SUBARU LEGACY 1999 Service Repair Manual

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

NOTE:
IAlign the end face of seal with surface A of left
side transmission main case when installing oil
seal.
B3M0528A
IBe careful not to drop oil seal when installing
right side transmission main case.
IMake sure straight pin is positioned in hole in
needle bearing's outer race.
10) Install drive pinion shaft assembly with shims
selected before into transmission case.
NOTE:
Ensure that the knock pin of the case is fitted into
the hole in the bearing outer race.
B3M0529C
11) Set transmission main shaft assembly and
drive pinion shaft assembly in position (so there is
no clearance between the two when moved all the
way to the front). Select suitable 1st-2nd, 3rd-4th
and 5th shifter fork so that coupling sleeve and
reverse driven gear are positioned in the center of
their synchronizing mechanisms.1st driven gear to reverse driven gear
Clearance (a): 9.5 mm (0.374 in)
Reverse driven gear to 2nd driven gear
Clearance (b): 9.5 mm (0.374 in)
S3M0034A
(A) 1st driven gear
(B) Reverse driven gear
(C) 2nd driven gear
1st-2nd shifter fork
Part No. No. 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 gear to coupling sleeve
Clearance (a): 9.3 mm (0.366 in)
Coupling sleeve to 4th driven gear
Clearance (b): 9.3 mm (0.366 in)
B3M1411A
(A) 3rd-4th
(B) Coupling sleeve
(C) 4th driven gear
3rd-4th shifter fork
Part No. No. 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)
24
3-1[W2B2]SERVICE PROCEDURE
2. Transmission Case

5th driven gear to coupling sleeve
Clearance (a): 9.3 mm (0.366 in)
B3M1403A
(A) 5th driven gear
(B) Coupling sleeve
5th shifter fork
Part No. No. Remarks
32812AA200 4Approach to 5th gear by
0.2 mm (0.008 in)
32812AA210 No mark Standard
32812AA220 6Become distant from 5th
gear by 0.2 mm (0.008 in)
12) Measure rod end clearances (A) and (B). If
any clearance is not within specifications, replace
rod or fork as required.
(A): 1st-2nd to 3rd-4th 0.4 Ð 1.4 mm (0.016 Ð 0.055 in)
(B): 3rd-4th to 5th 0.5 Ð 1.3 mm (0.020 Ð 0.051 in)
B3M0530A
13) Wipe off grease, oil and dust on the mating
surfaces of transmission cases with white
gasoline, and apply liquid gasket, and then put
case right side and left side together.
Liquid gasket:
THREE BOND 1215 or equivalent
14) Tighten 17 bolts with bracket, clip, etc. as
shown in the figure.
NOTE:
IInsert bolts from the bottom and tighten nuts at
the top.
IPut cases together so that drive pinion shim and
input shaft holder shim are not caught up in
between.
IConfirm that speedometer gear is meshed.
Tightening torque:
8 mm bolt
25
±2 N´m (2.5±0.2 kg-m, 18.1±1.4 ft-lb)
H10 mm bolt
39
±3 N´m (4.0±0.3 kg-m, 28.9±2.2 ft-lb)
B3M0399B
15) Tighten ball bearing attachment bolts.
Tightening torque:
29
±3 N´m (3.0±0.3 kg-m, 21.7±2.2 ft-lb)
S3M0099
25
[W2B2]3-1SERVICE PROCEDURE
2. Transmission Case

