SUBARU LEGACY 1996 Service Repair Manual

G3M0031
5) Lightly tap the head of front propeller shaft with a cop-
per hammer until center bearing is removed.
CAUTION:
Be careful not to damage the thread portion.
D: INSPECTION
NOTE:
Do not disassemble propeller shaft. Check the following
and replace if necessary.
1) Tube surfaces for dents or cracks
2) Splines for deformation or abnormal wear
3) Joints for non-smooth operation or abnormal noise
4) Center bearing for free play, noise or non-smooth
operation
5) Oil seals for abnormal wear or damage
6) Center bearing for breakage
G3M0030
E: ASSEMBLY
1) Install center bearing onto front propeller shaft.
2) Align marks and install companion flange.
G3M0029
3) Tighten stake nut until center bearing is set in position.
CAUTION:
Be sure to install new stake nut.
Tightening torque:
270±25 N⋅m (27.5±2.5 kg-m, 199±18 ft-lb)
NOTE:
Stake the nut after tightening.
12
3-4SERVICE PROCEDURE
1. Propeller Shaft

G3M0027
4) Align matching marks and connect front and rear pro-
peller shafts.
Tightening torque:
27.9±4.4 N⋅m (2.85±0.45 kg-m, 20.6±3.3 ft-lb)
G3M0024
F: INSTALLATION
1) Insert sleeve yoke into transmission and attach center
bearing to vehicle body.
Tightening torque:
52±5 N⋅m (5.3±0.5 kg-m, 38.3±3.6 ft-lb)
G3M0782
2) Align matching marks and connect flange yoke and rear
differential.
Tightening torque:
31±8 N⋅m (3.2±0.8 kg-m, 23.1±5.8 ft-lb)
G3M0022
3) Install differential mount front cover.
Tightening torque:
88±10 N⋅m (9.0±1.0 kg-m, 65±7 ft-lb)
G3M0021
4) Install front exhaust cover.
5) Install rear exhaust pipe and muffler.
13
3-4SERVICE PROCEDURE
1. Propeller Shaft

2. Rear Differential
A: ON-CAR SERVICE
1. FRONT OIL SEAL
1) Disconnect ground cable from battery.
2) Move selector lever or gear shift lever to“N”.
3) Release the parking brake.
B3M0316A
4) Remove oil drain plug, and drain gear oil.
G3M0024
5) Jack-up rear wheels and support the vehicle body with
sturdy racks.
6) Remove propeller shaft from body. [W1B0].>
CAUTION:
Wrap metal parts with a cloth or rubber material to
prevent damage from adjacent metal parts.
G3M0034
7) Remove self-locking nut while holding companion
flange with ST.
ST 498427200 FLANGE WRENCH
G3M0035
8) Extract companion flange with a puller.
14
3-4SERVICE PROCEDURE
2. Rear Differential

G3M0036
9) Remove oil seal using ST.
ST 499705401 PULLER ASSY
G3M0037
10) Fit a new oil seal using ST.
ST 498447120 OIL SEAL INSTALLER
G3M0034
11) Install companion flange.
12) Tighten self-locking nut within the specified torque
range so that the turning resistance of companion flange
becomes the same as that before replacing oil seal.
ST 498427200 FLANGE WRENCH
CAUTION:
Use a new self-locking nut.
Tightening torque:
181.4±14.7 N⋅m (18.50±1.50 kg-m, 133.8±10.8 ft-lb)
13) Reassembling procedure hereafter is the reverse of
the disassembling.
15
3-4SERVICE PROCEDURE
2. Rear Differential

2. SIDE OIL SEAL
1) Disconnect ground cable from battery.
2) Move selector lever or gear shift lever to“N”.
3) Release the parking brake.
4) Loosen both wheel nuts.
5) Jack-up the vehicle and support it with rigid racks.
6) Remove wheels.
7) Remove rear exhaust pipe and muffler.

