1995 SUBARU LEGACY light

G3M0564
(1) Place the transmission with case left side facing
downward and put ST1 on bearing cup.
(2) Screw retainer assembly into left case from the bot-
tom 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 pin-
ion shaft. Repeat the above sequence several times to
ensure the contact point.
ST1 399780104 WEIGHT
ST2 499787000 WRENCH ASSY
ST3 499927100 HANDLE
B3M0340A
(3) 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
B3M0334A
(4) Fit lock plate
11. 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.
(5) Turn in the retainer on the upper side additionally
by 1 notch in order to apply preload on taper roller
bearing.
(6) Tighten temporarily both the upper and lower lock
plates and mark both holder and lock plate for later
readjustment.
(7) Turn transmission main shaft several times while
tapping around retainer lightly with plastic hammer.
(8) Set ST1 and ST2. Insert the needle through trans-
mission oil drain plug hole so that the needle comes in
contact with the tooth surface at a right angle and check
the backlash.
46
3-1SERVICE PROCEDURE
4. Transmission Case

G3M0573
12) 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
Dimension“A”
mm (in)Part No. Mark
4.00—4.13
(0.1575—0.1626)32294AA040 1
3.87—3.99
(0.1524—0.1571)32294AA050 2
NOTE:
Before measuring, tap the end of main shaft with a plastic
hammer lightly in order to make the clearance zero
between the main case surface and the moving flange of
bearing.
B3M0336A
13) Install clutch release lever
1and bearing
2.
49
3-1SERVICE PROCEDURE
4. Transmission Case

G3M0291
2. INHIBITOR SWITCH
The inhibitor switch allows the back-up lights to turn on
when the select lever is in the R range and the starter
motor to start when the lever is in the N or P range. It also
monitors the input signal electronically controlled for each
range and turns on the corresponding range light on the
instrument panel.
When light operation, driving condition or starter motor
operation is erroneous, first check the shift linkage for
improper operation. If the shift linkage is functioning
properly, check the inhibitor switch.

(1) Disconnect cable end from select lever.
(2) Disconnect inhibitor switch connector.
(3) Check continuity in inhibitor switch circuits with
select lever moved to each position.
CAUTION:
Also check that continuity in ignition circuit does not
exist when selector lever is in R, D, 3, 2 and 1 ranges.
PinNo. 432187651211109
Lead color
B Y Br YG W BY R GW BY BW BW RW
Position
P





R




N




D


3


2


1


Signal sent to AT control unit Ignition circuitBack-up light
circuit
B3H0016A
28
3-2SERVICE PROCEDURE
2. On-Car Service

G3M0304
2. DUTY SOLENOID C AND TRANSFER VALVE BODY
1) Removal
(1) Remove pitching stopper.
G3M0297
(2) Raise vehicle and drain ATF.
G3M0305
(3) Remove front exhaust pipe.
Disconnect oxygen sensor connector, and remove
exhaust pipe.
G3M0782
(4) Remove propeller shaft.
NOTE:
Before removing propeller shaft, scribe matching marks on
propeller shaft and rear differential coupling.
G3M0306
(5) Remove rear crossmember.
Support transmission using a transmission jack and
raise slightly.
Remove bolts and nuts as shown in Figure.
34
3-2SERVICE PROCEDURE
2. On-Car Service

G3M0874
2. SEPARATION OF EACH SECTION
1) Separation of torque converter clutch case and trans-
mission case sections
CAUTION:
Be careful not to damage the oil seal and bushing
inside the torque converter clutch case by the oil pump
cover.
Be careful not to lose the rubber seal.
NOTE:
Separate these cases while tapping lightly on the housing.
G3M0336
2) Separation of transmission case and extension sections
(AWD)
(1) Remove vehicle speed sensor 1.
G3M0337
(2) While pulling the extension slightly, disconnect the
connector for the duty solenoid C (transfer).
CAUTION:
Be careful not to cut the harness.
3) Separate both sections.
G3M0338
3. TRANSMISSION CASE SECTION
1) Remove the reduction drive gear assembly.
G3M0339
2) Remove the reduction driven gear.
(1) Straighten the staked portion, and remove the lock
nut.
NOTE:
Set the range selector lever to“P”.
50
3-2SERVICE PROCEDURE
4. Overall Transmission

G3M0346
11) Remove the three accumulator springs.
G3M0347
12) Loosen the reverse clutch drum lightly by turning the
adjusting screw. Then remove the oil pump housing.
CAUTION:
Be careful not to lose the total end play adjusting
thrust washer.
G3M0348
13) Loosen the brake band adjusting screw with ST, and
take out the strut.
ST 398603610 SOCKET WRENCH
G3M0349
14) Remove the brake band and reverse clutch.
NOTE:
Contract the brake band with a clip.
G3M0350
15) Take out the high clutch.
CAUTION:
Thrust needle bearing and bearing race are removed
together with high clutch. Be careful not to lose them.
53
3-2SERVICE PROCEDURE
4. Overall Transmission

G3M0371
5) Remove the snap ring. Then remove the speedometer
driven gear.
G3M0372
6) Remove vehicle speed sensor 2.
7) Tap out the speedometer shaft to the outside of the
case, and remove the oil seal.
G3M0373
5. EXTENSION SECTION
1) Take out the transfer clutch by lightly tapping the end of
the rear drive shaft.
CAUTION:
Be careful not to damage the oil seal in the extension.
G3M0867
2) Remove duty solenoid C, transfer valve body and the
transfer pipe.
CAUTION:
Take out the inlet filter.
Do not damage the O-ring.
Be careful not to bend the pipe.
B3M0831A
3) Take out the roller bearing inner race with ST.
ST 398527700 PULLER
4) Take out the roller bearing outer race with ST.
NOTE:
Hook ST in the inner side of the roller bearing outer race.
ST 398527700 PULLER
58
3-2SERVICE PROCEDURE
4. Overall Transmission

7) Install the circlip to the axle shaft, insert the shaft into
the differential assembly, and tap it into position with a
plastic hammer.
Thrust play:
Approx. 0.3—0.5 mm (0.012—0.020 in)
CAUTION:
If no play is felt, check whether the shaft is fully
inserted. If shaft insertion is correct, replace the axle
shaft.
Be sure to use a new circlip.
G3M0368
8) Wrap vinyl tape around the splined portion of the axle
shaft.
9) Install the oil seal and outer race (taper roller bearing)
to the differential side retainer. Then screw in the retainer
and the O-ring after coating the threads with oil.
CAUTION:
Pay attention not to damage the oil seal lips.
Do not confuse the RH and LH oil seals.
Keep the O-ring removed from the retainer.
B3M0352A
10) Using the ST, screw in the retainer until light contact
is felt.
ST 499787000 WRENCH ASSY
NOTE:
Screw in the RH side slightly deeper than the LH side.
G3M0382
11) Hypoid gear backlash adjustment and tooth contact
check
(1) Assemble the drive pinion assembly to the oil pump
housing.
CAUTION:
Be careful not to bend the shims. [W8C0].>
Be careful not to force the pinion against the hous-
ing bore.
60
3-2SERVICE PROCEDURE
4. Overall Transmission