diff SUBARU LEGACY 1999 Service Owner's Guide

4) Remove main shaft rear plate.
S3M0100B
5) Put vinyl tape around splines of right and left
axle drive shafts to prevent damage to oil seals.
B3M1405A
6) Separate transmission case into right and left
cases by loosening seventeen coupling bolts and
nuts.
B3M1359
7) Remove drive pinion shaft assembly from left
side transmission case.
NOTE:
Use a hammer handle, etc. to remove if too tight.
B3M0101G
8) Remove main shaft assembly.
9) Remove differential assembly.
CAUTION:
IBe careful not to confuse right and left roller
bearing outer races.
IBe careful not to damage retainer oil seal.
G3M0557
16
3-1[W2A1]SERVICE PROCEDURE
2. Transmission Case

3) Drive out straight pin, and pull out 3-4 fork rod
and shifter fork.
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.
B3M0523C
(A) Straight pin
(B) 3-4 fork rod
(C) Shifter fork
4) Drive out straight pin, and pull out 1-2 fork rod
and shifter fork.
5) Pull out straight pin, and remove idler gear
shaft, reverse idler gear and washer.
B3M0524C
(A) Straight pin
(B) Idler gear shaft
(C) Idler gear
(D) Washer
6) Remove outer snap ring, and pull out reverse
shifter rod arm from reverse fork rod. Then take out
ball, spring and interlock plunger from rod.
And then remove rod.
NOTE:
When pulling out reverse shifter rod arm, be care-
ful not to let ball pop out of arm.
7) Remove reverse shifter lever.
8) Remove differential side retainers using ST.
ST 499787000 WRENCH ASSY
B3M1360A
9) Remove outer snap ring and pull out speedom-
eter driven gear. Next, remove vehicle speed sen-
sor 2, oil seal, speedometer shaft and washer.
B3M0525C
(A) Outer snap ring
(B) Speedometer driven gear
18
3-1[W2A2]SERVICE PROCEDURE
2. Transmission Case

2. COMBINATION OF TRANSMISSION CASE
S3M0190B
(1) Differential ASSY
(2) Drive pinion shim
(3) Drive pinion ASSY
(4) Main shaft ASSY
(5) Main shaft rear plate
(6) Transmission case (LH)
(7) Transmission case (RH)(8) Differential side retainer
(9) O-ring
(10) Oil seal
(11) Retainer lock plate
(12) Release lever
(13) Release bearing(14) Operating cylinder (2500 cc
model)
Tightening torque: N´m (kg-m, ft-lb)
T1:
25 (2.5, 18)
T2:29±3 (3.0±0.3, 21.7±2.2)
1) Alignment marks/numbers on hypoid gear set
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.
G3M0554
2) Place drive pinion shaft assembly on right hand
transmission main case without shim and tighten
bearing mounting bolts.
22
3-1[W2B2]SERVICE PROCEDURE
2. Transmission Case

3) Inspection and adjustment of ST
NOTE:
ILoosen the two bolts and adjust so that the scale
indicates 0.5 correctly when the plate end and the
scale end are on the same level.
ITighten the two bolts.
ST 499917500 DRIVE PINION GAUGE ASSY
B3M0064B
(A) Plate
(B) Scale
4) Position the ST by inserting the knock pin of ST
into the knock hole in the transmission case.
ST 499917500 DRIVE PINION GAUGE ASSY
5) 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.
ST 499917500 DRIVE PINION GAUGE ASSY
B3M0065C
(A) Adjust clearance to zero without shim.
6) The thickness of shim shall be determined by
adding 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 þ.)
ST 499917500 DRIVE PINION GAUGE ASSY7) 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)
8) Install differential assembly on left hand trans-
mission 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.
G3M0557
9) Install needle bearing and oil seal onto the front
of transmission main shaft assembly, and position
in left side transmission case.
CAUTION:
IWrap clutch splined section with vinyl tape
to prevent damage to oil seal.
IApply grease (Unilube #2 or equivalent) to
the sealing lip of oil seal.
IUse a new oil seal.
23
[W2B2]3-1SERVICE PROCEDURE
2. Transmission Case

