (1.6529—1.6534) 32231AA320
41.968—41.982 (1.6523—1.6528) 32231AA330
41.954—41.967 (1.6517—1.6522) 32231AA340
4
3-1SPECIFICATIONS AND SERVICE DATA
1. Manual Transmission and Differential

9. CENTER DIFFERENTIAL (AWD Model)
Snap ring (Inner-110) to center differential case clearance
0—0.15 mm (0—0.0059 in)
Snap ring (Inner-110)
Part No. Thickness mm (in)
805100061 2.10 (0.0827)
805100062 2.21 (0.0870)
805100063 2.32 (0.0913)
Backlash adjustment axial movement
0.62—0.86 mm (0.0244—0.0339 in)
Adjusting washer (45 x 62 x t)
Part No. Thickness mm (in)
803045041 1.60 (0.0630)
803045042 1.80 (0.0709)
803045043 2.00 (0.0787)
803045044 2.20 (0.0866)
803045045 2.40 (0.0945)
10. FRONT DIFFERENTIAL
Bevel gear to pinion backlash
0.13—0.18 mm (0.0051—0.0071 in)
Washer (38.1 x 50 x t)
Part No.Thickness
mm (in)Part No.Thickness
mm (in)
8030380210.925—
0.950
(0.0364—
0.0374)8030380231.025—
1.050
(0.0404—
0.0413)
8030380220.975—
1.000
(0.0384—
0.0394)
Pinion shaft to axle drive shaft clearance
0—0.2 mm (0—0.008 in)
Snap ring (Outer-28)
Part No.Thickness
mm (in)Part No.Thickness
mm (in)
805028011 1.05 (0.0413) 805028012 1.20 (0.0472)
5
3-1SPECIFICATIONS AND SERVICE DATA
1. Manual Transmission and Differential