SUBARU LEGACY 1997 Service Repair Manual

2. Transfer Case and Extension (AWD
Model)
A: REMOVAL
B3M0041A
1) Remove transfer cover
1.
2) Remove shifter fork screw

2which secures selector
arm to shifter arm.
3) Remove transfer case

4with extension assembly
3.
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3-1SERVICE PROCEDURE
2. Transfer Case and Extension (AWD Model)

B: DISASSEMBLY
1. SEPARATION OF TRANSFER CASE AND
EXTENSION ASSEMBLY
G3M0523
1) Separate transfer case
1and extension assembly
2.
2) Remove transfer driven gear

3and center differential


4as a set.
3) Remove thrust washer

5(52x61xt).
B3M0042A
2. TRANSFER CASE
1) Remove neutral switch

6.
NOTE:
Before removing shifter arm, disconnect neutral switch.
2) Draw out shifter arm

1and remove selector arm
8.
3) Remove plug

2, spring
3and reverse check ball
4.
Tightening torque:
T1: 6.4±0.5 N⋅m (0.65±0.05 kg-m, 4.7±0.4 ft-lb)
T2: 10±1 N⋅m (1.0±0.1 kg-m, 7.2±0.7 ft-lb)
T3: 19.6±1.5 N⋅m (2.00±0.15 kg-m, 14.5±1.1 ft-lb)
T4: 25±2 N⋅m (2.5±0.2 kg-m, 18.1±1.4 ft-lb)
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3-1SERVICE PROCEDURE
2. Transfer Case and Extension (AWD Model)

B3M0043A
4) Remove reverse check sleeve
5.
Disassembly procedure is as follows:
(1) Using a standard screwdriver, remove snap ring

A
(Inner-28).
NOTE:
Replace snap ring with a new one if deformed or weak-
ened.
(2) Remove reverse check plate

B.
(3) Remove reverse check spring

Cwith cam
D.
(4) Remove reverse return spring

E.
(5) Remove reverse accent shaft

F.
(6) Remove O-ring

G.
NOTE:
Reverse check sleeve assembly uses an O-ring which
should not be scratched.
Be careful not to break adjustment shim placed between
reverse check sleeve assembly and case.
B3M0042A
5) Remove back-up light switch
7.
6) Remove oil guide

9.
Tightening torque:
T1: 6.4±0.5 N⋅m (0.65±0.05 kg-m, 4.7±0.4 ft-lb)
T2: 10±1 N⋅m (1.0±0.1 kg-m, 7.2±0.7 ft-lb)
T3: 19.6±1.5 N⋅m (2.00±0.15 kg-m, 14.5±1.1 ft-lb)
T4: 25±2 N⋅m (2.5±0.2 kg-m, 18.1±1.4 ft-lb)
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3-1SERVICE PROCEDURE
2. Transfer Case and Extension (AWD Model)

3. EXTENSION
G3M0526
1) Remove extension cover
2and shift bracket
1.
2) Remove snap ring

4(Outer-30).
3) Remove transfer drive gear

5.
CAUTION:
Do not remove ball bearing unless replacing.
4) Remove snap ring

6(Inner-72).
5) Remove ball bearing

7.
CAUTION:
Do not reuse ball bearing.
6) Remove oil seal

8.
CAUTION:
Do not reuse oil seal.
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3-1SERVICE PROCEDURE
2. Transfer Case and Extension (AWD Model)

C: ASSEMBLY
1. EXTENSION
G3M0953
Tightening torque: N⋅m (kg-m, ft-lb)
T: 25±2 (2.5±0.2, 18.1±1.4)
1) Installation of ball bearing
1and selection of snap ring


2(Inner-72)
(1) Attach ball bearing

1(30 x 72 x 17) to extension
and install snap ring

2.
B3M0044A
(2) Measure clearance between snap ring
2and outer
race of ball bearing

1with a thickness gauge.
CAUTION:
Replace ball bearing with a new one.
Clearance:
0—0.15 mm (0—0.0059 in)
(3) If the measurement is not within the specification,
select suitable snap ring

2.
Snap ring (Inner-72)
Part No. Thickness mm (in)
805172071 1.78 (0.0701)
805172072 1.90 (0.0748)
805172073 2.02 (0.0795)
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3-1SERVICE PROCEDURE
2. Transfer Case and Extension (AWD Model)

B3M0045A
2) Installation of transfer drive gear
3
Press transfer drive gear into inner race of ball bearing.
B3M0046A
3) Selection of snap ring
4(Outer-30)
(1) Install snap ring

4on transfer drive shaft.
(2) Measure clearance between snap ring and inner
race of ball bearing with a thickness gauge.
Clearance:
0—0.15 mm (0—0.0059 in)
(3) If the measurement is not within the specification,
select suitable snap ring.
Snap Ring (Outer-30)
Part No. Thickness mm (in)
805030041 1.53 (0.0602)
805030042 1.65 (0.0650)
805030043 1.77 (0.0697)
B3M0047A
4) Install extension cover
6, gasket
5and shift bracket
7.
CAUTION:
Use new gasket.
5) Install oil seal

