shift SUBARU LEGACY 1996 Service Owner's Guide

B: INSTALLATION
1. Install transmission to engine.
2. Install transmission rear crossmember.
3. Take off transmission jack.
4. Tighten nuts which hold lower side of transmission to engine.
5. Tighten bolt which holds right upper side of transmission to
engine.
AT model
6. Install torque converter to drive plate.
7. Remove special tools.
8. Install pitching stopper.
9. Install front drive shafts into transmission.
10. Install stabilizer clamps onto front crossmember.
11. Install gear shift rod and stay.

B










36
2-11SERVICE PROCEDURE
3. Transmission

B
AT model
12. Install shift selector cable to selector lever.
13. Install ATF level gauge guide, and connect ATF cooler hose
to pipe.
AWD model
14. Install propeller shaft.
15. Install exhaust system.
Heat shield cover [AWD]
Rear exhaust pipe [AWD]
Front exhaust pipe
Center exhaust pipe
16. Install transmission connector holder bracket.
AT model
17. Install ATF level gauge.
18. Connect connectors and cables.
19. Install starter.
20. Install air intake duct.
21. Connect battery ground cable.
22. Fill ATF. [AT]
23. Check selector lever operation. [AT]
24. Take off the vehicle from lift arm.
25. Check the vehicle on the road tester. [AT]









37
2-11SERVICE PROCEDURE
3. Transmission

G2M0325
9) Install front drive shafts into transmission.
(1) Lift-up the vehicle.
(2) Install front drive shaft into transmission.
(3) Drive spring pin into chamfered hole of drive shaft.
CAUTION:
Always use a new spring pin.
G2M0324
(4) Install ball joints of lower arm into knuckle arm of
housing, and tighten installing bolts.
Tightening torque:
49±10 N⋅m (5.0±1.0 kg-m, 36±7 ft-lb)
G2M0323
10) Install stabilizer clamps onto front crossmember.
Tightening torque:
25±4 N⋅m (2.5±0.4 kg-m, 18.1±2.9 ft-lb)
G3M0697
11) Install gear shift rod and stay. (MT model)
(1) Install gear shift rod onto transmission.
(2) Install stay onto transmission.
(3) Install spring.
B2M0033A
12) Install shift selector cable onto selector lever. (AT
model)
(1) Install selector cable into selector lever.
(2) Install cable bracket onto body.
NOTE:
Tighten selector cable adjusting and lock nut after check-
ing selector lever operation [step. 24)].
40
2-11SERVICE PROCEDURE
3. Transmission

B: SERVICE DATA
1. EXTENSION (AWD Model)
Snap ring (Inner-72) to ball bearing side clearance
0—0.15 mm (0—0.0059 in)
Snap ring (Inner-72)
Part No. Thickness mm (in)
805172071 1.78 (0.0701)
805172072 1.90 (0.0748)
805172073 2.02 (0.0795)
Snap ring (Outer-30) to ball bearing side clearance
0—0.15 mm (0—0.0059 in)
Snap ring (Outer-30)
Part No. Thickness mm (in)
805030041 1.53 (0.0602)
805030042 1.65 (0.0650)
805030043 1.77 (0.0697)
2. EXTENSION ASSEMBLY (AWD Model)
Thrust washer (52 x 61 x t) to ball bearing side clearance
0.05—0.30 mm (0.0020—0.0118 in)
Thrust washer (52 x 61 x t)
Part No. Thickness mm (in)
803052021 0.50 (0.0197)
803052022 0.75 (0.0295)
803052023 1.00 (0.0394)
3. TRANSFER CASE OR REAR CASE
Neutral position adjustment
Adjustment shim
Part No. Thickness mm (in)
32190AA000 0.15 (0.0059)
32190AA010 0.30 (0.0118)
Reverse accent shaft
Part No. Mark Remarks
32188AA040 1Neutral position is closer to
1st.
32188AA011 No mark or 2 Standard
32188AA050 3Neutral position is closer to
reverse gear.
Reverse check plate adjustment
Reverse check plate
Part No. Mark AngleθRemarks
32189AA000 0 28°Arm stops closer to
5th gear.
32189AA010 1 31°Arm stops closer to
5th gear.
33189AA020 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.
4. REVERSE IDLER GEAR
Adjustment of reverse idler gear position
Reverse idler gear to transmission case (LH) wall clearance
6.0—7.5 mm (0.236—0.295 in)
Reverse shifter lever
Part No. Mark Remarks
32820AA000 0 Further from case wall
32820AA010 No mark Standard
32820AA020 2 Closer to the case wall
After installing a suitable reverse shifter lever, adjust reverse idler
gear to transmission case wall clearance to within 0 to 0.5 mm (0
to 0.020 in) using washers.
Washer (20.5 x 26 x t)
Part No.Thickness
mm (in)Part No.Thickness
mm (in)
803020151 0.4 (0.016) 803020154 1.9 (0.075)
803020152 1.1 (0.043) 803020155 2.3 (0.091)
803020153 1.5 (0.059)
3
3-1SPECIFICATIONS AND SERVICE DATA
1. Manual Transmission and Differential

