SUBARU LEGACY 1995 Service Repair Manual

G3M0484
9) Install the one-way clutch (1-2) and plate, and secure
with the snap ring.
NOTE:
Set the inner race. Make sure that the forward clutch is free
in the clockwise direction and locked in the counterclock-
wise direction, as viewed from the front of the vehicle.
G3M0911
12. One-way Clutch Outer Race
A: DISASSEMBLY
Remove the snap ring. Then remove the one-way clutch
(3-4).
B: INSPECTION
Check the sliding surface and one-way clutch (3-4) for any
harmful cuts, damage, or other faults.
G3M0486
C: ASSEMBLY
1) Assemble the one-way clutch (3-4), and secure with the
snap ring.
NOTE:
Pay attention to the orientation of the one-way clutch (3-4).
2) Assemble the rear internal gear, and secure the outer
race. Make sure that the internal gear is locked in the
clockwise direction, and free to rotate in the counterclock-
wise direction.
105
3-2SERVICE PROCEDURE
11. Forward Clutch Drum - 12. One-Way Clutch Outer Race

G3M0484
9) Install the one-way clutch (1-2) and plate, and secure
with the snap ring.
NOTE:
Set the inner race. Make sure that the forward clutch is free
in the clockwise direction and locked in the counterclock-
wise direction, as viewed from the front of the vehicle.
G3M0911
12. One-way Clutch Outer Race
A: DISASSEMBLY
Remove the snap ring. Then remove the one-way clutch
(3-4).
B: INSPECTION
Check the sliding surface and one-way clutch (3-4) for any
harmful cuts, damage, or other faults.
G3M0486
C: ASSEMBLY
1) Assemble the one-way clutch (3-4), and secure with the
snap ring.
NOTE:
Pay attention to the orientation of the one-way clutch (3-4).
2) Assemble the rear internal gear, and secure the outer
race. Make sure that the internal gear is locked in the
clockwise direction, and free to rotate in the counterclock-
wise direction.
105
3-2SERVICE PROCEDURE
11. Forward Clutch Drum - 12. One-Way Clutch Outer Race

B3M0407A
13. Servo Piston

1Band servo piston stem


2Spring


3Lathe cut seal ring


4Band servo piston (1-2)


5Lathe cut seal ring


6O-ring


7Band servo retainer


8O-ring


9Spring


10Retainer


11Snap ring


12Lathe cut seal ring


13Band servo piston (3-4)


14O-ring


15O.D. servo retainer


16Snap ring


17Washer
A: DISASSEMBLY
1) Remove the spring.
2) Remove the band servo piston (3-4).
3) While compressing the retainer from above, remove the
snap ring. Then remove the retainer, spring and stem.
4) Take out the band servo piston (1-2).
B: INSPECTION
1) Check each component for harmful cuts, damage, or
other faults.
2) Check the O-ring and lathe cut ring for damage.
C: ASSEMBLY
1) Install the band servo piston (1-2) to the retainer, and
insert the stem.
2) Put the spring and retainer on the piston. Fit the snap
ring securely while compressing the spring.
3) Install the band servo piston (3-4).
4) Install the spring securely to the band servo piston
(1-2).
CAUTION:
Many different O-rings and lathe cut rings are used.
Be careful not to confuse them when installing.
Be careful not to damage O-rings and lathe cut
rings.
106
3-2SERVICE PROCEDURE
13. Servo Piston

G3M0488
14. Differential Case Assembly
A: DISASSEMBLY
1) Using a press and ST, remove the taper roller bearing.
ST 498077000 REMOVER
CAUTION:
Be careful not to damage the speedometer drive gear.
G3M0489
2) Secure the case in a vise and remove the crown gear
tightening bolts, then separate the crown gear, case (RH)
and case (LH).
G3M0490
3) Pull out the straight pin and shaft, and remove the dif-
ferential bevel gear, washer, and differential bevel pinion.
B: INSPECTION
Check each component for harmful cuts, damage and
other faults.
G3M0490
C: ASSEMBLY
1) Install the washer, differential bevel gear and differen-
tial bevel pinion in the differential case (RH). Insert the
pinion shaft, and fit the straight pin.
NOTE:
Install straight pin from reverse direction.
107
3-2SERVICE PROCEDURE
14. Differential Case Assembly

