Rear differential SUBARU LEGACY 1996 Service Repair Manual
[x] Cancel search | Manufacturer: SUBARU, Model Year: 1996, Model line: LEGACY, Model: SUBARU LEGACY 1996Pages: 2890, PDF Size: 61.9 MB
Page 562 of 2890
![SUBARU LEGACY 1996 Service Repair Manual G2M0345
3. Fuel Tank
A: REMOVAL
1) Release fuel pressure. <Ref. to 2-8 [W1A0].>
2) Drain fuel from fuel tank. <Ref. to 2-8 [W1B0].>
G2M0382
3) Remove rear exhaust pipe.
(1) Lift-up the vehicle.
(2) Se](/img/17/57433/w960_57433-561.png "SUBARU LEGACY 1996 Service Repair Manual G2M0345
3. Fuel Tank
A: REMOVAL
1) Release fuel pressure. <Ref. to 2-8 [W1A0].>
2) Drain fuel from fuel tank. <Ref. to 2-8 [W1B0].>
G2M0382
3) Remove rear exhaust pipe.
(1) Lift-up the vehicle.
(2) Se")
G2M0345
3. Fuel Tank
A: REMOVAL
1) Release fuel pressure.
2) Drain fuel from fuel tank.
G2M0382
3) Remove rear exhaust pipe.
(1) Lift-up the vehicle.
(2) Separate rear exhaust pipe from center exhaust
pipe.
(3) Separate rear exhaust pipe from muffler.
(4) Remove bracket from rubber cushion, and remove
exhaust pipe.
NOTE:
To facilitate the removal of parts, apply a coat of SUBARU
CRC5-56 (Part No. 004301003)
G2M0384
4) Remove muffler assembly.
NOTE:
To facilitate the removal of parts, apply a coat of SUBARU
CRC5-56 (Part No. 004301003)
G3M0059
5) Remove rear differential assembly. (AWD model)
(1) Remove rear axle shafts from rear differential
assembly.
(2) Remove rear differential front cover.
(3) Remove propeller shaft.
(4) Remove lower differential bracket.
(5) Set transmission jack under rear differential.
(6) Remove bolts which install rear differential onto
rear crossmember.
13
2-8SERVICE PROCEDURE
3. Fuel Tank
Page 565 of 2890
![SUBARU LEGACY 1996 Service Repair Manual G3M0059
6) Install rear differential assembly. <Ref. to 3-4 [W2F0].>
G2M0384
7) Install muffler assembly.
G2M0382
8) Install heat sealed cover.
9) Install rear exhaust pipe.
G2M0340
10) Lower the vehi](/img/17/57433/w960_57433-564.png "SUBARU LEGACY 1996 Service Repair Manual G3M0059
6) Install rear differential assembly. <Ref. to 3-4 [W2F0].>
G2M0384
7) Install muffler assembly.
G2M0382
8) Install heat sealed cover.
9) Install rear exhaust pipe.
G2M0340
10) Lower the vehi")
G3M0059
6) Install rear differential assembly.
G2M0384
7) Install muffler assembly.
G2M0382
8) Install heat sealed cover.
9) Install rear exhaust pipe.
G2M0340
10) Lower the vehicle, and connect connector to fuel
pump.
11) Install access hole lid.
G2M0345
4. Fuel Filler Pipe
A: REMOVAL
1) Release fuel pressure.
2) Drain fuel from fuel tank.
16
2-8SERVICE PROCEDURE
3. Fuel Tank - 4. Fuel Filler Pipe
Page 671 of 2890
![SUBARU LEGACY 1996 Service Repair Manual G2M0345
3. Fuel Tank
A: REMOVAL
1) Release fuel pressure. <Ref. to 2-8 [W1A0].>
2) Drain fuel from fuel tank. <Ref. to 2-8 [W1B0].>
G2M0382
3) Remove rear exhaust pipe.
(1) Lift-up the vehicle.
(2) Se](/img/17/57433/w960_57433-670.png "SUBARU LEGACY 1996 Service Repair Manual G2M0345
3. Fuel Tank
A: REMOVAL
1) Release fuel pressure. <Ref. to 2-8 [W1A0].>
2) Drain fuel from fuel tank. <Ref. to 2-8 [W1B0].>
G2M0382
3) Remove rear exhaust pipe.
(1) Lift-up the vehicle.
(2) Se")
G2M0345
3. Fuel Tank
A: REMOVAL
1) Release fuel pressure.
2) Drain fuel from fuel tank.
G2M0382
3) Remove rear exhaust pipe.
(1) Lift-up the vehicle.
(2) Separate rear exhaust pipe from center exhaust
pipe.
(3) Separate rear exhaust pipe from muffler.
(4) Remove bracket from rubber cushion, and remove
exhaust pipe.
NOTE:
To facilitate the removal of parts, apply a coat of SUBARU
CRC5-56 (Part No. 004301003)
G2M0384
4) Remove muffler assembly.
NOTE:
To facilitate the removal of parts, apply a coat of SUBARU
CRC5-56 (Part No. 004301003)
G3M0059
5) Remove rear differential assembly. (AWD model)
(1) Remove rear axle shafts from rear differential
assembly.
(2) Remove rear differential front cover.
(3) Remove propeller shaft.
(4) Remove lower differential bracket.
(5) Set transmission jack under rear differential.
(6) Remove bolts which install rear differential onto
rear crossmember.
13
2-8SERVICE PROCEDURE
3. Fuel Tank
Page 674 of 2890
![SUBARU LEGACY 1996 Service Repair Manual G3M0059
6) Install rear differential assembly. <Ref. to 3-4 [W2F0].>
G2M0384
7) Install muffler assembly.