5. SHIFTER FORK AND ROD
Select suitable shifter forks so that both coupling sleeve and
reverse driven gear are positioned in the center of their synchro-
mesh mechanisms.
1st-2nd shifter fork
Part No. Mark Remarks
32804AA060 1Approach to 1st gear by
0.2 mm (0.008 in)
32804AA070 No mark Standard
32804AA080 3Approach to 2nd gear by
0.2 mm (0.008 in)
3rd-4th shifter fork
Part No. Mark Remarks
32810AA060 1Approach to 4th gear by
0.2 mm (0.008 in)
32810AA070 No mark Standard
32810AA100 3Approach to 3rd gear by
0.2 mm (0.008 in)
5th shifter fork
Part No. Mark Remarks
32812AA200 4Approach to 5th gear by
0.2 mm (0.008 in)
32812AA210 No mark Standard
32812AA220 6Become distant from 5th
gear by 0.2 mm (0.008 in)
Rod end clearance
A: 1st-2nd—3rd-4th
0.5—1.5 mm (0.020—0.059 in)
B: 3rd-4th—5th
0.6—1.4 mm (0.024—0.055 in)
6. TRANSMISSION CASE ASSEMBLY
Drive pinion shim adjustment
Drive pinion shim
Part No.Thickness
mm (in)Part No.Thickness
mm (in)
32295AA0310.150
(0.0059)32295AA0710.250
(0.0098)
32295AA0410.175
(0.0069)32295AA0810.275
(0.0108)
32295AA0510.200
(0.0079)32295AA0910.300
(0.0118)
32295AA0610.225
(0.0089)32295AA1010.500
(0.0197)
Hypoid gear backlash
0.13—0.18 mm (0.0051—0.0071 in)Selection of main shaft rear plate
Main shaft rear plate
Dimension“A”mm (in) Part No. Mark
4.00—4.13 (0.1575—0.1626) 32294AA040 1
3.87—3.99 (0.1524—0.1571) 32294AA050 2
7. DRIVE PINION ASSEMBLY
Preload adjustment of thrust bearing
Starting torque
0.3—0.8 N⋅m(3—8 kg-cm, 2.6—6.9 in-lb)
Adjusting washer No. 1
Part No. Thickness mm (in)
803025051 3.925 (0.1545)
803025052 3.950 (0.1555)
803025053 3.975 (0.1565)
803025054 4.000 (0.1575)
803025055 4.025 (0.1585)
803025056 4.050 (0.1594)
803025057 4.075 (0.1604)
Adjusting washer No. 2
Part No. Thickness mm (in)
803025059 3.850 (0.1516)
803025054 4.000 (0.1575)
803025058 4.150 (0.1634)
Assemble a driven shaft and 1st driven gear that are selected for
the proper radial clearance adjustment.
Driven shaft 1st driven gear
Part No.Diameter A
mm (in)Part No.
32229AA13049.959—49.966
(1.9669—
1.9672)32231AA270
32229AA12049.967—49.975
(1.9672—
1.9675)32231AA260
8. DRIVE PINION ASSEMBLY (FWD Model)
Selection of 1st driven gear:
1st driven gear
Outer diameter of bushing mm (in) Part No.
41.983—41.996 (1.6529—1.6534) 32231AA320
41.968—41.982 (1.6523—1.6528) 32231AA330
41.954—41.967 (1.6517—1.6522) 32231AA340
4
3-1SPECIFICATIONS AND SERVICE DATA
1. Manual Transmission and Differential

1. Transfer Case and Extension (AWD
Model)
B3M0326A

1Transfer cover


2Cover gasket


3Oil seal


4Gasket


5Neutral switch


6Back-up light switch


7Transfer case


8Gasket


9Oil guide


10Ball


11Reverse accent spring


12Gasket


13Plug


14Snap ring (Inner)


15Reverse check plate

16Reverse check spring


17Reverse return spring


18Reverse check cam


19Reverse accent shaft


20O-ring


21Adjusting select shim


22Reverse check sleeve


23Adjusting washer


24Ball bearing


25Transfer driven gear


26Ball bearing


27Oil seal


28Shift bracket


29Extension cover


30Gasket

31Snap ring (Outer-30)


32Gasket


33Ball bearing


34Snap ring (Inner-72)


35Transfer drive gear


36Extension
Tightening torque: N⋅m (kg-m, ft-lb)
T1: 5±1 (0.5±0.1, 3.6±0.7)
T2: 10±1 (1.0±0.1, 7.2±0.7)
T3: 15.7±1.5
(1.6±0.15, 11.6±1.1)
T4: 25±2 (2.5±0.2, 18.1±1.4)
T5: 37±3 (3.8±0.3, 27.5±2.2)
6
3-1COMPONENT PARTS
1. Transfer Case and Extension (AWD Model)

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

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

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