SUBARU LEGACY 1999 Service Repair Manual

4) Measurement of backlash (Selection of washer)
Measure the gear backlash with ST1 and ST2, and
insert ST2 through the access window of the case.
ST1 498247001 MAGNET BASE
ST2 498247100 DIAL GAUGE
NOTE:
Measure the backlash by applying a pinion tooth
between two bevel gear teeth.
Standard value:
0.13 Ð 0.18 mm (0.0051 Ð 0.0071 in)
G3M0491
5) Using ST, install taper roller bearing.
ST 398487700 DRIFT
G3M0492
20. Transfer Clutch
A: DISASSEMBLY
1) Remove the seal ring.
CAUTION:
Be careful not to damage the seal ring.
G3M0493
2) Using a press and ST, remove the ball bearing.
CAUTION:
Do not reuse the bearing.
ST 498077600 REMOVER
G3M0494
3) Remove the snap ring, and take out the pres-
sure plate, drive plates, and driven plates.
G3M0495
99
[W20A0]3-2SERVICE PROCEDURE
20. Transfer Clutch

4) Remove the snap ring with ST1, ST2 and ST3,
and take out the return spring and transfer clutch
piston seal.
ST1 399893600 PLIERS
ST2 398673600 COMPRESSOR
ST3 398623600 SEAT
B3M1415A
5) Apply compressed air to the rear drive shaft to
remove the piston.
G3M0497
B: INSPECTION
1) Check the drive plate facing for wear and dam-
age.
2) Check the snap ring for wear, return spring for
permanent set and breakage, and return spring for
deformation.
3) Check the lathe cut ring for damage.
C: ASSEMBLY
1) Install the transfer clutch piston.
B3M1400A
2) Install return spring to transfer piston.
B3M1177A
3) Install transfer clutch piston seal.
B3M1401A
4) Install ST to rear drive shaft.
ST 499257300 SNAP RING OUTER GUIDE
B3M1402A
5) Install snap ring to ST.
ST 499257300 SNAP RING OUTER GUIDE
B3M1180A
100
3-2[W20B0]SERVICE PROCEDURE
20. Transfer Clutch

6) Using ST1 and ST2, install snap ring to rear
drive shaft.
NOTE:
After installing snap ring, remove ST1 and ST2.
ST1 499257300 SNAP RING OUTER GUIDE
ST2 499247400 INSTALLER
B3M1181A
7) Install the driven plates, drive plates, pressure
plate and snap ring.
B3M1182A
8) Apply compressed air to see if the assembled
parts move smoothly.
G3M0502
9) Check the clearance.
NOTE:
Before measuring clearance, place the same thick-
ness of shim on both sides to prevent pressure
plate from tilting.
If the clearance is not within the specified range,
select a proper pressure plate.
Standard value:
0.2 Ð 0.6 mm (0.008 Ð 0.024 in)
Allowable limit:
1.6 mm (0.063 in)
G3M0503
Available pressure plates
Part No. Thickness mm (in)
31593AA151
31593AA161
31593AA171
31593AA1813.3 (0.130)
3.7 (0.146)
4.1 (0.161)
4.5 (0.177)
10) Press-fit the ball bearing with ST.
ST 899580100 INSTALLER
G3M0505
101
[W20C0]3-2SERVICE PROCEDURE
20. Transfer Clutch

11) Coat the seal ring with vaseline, and install it
in the seal ring groove of the shaft.
CAUTION:
Do not expand the seal ring excessively when
installing.
ST 899580100 INSTALLER
G3M0493
21. Transfer Valve Body
A: DISASSEMBLY
1) Separate duty solenoid C (transfer) and trans-
fer valve body.
2) Remove the stopper plate and pry out the plug
with a screwdriver. Then extract the spring and
transfer control valve together.
CAUTION:
Be careful not to damage the valve and valve
body.
B3M1183A
(A) Transfer valve body
(B) Return spring
(C) Transfer control valve
(D) Plug
(E) Stopper plate
B: INSPECTION
Check each component for harmful cuts, damage,
or other faults.
C: ASSEMBLY
To assemble, reverse the removal sequence.
NOTE:
Make sure the valve slides smoothly after assem-
bling.
102
3-2[W21A0]SERVICE PROCEDURE
21. Transfer Valve Body

11) Coat the seal ring with vaseline, and install it
in the seal ring groove of the shaft.
CAUTION:
Do not expand the seal ring excessively when
installing.
ST 899580100 INSTALLER
G3M0493
21. Transfer Valve Body
A: DISASSEMBLY
1) Separate duty solenoid C (transfer) and trans-
fer valve body.
2) Remove the stopper plate and pry out the plug
with a screwdriver. Then extract the spring and
transfer control valve together.
CAUTION:
Be careful not to damage the valve and valve
body.
B3M1183A
(A) Transfer valve body
(B) Return spring
(C) Transfer control valve
(D) Plug
(E) Stopper plate
B: INSPECTION
Check each component for harmful cuts, damage,
or other faults.
C: ASSEMBLY
To assemble, reverse the removal sequence.
NOTE:
Make sure the valve slides smoothly after assem-
bling.
102
3-2[W21A0]SERVICE PROCEDURE
21. Transfer Valve Body

