SUBARU LEGACY 1996 Service Repair Manual

G3M0606
4) If starting torque is not within specified limit, select new
adjusting washer No. 1

2and recheck starting torque.
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)
G3M0606
5) If specified starting torque range cannot be obtained
when a No. 1

2adjusting washer is used, then select a
suitable No. 2

3adjusting washer from those listed in the
following table. Repeat steps 1) through 4) to adjust start-
ing torque.
Starting torque Dimension H Washer No. 2
Low Small Select thicker one.
High Large Select thinner one.
Adjusting washer No. 2
Part No. Thickness mm (in)
803025059 3.850 (0.1516)
803025054 4.000 (0.1575)
803025058 4.150 (0.1634)
6) Recheck that starting torque is within specified range,
then clinch lock nut at four positions.
55
3-1SERVICE PROCEDURE
5. Drive Pinion Assembly (AWD Model)

G3M0628
6. Drive Pinion Assembly (FWD Model)
A: DISASSEMBLY
1) Loosen lock nut using ST1 and ST2.
ST1 499987100 or 499987003 or 899984103 SOCKET
WRENCH (35)
ST2 899884100 HOLDER
NOTE:
Remove caulking before taking off lock nut.
B3M0341A
2) Remove 5th driven gear using a press.
ST 498077000 5TH DRIVEN GEAR REMOVER
G3M0610
3) Remove woodruff key.
4) Remove roller bearing (29 x 74 x 38) and 3rd-4th driven
gear using ST1 and ST2.
ST1 899714110 REMOVER
ST2 499757002 SNAP RING PRESS
G3M0611
5) Remove 2nd driven gear assembly.
6) Remove 3rd-4th driven gear key.
7) Remove 1st driven gear, 2nd gear bushing, and gear &
hub assembly using ST1 and ST2.
Replace gear and hub if necessary. Do not attempt to dis-
assemble if at all possible because they must engage at a
specified point. If they have to be disassembled, mark the
engaging point beforehand.
ST1 499757002 SNAP RING PRESS
ST2 899714110 REMOVER
G3M0632
8) Remove 1st gear bushing, 1st driven gear thrust plate,
and roller bearing (41 x 71 x 23) using ST and press.
ST 498517000 REPLACER
CAUTION:
Replace roller bearing (41 x 71 x 23) with a new one if
this disassembly is performed.
56
3-1SERVICE PROCEDURE
6. Drive Pinion Assembly (FWD Model)

B3M0077A
B: ASSEMBLY
1) Assemble gear and hub assembly.


A: 1st gear side


B: 2nd gear side


C: Flush surface


D: Stepped surface
NOTE:
Use new gear and hub assembly, if gear or hub have
been replaced.
Position open ends of springs 120°apart.
G3M0634
2) Assemble sleeve and hub assembly.
NOTE:
Make sure bent sections of springs on both sides are kept
180°apart and hooked at hub’s holes.
G3M0635
3) Drive roller bearing onto drive pinion shaft and 1st
driven gear thrust washer

1using ST1 and ST2.
ST1 499877000 INSTALLER
ST2 499277100 INSTALLER
CAUTION:
Use new roller bearing, 1st gear thrust washer.
G3M0636
4) Install 1st-2nd driven gear bushing
1onto drive pinion
shaft.
NOTE:
Bushing may be installed with either side up.
ST1 499877000 INSTALLER
ST2 499277100 INSTALLER
57
3-1SERVICE PROCEDURE
6. Drive Pinion Assembly (FWD Model)

5) Measure outside diameter of 1st driven gear bushing to
determine suitable 1st driven gear.
Bushing outside diameter
mm (in)1st driven gear
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
G3M0637
6) Install 1st driven gear, 1st-2nd balk ring and gear and
hub assembly (already assembled in previous step) to
drive pinion shaft by hand.
NOTE:
Align ring groove with insert.
G3M0638
7) Install 1st-2nd driven gear bushing
1to drive pinion
shaft using ST1 and ST2.
ST1 499877000 INSTALLER
ST2 499277100 INSTALLER
G3M0639
8) Install 2nd driven gear
1and 1st-2nd balk ring to drive
pinion shaft by hand.
9) Install key into the groove on drive pinion shaft and
install 3rd-4th driven gear.
NOTE:
Ball bearing may be installed without using the tool. There
should be no problem.
ST 499877000 INSTALLER
58
3-1SERVICE PROCEDURE
6. Drive Pinion Assembly (FWD Model)

