SUBARU LEGACY 1999 Service Repair Manual

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

C: ADJUSTMENT
1. THRUST BEARING PRELOAD
1) After completing the preceding steps 1) through
3), select adjusting washer No. 2 so that dimension
(H) is zero through visual check. Position washer
(18.3´30´4) and lock washer (18´30´2) and
install lock nut (18´13.5).
B3M0538A
2) Using ST1, ST2 and ST3, tighten lock nut to the
specified torque.
ST1 899884100 HOLDER
ST2 498427100 STOPPER
ST3 899988608 SOCKET WRENCH (27)
Tightening torque:
11 8
±8 N´m (12±0.8 kg-m, 86.8±5.8 ft-lb)
G3M0626
3) After removing ST2, measure starting torque
using torque driver.
ST1 899884100 HOLDER
ST3 899988608 SOCKET WRENCH (27)
Starting torque:
54
±25 N´m (5.5±2.5 kg-m, 40±18 ft-lb)
B3M0085A
4) If starting torque is not within specified limit,
select new adjusting washer No. 1 and recheck
starting torque.
B3M0536H
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)
34
3-1[W3C1]SERVICE PROCEDURE
3. Drive Pinion Assembly

5) If specified starting torque range cannot be
obtained when a No. 1 adjusting washer is used,
then select a suitable No. 2 adjusting washer from
those listed in the following table. Repeat steps 1)
through 4) to adjust starting torque.
B3M0536I
(A) Adjusting washer No. 1
(B) Adjusting washer No. 2
Starting torque Dimension H Washer No. 2
Low Small Select thicker one.
High Large Select thinner one.
Adjusting washer No. 2
Part No. Thickness mm (in)
803025059 3.850 (0.1516)
803025054 4.000 (0.1575)
803025058 4.150 (0.1634)
6) Recheck that starting torque is within specified
range, then clinch lock nut at four positions.
4. Main Shaft Assembly
A: DISASSEMBLY
1. 2200 cc MODEL
1) Put vinyl tape around main shaft splines to pro-
tect oil seal from damage. Then pull out oil seal
and needle bearing by hand.
2) Remove lock nut from transmission main shaft
assembly.
NOTE:
Remove caulking before taking off lock nut.
ST1 498937000 TRANSMISSION HOLDER
ST2 499987003 SOCKET WRENCH (35)
B3M0087A
3) Remove insert stopper plate, sleeve and hub
assembly No. 2, baulk ring, 5th drive gear, and
needle bearing.
B3M1364A
(A) Insert stopper plate
(B) Sleeve and hub assembly No. 2
(C) Baulk ring
(D) 5th drive gear
(E) Needle bearing (32´36´25.7)
35
[W4A1]3-1SERVICE PROCEDURE
4. Main Shaft Assembly

4) Using ST1 and ST2, remove the rest of parts.
NOTE:
Replace sleeve and hub with new ones. Do not
attempt to disassemble because they must engage
at a specified point. If they should be
disassembled, marking engagement point on
splines beforehand.
ST1 899864100 REMOVER
ST2 899714110 REMOVER
B3M0834A
2. 2500 cc MODEL
1) Put vinyl tape around main shaft splines to pro-
tect oil seal from damage. Then pull out oil seal
and needle bearing by hand.
2) Remove lock nut from transmission main shaft
assembly.
NOTE:
Remove caulking before taking off lock nut.
ST1 498937000 TRANSMISSION HOLDER
ST2 499987003 SOCKET WRENCH (35)
B3M0439A
3) Remove 5th-Rev sleeve and hub assembly,
baulk ring, 5th drive gear and needle bearing (32
x 36 x 25.7).
B3M0437B
(A) 5th-Rev sleeve and hub ASSY
(B) Baulk ring
(C) 5th drive gear
4) Remove snap ring and synchro cone stopper
from 5th-Rev sleeve and hub assembly.
B3M0435B
(A) Synchro cone
(B) Snap ring
36
3-1[W4A2]SERVICE PROCEDURE
4. Main Shaft Assembly