16) Backlash adjustment of hypoid gear and pre-
load adjustment of roller bearing
NOTE:
Support drive pinion assembly with ST.
ST 498427100 STOPPER
B3M1362A
17) Place the transmission with case left side fac-
ing downward and put ST1 on bearing cup.
18) Screw retainer assembly into left case from
the bottom with ST2. Fit ST3 on the transmission
main shaft. Shift gear into 4th or 5th and turn the
shaft several times. Screw in the retainer while
turning ST3 until a slight resistance is felt on ST2.
This is the contact point of hypoid gear and drive
pinion shaft. Repeat the above sequence several
times to ensure the contact point.
ST1 399780104 WEIGHT
ST2 499787000 WRENCH ASSY
ST3 499927100 HANDLE
B3M1361A
19) Remove weight and screw in retainer without
O-ring on the upper side and stop at the point
where slight resistance is felt.
NOTE:
At this point, the backlash between the hypoid gear
and drive pinion shaft is zero.
ST 499787000 WRENCH ASSY
B3M1360A
20) Fit lock plate. Loosen the retainer on the lower
side by 1-1/2 notches of lock plate and turn in the
retainer on the upper side by the same amount in
order to obtain the backlash.
NOTE:
The notch on the lock plate moves by 1/2 notch if
the plate is turned upside down.
21) Turn in the retainer on the upper side addition-
ally by 1 notch in order to apply preload on taper
roller bearing.
22) Tighten temporarily both the upper and lower
lock plates and mark both holder and lock plate for
later readjustment.
23) Turn transmission main shaft several times
while tapping around retainer lightly with plastic
hammer.
26
3-1[W2B2]SERVICE PROCEDURE
2. Transmission Case

24) Set ST1 and ST2. Insert the needle through
transmission oil drain plug hole so that the needle
comes in contact with the tooth surface at a right
angle and check the backlash.
ST1 498247001 MAGNET BASE
ST2 498247100 DIAL GAUGE
ST3 498255400 PLATE
NOTE:
IIf backlash is outside specified range, adjust it
by turning holder in right side case.
IEach time holder rotates one tooth, backlash
changes by 0.05 mm (0.0020 in).
Backlash:
0.13 Ð 0.18 mm (0.0051 Ð 0.0071 in)
B3M1363A
25) Check tooth contact of hypoid gear as follows:
Apply a uniform thin coat of red lead on both tooth
surfaces of 3 or 4 teeth of the hypoid gear. Move
the hypoid gear back and forth by turning the trans-
mission main shaft until a definite contact pattern
is developed on hypoid gear, and judge whether
face contact is correct. If it is incorrect, make the
following correction.
ITooth contact is correct.
B3M0070D
(A) Toe
(B) Coast side
(C) Heel
(D) Drive side
IBacklash is excessive.
To reduce backlash, loosen holder on the upper
side (case right side) and turn in the holder on the
lower side (case left side) by the same amount.
B3M0071
IBacklash is insufficient.
To increase backlash, loosen holder on the lower
side (case left side) and turn in the holder on the
upper side (case right side) by the same amount.
B3M0072
IThe drive pinion shim selected before is too
thick. Reduce its thickness.
B3M0073
27
[W2B2]3-1SERVICE PROCEDURE
2. Transmission Case

IThe drive pinion shim selected before is too thin.
Increase its thickness.
B3M0074
26) After checking the tooth contact of hypoid
gears, remove the lock plate. Then loosen retainer
until the O-ring groove appears. Fit O-ring into the
groove and tighten retainer into the position where
retainer has been tightened in.
Tighten lock plate.
NOTE:
Carry out this job on both upper and lower retain-
ers.
Tightening torque:
T: 2 5
±3 N´m (2.5±0.3 kg-m, 18.1±2.2 ft-lb)
S3M0014A
27) Selecting of main shaft rear plate
Using ST, measure the amount (A) of ball bearing
protrusion from transmission main case surface
and select the proper plate in the following table:
ST 498147000 DEPTH GAUGE
NOTE:
Before measuring, tap the end of main shaft with
a plastic hammer lightly in order to make the clear-
ance zero between the main case surface and the
moving flange of bearing.
Dimension (A)
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
B3M0531A
28) Install clutch release lever and bearing. to 2-10 [W3C0].>
B3M0336I
(A) Clutch release lever
(B) Release bearing
28
3-1[W2B2]SERVICE 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

