SUBARU LEGACY 1999 Service Repair Manual

11) Remove propeller shaft.
CAUTION:
When removing propeller shaft, pay attention
not to damage the sliding surfaces of rear drive
shaft (extension) spline, oil seal and sleeve
yoke.
NOTE:
IPrepare an oil can and cap since the transmis-
sion oil flows out from the extension at removing
propeller shaft.
IInsert the cap into the extension to prevent
transmission oil from flowing out immediately after
removing the propeller shaft.
S3M0033A
12) Remove heat sealed cover.
13) Remove clamps and bracket of parking brake
cable.
G3M0053
14) Remove crossmember reinforcement lower
(Sedan only).15) Remove DOJ of rear drive shaft from rear dif-
ferential using ST.
ST 28099PA100 DRIVE SHAFT REMOVER
G3M1020
16) Secure rear drive shaft to rear crossmember
using wire.
G3M1022
17) Remove lower differential bracket.
G3M0054
18) Support rear differential with transmission
jack.
G3M0055
21
[W2B1]3-4SERVICE PROCEDURE
2. Rear Differential

19) Remove self-locking nuts connecting rear dif-
ferential to rear crossmember.
G3M1028
20) Remove bolts which secure rear differential
front member to body. Loosen bolt (A) first, then
remove bolts (B).
NOTE:
Support front member with the use of a helper to
prevent it from dropping.
B3M0657C
(A) Bolt A
(B) Bolt B
21) Remove bolt A.
22) While slowly lowering transmission jack, move
rear differential forward and remove front member
and rear differential from body.
G3M1029
23) Remove rear differential from front member.
G3M1030
2. VA-TYPE
1) Disconnect ground cable from battery.
2) Move selector lever or gear shift lever to ªNº.
3) Release the parking brake.
4) Loosen wheel nuts.
5) Jack-up vehicle and support it with sturdy
racks.
6) Remove wheels.
7) Remove rear exhaust pipe.

8) Remove muffler.

9) Remove front exhaust cover.
G3M0021
10) Remove front cover of rear differential mount.
G3M0022
22
3-4[W2B2]SERVICE PROCEDURE
2. Rear Differential

11) Remove propeller shaft.
CAUTION:
When removing propeller shaft, pay attention
not to damage the sliding surfaces of rear drive
shaft (extension) spline, oil seal and sleeve
yoke.
NOTE:
IPrepare an oil can and cap since the transmis-
sion oil flows out from the extension at removing
propeller shaft.
IInsert the cap into the extension to prevent
transmission oil from flowing out immediately after
removing the propeller shaft.
S3M0033A
12) Remove heat sealed cover.
13) Remove clamps and bracket of parking brake
cable.
G3M0053
14) Remove DOJ of rear drive shaft from rear dif-
ferential.
G3M0257
15) Secure rear drive shaft to rear crossmember
using wire.
G3M0046
16) Remove lower differential bracket.
G3M0054
17) Support rear differential with transmission
jack.
G3M0055
23
[W2B2]3-4SERVICE PROCEDURE
2. Rear Differential

18) Remove self-locking nuts connecting rear dif-
ferential to rear crossmember.
B3M0131
19) Remove bolts which secure rear differential
front member to body. Loosen bolt A first, then
removal bolts B .
NOTE:
Support front member with the use of a helper to
prevent it from dropping.
B3M0657C
(A) Bolt A
(B) Bolt B
20) Remove bolt A.
21) While slowly lowering transmission jack, move
rear differential forward and remove bolts from rear
crossmember.
22) Remove front member from body.
G3M0058
23) Remove rear differential from body.
G3M0059
C: DISASSEMBLY
1. T-TYPE
NOTE:
To detect real cause of trouble, inspect the follow-
ing items before disassembling.
ITooth contact of crown gear and pinion, and
backlash
IRunout of crown gear at its back surface
ITurning resistance of drive pinion
1) Set ST on vise and install the differential
assembly to ST.
ST 398217700 ATTACHMENT
G3M1031
2) Drain gear oil by removing plug.
3) Remove the air breather cap.
NOTE:
Do not attempt to replace the air breather cap
unless necessary.
G3M1033
24
3-4[W2C1]SERVICE PROCEDURE
2. Rear Differential

4) Remove rear cover by loosening retaining
bolts.
G3M1032
5) Make right and left side bearing retainers in
order to identify them at reassembly. Remove side
bearing retainer attaching bolts, set ST to differen-
tial carrier, and extract right and left side bearing
retainers with a puller.
CAUTION:
Each shim, which is installed to adjust the side
bearing preload, should be kept together with
its mating retainer.
ST 398457700 ATTACHMENT
G3M1034
6) Pull out differential assembly from differential
carrier.
CAUTION:
Be careful not to hit the teeth against the case.
G3M1035
7) When replacing side bearing, pull bearing race
from side bearing retainer using ST.
ST 398527700 PULLER ASSY
B3M0871A
8) Extract bearing cone with ST.
CAUTION:
Do not attempt to disassemble the parts unless
necessary.
NOTE:
ISet puller so that its claw catch the edge of the
bearing cone.
INever mix up the right and left hand bearing
races and cones.
ST 399527700 PULLER SET
G3M0068
9) Remove crown gear by loosening crown gear
bolts.
CAUTION:
Further disassembling is not allowed.
G3M0069
25
[W2C1]3-4SERVICE PROCEDURE
2. Rear Differential

