SUBARU LEGACY 1997 Service Repair Manual

4. Shifter Fork and Shifter Rod
B3M0338A

1Plug


2Gasket


3Reverse accent spring


4Ball


5Snap ring (Inner)


6Reverse check plate


7Reverse check spring


8Reverse return spring


9Reverse check cam


10Reverse accent shaft


11O-ring


12Adjusting select shim


13Reverse check sleeve

14Selector arm (AWD model)


15Shifter arm (AWD model)


16Reverse shifter lever


17Reverse fork rod arm


18Snap ring (Outer)


19Spring


20Ball


213rd-4th shifter fork


221st-2nd shifter fork


23Straight pin


24Reverse fork rod


255th shifter fork


26Interlock plunger

273rd-4th fork rod


281st-2nd fork rod


29Ball


30Checking ball spring


31Gasket


32Checking ball plug


33Shifter arm (FWD model)
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: 19.6±1.5
(2.00±0.15, 14.5±1.1)
9
3-1COMPONENT PARTS
4. Shifter Fork and Shifter Rod

5. Drive Pinion Assembly
1. AWD MODEL
B3M0613A

1Drive pinion shaft


2Roller bearing


3Washer


4Driven shaft


5Key


6Woodruff key


7Drive pinion collar


8Needle bearing


9Snap ring (Outer)


10Washer


11Sub gear


121st driven gear


13Baulk ring

141st-2nd synchronizer hub


15Insert key


16Reverse driven gear


17Outer baulk ring


18Synchro cone


19Inner baulk ring


202nd driven gear


212nd driven gear bush


223rd-4th driven gear


23Driven pinion shim


24Roller bearing


255th driven gear


26Lock washer

27Lock nut


28Washer


29Thrust bearing


30Differential bevel gear sleeve


31Washer


32Lock washer


33Lock nut
Tightening torque: N⋅m (kg-m, ft-lb)
T1: 29±3 (3.0±0.3, 21.7±2.2)
T2: 118±8 (12.0±0.8, 86.8±5.8)
T3: 265±10 (27±1, 195±7)
10
3-1COMPONENT PARTS
5. Drive Pinion Assembly

2. FWD MODEL
B3M0339A

1Drive pinion shaft


2Key


3Woodruff key


4Roller bearing


51st gear thrust plate


6Snap ring (Outer)


7Washer


81st sub gear


91st gear bushing


101st driven gear

111st-2nd baulk ring


121st-2nd synchronizer spring


131st-2nd synchronizer hub


141st-2nd shifting insert


15Reverse driven gear


162nd driven gear


172nd gear bushing


182nd sub gear


193rd-4th driven gear


20Drive pinion shim

21Ball bearing


225th driven gear


23Lock washer


24Lock nut
Tightening torque: N⋅m (kg-m, ft-lb)
T1: 29±3 (3.0±0.3, 22±2)
T2: 118±6 (12.0±0.6, 86.8±4.3)
11
3-1COMPONENT PARTS
5. Drive Pinion Assembly

6. Main Shaft Assembly
G3M0841

1Oil seal


2Needle bearing


3Transmission main shaft


44th needle bearing race


5Needle bearing


63rd drive gear


7Baulk ring


8Synchronizer spring


9Synchronizer hub


10Coupling sleeve

11Shifting insert


124th drive gear


134th gear thrust washer


14Ball bearing


155th gear thrust washer


165th needle bearing race


17Main shaft rear plate


185th drive gear


19Insert stopper plate


20Lock washer

21Lock nut


22Reverse idler gear shaft


23Straight pin


24Reverse idler gear


25Washer
Tightening torque: N⋅m (kg-m, ft-lb)
T: 118±6 (12.0±0.6, 86.8±4.3)
12
3-1COMPONENT PARTS
6. Main Shaft Assembly

7. Center Differential (AWD Model)
B3M0036A

1Ball bearing


2Snap ring (Inner-110)


3Center differential cover


4Needle bearing


5Adjusting washer


6Viscous coupling


7Pinion shaft

8Differential bevel pinion


9Retainer


10Differential bevel gear


11Washer


12Center differential case


13Snap ring


14Roller bearing
13
3-1COMPONENT PARTS
7. Center Differential (AWD Model)

8. Front Differential
G3M0515

1Drive pinion shaft


2Hypoid driven gear


3Pinion shaft


4Straight pin


5Washer


6Differential bevel gear


7Differential bevel pinion


8Snap ring (Outer)


