SUBARU LEGACY 1999 Service Repair Manual

1. Propeller Shaft
A: SPECIFICATIONS
Front propeller shaft Joint-to-joint length: L1mm (in)AT 693 (27.28)
MT 634 (24.96)
Rear propeller shaft Joint-to-joint
length: L
2mm (in)768 (30.24)
Outside dia. of tube mm (in)D
163.5 (2.500)
D
257.0 (2.244)
B3M0851A
2
3-4[S1A0]SPECIFICATIONS AND SERVICE DATA
1. Propeller Shaft

2. Rear Differential
A: SPECIFICATIONS
Type of gearHypoid
MT AT
2200 cc 2500 cc 2200 cc 2500 cc
Gear ratio (Number of gear teeth) 3.900 (39/10) 4.111 (37/9) 4.111 (37/9) 4.444 (40/9)
Oil capacity 0.8(0.8 US qt, 0.7 Imp qt)
Rear differential gear oil GL-5
B: IDENTIFICATION
When replacing a rear differential assembly, select
the correct one according to the following table.
CAUTION:
Using the different rear differential assembly
causes the drive line and tires to ªdragº or emit
abnormal noise when AWD is selected.
H3M1662A
Gear ratio Stamp or label on rear differential
2200 cc MT 3.900
B3M0124
2200 cc AT 4.111
H3M1159
3
[S2B0]3-4SPECIFICATIONS AND SERVICE DATA
2. Rear Differential

Gear ratio Stamp or label on rear differential
2500 cc MT 4.111
B3M0127
2500 cc AT 4.444
B3M0421
C: ADJUSTING PARTS
1. REAR DIFFERENTIAL (T-TYPE)
Front and rear bearing preload at com-
panion flange bolt holeNew bearing19.6 Ð 28.4 N
(2.0 Ð 2.9 kg, 4.4 Ð6.4 lb)
Used bearing8.34 Ð 16.67 N
(0.85 Ð 1.70 kg, 1.87 Ð 3.75 lb)
Preload adjusting spacerPart No. Length
383695201 56.2 mm (2.213 in)
383695202 56.4 mm (2.220 in)
383695203 56.6 mm (2.228 in)
383695204 56.8 mm (2.236 in)
383695205 57.0 mm (2.244 in)
383695206 57.2 mm (2.252 in)
Preload adjusting washerPart No. Thickness
383705200 2.59 mm (0.1020 in)
383715200 2.57 mm (0.1012 in)
383725200 2.55 mm (0.1004 in)
383735200 2.53 mm (0.0996 in)
383745200 2.51 mm (0.0988 in)
383755200 2.49 mm (0.0980 in)
383765200 2.47 mm (0.0972 in)
383775200 2.45 mm (0.0965 in)
383785200 2.43 mm (0.0957 in)
383795200 2.41 mm (0.0949 in)
383805200 2.39 mm (0.0941 in)
383815200 2.37 mm (0.0933 in)
383825200 2.35 mm (0.0925 in)
383835200 2.33 mm (0.0917 in)
383845200 2.31 mm (0.0909 in)
4
3-4[S2C1]SPECIFICATIONS AND SERVICE DATA
2. Rear Differential