G3M0489
2) Install the washer and differential bevel gear to the dif-
ferential case (LH). Then put the case over the differential
case (RH), and connect both cases.
3) Install the crown gear and secure by tightening the bolt.
Standard tightening torque:
62±5 N⋅m (6.3±0.5 kg-m, 45.6±3.6 ft-lb)
G3M0491
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
Standard value:
0.13—0.18 mm (0.0051—0.0071 in)
NOTE:
Measure the backlash by applying a pinion tooth between
two bevel gear teeth.
G3M0492
5) Install the speedometer drive gear. Then force-fit the
taper roller bearing with a press and ST.
ST 398487700 DRIFT
CAUTION:
Be sure to position correctly the locking end of the
speedometer drive gear.
108
3-2SERVICE PROCEDURE
14. Differential Case Assembly

G3M0493
15. Transfer Clutch
A: DISASSEMBLY
1) Remove the seal ring.
CAUTION:
Be careful not to damage the seal ring.
G3M0494
2) Using a press and ST, remove the ball bearing.
ST 498077000 REMOVER
CAUTION:
Do not reuse the bearing.
G3M0495
3) Remove the snap ring, and take out the pressure plate,
drive plates, and driven plates.
G3M0496
4) Remove the snap ring with ST1, ST2 and ST3, and take
out the spring retainer.
ST1 399893600 PLIERS
ST2 398673600 COMPRESSOR
ST3 498627000 SEAT
G3M0497
5) Apply compressed air to the rear drive shaft to remove
the piston.
109
3-2SERVICE PROCEDURE
15. Transfer Clutch

B: INSPECTION
1) Check the drive plate facing for wear and damage.
2) Check the snap ring for wear, return spring for perma-
nent set and breakage, and spring retainer for deformation.
3) Check the lathe cut ring for damage.
G3M0498
C: ASSEMBLY
1) Install the lathe cut seal ring to the I.D./O.D. of the
transfer clutch piston.
G3M0499
2) Install piston.
(1) Connect piston to rear drive shaft (until it reaches
hole in valve body).
(2) Install spring retainer to piston.
(3) Using ST1, ST2 and ST3, attach transfer piston
seal to ST2.
ST1 499247400 INSTALLER
ST2 499257400 PISTON GUIDE
ST3 498267400 TABLE
CAUTION:
Be careful not to tilt transfer piston seal.
G3M0500
(4) Place ST3 onto rear drive shaft so that spring can
be inserted into hole in transfer piston seal.
(5) Attach ST2 to rear drive shaft. Using ST1, press
into place.
ST1 499247400 INSTALLER
ST2 499257300 SNAP RING OUTER GUIDE
ST3 499257400 PISTON GUIDE
CAUTION:
Do not allow lip of transfer piston seal to fold back.
11 0
3-2SERVICE PROCEDURE
15. Transfer Clutch

G3M0501
3) Install the driven plates, drive plates, and pressure
plate, and secure with a snap ring with ST1, ST2 and a
press.
ST1 398673600 COMPRESSOR
ST2 498627000 SEAT
G3M0502
4) Apply compressed air to see if the assembled parts
move smoothly.
G3M0503
5) Check the clearance.
Standard value:
0.2—0.6 mm (0.008—0.024 in)
Allowable limit:
1.6 mm (0.063 in)
If the clearance is not within the specified range, select a
proper pressure plate.
NOTE:
Before measuring clearance, place the same thickness of
shim on both sides to prevent pressure plate from tilting.
Available pressure platesPart No. Thickness mm (in)
31593AA151
31593AA161
31593AA171
31593AA1813.3 (0.130)
3.7 (0.146)
4.1 (0.161)
4.5 (0.177)
G3M0505
6) Press-fit the ball bearing with ST.
ST 899580100 INSTALLER
111
3-2SERVICE PROCEDURE
15. Transfer Clutch

G3M0505
7) 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 install-
ing.
ST 899580100 INSTALLER
G3M0913
16. Transfer Valve Body
A: DISASSEMBLY
1) Remove the plate. Then remove the spring and pilot
valve together.
2) Remove the straight pin and pry out the plug with a
screwdriver. Then extract the spring and transfer clutch
valve together.
CAUTION:
Be careful not to damage the valve and valve body.
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 assembling.
11 2
3-2SERVICE PROCEDURE
15. Transfer Clutch - 16. Transfer Valve Body

G3M0505
7) 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 install-
ing.
ST 899580100 INSTALLER
G3M0913
16. Transfer Valve Body
A: DISASSEMBLY
1) Remove the plate. Then remove the spring and pilot
valve together.
2) Remove the straight pin and pry out the plug with a
screwdriver. Then extract the spring and transfer clutch
valve together.
CAUTION:
Be careful not to damage the valve and valve body.
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 assembling.
11 2
3-2SERVICE PROCEDURE
15. Transfer Clutch - 16. Transfer Valve Body