9Roller bearing


10Differential case

11Oil seal


12Differential side retainer


13O-ring


14Axle drive shaft


15Retainer lock plate
Tightening torque: N⋅m (kg-m, ft-lb)
T1: 25±5 (2.5±0.5, 18.1±3.6)
T2: 62±5 (6.3±0.5, 45.6±3.6)
14
3-1COMPONENT PARTS
8. Front Differential

1. General
A: APPLICATION
Large titleModel
AWD FWD
1 General


2Transfer Case and Extension
(AWD Model)

3 Rear Case (FWD Model)

4 Transmission Case


5 Drive Pinion Assembly (AWD Model)

6 Drive Pinion Assembly (FWD Model)

7 Main Shaft Assembly


8 Center Differential (AWD Model)

9 Front Differential


The table above shows the titles of the main sections in
Service Procedures and the applicable vehicle models.
Carry out service operations by referring to the sections
applicable to the vehicle to be serviced.
15
3-1SERVICE PROCEDURE
1. General

B3M0037A
B: PRECAUTIONS
1) The following job should be followed before disassem-
bly:
(1) Clean oil, grease, dirt and dust from transmission.
(2) Remove drain plug

1to drain oil. After draining,
retighten it as before.
CAUTION:
Replace gasket with a new one.
Tightening torque:
44±3 N⋅m (4.5±0.3 kg-m, 32.5±2.2 ft-lb)
G3M0517
(3) Attach transmission to ST.
ST 499937100 TRANSMISSION STAND SET
2) Rotating parts should be coated with oil prior to assem-
bly.
3) All disassembled parts, if to be reused, should be rein-
stalled in the original positions and directions.
4) Gaskets and lock washers must be replaced with new
ones.
5) Liquid gasket should be used where specified to pre-
vent leakage.
6) Fill transmission gear oil through the oil level gauge
hole up to upper point level gauge. <Ref. to 1-5 [09A1].>
C: INSPECTION
Disassembled parts should be washed clean first and then
inspected carefully.
1) Bearings
Replace bearings in the following cases:
Bearings whose balls, outer races and inner races are
broken or rusty.
Worn bearings
Bearings that fail to turn smoothly or make abnormal
noise when turned after gear oil lubrication.
B3M0038A
The ball bearing
3on the rear side of the drive pinion shaft


2should be checked for smooth rotation before the drive
pinion assembly is disassembled. In this case, because a
preload is working on the bearing, its rotation feels like it is
slightly dragging unlike the other bearings.
Bearings having other defects
16
3-1SERVICE PROCEDURE
1. General

2) Bushing (each gear)
Replace the bushing in the following cases:
(1) When the sliding surface is damaged or abnormally
worn.
(2) When the inner wall is abnormally worn.
3) Gears
(1) Replace gears with new ones if their tooth surfaces
are broken, damaged, or excessively worn.
(2) Correct or replace if the cone that contacts the
baulk ring is rough or damaged.
(3) Correct or replace if the inner surface or end face
is damaged.
B3M0039A
4) Baulk ring
Replace the ring in the following cases:
When the inner surface and end face are damaged.
When the ring inner surface is abnormally or partially
worn down.
If the gap between the end faces of the ring and the gear
splined part is excessively small when the ring is pressed
against the cone.
Clearance

A:
0.5 — 1.0 mm (0.020 — 0.040 in)
When the contact surface of the synchronizer ring

4
insert is scored or abnormally worn down.
B3M0040A
5) Insert
5(shifting)
Replace the insert if deformed, excessively worn, or defec-
tive in any way.
17
3-1SERVICE PROCEDURE
1. General

6) Oil seal
Replace the oil seal if the lip is deformed, hardened,
damaged, worn, or defective in any way.
7) O-ring
Replace the O-ring if the sealing face is deformed,
hardened, damaged, worn, or defective in any way.
8) Gearshift mechanism
Repair or replace the gearshift mechanism if excessively
worn, bent, or defective in any way.
G3M0521
9) Differential gear
Repair or replace the differential gear in the following
cases:
(1) The hypoid drive gear and drive pinion shaft tooth
surface are damaged, excessively worn, or seized.
(2) The roller bearing on the drive pinion shaft has a
worn or damaged roller path.
(3) There is damage, wear, or seizure of the differen-
tial bevel pinion, differential bevel gear, washer, pinion
shaft, and straight pin.
(4) The differential case has worn or damaged sliding
surfaces.
18
3-1SERVICE PROCEDURE
1. General