SUBARU LEGACY 1999 Service Repair Manual

1. General
A: PRECAUTIONS
1) Clean oil, grease, dirt and dust from transmis-
sion.
2) Remove drain plug to drain oil. After draining,
retighten it as before.
CAUTION:
Replace gasket with a new one.
Tightening torque:
44
±3 N´m (4.5±0.3 kg-m, 32.5±2.2 ft-lb)
B3M0037D
3) Attach transmission to ST.
ST 499937100 TRANSMISSION STAND SET
G3M0517
4) Rotating parts should be coated with oil prior to
assembly.
5) All disassembled parts, if to be reused, should
be reinstalled in the original positions and direc-
tions.
6) Gaskets and lock washers must be replaced
with new ones.
7) Liquid gasket should be used where specified
to prevent leakage.
8) Fill transmission gear oil through the oil level
gauge hole up to upper point level gauge. 1-5 [G9A1].>
B: INSPECTION
Disassembled parts should be washed clean first
and then inspected carefully.
1) Bearings
Replace bearings in the following cases:IBearings whose balls, outer races and inner
races are broken or rusty.
IWorn bearings
IBearings that fail to turn smoothly or make
abnormal noise when turned after gear oil lubrica-
tion.
IThe ball bearing on the rear side of the drive
pinion shaft should be checked for smooth rotation
before the drive pinion assembly is disassembled.
In this case, because a preload is working on the
bearing, its rotation feels like it is slightly dragging
unlike the other bearings.
B3M0038E
(A) Drive pinion shaft
(B) Ball bearing
IBearings having other defects
2) Bushing (each gear)
Replace the bushing in the following cases:
IWhen the sliding surface is damaged or abnor-
mally worn.
IWhen the inner wall is abnormally worn.
3) Gears
IReplace gears with new ones if their tooth sur-
faces are broken, damaged, or excessively worn.
ICorrect or replace if the cone that contacts the
baulk ring is rough or damaged.
ICorrect or replace if the inner surface or end
face is damaged.
4) Baulk ring
Replace the ring in the following cases:
IWhen the inner surface and end face are dam-
aged.
IWhen the ring inner surface is abnormally or
partially worn down.
13
[W1B0]3-1SERVICE PROCEDURE
1. General

IIf the gap between the end faces of the ring and
the gear splined part is excessively small when the
ring is pressed against the cone.
Clearance (A):
0.5 Ð 1.0 mm (0.020 Ð 0.040 in)
S3M0188
IWhen the contact surface of the synchronizer
ring insert is scored or abnormally worn down.
5) Shifting insert
Replace the insert if deformed, excessively worn,
or defective in any way.
S3M0189
6) Oil seal
Replace the oil seal if the lip is deformed,
hardened, damaged, worn, or defective in any way.
7) O-ring
Replace the O-ring if the sealing face is deformed,
hardened, damaged, worn, or defective in any way.
8) Gearshift mechanism
Repair or replace the gearshift mechanism if
excessively worn, bent, or defective in any way.9) Differential gear
Repair or replace the differential gear in the follow-
ing cases:
IThe hypoid drive gear and drive pinion shaft
tooth surface are damaged, excessively worn, or
seized.
IThe roller bearing on the drive pinion shaft has
a worn or damaged roller path.
IThere is damage, wear, or seizure of the differ-
ential bevel pinion, differential bevel gear, washer,
pinion shaft, and straight pin.
IThe differential case has worn or damaged slid-
ing surfaces.B3M0558C
(A) Drive pinion shaft
(B) Hypoid driven gear
(C) Pinion shaft
(D) Straight pin
(E) Washer
(F) Differential bevel gear
(G) Differential bevel pinion
(H) Snap ring
(I) Roller bearing
(J) Differential case
14
3-1[W1B0]SERVICE PROCEDURE
1. General

2. Transmission Case
A: DISASSEMBLY
1. SEPARATION OF TRANSMISSION
S3M0190A
(1) Operating cylinder
(2) Release lever
(3) Release bearing
(4) Release lever sealing(5) Bolt
(6) Main shaft rear plate
(7) Transmission case
(8) Drive pinion ASSY(9) Main shaft ASSY
(10) Front differential
1) Remove clutch release lever. [W3A0].>
B3M0336I
(A) Clutch release lever
(B) Release bearing
2) Remove transfer case assembly. [W5A0].>3) Remove bearing mounting bolts.
S3M0099
15
[W2A1]3-1SERVICE PROCEDURE
2. Transmission Case

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

2. TRANSMISSION CASE
B3M0060B
(1) Straight pin
(2) 5th shifter fork
(3) Checking ball plug
(4) Gasket
(5) Checking ball spring
(6) Ball
(7) 3rd-4th fork rod
(8) 3rd-4th shifter fork(9) 1st-2nd fork rod
(10) 1st-2nd shifter fork
(11) Straight pin
(12) Reverse idler gear shaft
(13) Reverse idler gear
(14) Washer
(15) Snap ring
(16) Reverse fork rod arm(17) Reverse fork rod
(18) Reverse shifter lever
(19) Snap ring (RH side)
(20) Speedometer driven gear (RH
side)
(21) Speedometer shaft (RH side)
(A) Front right hand transmission
case
1) Drive out straight pin with ST, and remove 5th
shifter fork.
ST 398791700 STRAIGHT PIN REMOVER
B3M0333I
(A) Straight pin
(B) 5th shifter fork
2) Remove plugs, springs and checking balls.
17
[W2A2]3-1SERVICE 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

