shift SUBARU LEGACY 1996 Service Workshop Manual

CAUTION:
Be careful not to break O-ring when placing shim(s).
Adjustment shim
Part No. Thickness mm (in)
32190AA000 0.15 (0.0059)
32190AA010 0.30 (0.0118)
NOTE:
When shim is removed, the neutral position will move
closer to reverse; when shim is added, the neutral position
will move closer to 1st gear.
If shims alone cannot adjust the clearance, replace
reverse accent shaft and re-adjust.
Reverse accent shaft
Part No. Mark Remarks
32188AA040 1Neutral position is closer to 1st
gear.
32188AA011 No mark or 2 Standard
32188AA050 3Neutral position is closer to
reverse gear.
B3M0054A
4) Reverse check plate adjustment
NOTE:
After assembling and installing rear case, adjust reverse
check plate.
Shift shifter arm to“5th”and then to reverse to see if
reverse checking mechanism operates properly. Also
check to see if arm returns to Neutral when released from
the reverse position. If arm does not return properly,
replace reverse check plate.
Reverse check plate
Part No.

A: No. AngleθRemarks
32189AA000 0 28°Arm stops closer to 5th gear.
32189AA010 1 31°Arm stops closer to 5th gear.
32189AA020 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.
32
3-1SERVICE PROCEDURE
3. Rear Case (FWD Model)

2. TRANSMISSION CASE
B3M0060A

A: Front right hand transmission case
B3M0333A
1) Drive out spring pin
1with ST, and remove 5th shifter
fork

2.
ST 398791700 STRAIGHT PIN REMOVER
2) Remove plugs

3, springs
4and checking balls
5.
35
3-1SERVICE PROCEDURE
4. Transmission Case

B3M0333B
3) Drive out spring pin
6, and pull out 3-4 fork rod
7and
shifter fork

8.
NOTE:
When removing rod, keep other rods in neutral. Also, when
pulling out straight pin, remove it toward inside of case so
that it may not hit against case.
4) Drive out straight pin

9, and pull out 1-2 fork rod
10and
shifter fork

11.
G3M0602
5) Pull out straight pin
12, and remove idler gear shaft
13,
reverse idler gear

14and washer
15.
6) Remove outer snap ring

16, and pull out reverse shifter
rod arm

17from reverse fork rod
18. Then take out ball,
spring and interlock plunger from rod.
And then remove rod.
NOTE:
When pulling out reverse shifter rod arm, be careful not to
let ball pop out of arm.
7) Remove reverse shifter lever

19.
G3M0546
8) Remove differential side retainers using ST.
ST 499787000 WRENCH ASSY
G3M0547
9) Remove outer snap ring
20and pull out speedometer
driven gear

21. Next, remove vehicle speed sensor 2, oil
seal, speedometer shaft

22and washer.
36
3-1SERVICE PROCEDURE
4. Transmission Case

B: ASSEMBLY
1. TRANSMISSION CASE
B3M0061A

A: To right hand transmission case
Tightening torque: N⋅m (kg-m, ft-lb)
T: 19.6±0.1 (2.00±0.015, 14.5±0.1)
B3M0062A
1) Position interlock plungers (5.56 x 19.6), one plunger in
hole between 1-2 and 3-4 fork rod holes, and one plunger
in hole between 3-4 and reverse fork rod holes.


B: Rod holes
G3M0604
2) Install reverse shifter lever
1, reverse idler gear
2and
reverse idler gear shaft

3, and secure with straight pin
4.
NOTE:
Be sure to install reverse idler shaft from the rear side.
37
3-1SERVICE PROCEDURE
4. Transmission Case

3) Install reverse arm fork spring, ball and interlock
plunger (5.56 x 19.6) to reverse fork rod arm

5. Insert
reverse fork rod

6into hole in reverse fork rod arm
5, and
hold it with outer snap ring

7using ST.
ST 399411700 ACCENT BALL INSTALLER
CAUTION:
Apply grease to plunger to prevent it from falling.
4) Position ball

8(7.1438), spring
9and gasket
10in
reverse shifter rod hole, on left side transmission case, and
tighten checking ball plug

11.
CAUTION:
Replace gasket with a new one.
G3M0796
5) Adjustment of reverse idler gear position
(1) Move reverse shifter rod toward REV side. Adjust
clearance between reverse idler gear and transmission
case wall, using reverse shifter lever

