SUBARU LEGACY 1999 Service Repair Manual
Manufacturer: SUBARU, Model Year: 1999, Model line: LEGACY, Model: SUBARU LEGACY 1999Pages: 1456, PDF Size: 59.93 MB
Page 461 of 1456
12) Install stabilizer clamps onto front crossmem-
ber.
Tightening torque:
25
±4 N´m (2.5±0.4 kg-m, 18.1±2.9 ft-lb)
G2M0323
13) Install gear shift rod and stay. (MT vehicles)
(1) Install gear shift rod onto transmission.
G3M0697
(2) Install stay onto transmission.
(3) Install spring.
14) Install shift selector cable onto selector lever.
(AT vehicles)
(1) Install selector cable into selector lever.
(2) Install cable bracket onto body.
NOTE:
Tighten selector cable adjusting and lock nut after
checking selector lever operation.
S3M0013A
15) Install ATF level gauge guide, and ATF cooler
hoses onto pipe. (AT vehicles)
G2M0317
16) Install propeller shaft.
(1) Install propeller shaft into transmission.
(2) Tighten bolts which install propeller shaft
onto companion flange of rear differential.
Tightening torque:
31
±8 N´m (3.2±0.8 kg-m, 23.1±5.8 ft-lb)
G3M0023
(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)
S2M0219A
17) Install exhaust system.
29
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2. Transmission
Page 462 of 1456
(1) Install heat shield cover.
G2M0830
(2) Install rear exhaust pipe to muffler.
Tightening torque:
48
±9 N´m (4.9±0.9 kg-m, 35.4±6.5 ft-lb)
G2M0382
(3) Install hanger bracket on right side of trans-
mission.
B2M0032
(4) Install front exhaust pipe onto engine.
Tightening torque:
30
±5 N´m (3.1±0.5 kg-m, 22.4±3.6 ft-lb)
G2M0290
(5) Install center exhaust pipe to rear exhaust
pipe.
Tightening torque:
18
±5 N´m (1.8±0.5 kg-m, 13.0±3.6 ft-lb)
G2M0291
(6) Tighten bolt which installs center exhaust
pipe to hanger bracket.
Tightening torque:
30
±5 N´m (3.1±0.5 kg-m, 22.4±3.6 ft-lb)
S2M0206
(7) Connect connector to rear oxygen sensor.
(Except 2500 cc California spec. vehicles)
B2M0335
(8) Install under cover.
30
2-11[W2C0]SERVICE PROCEDURE
2. Transmission
Page 463 of 1456
18) Install ATF level gauge. (AT vehicles)
S2M0214
19) Connect the following connectors.
(1) Transmission harness connectors (AT
vehicles)
(2) Transmission ground terminal
(3) Front oxygen sensor connector
(4) Rear oxygen sensor connector (California
spec. vehicles)
(5) Neutral position switch connector (MT
vehicles)
(6) Back-up light switch connector (MT
vehicles)
20) Connect the following cables.
(1) Cruise control cable
(With cruise control vehicles)
(2) Clutch cable (2200 cc MT vehicles)
21) Install return spring.
(Without hill holder vehicles)
22) Install starter.
(1) Install starter onto transmission case, and
connect connectors and terminals.
(2) Tighten bolt and nut which install starter
onto transmission.
Tightening torque:
40
±4 N´m (4.1±0.4 kg-m, 29.7±2.9 ft-lb)
G2M0309
23) Install chamber stay.
IMT vehicles
S2M0210
IAT vehicles
S6M0023
24) Install air intake duct and chamber. (Except
2200 cc California spec. vehicles)
25) Install air intake duct with air cleaner case.
(2200 cc California spec. vehicles)
26) Connect battery ground cable.
27) Fill ATF and differential gear oil. (AT vehicles)
28) Check selector lever operation. (AT vehicles)
29) Take off vehicle from lift arms.
30) Check the vehicle on road tester. (AT vehicles)
31
[W2C0]2-11SERVICE PROCEDURE
2. Transmission
Page 464 of 1456
MEMO:
32
2-11SERVICE PROCEDURE
Page 465 of 1456
1. Manual Transmission and Differential
ItemModel
AWD
2200 cc 2500 cc 2500 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 0.780 0.871
Reverse 3.333
Front reduction
gearFinalType of gear Hypoid
Gear ratio 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 differential Type and number of gear Straight bevel gear (Bevel pinion: 2, Bevel gear: 2)
Center differential Type and number of gearStraight bevel gear (Bevel pinion: 2, Bevel gear: 2 and vis-
cous coupling)
Transmission gear oilGL-5
Transmission oil capacity 3.5(3.7 US qt, 3.1 Imp qt)
2. Transmission Gear Oil
Recommended oil
B1H0024
3. 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 Ð 0.18 mm (0.0051 Ð 0.0071 in)
Selection of main shaft rear plate
Main shaft rear plate
Dimension ªAº mm
(in)Part No. Mark
4.00 Ð 4.13
(0.1575 Ð 0.1626)32294AA041 1
3.87 Ð 3.99
(0.1524 Ð 0.1571)32294AA051 2
2
3-1[S100]SPECIFICATIONS AND SERVICE DATA
1. Manual Transmission and Differential
Page 466 of 1456
1. Manual Transmission and Differential
ItemModel
AWD
2200 cc 2500 cc 2500 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 0.780 0.871
Reverse 3.333
Front reduction
gearFinalType of gear Hypoid
