SUBARU LEGACY 1996 Service Repair Manual

B3M0043A
2. TRANSFER CASE
Assembly of transfer case is in the reverse order of disas-
sembly. Do the following:
1) Assembly of reverse check sleeve
(1) Install reverse accent shaft

F, check cam
D, return
spring

Eand check spring
Conto reverse check
sleeve.
NOTE:
Be sure the bent section of reverse check spring is posi-
tioned in the groove in check cam.
(2) Hook the bent section of reverse check spring over
reverse check plate

B.
(3) Rotate cam so that the protrusion of reverse check
cam is at the opening in plate.
(4) With cam held in that position, install plate onto
reverse check sleeve and hold with snap ring

A(Inner-
28).
(5) Position O-ring

G(35.4 x 1.5) in groove in sleeve.
B3M0048A
CAUTION:
Make sure the cutout section of reverse accent shaft
is aligned with the opening in reverse check sleeve.
Spin cam by hand for smooth rotation.
If it does not return properly, replace reverse check
spring.
Move cam and shaft all the way toward plate and
release.
If cam does not return properly, replace reverse check
spring; if shaft does not, check for scratches on the
inner surface of sleeve. If sleeve is in good order,
replace spring.
Select a suitable reverse accent shaft and reverse
check plate by referring to “Neutral Position Adjust-
ment.”
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3-1SERVICE PROCEDURE
2. Transfer Case and Extension (AWD Model)

B3M0042A
2) Installation of shifter arm
1and selector arm
8
Install shifter arm into the partition from the front while
inserting selector arm into the opening in reverse check
sleeve. Pass shaft through hole in selector arm until its end
comes out of the rear of transfer case.
NOTE:
Apply a coat of gear oil to shifter arm. Also make sure oil
seal is positioned properly.
Tightening torque:
T1: 6.4±0.5 N⋅m (0.65±0.05 kg-m, 4.7±0.4 ft-lb)
T2: 10±1 N⋅m (1.0±0.1 kg-m, 7.2±0.7 ft-lb)
T3: 19.6±1.5 N⋅m (2.00±0.15 kg-m, 14.5±1.1 ft-lb)
T4: 25±2 N⋅m (2.5±0.2 kg-m, 18.1±1.4 ft-lb)
B3M0049A
3. COMBINATION OF TRANSFER CASE AND
EXTENSION ASSEMBLY
1) Install center differential

1and transfer driven gear
2
into transfer case.
Tightening torque:
T: 37±3 N⋅m (3.8±0.3 kg-m, 27.5±2.2 ft-lb)
B3M0050A
2) Selection of thrust washer (52 x 61 x t)
(1) Measure height“W”between transfer case and ball
bearing on the transfer driven gear

3.
26
3-1SERVICE PROCEDURE
2. Transfer Case and Extension (AWD Model)

B3M0051A
(2) Measure depth“X”as shown in figure.


4Extension
(3) Calculate space“Y”using the following equation: Y
=XW+0.24 mm (0.0094 in) [Thickness of gasket]
(4) Select suitable washer in the following table:
Space “Y” mm (in)Thrust washer (52 x 61 x t)
Part No.Thickness
mm (in)
0.55 — 0.79 (0.0217 — 0.0311) 803052021 0.50 (0.0197)
0.80 — 1.04 (0.0315 — 0.0409) 803052022 0.75 (0.0295)
1.05 — 1.30 (0.0413 — 0.0512) 803052023 1.00 (0.0394)
Standard clearance between thrust washer and ball
bearing:
0.05—0.30 mm (0.0020—0.0118 in)
(5) Fit thrust washers on transfer drive shaft.
B3M0052
3) Install extension assembly into transfer case.
27
3-1SERVICE PROCEDURE
2. Transfer Case and Extension (AWD Model)

D: INSTALLATION
B3M0053A
Tightening torque: N⋅m (kg-m, ft-lb)
T1: 15.7±1.5 (1.6±0.15, 11.6±1.1)
T2: 19.6±1.5 (2.00±0.15, 14.5±1.1)
T3: 24.5±2.0 (2.50±0.20, 18.1±1.4)
1) Install transfer case
2with extension assembly
1.
2) Secure selector arm to shifter arm with shifter fork
screw

3. Shifter arm should be caught by pawl of rod.
Selector arm must be engaged with reverse check sleeve
assembly.
3) Adjustment of neutral position
(1) Shift gear into 3rd gear position.
(2) Shifter arm turns lightly toward the 1st/2nd gear
side but heavily toward the reverse gear side because
of the function of the return spring, until arm contacts
the stopper.
(3) Make adjustment so that the heavy stroke (reverse
side) is a little more than the light stroke (1st/2nd side).
(4) To adjust, remove bolts holding reverse check
sleeve assembly

4to the case, move sleeve assem-
bly outward, and place adjustment shim (0 to 1 ea.)
between sleeve assembly and case to adjust the clear-
ance.
28
3-1SERVICE PROCEDURE
2. Transfer Case and Extension (AWD Model)

CAUTION:
Be careful not to break O-ring when placing shim(s).
Adjustment shim
Part No. Thickness mm (in)
32190AA000 0.15 (0.0059)
32190AA010 0.30 (0.0118)
When shim is removed, the neutral position will move
closer to reverse; when shim is added, the neutral position
will move closer to 1st gear.
If shims alone cannot adjust the clearance, replace
reverse accent shaft and re-adjust.
Reverse accent shaft
Part No. Mark Remarks
32188AA040 1 Neutral position is closer to 1st gear.
32188AA011No mark
or 2Standard
32188AA050 3Neutral position is closer to reverse
gear.
B3M0054A
4) Reverse check plate
5adjustment
Shift shifter arm to“5th”and then to reverse to see if
reverse check mechanism operates properly. Also check to
see if arm returns to neutral when released from the
reverse position. If arm does not return properly, replace
reverse check plate.
Reverse check plate
Part No.

