1996 SUBARU LEGACY manual transmission

1-3
[0301]
GENERAL
INFORMATION

3
.
Vehicle
Identification
Numbers
(V
.I
.N)

3
.
Vehicle
Identification
Numbers
(V
.I
.N)

1
.
APPLICABLE
V
.I
.N
.
IN
THIS
MANUAL

Station
2200
cc
AWD
~
4AT
T
4
TS
3
1
B
I
KT
I
9
I
5X
I
T
I
8
I
T
2
00
1
and
after
Wagon
engine
POST

2
.
THE
MEANINGOF
V
.I
.N
.

Marker
identifier

l

Stop-
mark

4
S
3

Sequential
number
302001
and
after
:
Station
Wagon

Plant
of
manufacture
and
transmission
type

Plant
of
manufacture
Transmissiontype
SIA

POST
8
(Full-time
AWD
4AT)

Model
year
T
1996

Check
digit

Weight
class
and
restraint
type
Passenger
car
5
:
Withoutpassive
restraint,
with
Dual
SRS
airbag

Model
9
:
POST

Engine
type
4
:
2
.2
liter
engine

Body
type
K
:
Station
Wagon

Line
B
:
SUBARU
B
line

Plant
of
manufacture

Plant
of
manufacture
Type
of
vehicle

SIA

I
4S3
~
Passenger
car
I

Vehicle
attributes
Check
digit
Vehicle
identification

BK
495
X
T
83
0200
1
[

TT
I
T
T
ITT
Z
Stop
mark

2

1. Manual Transmission and
Differential
A: SPECIFICATIONS
ItemModel
FWD AWD
2200 cc 2200 cc*2200 cc
OUTBACK
Type 5-forward speeds with synchromesh and 1-reverse
Transmission gear ratio1st 3.545
2nd 2.111
3rd 1.448
4th 1.088
5th 0.825 0.780 0.871
Reverse 3.416
Front
reduction
gearFinalType of gear Hypoid
Gear ratio 3.454 3.900 4.111
Rear
reduction
gearTransferType of gear — Helical
Gear ratio — 1.000
FinalType of gear — Hypoid
Gear ratio — 3.900 4.111
Front
differentialType and number of gear Straight bevel gear (Bevel pinion: 2, Bevel gear: 2)
Center
differentialType and number of gear —Straight bevel gear
(Bevel pinion: 2, Bevel gear: 2 and viscous coupling)
Transmission gear oil GL-5
Transmission oil capacity3.3
(3.5 US qt, 2.9 Imp
qt)3.5
(3.7 US qt, 3.1 Imp qt)
*: Step roof model only
2
3-1SPECIFICATIONS AND SERVICE DATA
1. Manual Transmission and Differential

B: SERVICE DATA
1. EXTENSION (AWD Model)
Snap ring (Inner-72) to ball bearing side clearance
0—0.15 mm (0—0.0059 in)
Snap ring (Inner-72)
Part No. Thickness mm (in)
805172071 1.78 (0.0701)
805172072 1.90 (0.0748)
805172073 2.02 (0.0795)
Snap ring (Outer-30) to ball bearing side clearance
0—0.15 mm (0—0.0059 in)
Snap ring (Outer-30)
Part No. Thickness mm (in)
805030041 1.53 (0.0602)
805030042 1.65 (0.0650)
805030043 1.77 (0.0697)
2. EXTENSION ASSEMBLY (AWD Model)
Thrust washer (52 x 61 x t) to ball bearing side clearance
0.05—0.30 mm (0.0020—0.0118 in)
Thrust washer (52 x 61 x t)
Part No. Thickness mm (in)
803052021 0.50 (0.0197)
803052022 0.75 (0.0295)
803052023 1.00 (0.0394)
3. TRANSFER CASE OR REAR CASE
Neutral position adjustment
Adjustment shim
Part No. Thickness mm (in)
32190AA000 0.15 (0.0059)
32190AA010 0.30 (0.0118)
Reverse accent shaft
Part No. Mark Remarks
32188AA040 1Neutral position is closer to
1st.
32188AA011 No mark or 2 Standard
32188AA050 3Neutral position is closer to
reverse gear.
Reverse check plate adjustment
Reverse check plate
Part No. Mark AngleθRemarks
32189AA000 0 28°Arm stops closer to
5th gear.
32189AA010 1 31°Arm stops closer to
5th gear.
33189AA020 2 34°Arm stops in the
center.
32189AA030 3 37°Arm stops closer to
reverse gear.
32189AA040 4 40°Arm stops closer to
reverse gear.
4. REVERSE IDLER GEAR
Adjustment of reverse idler gear position
Reverse idler gear to transmission case (LH) wall clearance
6.0—7.5 mm (0.236—0.295 in)
Reverse shifter lever
Part No. Mark Remarks
32820AA000 0 Further from case wall
32820AA010 No mark Standard
32820AA020 2 Closer to the case wall
After installing a suitable reverse shifter lever, adjust reverse idler
gear to transmission case wall clearance to within 0 to 0.5 mm (0
to 0.020 in) using washers.
Washer (20.5 x 26 x t)
Part No.Thickness
mm (in)Part No.Thickness
mm (in)
803020151 0.4 (0.016) 803020154 1.9 (0.075)
803020152 1.1 (0.043) 803020155 2.3 (0.091)
803020153 1.5 (0.059)
3
3-1SPECIFICATIONS AND SERVICE DATA
1. Manual Transmission and Differential