5) Using ST1 and ST2 and a press, remove ball
bearing, synchro cone and baulk ring (Rev).
NOTE:
IReplace sleeve and hub with new ones. Do not
attempt to disassemble because they must engage
at a specified point. If they should be
disassembled, mark engagement point on splines
beforehand.
IDo not reuse ball bearing.
ST1 499757002 SNAP RING PRESS
ST2 498077400 SYNCHRO CONE
REMOVER
B3M1365A
(A) Ball bearing
(B) Synchro cone
(C) Baulk ring
6) Using ST1 and ST2, remove the rest of parts.
NOTE:
Replace sleeve and hub with new ones. Do not
attempt to disassemble because they must engage
at a specified point. If they should be
disassembled, marking engagement point on
splines beforehand.
ST1 899864100 REMOVER
ST2 899714110 REMOVER
B3M0835A
37
[W4A2]3-1SERVICE PROCEDURE
4. Main Shaft Assembly

5) If specified starting torque range cannot be
obtained when a No. 1 adjusting washer is used,
then select a suitable No. 2 adjusting washer from
those listed in the following table. Repeat steps 1)
through 4) to adjust starting torque.
B3M0536I
(A) Adjusting washer No. 1
(B) Adjusting washer No. 2
Starting torque Dimension H Washer No. 2
Low Small Select thicker one.
High Large Select thinner one.
Adjusting washer No. 2
Part No. Thickness mm (in)
803025059 3.850 (0.1516)
803025054 4.000 (0.1575)
803025058 4.150 (0.1634)
6) Recheck that starting torque is within specified
range, then clinch lock nut at four positions.
4. Main Shaft Assembly
A: DISASSEMBLY
1. 2200 cc MODEL
1) Put vinyl tape around main shaft splines to pro-
tect oil seal from damage. Then pull out oil seal
and needle bearing by hand.
2) Remove lock nut from transmission main shaft
assembly.
NOTE:
Remove caulking before taking off lock nut.
ST1 498937000 TRANSMISSION HOLDER
ST2 499987003 SOCKET WRENCH (35)
B3M0087A
3) Remove insert stopper plate, sleeve and hub
assembly No. 2, baulk ring, 5th drive gear, and
needle bearing.
B3M1364A
(A) Insert stopper plate
(B) Sleeve and hub assembly No. 2
(C) Baulk ring
(D) 5th drive gear
(E) Needle bearing (32´36´25.7)
35
[W4A1]3-1SERVICE PROCEDURE
4. Main Shaft Assembly

4) Using ST1 and ST2, remove the rest of parts.
NOTE:
Replace sleeve and hub with new ones. Do not
attempt to disassemble because they must engage
at a specified point. If they should be
disassembled, marking engagement point on
splines beforehand.
ST1 899864100 REMOVER
ST2 899714110 REMOVER
B3M0834A
2. 2500 cc MODEL
1) Put vinyl tape around main shaft splines to pro-
tect oil seal from damage. Then pull out oil seal
and needle bearing by hand.
2) Remove lock nut from transmission main shaft
assembly.
NOTE:
Remove caulking before taking off lock nut.
ST1 498937000 TRANSMISSION HOLDER
ST2 499987003 SOCKET WRENCH (35)
B3M0439A
3) Remove 5th-Rev sleeve and hub assembly,
baulk ring, 5th drive gear and needle bearing (32
x 36 x 25.7).
B3M0437B
(A) 5th-Rev sleeve and hub ASSY
(B) Baulk ring
(C) 5th drive gear
4) Remove snap ring and synchro cone stopper
from 5th-Rev sleeve and hub assembly.
B3M0435B
(A) Synchro cone
(B) Snap ring
36
3-1[W4A2]SERVICE PROCEDURE
4. Main Shaft Assembly