Pinion height adjusting shimPart No. Thickness
383495200 3.09 mm (0.1217 in)
383505200 3.12 mm (0.1228 in)
383515200 3.15 mm (0.1240 in)
383525200 3.18 mm (0.1252 in)
383535200 3.21 mm (0.1264 in)
383545200 3.24 mm (0.1276 in)
383555200 3.27 mm (0.1287 in)
383565200 3.30 mm (0.1299 in)
383575200 3.33 mm (0.1311 in)
383585200 3.36 mm (0.1323 in)
383595200 3.39 mm (0.1335 in)
383605200 3.42 mm (0.1346 in)
383615200 3.45 mm (0.1358 in)
383625200 3.48 mm (0.1370 in)
383635200 3.51 mm (0.1382 in)
383645200 3.54 mm (0.1394 in)
383655200 3.57 mm (0.1406 in)
383665200 3.60 mm (0.1417 in)
383675200 3.63 mm (0.1429 in)
383685200 3.66 mm (0.1441 in)
Side gear backlash Ð 0.10 Ð 0.20 mm (0.0039 Ð 0.0079 in)
Side gear thrust washerPart No. Thickness
383445201 0.75 Ð 0.80 mm (0.0295 Ð 0.0315 in)
383445202 0.80 Ð 0.85 mm (0.0315 Ð 0.0335 in)
383445203 0.85 Ð 0.90 mm (0.0335 Ð 0.0354 in)
Side bearing standard width Ð 20.00 mm (0.7874 in)
Side bearing retainer shimPart No. Thickness
383475201 0.20 mm (0.0079 in)
383475202 0.25 mm (0.0098 in)
383475203 0.30 mm (0.0118 in)
383475204 0.40 mm (0.0157 in)
383475205 0.50 mm (0.0197 in)
Crown gear to drive pinion backlash
Limit0.10 Ð 0.20 mm (0.0039 Ð 0.0079 in)
Crown gear runout on its back surface 0.05 mm (0.0020 in)
Oil capacity0.8(0.8 US qt, 0.7 Imp qt)
2. REAR DIFFERENTIAL (VA-TYPE)
Front and rear bearing preload at
companion flange bolt holeNew bearing12.7 Ð 32.4 N
(1.3 Ð 3.3 kg, 2.9 Ð 7.3 lb)
Preload adjusting spacerPart No. Length mm (in)
32288AA040
32288AA050
31454AA100
32288AA060
31454AA110
32288AA070
31454AA120
32288AA080
32288AA09052.3 (2.059)
52.5 (2.067)
52.6 (2.071)
52.7 (2.075)
52.8 (2.079)
52.9 (2.083)
53.0 (2.087)
53.1 (2.091)
53.3 (2.098)
5
[S2C2]3-4SPECIFICATIONS AND SERVICE DATA
2. Rear Differential

Preload adjusting washerPart No. Thickness mm (in)
38336AA000
38336AA120
38336AA010
38336AA130
38336AA020
38336AA140
38336AA030
38336AA150
38336AA040
38336AA160
38336AA050
38336AA170
38336AA060
38336AA180
38336AA070
38336AA190
38336AA080
38336AA200
38336AA090
38336AA210
38336AA100
38336AA220
38336AA1101.500 (0.0591)
1.513 (0.0596)
1.525 (0.0600)
1.538 (0.0606)
1.550 (0.0610)
1.563 (0.0615)
1.575 (0.0620)
1.588 (0.0625)
1.600 (0.0630)
1.613 (0.0635)
1.625 (0.0640)
1.638 (0.0645)
1.650 (0.0650)
1.663 (0.0655)
1.675 (0.0659)
1.688 (0.0665)
1.700 (0.0669)
1.713 (0.0674)
1.725 (0.0679)
1.738 (0.0684)
1.750 (0.0689)
1.763 (0.0694)
1.775 (0.0699)
Pinion height adjusting shimPart No. Thickness mm (in)
32295AA200
32295AA210
32295AA220
32295AA230
32295AA240
32295AA2500.150 (0.0059)
0.175 (0.0069)
0.200 (0.0079)
0.225 (0.0089)
0.250 (0.0098)
0.275 (0.0108)
Side gear backlash 0.05 Ð 0.15 mm (0.0020 Ð 0.0059 in)
Side gear thrust washerPart No. Thickness mm (in)
803135011
803135012
803135013
803135014
8031350150.925 Ð 0.950 (0.0364 Ð 0.0374)
0.950 Ð 0.975 (0.0374 Ð 0.0384)
0.975 Ð 1.000 (0.0384 Ð 0.0394)
1.000 Ð 1.025 (0.0394 Ð 0.0404)
1.025 Ð 1.050 (0.0404 Ð 0.0413)
Crown gear to drive pinion backlash
Limit0.10 Ð 0.15 (0.0039 Ð 0.0059)
Crown gear runout on its back surface 0.05 (0.0020)
Oil capacity0.8(0.8 US qt, 0.7 Imp qt)
D: REAR DIFFERENTIAL GEAR OIL
IRecommended oil
CAUTION:
Each oil manufacturer has its base oil and addi-
tives. Thus, do not mix two or more brands.
H3M1272A
6
3-4[S2D0]SPECIFICATIONS AND SERVICE DATA
2. Rear Differential