8with ST.
ST 498057300 INSTALLER
CAUTION:
Use new oil seal.
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3-1SERVICE PROCEDURE
2. Transfer Case and Extension (AWD Model)

B3M0043A
2. TRANSFER CASE
Assembly of transfer case is in the reverse order of disas-
sembly. Do the following:
1) Assembly of reverse check sleeve
(1) Install reverse accent shaft

F, check cam
D, return
spring

Eand check spring
Conto reverse check
sleeve.
NOTE:
Be sure the bent section of reverse check spring is posi-
tioned in the groove in check cam.
(2) Hook the bent section of reverse check spring over
reverse check plate

B.
(3) Rotate cam so that the protrusion of reverse check
cam is at the opening in plate.
(4) With cam held in that position, install plate onto
reverse check sleeve and hold with snap ring

A(Inner-
28).
(5) Position O-ring

G(35.4 x 1.5) in groove in sleeve.
B3M0048A
CAUTION:
Make sure the cutout section of reverse accent shaft
is aligned with the opening in reverse check sleeve.
Spin cam by hand for smooth rotation.
If it does not return properly, replace reverse check
spring.
Move cam and shaft all the way toward plate and
release.
If cam does not return properly, replace reverse check
spring; if shaft does not, check for scratches on the
inner surface of sleeve. If sleeve is in good order,
replace spring.
Select a suitable reverse accent shaft and reverse
check plate by referring to “Neutral Position Adjust-
ment.”
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3-1SERVICE PROCEDURE
2. Transfer Case and Extension (AWD Model)

B3M0042A
2) Installation of shifter arm
1and selector arm
8
Install shifter arm into the partition from the front while
inserting selector arm into the opening in reverse check
sleeve. Pass shaft through hole in selector arm until its end
comes out of the rear of transfer case.
NOTE:
Apply a coat of gear oil to shifter arm. Also make sure oil
seal is positioned properly.
Tightening torque:
T1: 6.4±0.5 N⋅m (0.65±0.05 kg-m, 4.7±0.4 ft-lb)
T2: 10±1 N⋅m (1.0±0.1 kg-m, 7.2±0.7 ft-lb)
T3: 19.6±1.5 N⋅m (2.00±0.15 kg-m, 14.5±1.1 ft-lb)
T4: 25±2 N⋅m (2.5±0.2 kg-m, 18.1±1.4 ft-lb)
B3M0049A
3. COMBINATION OF TRANSFER CASE AND
EXTENSION ASSEMBLY
1) Install center differential

1and transfer driven gear
2
into transfer case.
Tightening torque:
T: 37±3 N⋅m (3.8±0.3 kg-m, 27.5±2.2 ft-lb)
B3M0050A
2) Selection of thrust washer (52 x 61 x t)
(1) Measure height“W”between transfer case and ball
bearing on the transfer driven gear

3.
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3-1SERVICE PROCEDURE
2. Transfer Case and Extension (AWD Model)

B3M0051A
(2) Measure depth“X”as shown in figure.


4Extension
(3) Calculate space“Y”using the following equation: Y
=XW+0.24 mm (0.0094 in) [Thickness of gasket]
(4) Select suitable washer in the following table:
Space “Y” mm (in)Thrust washer (52 x 61 x t)
Part No.Thickness
mm (in)
0.55 — 0.79 (0.0217 — 0.0311) 803052021 0.50 (0.0197)
0.80 — 1.04 (0.0315 — 0.0409) 803052022 0.75 (0.0295)
1.05 — 1.30 (0.0413 — 0.0512) 803052023 1.00 (0.0394)
Standard clearance between thrust washer and ball
bearing:
0.05—0.30 mm (0.0020—0.0118 in)
(5) Fit thrust washers on transfer drive shaft.
B3M0052
3) Install extension assembly into transfer case.
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3-1SERVICE PROCEDURE
2. Transfer Case and Extension (AWD Model)

D: INSTALLATION
B3M0053A
Tightening torque: N⋅m (kg-m, ft-lb)
T1: 15.7±1.5 (1.6±0.15, 11.6±1.1)
T2: 19.6±1.5 (2.00±0.15, 14.5±1.1)
T3: 24.5±2.0 (2.50±0.20, 18.1±1.4)
1) Install transfer case
2with extension assembly
1.
2) Secure selector arm to shifter arm with shifter fork
screw

3. Shifter arm should be caught by pawl of rod.
Selector arm must be engaged with reverse check sleeve
assembly.
3) Adjustment of neutral position
(1) Shift gear into 3rd gear position.
(2) Shifter arm turns lightly toward the 1st/2nd gear
side but heavily toward the reverse gear side because
of the function of the return spring, until arm contacts
the stopper.
(3) Make adjustment so that the heavy stroke (reverse
side) is a little more than the light stroke (1st/2nd side).
(4) To adjust, remove bolts holding reverse check
sleeve assembly

4to the case, move sleeve assem-
bly outward, and place adjustment shim (0 to 1 ea.)
between sleeve assembly and case to adjust the clear-
ance.
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3-1SERVICE PROCEDURE
2. Transfer Case and Extension (AWD Model)