SUBARU LEGACY 1999 Service Repair Manual

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

8. Extension Assembly
Thrust washer (52´61´t) to ball bearing side
clearance
0.05 Ð 0.30 mm (0.0020 Ð 0.0118 in)
Thrust washer (52´61´t)
Part No. Thickness mm (in)
803052021 0.50 (0.0197)
803052022 0.75 (0.0295)
803052023 1.00 (0.0394)
Thrust washer to center differential side clearance
0.15 Ð 0.35 mm (0.0059 Ð 0.0138 in)
Thrust washer (52´61´t)
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)
9. Front Differential
Bevel gear to pinion backlash
0.13 Ð 0.18 mm (0.0051 Ð 0.0071 in)
Washer (38.1´50´t)
Part No.Thickness
mm (in)Part No.Thickness
mm (in)
8030380210.925 Ð
0.950
(0.0364 Ð
0.0374)8030380231.025 Ð
1.050
(0.0404 Ð
0.0413)
8030380220.975 Ð
1.000
(0.0384 Ð
0.0394)ÐÐ
Pinion shaft to axle drive shaft clearance
0 Ð 0.2 mm (0 Ð 0.008 in)
Snap ring (Outer-28)
Part No.Thickness
mm (in)Part No.Thickness
mm (in)
805028011 1.05 (0.0413) 805028012 1.20 (0.0472)
5
[S900]3-1SPECIFICATIONS AND SERVICE DATA
9. Front Differential

8. Extension Assembly
Thrust washer (52´61´t) to ball bearing side
clearance
0.05 Ð 0.30 mm (0.0020 Ð 0.0118 in)
Thrust washer (52´61´t)
Part No. Thickness mm (in)
803052021 0.50 (0.0197)
803052022 0.75 (0.0295)
803052023 1.00 (0.0394)
Thrust washer to center differential side clearance
0.15 Ð 0.35 mm (0.0059 Ð 0.0138 in)
Thrust washer (52´61´t)
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)
9. Front Differential
Bevel gear to pinion backlash
0.13 Ð 0.18 mm (0.0051 Ð 0.0071 in)
Washer (38.1´50´t)
Part No.Thickness
mm (in)Part No.Thickness
mm (in)
8030380210.925 Ð
0.950
(0.0364 Ð
0.0374)8030380231.025 Ð
1.050
(0.0404 Ð
0.0413)
8030380220.975 Ð
1.000
(0.0384 Ð
0.0394)ÐÐ
Pinion shaft to axle drive shaft clearance
0 Ð 0.2 mm (0 Ð 0.008 in)
Snap ring (Outer-28)
Part No.Thickness
mm (in)Part No.Thickness
mm (in)
805028011 1.05 (0.0413) 805028012 1.20 (0.0472)
5
[S900]3-1SPECIFICATIONS AND SERVICE DATA
9. Front Differential

1. Transmission Case
B3M1356A
(1) Transmission case ASSY
(2) Gasket
(3) Drain plug
(4) Snap ring (Outer)
(5) Speedometer driven gear
(6) Washer(7) Speedometer shaft
(8) Snap ring (Outer)
(9) Oil seal
(10) Oil level gauge
(11) Pitching stopper bracket
(12) Clamp(13) Clip
Tightening torque: N´m (kg-m, ft-lb)
T:
44±3 (4.5±0.3, 32.5±2.2)
Size All models Torque
8 mm bolt <5> Ð <15>25±2 N´m
(2.5±0.2 kg-m,
18.1±1.4 ft-lb)
10 mm bolt<1> Ð <4>
<16> Ð <17>39±2 N´m
(4.0±0.2 kg-m,
28.9±1.4 ft-lb)
6
3-1[C100]COMPONENT PARTS
1. Transmission Case

2. Drive Pinion Assembly
B3M0613C
(1) Drive pinion shaft
(2) Roller bearing
(3) Washer
(4) Driven shaft
(5) Key
(6) Woodruff key
(7) Drive pinion collar
(8) Needle bearing
(9) Snap ring (Outer)
(10) Washer
(11) Sub gear
(12) 1st driven gear
(13) Baulk ring(14) 1st-2nd synchronizer hub
(15) Insert key
(16) Reverse driven gear
(17) Outer baulk ring
(18) Synchro cone
(19) Inner baulk ring
(20) 2nd driven gear
(21) 2nd driven gear bush
(22) 3rd-4th driven gear
(23) Driven pinion shim
(24) Roller bearing
(25) 5th driven gear
(26) Lock washer(27) Lock nut
(28) Washer
(29) Thrust bearing
(30) Differential bevel gear sleeve
(31) Washer
(32) Lock washer
(33) Lock nut
Tightening torque: N´m (kg-m, ft-lb)
T1:
29±3 (3.0±0.3, 21.7±2.2)
T2:11 8±8 (12.0±0.8, 86.8±5.8)
T3:265±10 (27±1, 195±7)
7
[C200]3-1COMPONENT PARTS
2. Drive Pinion Assembly