1.
Clearance A:
6.0—7.5 mm (0.236—0.295 in)
Reverse shifter lever
Part No. No. Remarks
32820AA000 0 Further from case wall
32820AA010 No mark Standard
32820AA020 2 Closer to case wall
38
3-1SERVICE PROCEDURE
4. Transmission Case

B3M0063
(2) After installing a suitable reverse shifter lever, shift
into neutral. Using a thickness gauge, measure clear-
ance between reverse idler gear and transmission case
wall and adjust with washer(s).
Clearance:
0—0.5 mm (0—0.020 in)
Washer (20.5 x 26 x t)
Part No. Thickness mm (in)
803020151 0.4 (0.016)
803020152 1.1 (0.043)
803020153 1.5 (0.059)
803020154 1.9 (0.075)
803020155 2.3 (0.091)
B3M0333C
6) Installation of 1-2 shifter fork
12and rod
13
(1) Install 1-2 fork rod into 1-2 shifter fork via the hole
on the rear of transmission case.
(2) Align the holes in rod and fork, and drive straight
pin (6 x 22) into these holes using ST.
ST 398791700 STRAIGHT PIN REMOVER
NOTE:
Set other rods to neutral.
Make sure interlock plunger (5.56 x 19.6) is on the 3-4
fork rod side.
7) Installation of 3-4 shifter fork

14and rod
15
(1) Install interlock plunger (3 x 11.9) onto 3-4 fork rod.
CAUTION:
Apply a coat of grease to plunger to prevent it from
falling.
(2) Install 3-4 fork rod into 3-4 shifter fork via the hole
on the rear of transmission case.
(3) Align the holes in rod and fork, and drive straight
pin (6 x 22) into these holes.
ST 398791700 STRAIGHT PIN REMOVER
NOTE:
Set reverse fork rod to neutral.
Make sure interlock plunger (installed before) is on the
reverse fork rod side.
8) Install 5th shifter fork

16onto the rear of reverse fork rod


6. Align holes in the two parts and drive straight pin into
place.
ST 398791700 STRAIGHT PIN REMOVER
39
3-1SERVICE PROCEDURE
4. Transmission Case

B3M0066A
B3M0067A
B3M0068A
6) Selection of suitable 1st-2nd, 3rd-4th and 5th shifter
fork
Set transmission main shaft assembly and drive pinion
shaft assembly in position (so there is no clearance
between the two when moved all the way to the front).
Select suitable 1st-2nd, 3rd-4th and 5th shifter fork so that
coupling sleeve and reverse driven gear are positioned in
the center of their synchronizing mechanisms.
Clearance mm (in)
1st driven gear

Ato reverse driven gear
B
a: 9.5 (0.374)
2nd driven gear

Cto reverse driven gear
B
b: 9.5 (0.374)
3rd drive gear

Dto coupling sleeve
E
c: 9.3 (0.366)
4th drive gear

Fto coupling sleeve
E
d: 9.3 (0.366)
5th drive gear

Gto coupling sleeve
H
e: 9.3 (0.366)
1st-2nd shifter fork
Part No. No. Remarks
32804AA060 1Approach to 1st gear by
0.2 mm (0.008 in)
32804AA070No
markStandard
32804AA080 3Approach to 2nd gear by
0.2 mm (0.008 in)
3rd-4th shifter fork
Part No. No. Remarks
32810AA060 1Approach to 4th gear by
0.2 mm (0.008 in)
32810AA070No
markStandard
32810AA100 3Approach to 3rd gear by
0.2 mm (0.008 in)
5th shifter fork
Part No. No. Remarks
32812AA200 4Approach to 5th gear by
0.2 mm (0.008 in)
32812AA210No
markStandard
32812AA220 5Become distant from 5th gear
by 0.2 mm (0.008 in)
G3M0798
7) Inspection of rod end clearance
Measure rod end clearances A and B. If any clearance is
not within specifications, replace rod or fork as required.
A: 1st-2nd to 3rd-4th 0.5—1.5 mm (0.020—0.059 in)
B: 3rd-4th to 5th 0.6—1.4 mm (0.024—0.055 in)
44
3-1SERVICE PROCEDURE
4. Transmission Case