3. Drive Pinion Assembly
A: DISASSEMBLY
1. DRIVE PINION SHAFT
1) Straighten lock nut at staked portion. Remove
the lock nut using ST1, ST2 and ST3.
ST1 899884100 HOLDER
ST2 498427100 STOPPER
ST3 899988608 SOCKET WRENCH
G3M0595
2) Withdraw drive pinion from driven shaft.
Remove differential bevel gear sleeve, adjusting
washer No. 1, adjusting washer No. 2, thrust
bearing, needle bearing, drive pinion collar, needle
bearing and thrust bearing.
B3M0536G
(A) Differential bevel gear sleeve
(B) Washer No. 1 (25´37.5´t)
(C) Thrust bearing (25´37.5´3)
(D) Washer No. 2 (25´37.5´4)
(E) Needle bearing (25´30´20)
(F) Drive pinion collar
(G) Needle bearing (30´37´23)
(H) Thrust bearing (33´50´3)
3) Remove roller bearing and washer (33´50´
5) using ST and press.
CAUTION:
Do not reuse roller bearing.
ST 498077000 REMOVER
G3M0607
2. DRIVEN GEAR ASSEMBLY
CAUTION:
Attach a cloth to the end of driven shaft (on the
frictional side of thrust needle bearing) during
disassembly or reassembly to prevent damage.
1) Straighten lock nut at staked portion. Remove
the lock nut using ST1 and ST2.
ST1 499987300 SOCKET WRENCH (50)
ST2 899884100 HOLDER
G3M0608
2) Remove 5th driven gear using ST.
ST 499857000 5TH DRIVEN GEAR
REMOVER
G3M0609
3) Remove woodruff key.
29
[W3A2]3-1SERVICE PROCEDURE
3. Drive Pinion Assembly

NOTE:
When installing roller bearing, note its directions
(front and rear) because knock pin hole in outer
race is offset.
B3M0081D
(A) Roller bearing
(B) Knock pin hole
2) Install thrust bearing (33´50´3) and needle
bearing (30´37´23). Install driven shaft assem-
bly.
B3M0082D
3) Install drive pinion collar, needle bearing,
adjusting washer No. 2, thrust bearing, adjusting
washer No. 1 and differential bevel gear sleeve in
that order.
NOTE:
Be careful because spacer must be installed in
proper direction.
B3M0083D
(A) Driven shaft
(B) Drive shaft
(C) Drive pinion collar
(D) Needle bearing (25´30´20)
(E) Washer No. 2 (25´36´4)
(F) Thrust bearing (25´37.5´3)
(G) Washer No. 1 (25´36´t)
(H) Differential bevel gear sleeve
33
[W3B3]3-1SERVICE PROCEDURE
3. Drive Pinion Assembly

5. Transfer Case and Extension
A: REMOVAL
1) Remove back-up light switch and neutral
switch.
B3M1372A
2) Remove transfer case with extension assembly.
B3M1373
3) Remove shifter arm.
B: DISASSEMBLY
1. SEPARATION OF TRANSFER CASE
AND EXTENSION ASSEMBLY
1) Separate transfer case and extension assem-
bly.
B3M1374A
2) Remove transfer driven gear and center differ-
ential as a set.
B3M1375A
3) Remove thrust washer.
2. TRANSFER CASE
1) Remove plug, spring and reverse check ball.
B3M1376
2) Remove reverse check assembly.
B3M1377
3) Remove oil guide.
B3M1378
42
3-1[W5A0]SERVICE PROCEDURE
5. Transfer Case and Extension