3. Main Shaft Assembly
A: 2200 cc MODEL
B3M1404A
(1) Oil seal
(2) Needle bearing
(3) Transmission main shaft
(4) Needle bearing
(5) 3rd drive gear
(6) Inner baulk ring
(7) Synchro cone
(8) Outer baulk ring
(9) Coupling sleeve (3rd-4th)
(10) Synchronizer hub (3rd-4th)
(11) Shifting insert key (3rd-4th)
(12) Baulk ring (4th)(13) 4th drive gear
(14) 4th needle bearing race
(15) Needle bearing
(16) 4th gear thrust washer
(17) Ball bearing
(18) 5th gear thrust washer
(19) 5th needle bearing race
(20) Needle bearing
(21) Main shaft rear plate
(22) 5th drive gear
(23) Baulk ring (5th)
(24) Shifting insert key (5th-Rev)(25) Synchronizer hub (5th-Rev)
(26) Coupling sleeve (5th-Rev)
(27) Insert stopper plate
(28) Lock washer
(29) Lock nut
(30) Straight pin
(31) Reverse idler gear shaft
(32) Reverse idler gear
(33) Washer
Tightening torque: N´m (kg-m, ft-lb)
T:
11 8±6 (12.0±0.6, 86.8±4.3)
8
3-1[C3A0]COMPONENT PARTS
3. Main Shaft Assembly

B: 2500 cc MODEL
B3M1357A
(1) Oil seal
(2) Needle bearing
(3) Transmission main shaft
(4) Needle bearing
(5) 3rd drive gear
(6) Inner baulk ring
(7) Synchro cone (3rd)
(8) Outer baulk ring
(9) Coupling sleeve (3rd-4th)
(10) Synchronizer hub (3rd-4th)
(11) Shift insert key (3rd-4th)
(12) 4th baulk ring
(13) 4th drive gear
(14) 4th needle bearing race(15) Needle bearing
(16) 4th gear thrust washer
(17) Ball bearing
(18) 5th gear thrust washer
(19) 5th needle bearing race
(20) Needle bearing
(21) Main shaft rear plate
(22) 5th drive gear
(23) 5th baulk ring
(24) Shift insert key (5th-Rev)
(25) Synchronizer hub (5th-Rev)
(26) Coupling sleeve
(27) Rev baulk ring
(28) Synchro cone (Rev)(29) Ball bearing
(30) Synchro cone stopper
(31) Snap ring
(32) Lock washer
(33) Lock nut
(34) Straight pin
(35) Reverse idler gear shaft
(36) Reverse idler gear
(37) Washer
Tightening torque: N´m (kg-m, ft-lb)
T:
11 8±6 (12.0±0.6, 86.8±4.3)
9
[C3B0]3-1COMPONENT PARTS
3. Main Shaft Assembly

4. Shifter Fork and Shifter Rod
B3M1013A
(1) Shifter arm
(2) 5th shifter fork
(3) Straight pin
(4) Reverse fork rod
(5) Checking ball plug
(6) Gasket
(7) Checking ball spring
(8) Ball(9) 3rd-4th fork rod
(10) Interlock plunger
(11) 1st-2nd fork rod
(12) 3rd-4th shifter fork
(13) 1st-2nd shifter fork
(14) Ball
(15) Spring
(16) Snap ring (Outer)(17) Reverse fork rod arm
(18) Reverse shifter lever
Tightening torque: N´m (kg-m, ft-lb)
T:
19.6±1.5 (2.00±0.15, 14.5±1.1)
10
3-1[C400]COMPONENT PARTS
4. Shifter Fork and Shifter Rod

5. Transfer Case and Extension
B3M1358A
(1) Oil guide
(2) Gasket
(3) Transfer case
(4) Ball
(5) Reverse accent spring
(6) Gasket
(7) Plug
(8) Snap ring (Inner)
(9) Reverse check plate
(10) Reverse check spring
(11) Reverse return spring
(12) Reverse check cam
(13) Reverse accent shaft
(14) Return spring cap
(15) Return spring(16) O-ring
(17) Adjusting select shim
(18) Reverse check sleeve
(19) Gasket
(20) Neutral switch
(21) Gasket
(22) Back-up light switch
(23) Ball bearing
(24) Adjusting washer
(25) Ball bearing
(26) Adjusting washer
(27) Ball bearing
(28) Center differential
(29) Adjusting washer
(30) Transfer drive gear(31) Ball bearing
(32) Gasket
(33) Extension
(34) Oil seal
(35) Dust cover
(36) Shift bracket
Tightening torque: N´m (kg-m, ft-lb)
T1:
5±1 (0.5±0.1, 3.6±0.7)
T2:10±1 (1.0±0.1, 7.2±0.7)
T4:25±2 (2.5±0.2, 18.1±1.4)
T4:37±3 (3.8±0.3, 27.5±2.2)
11
[C500]3-1COMPONENT PARTS
5. Transfer Case and Extension

6. Front Differential
B3M0521B
(1) Drive pinion shaft
(2) Hypoid driven gear
(3) Pinion shaft
(4) Straight pin
(5) Washer
(6) Differential bevel gear
(7) Differential bevel pinion(8) Snap ring (Outer)
(9) Roller bearing
(10) Differential case
(11) Oil seal
(12) Differential side retainer
(13) O-ring
(14) Axle drive shaft(15) Retainer lock plate
Tightening torque: N´m (kg-m, ft-lb)
T1:
25±5 (2.5±0.5, 18.1±3.6)
T2:62±5 (6.3±0.5, 45.6±3.6)
12
3-1[C600]COMPONENT PARTS
6. Front Differential