1995 SUBARU LEGACY Service Repair Manual

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Page 337 of 2248

SUBARU LEGACY 1995 Service Repair Manual G3M0650
5) Drive ball bearing1onto the rear section of transmis-
sion main shaft using ST1, ST2 and a press.
ST1 899714110 REMOVER
ST2 499877000 RACE 4-5 INSTALLER
B3M0091A
6) Using the same tools as

Page 338 of 2248

SUBARU LEGACY 1995 Service Repair Manual 8. Center Differential (AWD Model)
A: DISASSEMBLY
B3M0288A
1) Remove snap ring1(Inner-110) using flat bladed
screwdriver.
2) Remove center differential cover
2.
3) Remove snap ring
4and roller bear

Page 339 of 2248

SUBARU LEGACY 1995 Service Repair Manual B3M0337
B: ASSEMBLY
Assembly is in the reverse order of disassembly.
Do the following:
Install thrust washer with chamfered side of inner perim-
eter facing the side gear.
Install adjusting washer w

Page 340 of 2248

SUBARU LEGACY 1995 Service Repair Manual G3M0666
9. Front Differential
A: DISASSEMBLY
1) Remove right and left snap rings1from differential,
and then remove two axle drive shafts
2.
NOTE:
During reassembly, reinstall each axle drive shaft

Page 341 of 2248

SUBARU LEGACY 1995 Service Repair Manual G3M0668
5) Remove roller bearing using ST.
ST 399527700 PULLER SET
B3M0099A
B: ASSEMBLY
1) Install bevel gear and bevel pinion together with
washers, and insert pinion shaft
1.
NOTE:
Face the chamfer

Page 342 of 2248

SUBARU LEGACY 1995 Service Repair Manual G3M0666
3) Align pinion shaft and differential case at their holes,
and drive straight pin
5into holes from the hypoid driven
gear side, using ST.
ST 899904100 REMOVER
NOTE:
Lock straight pin after i

Page 343 of 2248

SUBARU LEGACY 1995 Service Repair Manual B3M0100
6) Position drive axle shaft in differential case and hold it
with outer snap ring (28). Using a thickness gauge, mea-
sure clearance between the shaft and case is within speci-
fications.
Cle

Page 344 of 2248

SUBARU LEGACY 1995 Service Repair Manual 1. Manual Transmission and
Differential
Symptom and possible cause Remedy
1. Gears are difficult to intermesh.
The cause for difficulty in shifting gears can be classified into two kinds: one is malfu

1. Manual Transmission and
Differential
Symptom and possible cause Remedy
1. Gears are difficult to intermesh.
The cause for difficulty in shifting gears can be classified into two kinds: one is malfunction of the gear shift system and the
other is malfunction of the transmission. However, if the operation is heavy and engagement of the gears is difficult, defective
clutch disengagement may also be responsible. Check whether the clutch is correctly functioning, before checking the gear
shift system and transmission.
(a) Worn, damaged or burred chamfer of internal spline of
sleeve and reverse driven gearReplace.
(b) Worn, damaged or burred chamfer of spline of gears Replace.
(c) Worn or scratched bushings Replace.
(d) Incorrect contact between synchronizer ring and gear
cone or wearCorrect or replace.
2. Gear slips out.
(1) Gear slips out when coasting on rough road.
(2) Gear slips out during acceleration.
(a) Defective pitching stopper adjustment Adjust.
(b) Loose engine mounting bolts Tighten or replace.
(c) Worn fork shifter, broken shifter fork rail spring Replace.
(d) Worn or damaged ball bearing Replace.
(e) Excessive clearance between splines of synchronizer hub
and synchronizer sleeveReplace.
(f) Worn tooth step of synchronizer hub (responsible for slip-
out of 3rd gear)Replace.
(g) Worn 1st driven gear, needle bearing and race Replace.
(h) Worn 2nd driven gear, needle bearing and race Replace.
(i) Worn 3rd drive gear and bushing Replace.
(j) Worn 4th drive gear and bushing Replace.
(k) Worn reverse idler gear and bushing Replace.
3. Unusual noise comes from transmission.
If an unusual noise is heard when the vehicle is parked with its engine idling and if the noise ceases when the clutch is
disengaged, it may be considered that the noise comes from the transmission.
(a) Insufficient or improper lubrication Lubricate or replace with specified oil.
(b) Worn or damaged gears and bearings Replace.
NOTE: If the trouble is only wear of the tooth surfaces, merely
a high roaring noise will occur at high speeds, but if any part
is broken, rhythmical knocking sound will be heard even at
low speeds.
69
3-1DIAGNOSTICS
1. Manual Transmission and Differential

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