2) Install reverse check sleeve assembly to trans-
fer case.
Tightening torque:
6.4
±0.5 N´m (0.65±0.05 kg-m, 4.7±0.4 ft-lb)
B3M1377
3) Install ball, reverse accent spring, washer and
plug to transfer case.
Tightening torque:
10
±1 N´m (1.0±0.1 kg-m, 7.2±0.7 ft-lb)
B3M1376
4. TRANSFER DRIVEN GEAR
1) Install ball bearing to transfer driven gear.
B3M1389A
2) Install ball bearing to transfer driven gear.
B3M1390A
5. COMBINATION OF TRANSFER CASE
AND EXTENSION ASSEMBLY
1) Install center differential and transfer driven
gear into transfer case.
B3M1375A
2) Measure height ªWº between transfer case and
ball bearing on the transfer driven gear.
B3M1392A
3) Measure depth ªXº.
B3M1406A
46
3-1[W5C4]SERVICE PROCEDURE
5. Transfer Case and Extension

4) Calculate space ªYº using the following equa-
tion: Y=XþW+0.24 mm (0.0094 in) [Thickness
of gasket]
5) Select suitable washer in the following table:
Standard clearance between thrust washer
and ball bearing:
0.05 Ð 0.30 mm (0.0020 Ð 0.0118 in)
Space ªYº mm (in)Thrust washer (52´61´t)
Part No.Thickness
mm (in)
0.55 Ð 0.79
(0.0217 Ð 0.0311)803052021 0.50 (0.0197)
0.80 Ð 1.04
(0.0315 Ð 0.0409)803052022 0.75 (0.0295)
1.05 Ð 1.30
(0.0413 Ð 0.0512)803052023 1.00 (0.0394)
6) Fit thrust washers on transfer drive shaft.
7) Measure depth ªSº between transfer case and
center differential.
ST 398643600 GAUGE
B3M1407A
8) Measure depth ªTº between extension case
and transfer drive grar.
ST 398643600 GAUGE
B3M1395A
9) Calculate space ªUº using the following equa-
tion:U=S+T-0.24 mm (0.0094 in) [Thickness
of gasket]
10) Select suitable washer inthe following table:
Standard clearance:
0.15 Ð 0.35 mm (0.0059 Ð 0.0138 in)
Thrust washer
Part No. Thickness mm (in)
803036050 0.9 (0.035)
803036054 1.0 (0.039)
803036051 1.1 (0.043)
803036055 1.2 (0.047)
803036052 1.3 (0.051)
803036056 1.4 (0.055)
803036053 1.5 (0.059)
803036057 1.6 (0.063)
803036058 1.7 (0.067)
11) Fit thrust washer on center differential.
12) Install extension assembly into transfer case.
Tightening torque:
37
±3 N´m (3.8±0.3 kg-m, 27.5±2.2 ft-lb)
B3M0052A
D: INSTALLATION
1) Install shifter arm to transfer case.
B3M1396
2) Hang the shifter arm on the 3rd-4th fork rod.
B3M1397A
47
[W5D0]3-1SERVICE PROCEDURE
5. Transfer Case and Extension

6. Front Differential
A: DISASSEMBLY
1) Remove right and left snap rings from
differential, and then remove two axle drive shafts.
NOTE:
During reassembly, reinstall each axle drive shaft
in the same place from which it was removed.
2) Loosen twelve bolts and remove hypoid drive
gear.
B3M0551C
(A) Snap ring
(B) Axle drive shaft
(C) Hypoid drive gear
3) Drive out straight pin from differential assembly
toward hypoid driven gear.
ST 899904100 REMOVER
G3M0667
4) Pull out pinion shaft, and remove differential
bevel pinion and gear and washer.
B3M0552C
(A) Pinion shaft
(B) Bevel pinion
(C) Bevel gear
(D) Washer
5) Remove roller bearing using ST.
ST 399527700 PULLER SET
G3M0668
B: ASSEMBLY
1) Install bevel gear and bevel pinion together with
washers, and insert pinion shaft.
NOTE:
Face the chamfered side of washer toward gear.
B3M0099D
(A) Bevel pinion
(B) Bevel gear
(C) Pinion shaft
49
[W6B0]3-1SERVICE PROCEDURE
6. Front Differential