Gear ratio 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 differential Type and number of gear Straight bevel gear (Bevel pinion: 2, Bevel gear: 2)
Center differential Type and number of gearStraight bevel gear (Bevel pinion: 2, Bevel gear: 2 and vis-
cous coupling)
Transmission gear oilGL-5
Transmission oil capacity 3.5(3.7 US qt, 3.1 Imp qt)
2. Transmission Gear Oil
Recommended oil
B1H0024
3. 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 Ð 0.18 mm (0.0051 Ð 0.0071 in)
Selection of main shaft rear plate
Main shaft rear plate
Dimension ªAº mm
(in)Part No. Mark
4.00 Ð 4.13
(0.1575 Ð 0.1626)32294AA041 1
3.87 Ð 3.99
(0.1524 Ð 0.1571)32294AA051 2
2
3-1[S100]SPECIFICATIONS AND SERVICE DATA
1. Manual Transmission and Differential
Page 467 of 1456
1. Manual Transmission and Differential
ItemModel
AWD
2200 cc 2500 cc 2500 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 0.780 0.871
Reverse 3.333
Front reduction
gearFinalType of gear Hypoid
Gear ratio 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 differential Type and number of gear Straight bevel gear (Bevel pinion: 2, Bevel gear: 2)
Center differential Type and number of gearStraight bevel gear (Bevel pinion: 2, Bevel gear: 2 and vis-
cous coupling)
Transmission gear oilGL-5
Transmission oil capacity 3.5(3.7 US qt, 3.1 Imp qt)
2. Transmission Gear Oil
Recommended oil
B1H0024
3. 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 Ð 0.18 mm (0.0051 Ð 0.0071 in)
Selection of main shaft rear plate
Main shaft rear plate
Dimension ªAº mm
(in)Part No. Mark
4.00 Ð 4.13
(0.1575 Ð 0.1626)32294AA041 1
3.87 Ð 3.99
(0.1524 Ð 0.1571)32294AA051 2
2
3-1[S100]SPECIFICATIONS AND SERVICE DATA
1. Manual Transmission and Differential
Page 468 of 1456
4. Drive Pinion Assembly
Preload adjustment of thrust bearing
Starting torque
0.3 Ð 0.8 N´m (3 Ð 8 kg-m, 2.6 Ð 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 adjust-
ment
Driven shaft 1st driven gear
Part No.Diameter A
mm (in)Part No.
32229AA15049.959 Ð 49.966
(1.9669 Ð 1.9672)32231AA730
32229AA14049.967 Ð 49.975
(1.9672 Ð 1.9675)32231AA720
5. Reverse Idler Gear
Adjustment of reverse idler gear position
Reverse idler gear to transmission case (LH) wall
clearance
6.0 Ð 7.5 mm (0.236 Ð 0.295 in)
Reverse shifter lever
Part No. Mark Remarks
32820AA070 7Further from case
wall
32820AA080 8 Standard
32820AA090 9Closer 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´26´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) Ð Ð
3
[S500]3-1SPECIFICATIONS AND SERVICE DATA
5. Reverse Idler Gear
Page 469 of 1456
4. Drive Pinion Assembly
Preload adjustment of thrust bearing
Starting torque
0.3 Ð 0.8 N´m (3 Ð 8 kg-m, 2.6 Ð 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 adjust-
ment
Driven shaft 1st driven gear
Part No.Diameter A
mm (in)Part No.
32229AA15049.959 Ð 49.966
(1.9669 Ð 1.9672)32231AA730
32229AA14049.967 Ð 49.975
(1.9672 Ð 1.9675)32231AA720
5. Reverse Idler Gear
Adjustment of reverse idler gear position
Reverse idler gear to transmission case (LH) wall
clearance
6.0 Ð 7.5 mm (0.236 Ð 0.295 in)
Reverse shifter lever
Part No. Mark Remarks
32820AA070 7Further from case
wall
32820AA080 8 Standard
32820AA090 9Closer 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´26´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) Ð Ð
3
[S500]3-1SPECIFICATIONS AND SERVICE DATA
5. Reverse Idler Gear
Page 470 of 1456
6. Shifter Fork And Rod
Select suitable shifter forks so that both coupling
sleeve and reverse driven gear are positioned in
the center of their synchromesh 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
32810AA061 1Approach to 4th gear
by 0.2 mm (0.008 in)
32810AA071 No mark Standard
32810AA101 3Approach to 3rd gear
by 0.2 mm (0.008 in)
5th shifter fork
Part No. Mark Remarks
32812AA200 1Approach to 5th gear
by 0.2 mm (0.008 in)
32812AA210 No mark Standard
32812AA220 3Become distant from
5th gear by 0.2 mm
(0.008 in)
Rod end clearance
A: 1st-2nd Ð 3rd-4th
0.5 Ð 1.5 mm (0.020 Ð 0.059 in)
B: 3rd-4th Ð 5th
0.6 Ð 1.4 mm (0.024 Ð 0.055 in)
7. Transfer 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
32188AA090 XNeutral position is
closer to 1st.
32188AA100 Y Standard
32188AA110 ZNeutral position is
closer to reverse
gear.
Reverse check plate adjustment
Reverse check plate
Part No. Mark AngleqRemarks
32189AA000 0 28ÉArm stops closer to
5th gear.
32189AA010 1 31ÉArm stops closer to
5th gear.
33189AA020 2 34ÉArm stops in the cen-
ter.
32189AA030 3 37ÉArm stops closer to
reverse gear.
32189AA040 4 40ÉArm stops closer to
reverse gear.
4
3-1[S600]SPECIFICATIONS AND SERVICE DATA
6. Shifter Fork And Rod