MEMO:
7
[S2D0]3-4SPECIFICATIONS AND SERVICE DATA
2. Rear Differential

1. Propeller Shaft
B3M0852A
(1) Propeller shaft
(2) Rear differential (VA-type)
(3) Rear differential (T-type)Tightening torque: N´m (kg-m, ft-lb)
T1:
31±8 (3.2±0.8, 23.1±5.8)
T2:52±5 (5.3±0.5, 38.3±3.6)
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3-4[C100]COMPONENT PARTS
1. Propeller Shaft

2. Rear Differential Assembly
A: T-TYPE
B3M0130C
(1) Pinion crown gear set
(2) Pinion height adjusting washer
(3) Rear bearing
(4) Bearing preload adjusting spacer
(5) Bearing preload adjusting
washer
(6) Differential carrier
(7) Front bearing
(8) Spacer
(9) Pilot bearing
(10) Front oil seal
(11) Companion flange
(12) Self-locking nut
(13) Side bearing(14) O-ring
(15) Side bearing retainer shim
(16) Side bearing retainer
(17) Side oil seal
(18) Side gear thrust washer
(19) Side gear
(20) Pinion mate gear
(21) Pinion mate gear washer
(22) Pinion shaft lock pin
(23) Circlip
(24) Pinion mate shaft
(25) Air breather cap
(26) Stud bolt
(27) Oil filler plug(28) Oil drain plug
(29) Rear cover
(30) Differential case
Tightening torque: N´m (kg-m, ft-lb)
T1:
10.3±1.5 (1.05±0.15, 7.6±1.1)
T2:29.4±4.9 (3.00±0.50, 21.7±3.6)
T3:44.1±3.9 (4.50±0.40, 32.5±2.9)
T4:103.0±9.8 (10.50±1.00,
75.9
±7.2)
T5:181.4±14.7 (18.50±1.50,
133.8
±10.8)
9
[C2A0]3-4COMPONENT PARTS
2. Rear Differential Assembly

B: VA-TYPE
H3M1663A
(1) Pinion crown gear set
(2) Pinion height adjusting shim
(3) Rear bearing
(4) Bearing preload adjusting spacer
(5) Bearing preload adjusting
washer
(6) Differential carrier
(7) Front bearing
(8) Collar
(9) Pilot bearing
(10) Front oil seal
(11) Companion flange
(12) Self-locking nut(13) Lock plate
(14) Side bearing
(15) O-ring
(16) Axle shaft holder
(17) Side oil seal
(18) Side gear thrust washer
(19) Side gear
(20) Pinion mate gear
(21) Pinion shaft lock pin
(22) Differential case
(23) Pinion mate shaft
(24) Air breather cap
(25) Stud bolt(26) Gasket
(27) Oil filler plug
(28) Oil drain plug
(29) Rear cover
Tightening torque: N´m (kg-m, ft-lb)
T1:
25±3 (2.5±0.3, 18.1±2.2)
T2:25±2 (2.5±0.2, 18.1±1.4)
T3:34±4 (3.5±0.4, 25.3±2.9)
T4:62±5 (6.3±0.5, 45.6±3.6)
T5:188±26 (19.2±2.7, 139±20)
10
3-4[C2B0]COMPONENT PARTS
2. Rear Differential Assembly

3. Rear Differential Mounting System
B3M0517C
(1) Plate
(2) Crossmember
(3) Rear bushing
(4) Differential mount lower bracket
(5) Differential mount bracket (OUT-
BACK model)
(6) Differential mount bracket
(7) Boss (OUTBACK model)
(8) Stopper (OUTBACK model)(9) Stopper
(10) Front bushing
(11) Dynamic damper (2500 cc MT
model)
(12) Differential mount front cover
(13) Differential front memberTightening torque: N´m (kg-m, ft-lb)
T1:
20±5 (2.0±0.5, 14.5±3.6)
T2:32±8 (3.3±0.8, 23.9±5.8)
T3:64±8 (6.5±0.8, 47.0±5.8)
T4:69±8 (7.0±0.8, 50.6±5.8)
T5:69±10 (7.0±1.0, 51.0±7.2)
T6:88±10 (9.0±1.0, 65.0±7.2)
T7:98±10 (10.0±1.0, 72.0±7.2)
11
[C300]3-4COMPONENT PARTS
3. Rear Differential Mounting System