SUBARU LEGACY 1996 Service Repair Manual

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.
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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.
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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.
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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
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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

G3M0552
9) Position balls
17, checking ball springs
18and gaskets


19into 3-4 and 1-2 rod holes, and install plugs
20.
CAUTION:
Replace gasket with a new one.
G3M0547
10) Installation of speedometer driven gear
21
(1) Install washer and speedometer shaft, and press fit
oil seal with ST.
ST 899824100 or 499827000 PRESS
CAUTION:
Use new oil seal, if it has been removed.
(2) Install vehicle speed sensor 2.
CAUTION:
Use new vehicle speed sensor 2, if it has been
removed.
Tightening torque:
5.9±1.5 N⋅m (60±15 kg-cm, 52±13 in-lb)
(3) Install speedometer driven gear and snap ring.
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3-1SERVICE PROCEDURE
4. Transmission Case

2. COMBINATION OF TRANSMISSION CASE
B3M0356A
Tightening torque: N⋅m (kg-m, ft-lb)
T1: 25 (2.5, 18)
T2: 29±3 (3.0±0.3, 21.7±2.2)
G3M0554
1) Alignment marks/numbers on hypoid gear set
1
The upper number on driven pinion is the match number for
combining it with hypoid driven gear. The lower number is
for shim adjustment. If no lower number is shown, the value
is zero. The number on hypoid driven gear indicates a
number for combination with drive pinion.
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3-1SERVICE PROCEDURE
4. Transmission Case

B3M0064A
2) Adjustment of drive pinion shim
2
(1) Place drive pinion shaft assembly on right hand
transmission main case without shim and tighten bear-
ing mounting bolts.
(2) Inspection and adjustment of ST
NOTE:
Loosen the two bolts and adjust so that the scale indi-
cates 0.5 correctly when the plate end and the scale end
are on the same level.
Tighten the two bolts.
ST 499917500 DRIVE PINION GAUGE ASSY


A: Plate


B: Scale
B3M0065A
(3) Position the ST by inserting the knock pin of ST into
the knock hole in the transmission case.
(4) Slide the drive pinion gauge scale with finger tip
and read the value at the point where it matches with
the end face of drive pinion.


C: Adjust clearance to zero without shim.
(5) The thickness of shim shall be determined by add-
ing the value indicated on drive pinion to the value
indicated on the ST. (Add if the number on drive pinion
is prefixed by + and subtract if the number is prefixed
by.)
ST 499917500 DRIVE PINION GAUGE ASSY
Select one to three shims from the next table for the value
determined as described above and take a shim thickness
which is closest to the said value.
Drive pinion shim
Part No. Thickness mm (in)
32295AA031 0.150 (0.0059)
32295AA041 0.175 (0.0069)
32295AA051 0.200 (0.0079)
32295AA061 0.225 (0.0089)
32295AA071 0.250 (0.0098)
32295AA081 0.275 (0.0108)
32295AA091 0.300 (0.0118)
32295AA101 0.500 (0.0197)
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3-1SERVICE PROCEDURE
4. Transmission Case

G3M0557
3) Install differential assembly
3on left hand transmission
case.
CAUTION:
Be careful not to fold the sealing lip of oil seal.
NOTE:
Wrap the left and right splined sections of axle shaft with
vinyl tape to prevent scratches.
G3M0558
4) Install needle bearing and oil seal onto the front of
transmission main shaft assembly

4, and position in left
side transmission case.
CAUTION:
Wrap clutch splined section with vinyl tape to pre-
vent damage to oil seal.
Apply grease (Unilube #2 or equivalent) to the seal-
ing lip of oil seal.
NOTE:
Align the end face of seal with surface A of left side
transmission main case when installing oil seal.
Be careful not to drop oil seal when installing right side
transmission main case.
Make sure straight pin is positioned in hole in needle
bearing’s outer race.
G3M0575
5) Install drive pinion shaft assembly
5with shims
selected before into transmission case.
NOTE:
Ensure that the knock pin of the case is fitted into the hole
in the bearing outer race.
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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)
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3-1SERVICE PROCEDURE
4. Transmission Case