A: No. AngleθRemarks
32189AA000 0 28°Arm stops closer to 5th
gear.
32189AA010 1 31°Arm stops closer to 5th
gear.
32189AA020 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.
B3M0055A
5) Install transfer
6cover and gasket.
6) Connect each connector

7.
29
3-1SERVICE PROCEDURE
2. Transfer Case and Extension (AWD Model)

3. Rear Case (FWD Model)
A: DISASSEMBLY
G3M0952
Tightening torque: N⋅m (kg-m, ft-lb)
T1: 6.4±0.5 (0.65±0.05, 4.7±0.4)
T2: 10±1 (1.0±0.1, 7.2±0.7)
T3: 25±2 (2.5±0.2, 18.1±1.4)
1) Remove rear case
1.
2) Remove plug

2, spring
3and reverse check ball
4.
3) Remove neutral switch

5.
4) Pull out shifter arm

6.
5) Remove reverse check sleeve

7.
NOTE:
The disassembly procedure is the same as for AWD model.
B3M0056A
6) Remove back-up light switch
8.
7) Remove oil seal

9.
CAUTION:
Do not reuse oil seal.
30
3-1SERVICE PROCEDURE
3. Rear Case (FWD Model)

B: ASSEMBLY
1) Assembly of rear case is in the reverse order of disas-
sembly.
G3M0952
Tightening torque: N⋅m (kg-m, ft-lb)
T1: 6.4±0.5 (0.65±0.05, 4.7±0.4)
T2: 10±1 (1.0±0.1, 7.2±0.7)
T3: 25±5 (2.5±0.5, 18.1±3.6)
2) Installation of shifter arm
6
Install shifter arm into the partition from the front while
inserting selector arm into the opening in reverse check
sleeve. Pass shaft through hole in selector arm until its end
comes out of the rear of transmission case assembly.
CAUTION:
Apply a coat of gear oil to shifter arm. Also make sure
oil seal is positioned properly.
3) Adjustment of neutral position
NOTE:
After assembling and installing rear case, adjust neutral
position.
(1) Shift gear into 3rd gear position.
(2) Shifter arm turns lightly toward the 1st/2nd gear
side but heavily toward the reverse gear side because
of the function of the return spring, until arm contacts
the stopper.
(3) Make adjustment so that the heavy stroke (reverse
side) is a little more than the light stroke (1st/2nd side).
(4) To adjust, remove bolts holding reverse check
sleeve assembly to the case, move sleeve assembly
outward, and place adjustment shim (0 to 1 ea.)
between sleeve assembly and case to adjust the clear-
ance.
31
3-1SERVICE PROCEDURE
3. Rear Case (FWD Model)

CAUTION:
Be careful not to break O-ring when placing shim(s).
Adjustment shim
Part No. Thickness mm (in)
32190AA000 0.15 (0.0059)
32190AA010 0.30 (0.0118)
NOTE:
When shim is removed, the neutral position will move
closer to reverse; when shim is added, the neutral position
will move closer to 1st gear.
If shims alone cannot adjust the clearance, replace
reverse accent shaft and re-adjust.
Reverse accent shaft
Part No. Mark Remarks
32188AA040 1Neutral position is closer to 1st
gear.
32188AA011 No mark or 2 Standard
32188AA050 3Neutral position is closer to
reverse gear.
B3M0054A
4) Reverse check plate adjustment
NOTE:
After assembling and installing rear case, adjust reverse
check plate.
Shift shifter arm to“5th”and then to reverse to see if
reverse checking mechanism operates properly. Also
check to see if arm returns to Neutral when released from
the reverse position. If arm does not return properly,
replace reverse check plate.
Reverse check plate
Part No.

A: No. AngleθRemarks
32189AA000 0 28°Arm stops closer to 5th gear.
32189AA010 1 31°Arm stops closer to 5th gear.
32189AA020 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.
32
3-1SERVICE PROCEDURE
3. Rear Case (FWD Model)

4. Transmission Case
A: DISASSEMBLY
1. SEPARATION OF TRANSMISSION
B3M0329A
B3M0336A
1) Remove clutch release lever
1and bearing
2. (Refer
to 2-10 clutch.)
G3M0597
2) Remove bearing mounting bolts.
33
3-1SERVICE PROCEDURE
4. Transmission Case

G3M0598
3) Remove main shaft rear plate
4.
B3M0330
4) Separating transmission case
(1) Put vinyl tape around splines of right and left axle
drive shafts to prevent damage to oil seals.
B3M0331
(2) Separate transmission case into right and left
cases by loosening seventeen coupling bolts and nuts.
B3M0101B
5) Remove drive pinion shaft assembly
6from left side
transmission case.
NOTE:
Use a hammer handle, etc. to remove if too tight.
6) Remove main shaft assembly

7.
G3M0557
7) Remove differential assembly.
CAUTION:
Be careful not to confuse right and left roller bear-
ing outer races.
Be careful not to damage retainer oil seal.
34
3-1SERVICE PROCEDURE
4. Transmission Case