5) Using ST1 and ST2 and a press, remove ball
bearing, synchro cone and baulk ring (Rev).
NOTE:
IReplace sleeve and hub with new ones. Do not
attempt to disassemble because they must engage
at a specified point. If they should be
disassembled, mark engagement point on splines
beforehand.
IDo not reuse ball bearing.
ST1 499757002 SNAP RING PRESS
ST2 498077400 SYNCHRO CONE
REMOVER
B3M1365A
(A) Ball bearing
(B) Synchro cone
(C) Baulk ring
6) Using ST1 and ST2, remove the rest of parts.
NOTE:
Replace sleeve and hub with new ones. Do not
attempt to disassemble because they must engage
at a specified point. If they should be
disassembled, marking engagement point on
splines beforehand.
ST1 899864100 REMOVER
ST2 899714110 REMOVER
B3M0835A
37
[W4A2]3-1SERVICE PROCEDURE
4. Main Shaft Assembly

B: ASSEMBLY
1. 2200 cc MODEL
1) Assemble sleeve and hub assembly for 3rd-4th
and, 5th synchronizing.
NOTE:
Position open ends of spring 120É apart.
B3M1366A
2) Install 3rd drive gear, baulk ring, and sleeve and
hub assembly for 3rd-4th needle bearing (32´36
´25.7) on transmission main shaft.
NOTE:
Align groove in baulk ring with shifting insert.
3) Install 4th needle bearing race onto transmis-
sion main shaft using ST1, ST2 and a press.
ST1 899714110 REMOVER
ST2 499877000 RACE 4-5 INSTALLER
B3M0543C
4) Install baulk ring, needle bearing (32´30´
25.7), 4th drive gear and 4th gear thrust washer to
transmission main shaft.
S3M0045A
(A) Groove
(B) 4th gear side
5) Drive ball bearing onto the rear section of trans-
mission main shaft using ST1, ST2 and a press.
ST1 899714110 REMOVER
ST2 499877000 RACE 4-5 INSTALLER
B3M0553D
6) Using ST1 and ST2, install the 5th gear thrust
washer and 5th needle bearing race onto the rear
section of transmission main shaft.
NOTE:
Face thrust washer in the correct direction.
ST1 899714110 REMOVER
ST2 499877000 RACE 4-5 INSTALLER
B3M0091D
(A) Face this surface to 5th gear side.
38
3-1[W4B1]SERVICE PROCEDURE
4. Main Shaft Assembly

7) Install the following parts to the rear section of
transmission main shaft.
NOTE:
IAlign groove in baulk ring with shifting insert.
IBe sure to fit pawl of insert stopper plate into 4
mm (0.16 in) dia. hole in the boss section of syn-
chronizer hub.
B3M1367A
(A) Needle bearing (32´36´25.7)
(B) 5th drive gear
(C) Baulk ring
(D) Sleeve and hub assembly
(E) Insert stopper plate
(F) Lock washer (22´38´2)
(G) Lock nut
8) Tighten lock nuts (22´13) to the specified
torque using ST1 and ST2.
NOTE:
Secure lock nuts in two places after tightening.
ST1 499987003 SOCKET WRENCH (35)
ST2 498937000 TRANSMISSION HOLDER
Tightening torque:
11 8
±6 N´m (12.0±0.6 kg-m, 86.8±4.3 ft-lb)
2. 2500 cc MODEL
1) Assemble sleeve and hub assembly for 3rd-4th
and, 5th synchronizing.
NOTE:
Position open ends of spring 120É apart.
B3M1366A
2) Install 3rd drive gear, outer baulk ring, synchro
cone, inner baulk ring, sleeve and hub assembly
for 3rd needle bearing on transmission main shaft.
NOTE:
Align groove in baulk ring with insert key.
B3M0837A
(A) 3rd needle bearing (32´36´25.7)
(B) 3rd drive gear
(C) Inner baulk ring
(D) Synchro cone
(E) Outer baulk ring
(F) Sleeve and hub ASSY
39
[W4B2]3-1SERVICE PROCEDURE
4. Main Shaft Assembly