G2M0382
8) Install heat sealed cover.
9) Install rear exhaust pipe.
G2M0340
10) Lower the vehi](/img/17/57433/w960_57433-673.png "SUBARU LEGACY 1996 Service Repair Manual G3M0059
6) Install rear differential assembly. <Ref. to 3-4 [W2F0].>
G2M0384
7) Install muffler assembly.
G2M0382
8) Install heat sealed cover.
9) Install rear exhaust pipe.
G2M0340
10) Lower the vehi")
G3M0059
6) Install rear differential assembly.
G2M0384
7) Install muffler assembly.
G2M0382
8) Install heat sealed cover.
9) Install rear exhaust pipe.
G2M0340
10) Lower the vehicle, and connect connector to fuel
pump.
11) Install access hole lid.
G2M0345
4. Fuel Filler Pipe
A: REMOVAL
1) Release fuel pressure.
2) Drain fuel from fuel tank.
16
2-8SERVICE PROCEDURE
3. Fuel Tank - 4. Fuel Filler Pipe
Page 675 of 2890
![SUBARU LEGACY 1996 Service Repair Manual G3M0059
6) Install rear differential assembly. <Ref. to 3-4 [W2F0].>
G2M0384
7) Install muffler assembly.
G2M0382
8) Install heat sealed cover.
9) Install rear exhaust pipe.
G2M0340
10) Lower the vehi](/img/17/57433/w960_57433-674.png "SUBARU LEGACY 1996 Service Repair Manual G3M0059
6) Install rear differential assembly. <Ref. to 3-4 [W2F0].>
G2M0384
7) Install muffler assembly.
G2M0382
8) Install heat sealed cover.
9) Install rear exhaust pipe.
G2M0340
10) Lower the vehi")
G3M0059
6) Install rear differential assembly.
G2M0384
7) Install muffler assembly.
G2M0382
8) Install heat sealed cover.
9) Install rear exhaust pipe.
G2M0340
10) Lower the vehicle, and connect connector to fuel
pump.
11) Install access hole lid.
G2M0345
4. Fuel Filler Pipe
A: REMOVAL
1) Release fuel pressure.
2) Drain fuel from fuel tank.
16
2-8SERVICE PROCEDURE
3. Fuel Tank - 4. Fuel Filler Pipe
Page 746 of 2890
G2M0316
13) Drain ATF to remove ATF drain plug. (AT model)
1Front differential oil drain plug
2ATF drain plug
G2M0317
14) Disconnect ATF cooler hoses from pipes of transmis-
sion side, and remove ATF level gauge guide. (AT model)
G3M0023
15) Remove propeller shaft. (AWD model)
(1) Remove front cover of rear differential mount.
(2) Separate propeller shaft from rear differential.
G3M0024
(3) Remove bolts which hold center bearing onto body.
CAUTION:
Be careful not to drop propeller shaft.
G3M0025
(4) Remove propeller shaft from transmission.
CAUTION:
Be sure to use an empty container to catch oil flow-
ing out when removing propeller shaft.
Be sure not to damage oil seals and the frictional
surface of sleeve yoke.
Be sure to plug the opening in transmission after
removal of propeller shaft.
33
2-11SERVICE PROCEDURE
3. Transmission
Page 754 of 2890
G2M0317
13) Install ATF level gauge guide, and ATF cooler hoses
onto pipe. (AT model)
G3M0023
14) Install propeller shaft. (AWD model)
(1) Install propeller shaft into transmission.
(2) Tighten bolts which install propeller shaft onto com-
panion flange of rear differential.
Tightening torque:
31±8 N⋅m (3.2±0.8 kg-m, 23.1±5.8 ft-lb)
G3M0024
(3) Install center bearing bracket on body.
Tightening torque:
52±5 N⋅m (5.3±0.5 kg-m, 38.3±3.6 ft-lb)
G2M0830
15) Install exhaust system.
(1) Install heat shield cover. (AWD model)
G2M0382
(2) Install rear exhaust pipe to muffler. (AWD model)
Tightening torque:
48±9 N⋅m (4.9±0.9 kg-m, 35.4±6.5 ft-lb)
41
2-11SERVICE PROCEDURE
3. Transmission
Page 758 of 2890
1. Manual Transmission and
Differential
A: SPECIFICATIONS
ItemModel
FWD AWD
2200 cc 2200 cc*2200 cc
OUTBACK
Type 5-forward speeds with synchromesh and 1-reverse
Transmission gear ratio1st 3.545
2nd 2.111
3rd 1.448
4th 1.088
5th 0.825 0.780 0.871
Reverse 3.416
Front
reduction
gearFinalType of gear Hypoid
Gear ratio 3.454 3.900 4.111
Rear
reduction
gearTransferType of gear — Helical
Gear ratio — 1.000
FinalType of gear — Hypoid
Gear ratio — 3.900 4.111
Front
differentialType and number of gear Straight bevel gear (Bevel pinion: 2, Bevel gear: 2)
Center
differentialType and number of gear —Straight bevel gear
(Bevel pinion: 2, Bevel gear: 2 and viscous coupling)
Transmission gear oil GL-5
Transmission oil capacity3.3(3.5 US qt, 2.9 Imp
qt)3.5(3.7 US qt, 3.1 Imp qt)
*: Step roof model only
2
3-1SPECIFICATIONS AND SERVICE DATA
1. Manual Transmission and Differential
Page 759 of 2890
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
Page 760 of 2890
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