B: ASSEMBLY
1. TRANSMISSION CASE
B3M0061D
(1) Reverse shifter lever
(2) Reverse idler gear
(3) Reverse idler gear shaft
(4) Straight pin
(5) Reverse fork rod arm
(6) Reverse fork rod
(7) Snap ring
(8) Ball
(9) Checking ball spring(10) Washer
(11) Checking ball plug
(12) Washer
(13) 1st-2nd fork rod
(14) 1st-2nd shifter fork
(15) Straight pin
(16) 3rd-4th fork rod
(17) 3rd-4th shifter fork
(18) 5th shifter fork(19) Speedometer shaft
(20) Speedometer driven gear
(21) Snap ring
(A) To right hand transmission case
Tightening torque: N´m (kg-m, ft-lb)
T:
19.6±0.1
(2.00
±0.015, 14.5±0.1)
1) Position interlock plungers (5.56´19.6), one
plunger in hole between 1-2 and 3-4 fork rod holes,
and one plunger in hole between 3-4 and reverse
fork rod holes.
B3M0062D
19
[W2B1]3-1SERVICE PROCEDURE
2. Transmission Case

2) Install reverse shifter lever, reverse idler gear
and reverse idler gear shaft, and secure with
straight pin.
NOTE:
Be sure to install reverse idler shaft from the rear
side.
B3M0526C
(A) Reverse shifter lever
(B) Reverse idler gear
(C) Reverse idler gear shaft
(D) Straight pin
3) Install reverse arm fork spring, ball and inter-
lock plunger (5.56´19.6) to reverse fork rod arm.
Insert reverse fork rod into hole in reverse fork rod
arm, and hold it with outer snap ring using ST.
CAUTION:
Apply grease to plunger to prevent it from fall-
ing.
ST 399411700 ACCENT BALL INSTALLER
4) Position ball (7.1438), spring and gasket in
reverse shifter rod hole, on left side transmission
case, and tighten checking ball plug.
CAUTION:
Replace gasket with a new one.5) Move reverse shifter rod toward REV side.
Adjust clearance between reverse idler gear and
transmission case wall, using reverse shifter lever.
Clearance A:
6.0 Ð 7.5 mm (0.236 Ð 0.295 in)
G3M0796
Reverse shifter lever
Part No. No. Remarks
32820AA070 7 Further from case wall
32820AA080 8 Standard
32820AA090 9 Closer to case wall
6) After installing a suitable reverse shifter lever,
shift into neutral. Using a thickness gauge, mea-
sure clearance between reverse idler gear and
transmission case wall and adjust with washer(s).
Clearance:
0 Ð 0.5 mm (0 Ð 0.020 in)
B3M0063
Washer (20.5´26´t)
Part No. Thickness mm (in)
803020151 0.4 (0.016)
803020152 1.1 (0.043)
803020153 1.5 (0.059)
803020154 1.9 (0.075)
803020155 2.3 (0.091)
7) Install 1-2 fork rod into 1-2 shifter fork via the
hole on the rear of transmission case.
8) Align the holes in rod and fork, and drive
straight pin (6´22) into these holes using ST.
ST 398791700 STRAIGHT PIN REMOVER
20
3-1[W2B1]SERVICE PROCEDURE
2. Transmission Case

CAUTION:
Replace straight pin with a new one.
NOTE:
ISet other rods to neutral.
IMake sure interlock plunger (5.56´19.6) is on
the 3-4 fork rod side.
9) Install interlock plunger (3´11.9) onto 3-4 fork
rod.
CAUTION:
Apply a coat of grease to plunger to prevent it
from falling.
10) Install 3-4 fork rod into 3-4 shifter fork via the
hole on the rear of transmission case.
11) Align the holes in rod and fork, and drive
straight pin (6´22) into these holes.
ST 398791700 STRAIGHT PIN REMOVER
CAUTION:
Replace straight pin with a new one.
NOTE:
ISet reverse fork rod to neutral.
IMake sure interlock plunger (installed before) is
on the reverse fork rod side.
12) Install 5th shifter fork onto the rear of reverse
fork rod. Align holes in the two parts and drive
straight pin into place.
CAUTION:
Replace straight pin with a new one.
ST 398791700 STRAIGHT PIN REMOVER
B3M0333J
(A) 5th shifter fork
(B) Reverse fork rod
(C) Straight pin
13) Position balls, checking ball springs and gas-
kets into 3-4 and 1-2 rod holes, and install plugs.
CAUTION:
Replace gasket with a new one.
G3M0552
14) Install washer and speedometer shaft, and
press fit oil seal with ST.
CAUTION:
Use new oil seal, if it has been removed.
ST 899824100 or 499827000 PRESS
15) Install vehicle speed sensor 2.
CAUTION:
Use new vehicle speed sensor 2, if it has been
removed.
Tightening torque:
5.9
±1.5 N´m (60±15 kg-cm, 52±13 in-lb)
16) Install speedometer driven gear and snap
ring.
CAUTION:
Use a new snap ring, if it has been removed.
B3M0527C
(A) Speedometer driven gear
(B) Snap ring
21
[W2B1]3-1SERVICE 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