4) Remove roller bearing (42´74´40), 3rd-4th
driven gear using ST1 and ST2.
ST1 499757002 SNAP RING PRESS
ST2 899714110 REMOVER
G3M0610
5) Remove the key.
6) Remove 2nd driven gear, inner baulk ring, syn-
chro cone and outer baulk ring.
B3M0426C
(A) 2nd driven gear
(B) Inner baulk ring
(C) Synchro coner
(D) Outer baulk ring
7) Remove 1st driven gear, 2nd gear bushing,
gear and hub using ST1 and ST2.
NOTE:
Replace gear and hub if necessary. Do not attempt
to disassemble if at all possible because they must
engage at a specified point. If they have to be
disassembled, mark the engaging point before-
hand.
ST1 499757002 SNAP RING PRESS
ST2 899714110 REMOVER
G3M0611
8) Remove sub gears for 1st and 2nd driven gear.
B: ASSEMBLY
1. GEAR AND HUB ASSEMBLY
Assemble gear and hub assembly.
NOTE:
IUse new gear and hub assembly, if gear or hub
have been replaced.
IBe sure the insert keys are correctly located in
the insert key grooves inside the reverse driven
gear.
B3M0431B
(A) Key grooves
(B) Reverse driven gear
30
3-1[W3B1]SERVICE PROCEDURE
3. Drive Pinion Assembly

B3M0077E
(A) 1st gear side
(B) 2nd gear side
(C) Flush surface
(D) Stepped surface
2. DRIVEN GEAR ASSEMBLY
Assemble a driven shaft and 1st driven gear that
select for adjustment the proper radial clearance.
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
B3M0537A
1) Install sub gear to 1st driven gear.
2) Install 1st driven gear, 1st baulk ring, gear and
hub assembly onto driven shaft.
NOTE:
Take care to install gear hub in proper direction.3) Install 2nd driven gear bushing onto driven
shaft using ST1, ST2 and press.
ST1 499277200 INSTALLER
ST2 499587000 INSTALLER
CAUTION:
Attach a cloth to the end of driven shaft to pre-
vent damage.
NOTE:
When press ftting, align oil holes of shaft and bush.
B3M0078D
4) Install 2nd driven gear, inner baulk ring, syn-
chro cone, outer baulk ring and insert onto driven
shaft.
B3M0426C
(A) 2nd driven gear
(B) Inner baulk ring
(C) Synchro cone
(D) Outer baulk ring
31
[W3B2]3-1SERVICE PROCEDURE
3. Drive Pinion Assembly

5) After installing key on driven shaft, install 3rd-
4th driven gear using ST and press.
NOTE:
Align groove in baulk ring with insert.
ST 499277200 INSTALLER
G3M0615
6) Install a set of roller bearings (42´74´40)
onto the driven shaft using ST and press.
ST 499277200 INSTALLER
G3M0616
7) Position woodruff key in groove on the rear of
driven shaft. Install 5th driven gear onto drive shaft
using ST and press.
ST 499277200 INSTALLER
G3M0617
8) Install lock washer (42´53´2). Install lock nut
(42´13) and tighten to the specified torque using
ST.
ST 499987300 SOCKET WRENCH (50)
Tightening torque:
265
±10 N´m (27±1 kg-m, 195±7 ft-lb)
G3M0618
NOTE:
IStake lock nut at two points.
IUsing spring balancer, check that starting torque
of roller bearing is 0.1 to 1.5 N´m (0.01 to 0.15
kg-m, 0.07 to 1.1 ft-lb).
B3M0079D
3. DRIVE PINION SHAFT
1) Install roller bearing onto drive pinion. Install
washer (33´50´5) using ST1, ST2 and press.
ST1 499277100 BUSH 1-2 INSTALLER
ST2 499277200 INSTALLER
B3M0080D
32
3-1[W3B3]SERVICE PROCEDURE
3. Drive Pinion Assembly