1996 SUBARU LEGACY torque

B: ASSEMBLY
1. TRANSMISSION CASE
B3M0061A

A: To right hand transmission case
Tightening torque: N⋅m (kg-m, ft-lb)
T: 19.6±0.1 (2.00±0.015, 14.5±0.1)
B3M0062A
1) Position interlock plungers (5.56 x 19.6), one plunger in
hole between 1-2 and 3-4 fork rod holes, and one plunger
in hole between 3-4 and reverse fork rod holes.


B: Rod holes
G3M0604
2) Install reverse shifter lever
1, reverse idler gear
2and
reverse idler gear shaft

3, and secure with straight pin
4.
NOTE:
Be sure to install reverse idler shaft from the rear side.
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3-1SERVICE PROCEDURE
4. Transmission Case

G3M0552
9) Position balls
17, checking ball springs
18and gaskets


19into 3-4 and 1-2 rod holes, and install plugs
20.
CAUTION:
Replace gasket with a new one.
G3M0547
10) Installation of speedometer driven gear
21
(1) Install washer and speedometer shaft, and press fit
oil seal with ST.
ST 899824100 or 499827000 PRESS
CAUTION:
Use new oil seal, if it has been removed.
(2) Install vehicle speed sensor 2.
CAUTION:
Use new vehicle speed sensor 2, if it has been
removed.
Tightening torque:
5.9±1.5 N⋅m (60±15 kg-cm, 52±13 in-lb)
(3) Install speedometer driven gear and snap ring.
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3-1SERVICE PROCEDURE
4. Transmission Case

2. COMBINATION OF TRANSMISSION CASE
B3M0356A
Tightening torque: N⋅m (kg-m, ft-lb)
T1: 25 (2.5, 18)
T2: 29±3 (3.0±0.3, 21.7±2.2)
G3M0554
1) Alignment marks/numbers on hypoid gear set
1
The upper number on driven pinion is the match number for
combining it with hypoid driven gear. The lower number is
for shim adjustment. If no lower number is shown, the value
is zero. The number on hypoid driven gear indicates a
number for combination with drive pinion.
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3-1SERVICE PROCEDURE
4. Transmission Case

B3M0399A
B3M0331
8) Combination of transmission case
(1) Wipe off grease, oil and dust on the mating sur-
faces 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
(2) Tighten 17 bolts with bracket, clip, etc. as shown in
the figure.
Tightening torque:
8 mm bolt
25±2 N⋅m (2.5±0.2 kg-m, 18.1±1.4 ft-lb)

10 mm bolt
39±3 N⋅m (4.0±0.3 kg-m, 28.9±2.2 ft-lb)
NOTE:
Insert bolts from the bottom and tighten nuts at the top.
Put cases together so that drive pinion shim and input
shaft holder shim are not caught up in between.
Confirm that counter gear and speedometer gear are
meshed.
G3M0597
9) Tighten ball bearing attachment bolts.
Tightening torque:
29±3 N⋅m (3.0±0.3 kg-m, 21.7±2.2 ft-lb)
G3M0563
10) Backlash adjustment of hypoid gear and preload
adjustment of roller bearing
NOTE:
Support drive pinion assembly with ST.
ST 498427100 STOPPER
45
3-1SERVICE PROCEDURE
4. Transmission Case

B3M0073
The drive pinion shim selected before is too thick.
Reduce its thickness.
B3M0074
The drive pinion shim selected before is too thin.
Increase its thickness.
B3M0334A
11) After checking the tooth contact of hypoid gears,
remove the lock plate

11. 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

11.
Tightening torque:
25±3 N⋅m (2.5±0.3 kg-m, 18.1±2.2 ft-lb)
NOTE:
Carry out this job on both upper and lower retainers.
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3-1SERVICE PROCEDURE
4. Transmission Case

G3M0618
6) Install lock washer (42 x 53 x 2). Install lock nut (42 x
13) and tighten to the specified torque using ST.
ST 499987300 SOCKET WRENCH (50)
Tightening torque:
245±10 N⋅m (25±1 kg-m, 181±7 ft-lb)
B3M0079A
NOTE:
Stake lock nut at two points.
Using spring balancer, check that starting torque of roller
bearing

2is 0.1 to 1.5 N⋅m (1 to 15 kg-cm, 0.9 to 13.0 in-
lb).
B3M0080A
3. DRIVE PINION SHAFT
1) Install roller bearing onto drive pinion. Install washer

1
(33 x 50 x 5) using ST1, ST2 and press.
ST1 499277100 BUSH 1-2 INSTALLER
ST2 499277200 INSTALLER
B3M0081A
NOTE:
When installing roller bearing

2, note its directions (front
and rear) because knock pin hole

3in outer race is offset.
B3M0082A
2) Install thrust bearing (33 x 50 x 3) and needle bearing
(30 x 37 x 23). Install driven shaft assembly

4.
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3-1SERVICE PROCEDURE
5. Drive Pinion Assembly (AWD Model)

B3M0083A
3) Install drive pinion collar
5, needle bearing
6(25x30
x 20), adjusting washer No. 2

7(25 x 36 x 4), thrust bear-
ing

8(25 x 37.5 x 3), adjusting washer No. 1
9(25x36
x t) and differential bevel gear sleeve

10in that order.
NOTE:
Be careful because spacer must be installed in proper
direction.


A: Driven shaft


B: Driven pinion shaft
B3M0084A
G3M0625
4. ADJUSTMENT OF THRUST BEARING PRELOAD
1) After completing the preceding steps 1) through 3),
select adjusting washer No. 2 so that dimension

His zero
through visual check. Position washer (18.3 x 30 x 4) and
lock washer (18 x 30 x 2) and install lock nut (18 x 13.5).
G3M0626
2) Using ST1, ST2 and ST3, tighten lock nut to the speci-
fied torque.
ST1 899884100 HOLDER
ST2 498427100 STOPPER
ST3 899988608 SOCKET WRENCH (27)
Tightening torque:
118±8 N⋅m (12±0.8 kg-m, 86.8±5.8 ft-lb)
B3M0085A
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)
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3-1SERVICE PROCEDURE
5. Drive Pinion Assembly (AWD Model)

G3M0606
4) If starting torque is not within specified limit, select new
adjusting washer No. 1

2and recheck starting torque.
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)
G3M0606
5) If specified starting torque range cannot be obtained
when a No. 1

2adjusting washer is used, then select a
suitable No. 2

3adjusting washer from those listed in the
following table. Repeat steps 1) through 4) to adjust start-
ing torque.
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.
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3-1SERVICE PROCEDURE
5. Drive Pinion Assembly (AWD Model)