G3M0564
(1) Place the transmission with case left side facing
downward and put ST1 on bearing cup.
(2) Screw retainer assembly into left case from the bot-
tom with ST2. Fit ST3 on the transmission main shaft.
Shift gear into 4th or 5th and turn the shaft several
times. Screw in the retainer while turning ST3 until a
slight resistance is felt on ST2.
This is the contact point of hypoid gear and drive pin-
ion shaft. Repeat the above sequence several times to
ensure the contact point.
ST1 399780104 WEIGHT
ST2 499787000 WRENCH ASSY
ST3 499927100 HANDLE
B3M0340A
(3) Remove weight and screw in retainer without
O-ring on the upper side and stop at the point where
slight resistance is felt.
NOTE:
At this point, the backlash between the hypoid gear and
drive pinion shaft is zero.
ST 499787000 WRENCH ASSY
B3M0334A
(4) Fit lock plate
11. Loosen the retainer on the lower
side by 1-1/2 notches of lock plate and turn in the
retainer on the upper side by the same amount in order
to obtain the backlash.
NOTE:
The notch on the lock plate moves by 1/2 notch if the plate
is turned upside down.
(5) Turn in the retainer on the upper side additionally
by 1 notch in order to apply preload on taper roller
bearing.
(6) Tighten temporarily both the upper and lower lock
plates and mark both holder and lock plate for later
readjustment.
(7) Turn transmission main shaft several times while
tapping around retainer lightly with plastic hammer.
(8) Set ST1 and ST2. Insert the needle through trans-
mission oil drain plug hole so that the needle comes in
contact with the tooth surface at a right angle and check
the backlash.
46
3-1SERVICE PROCEDURE
4. Transmission Case

B3M0088A
B: ASSEMBLY
1) Assemble sleeve and hub assembly for 3rd-4th and, 5th
and high-low synchronizing.
NOTE:
Position open ends of spring 120°apart.


A: Two holes for discrimination (3rd-4th hub)
B3M0089A

B: One hole for discrimination (5th hub)
2) Install 3rd drive gear, baulk ring, and sleeve and hub
assembly for 3rd-4th needle bearing (32 x 36 x 25.7) on
transmission main shaft.
NOTE:
Align groove in baulk ring with shifting insert.
G3M0648
3) Install 4th needle bearing race
1onto transmission
main shaft using ST1, ST2 and a press.
ST1 899714110 REMOVER
ST2 499877000 RACE 4-5 INSTALLER
B3M0090A
4) Install baulk ring, needle bearing (32 x 30 x 25.7), 4th
drive gear and 4th gear thrust washer to transmission main
shaft.
NOTE:
Face thrust washer in the correct direction.


a: Groove


b: 4th gear side
61
3-1SERVICE PROCEDURE
7. Main Shaft Assembly

G3M0650
5) Drive ball bearing
1onto the rear section of transmis-
sion main shaft using ST1, ST2 and a press.
ST1 899714110 REMOVER
ST2 499877000 RACE 4-5 INSTALLER
B3M0091A
6) Using the same tools as in step 5) above, install the
following parts onto the rear section of transmission main
shaft.
5th gear thrust washer
NOTE:
Face thrust washer in the correct direction.


c: Face this surface to 5th gear side.
ST1 899714110 REMOVER
ST2 499877000 RACE 4-5 INSTALLER
5th needle bearing race
B3M0092A
7) Install the following parts to the rear section of transmis-
sion main shaft.
Needle bearing (32 x 36 x 25.7)
5th drive gear
Baulk ring
Sleeve

Aand hub assembly
Insert stopper plate

B
Lock washer
C(22x38x2)
Tighten lock nuts

D(22 x 13) to the specified torque
using ST1 and ST2.
ST1 499987003 SOCKET WRENCH (35)
ST2 498937000 TRANSMISSION HOLDER
NOTE:
Align groove

Ein baulk ring with shifting insert.
Be sure to fit pawl

Fof insert stopper plate into 4 mm
(0.16 in) dia. hole in the boss section of synchronizer hub.
Secure lock nuts in two places after tightening.
Tightening torque:
118±6 N⋅m (12.0±0.6 kg-m, 86.8±4.3 ft-lb)
62
3-1SERVICE PROCEDURE
7. Main Shaft Assembly