G3M0038
8) Remove the DOJ of rear drive shaft from rear differen-
tial.
(1) Remove the A.B.S. sensor cable clamp and park-
ing brake cable clamp from bracket.
G3M0039
(2) Remove the A.B.S. sensor cable clamp from the
trailing link.
G3M0040
(3) Remove the A.B.S. sensor cable clamp and park-
ing brake cable guide from the trailing link.
G3M0041
(4) Remove the rear stabilizer link.
16
3-4SERVICE PROCEDURE
2. Rear Differential

G3M0042
(5) Remove the bolts which secure the trailing link to
the rear housing.
G3M0043
(6) Remove the bolts which secure the front and rear
lateral link to the rear housing.
G3M1020
(7) Remove crossmember reinforcement lower (AWD
Sedan only).
(8) Remove the DOJ from the rear differential by using
ST.
ST 208099PA100 DRIVE SHAFT REMOVER
G3M1021
CAUTION:
When removing the DOJ from the rear differential, fit
tire lever to the bolt as shown in figure so as not to
damage the side bearing retainer.
G3M1022
9) Secure rear drive shaft to rear crossmember using wire.
17
3-4SERVICE PROCEDURE
2. Rear Differential

G3M1023
10) Remove side oil seal with ST.
ST 398527700 PULLER ASSY
G3M1024
11) Drive in a new side oil seal with ST.
CAUTION:
Apply chassis grease between the oil seal lips.
ST 398437700 DRIFT
G3M1025
12) Insert the DOJ into rear differential.
(1) Install ST to rear differential.
ST 28099PA090 SIDE OIL SEAL PROTECTOR
G3M1026
(2) Insert the spline shaft until the spline portion is
inside the side oil seal.
(3) Remove ST.
ST 28099PA090 SIDE OIL SEAL PROTECTOR
13) Hereafter, re-assemble in reverse order of disassem-
bly.
18
3-4SERVICE PROCEDURE
2. Rear Differential

B: REMOVAL
1) Disconnect ground cable from battery.
2) Move selector lever or gear shift lever to“N”.
3) Release the parking brake.
4) Loosen wheel nuts.
5) Jack-up vehicle and support it with sturdy racks.
6) Remove wheels.
7) Remove rear exhaust pipe and muffler.

G3M0021
8) Remove front exhaust cover.
G3M0022
9) Remove front cover of rear differential mount.
G3M0024
10) Remove propeller shaft.
CAUTION:
When removing propeller shaft, pay attention not to
damage the sliding surfaces of rear drive shaft (exten-
sion) spline, oil seal and sleeve yoke.
NOTE:
Prepare an oil can and cap since the transmission oil flows
out from the extension at removing propeller shaft.
G3M0026
NOTE:
Insert the cap into the extension to prevent transmission oil
from flowing out immediately after removing the propeller
shaft.
19
3-4SERVICE PROCEDURE
2. Rear Differential

G3M0053
11) Remove heat sealed cover.
12) Remove clamps and bracket of parking brake cable.
13) Remove crossmember reinforcement lower (AWD
Sedan only).
G3M1020
14) Remove DOJ of rear drive shaft from rear differential
using ST.
ST 28099PA100 DRIVE SHAFT REMOVER
G3M1022
15) Secure rear drive shaft to rear crossmember using
wire.
G3M0054
16) Remove lower differential bracket.
G3M0055
17) Support rear differential with transmission jack.
20
3-4SERVICE PROCEDURE
2. Rear Differential

G3M1028
18) Remove self-locking nuts connecting rear differential
to rear crossmember.
G3M0057
19) Remove bolts which secure rear differential front
member to body.
Loosen bolt

1first, then remove bolts
2.
NOTE:
Support front member with the use of a helper to prevent
it from dropping.
20) Remove bolt

1.
G3M1029
21) While slowly lowering transmission jack, move rear
differential forward and remove front member and rear dif-
ferential from body.
G3M1030
22) Remove rear differential from front member.
21
3-4SERVICE PROCEDURE
2. Rear Differential