10) Drive out pinion shaft lock pin from crown gear
side.
NOTE:
The lock pin is staked at the pin hole end on the
differential case; do not drive it out forcibly before
unstaking it.
ST 899904100 STRAIGHT PIN REMOVER
B3M0133
11) Draw out pinion mate shaft and remove pinion
mate gears, side gears and thrust washers.
NOTE:
The gears as well as thrust washers should be
marked or kept separated left and right, and front
and rear.
G3M0071
12) Hold companion flange with ST and remove
drive pinion nut.
ST 498427200 FLANGE WRENCH
G3M1052
13) Extract the companion flange with a puller.
G3M0073
14) Press the end of drive pinion shaft and extract
it together with rear bearing cone, preload adjust-
ing spacer and washer.
NOTE:
Hold the drive pinion so as not to drop it.
ST 398467700 DRIFT
G3M0074
15) Remove rear bearing cone from drive pinion
by supporting cone with ST.
NOTE:
Place the replacer so that its center-recessed side
faces the pinion gear.
ST 498515500 REPLACER
G3M0075
26
3-4[W2C1]SERVICE PROCEDURE
2. Rear Differential

16) Remove front oil seal from differential carrier
using ST.
ST 398527700 PULLER ASSY
G3M0076
17) Remove pilot bearing together with front bear-
ing cone using ST.
ST 398467700 DRIFT
B3M0872A
18) When replacing bearings, tap front bearing
cup and rear bearing cup in this order out of case
by using a brass bar.
G3M0078
2. VA-TYPE
To detect real cause of trouble, inspect the follow-
ing items before disassembling.
ITooth contact of crown gear and pinion, and
backlash
IRunout of crown gear at its back surface
ITurning resistance of drive pinion1) Set ST on vise and install the differential
assembly to ST.
ST 398217700 ATTACHMENT
G3M0060
2) Drain gear oil by removing plug.
3) Remove rear cover by loosening retaining
bolts.
G3M0061
4) Replace air breather cap.
NOTE:
Do not attempt to replace the air breather cap
unless necessary.
G3M0062
27
[W2C2]3-4SERVICE PROCEDURE
2. Rear Differential

5) Remove right and left lock plates.
G3M0063
6) Remove right and left holders with ST.
ST 399780111 WRENCH
G3M0064
7) Pull out differential assembly from differential
carrier.
CAUTION:
Be careful not to hit the teeth against the case.
G3M0065
8) Remove bearing race from right and left holders
with ST1 and ST2.
ST1 499705401 BEARING OUTER RACE
PULLER ASSY
ST2 499705404 OUTER RACE PULLER
SEAT
G3M0066
9) Remove oil seal from right and left holders with
screwdriver.
CAUTION:
Perform this operation only when changing oil
seal.
B3M0132
28
3-4[W2C2]SERVICE PROCEDURE
2. Rear Differential

10) Extract bearing cone with ST.
CAUTION:
Do not attempt to disassemble the parts unless
necessary.
NOTE:
ISet Puller so that its claws catch the edge of the
bearing cone.
INever mix up the right and left hand bearing
cones.
ST 899524100 PULLER SET
G3M0068
11) Remove crown gear by loosening crown gear
bolts.
G3M0069
12) Drive out pinion shaft lock pin from crown gear
side.
NOTE:
The lock pin is staked at the pin hole end on the
differential case; do not drive it out forcibly before
unstaking it.
ST 899904100 STRAIGHT PIN REMOVER
B3M0133
13) Draw out pinion mate shaft and remove pinion
mate gears, side gears and thrust washers.
NOTE:
The gears as well as thrust washers should be
marked or kept separated left and right, and front
and rear.
G3M0071
14) Hold companion flange with ST and remove
drive pinion nut.
ST 498427200 FLANGE WRENCH
G3M0072
15) Extract the companion flange with a puller.
G3M0073
29
[W2C2]3-4SERVICE PROCEDURE
2. Rear Differential

16) Press the end of drive pinion shaft and extract
it together with rear bearing cone, preload adjust-
ing spacer and washer.
NOTE:
Hold the drive pinion so as not to drop it.
ST 398467700 DRIFT
G3M0074
17) Remove rear bearing cone from drive pinion
by supporting cone with ST.
NOTE:
Place the replacer so that its center-recessed side
faces the pinion gear.
ST 498515500 REPLACER
G3M0075
18) Remove front oil seal from differential carrier.
ST 499705401 PULLER ASSY
G3M0076
19) Remove pilot bearing together with front bear-
ing cone using ST.
ST 398467700 DRIFT
B3M0872A
20) When replacing bearings, tap front bearing
race and rear bearing race in this order out of case
by using a brass bar.
G3M0078
D: INSPECTION
Wash all the disassembled parts clean, and exam-
ine them for wear, damage, or other defects.
Repair or replace defective parts as necessary.
1) Crown gear and drive pinion
IIf abnormal tooth contact is evident, find out the
cause and adjust to give correct tooth contact at
assembly. Replace the gear if excessively worn or
incapable of adjustment.
IIf crack, score, or seizure is evident, replace as
a set. Slight damage of tooth can be corrected by
oil stone or the like.
2) Side gear and pinion mate gear
IReplace if crack, score, or other defects are evi-
dent on tooth surface.
IReplace if thrust washer contacting surface is
worn or seized. Slight damage of the surface can
be corrected by oil stone or the like.
3) Bearing
Replace if seizure, peeling, wear, rust, dragging
during rotation, abnormal noise or other defect is
evident.
4) Thrust washers of side gear and pinion mate
gear Replace if seizure, flaw, abnormal wear or
other defect is evident.
5) Oil seal
30
3-4[W2D0]SERVICE PROCEDURE
2. Rear Differential