22. Transmission Control
Module
A: REMOVAL
1. LHD
1) Disconnect battery ground cable.
G6M0095
2) Remove lower cover and then disconnect con-
nector.
B3M0377A
3) Remove transmission control module.
B3M0443L
(A) Transmission control module
(B) Pedal bracket
4) Disconnect connectors form TCM.
2. RHD
1) Disconnect battery ground cable.
G6M0095
2) Remove lower cover and then disconnect con-
nector.
3) Remove transmission control module.
B3M0445F
(A) Transmission control module
(B) Column shaft
4) Disconnect connectors from transmission con-
trol module.
B: INSTALLATION
1. LHD
1) Connect connectors to TCM.
2) Install TCM to steering support beam.
Tightening torque:
7.4
±2.0 N´m (0.75±0.2 kg-m, 5.4±1.4 ft-lb)
B3M0443L
(A) Transmission control module
(B) Pedal bracket
103
[W22B1]3-2SERVICE PROCEDURE
22. Transmission Control Module

3) Remove TCM from steering support beam.
2. RHD
1) Connect connectors to transmission control
module.
2) Install transmission control module.
Tightening torque:
25
±5 N´m (2.5±0.5 kg-m, 18.1±3.6 ft-lb)
B3M0445F
(A) Transmission control module
(B) Column shaft
3) Installing procedure hereafter is in the reverse
order of removal.
23. Dropping Resistor
A: REMOVAL AND INSTALLATION
1) Disconnect battery ground cable.
G6M0095
2) Remove air intake duct. <Ref. to 2-7 [W1A0].>
3) Disconnect connector from dropping resistor.
4) Remove dropping resistor from bracket.
B3M1408A
5) Installation is in the reverse order of removal.
Tightening torque:
6.4
±0.5 N´m (0.65±0.05 kg-m, 4.7±0.4 ft-lb)
B3M1408A
104
3-2[W22B2]SERVICE PROCEDURE
23. Dropping Resistor

3) Remove TCM from steering support beam.
2. RHD
1) Connect connectors to transmission control
module.
2) Install transmission control module.
Tightening torque:
25
±5 N´m (2.5±0.5 kg-m, 18.1±3.6 ft-lb)
B3M0445F
(A) Transmission control module
(B) Column shaft
3) Installing procedure hereafter is in the reverse
order of removal.
23. Dropping Resistor
A: REMOVAL AND INSTALLATION
1) Disconnect battery ground cable.
G6M0095
2) Remove air intake duct. <Ref. to 2-7 [W1A0].>
3) Disconnect connector from dropping resistor.
4) Remove dropping resistor from bracket.
B3M1408A
5) Installation is in the reverse order of removal.
Tightening torque:
6.4
±0.5 N´m (0.65±0.05 kg-m, 4.7±0.4 ft-lb)
B3M1408A
104
3-2[W22B2]SERVICE PROCEDURE
23. Dropping Resistor

1. Manual Transmission
A: AWD MODEL
B3M0607B
(1) Gear shift knob
(2) Console boot
(3) Boot plate
(4) Gear shift lever
(5) Bush
(6) Spacer
(7) Locking wire
(8) Boot
(9) Snap ring
(10) O-ring(11) Bush (Shift lever)
(12) Cushion rubber
(13) Bush (Stay rear)
(14) Joint
(15) Rod
(16) Bracket
(17) Spring
(18) Washer
(19) Stay
(20) Bush (Stay front)Tightening torque: N´m (kg-m, ft-lb)
T1:
4.4±1.5 (0.45±0.15, 3.3±1.1)
T2:5 (0.51, 3.7)
T3:12±3 (1.2±0.3, 8.7±2.2)
T4:18±5 (1.8±0.5, 13.0±3.6)
T5:24.5±2 (2.50±0.20,
18.07
±1.48)
2
3-3[C1A0]COMPONENT PARTS
1. Manual Transmission

B: FWD MODEL
B3M0606B
(1) Gear shift knob
(2) Console boot
(3) Boot plate
(4) Gear shift lever
(5) Bush
(6) Spacer
(7) Locking wire
(8) Boot
(9) Snap ring(10) O-ring
(11) Bush (Shift lever)
(12) Cushion rubber
(13) Bush (Stay rear)
(14) Joint
(15) Rod
(16) Bracket
(17) Spring
(18) Stay(19) Bush (Stay front)
Tightening torque: N´m (kg-m, ft-lb)
T1:
4.4±1.5 (0.45±0.15, 3.3±1.1)
T2:5 (0.51, 3.7)
T3:12±3 (1.2±0.3, 8.7±2.2)
T4:18±5 (1.8±0.5, 13.0±3.6)
T5:29±5 (3.0±0.5, 21.7±3.6)
3
[C1B0]3-3COMPONENT PARTS
1. Manual Transmission