G3M0640
10) Install ball bearing (29 x 74 x 38) on drive pinion shaft
with ST.
ST 499277100 INSTALLER
G3M0617
11) Position woodruff key in groove on the rear of drive
pinion shaft. Install 5th driven gear onto drive shaft using
ST and press.
ST 499277100 INSTALLER
CAUTION:
Face 5th driven gear in the correct direction.
Be careful not to dislocate woodruff key while
installing 5th gear.
B3M0353A
G3M0628
12) Install lock washer and tighten lock nut to the specified
torque using ST1 and ST2.
ST1 499987100 or 499987003 or 899984103 SOCKET
WRENCH (35)
ST2 899884100 HOLDER
CAUTION:
Discard old lock nuts, replace with new ones.
Secure lock nut in four places.
Tightening torque:
11 2—124 N⋅m (11.4—12.6 kg-m, 82—91 ft-lb)
59
3-1SERVICE PROCEDURE
6. Drive Pinion Assembly (FWD Model)

B3M0087A
7. Main Shaft Assembly
A: DISASSEMBLY
1) Put vinyl tape around main shaft splines to protect oil
seal from damage. Then pull out oil seal and needle bear-
ing by hand.
2) Remove lock nut from transmission main shaft assem-
bly.
NOTE:
Remove caulking before taking off lock nut.
ST1 498937000 TRANSMISSION HOLDER
ST2 499987003 SOCKET WRENCH (35)
G3M0644
3) Remove insert stopper plate
1, sleeve and hub assem-
bly No. 2, baulk ring

3, 5th drive gear
4, and needle
bearing

5(32 x 36 x 25.7).
G3M0645
4) Using ST1, ST2 and a press, remove:
5th needle bearing inner race

1
5th gear thrust washer
2
Ball bearing
3(25.5 x 65 x 31)
4th gear thrust washer

4
4th drive gear
5
Sleeve and hub assembly
6
Baulk ring
7
4th needle bearing
8
4th needle bearing inner race
9
3rd drive gear
10
ST1 899864100 REMOVER
ST2 899714110 REMOVER
NOTE:
Replace sleeve and hub with new ones. Do not attempt to
disassemble because they must engage at a specified
point. If they should be disassembled, mark engagement
point on splines beforehand.
60
3-1SERVICE PROCEDURE
7. Main Shaft Assembly

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

8. Center Differential (AWD Model)
A: DISASSEMBLY
B3M0288A
1) Remove snap ring
1(Inner-110) using flat bladed
screwdriver.
2) Remove center differential cover

2.
3) Remove snap ring

4and roller bearing
3.
4) Remove viscous coupling

5.
5) Remove needle bearings

6.
6) Remove adjusting washer

7(45x62xt).
7) Remove pinion shaft

8, bevel pinions
9and retainers


10.
8) Remove side gear

11.
9) Remove thrust washer

12.
G3M0662
10) Remove ball bearing
13using ST.
ST 498077300 CENTER DIFFERENTIAL BEARING
REMOVER
CAUTION:
Do not reuse ball bearing.
63
3-1SERVICE PROCEDURE
8. Center Differential (AWD Model)

B3M0337
B: ASSEMBLY
Assembly is in the reverse order of disassembly.
Do the following:
Install thrust washer with chamfered side of inner perim-
eter facing the side gear.
Install adjusting washer with chamfered side of inner
perimeter facing the viscous coupling using ST.
ST 499547300 INSTALLER SET
B3M0095A
1) Selection of snap ring (Inner-110)
(1) After assembling, using a thickness gauge mea-
sure clearance between snap ring

1and center differ-
ential case.
Clearance:
0—0.15 mm (0—0.0059 in)
(2) If the measurement is not within the specification,
select suitable snap ring.
Snap ring (Inner-110)
Part No. Thickness mm (in)
805100061 2.10 (0.0827)
805100062 2.21 (0.0870)
805100063 2.32 (0.0913)
B3M0096A
2) Selection of adjusting washer (Backlash adjustment)
(1) After assembling, set up a ST1 and ST2 to end of
viscous coupling shaft. Move viscous coupling up and
down, and measure backlash in the axial direction.
ST1 498247001 MAGNET BASE
ST2 498247100 DIAL GAUGE
Backlash:
0.62—0.86 mm (0.0244—0.0339 in)
(2) If the measurement is not within the specification,
select suitable washer.
Adjusting washer (45 x 62 x t)
Part No. Thickness mm (in)
803045041 1.60 (0.0630)
803045042 1.80 (0.0709)
803045043 2.00 (0.0787)
803045044 2.20 (0.0866)
803045045 2.40 (0.0945)
64
3-1SERVICE PROCEDURE
8. Center Differential (AWD Model)