5. SHIFTER FORK AND ROD
Select suitable shifter forks so that both coupling sleeve and
reverse driven gear are positioned in the center of their synchro-
mesh mechanisms.
1st-2nd shifter fork
Part No. Mark Remarks
32804AA060 1Approach to 1st gear by
0.2 mm (0.008 in)
32804AA070 No mark Standard
32804AA080 3Approach to 2nd gear by
0.2 mm (0.008 in)
3rd-4th shifter fork
Part No. Mark Remarks
32810AA060 1Approach to 4th gear by
0.2 mm (0.008 in)
32810AA070 No mark Standard
32810AA100 3Approach to 3rd gear by
0.2 mm (0.008 in)
5th shifter fork
Part No. Mark Remarks
32812AA200 4Approach to 5th gear by
0.2 mm (0.008 in)
32812AA210 No mark Standard
32812AA220 6Become distant from 5th
gear by 0.2 mm (0.008 in)
Rod end clearance
A: 1st-2nd—3rd-4th
0.5—1.5 mm (0.020—0.059 in)
B: 3rd-4th—5th
0.6—1.4 mm (0.024—0.055 in)
6. TRANSMISSION CASE ASSEMBLY
Drive pinion shim adjustment
Drive pinion shim
Part No.Thickness
mm (in)Part No.Thickness
mm (in)
32295AA0310.150
(0.0059)32295AA0710.250
(0.0098)
32295AA0410.175
(0.0069)32295AA0810.275
(0.0108)
32295AA0510.200
(0.0079)32295AA0910.300
(0.0118)
32295AA0610.225
(0.0089)32295AA1010.500
(0.0197)
Hypoid gear backlash
0.13—0.18 mm (0.0051—0.0071 in)Selection of main shaft rear plate
Main shaft rear plate
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
7. DRIVE PINION ASSEMBLY
Preload adjustment of thrust bearing
Starting torque
0.3—0.8 N⋅m(3—8 kg-cm, 2.6—6.9 in-lb)
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)
Adjusting washer No. 2
Part No. Thickness mm (in)
803025059 3.850 (0.1516)
803025054 4.000 (0.1575)
803025058 4.150 (0.1634)
Assemble a driven shaft and 1st driven gear that are selected for
the proper radial clearance adjustment.
Driven shaft 1st driven gear
Part No.Diameter A
mm (in)Part No.
32229AA13049.959—49.966
(1.9669—
1.9672)32231AA270
32229AA12049.967—49.975
(1.9672—
1.9675)32231AA260
8. DRIVE PINION ASSEMBLY (FWD Model)
Selection of 1st driven gear:
1st driven gear
Outer diameter of bushing mm (in) Part No.
41.983—41.996 (1.6529—1.6534) 32231AA320
41.968—41.982 (1.6523—1.6528) 32231AA330
41.954—41.967 (1.6517—1.6522) 32231AA340
4
3-1SPECIFICATIONS AND SERVICE DATA
1. Manual Transmission and Differential

9. CENTER DIFFERENTIAL (AWD Model)
Snap ring (Inner-110) to center differential case clearance
0—0.15 mm (0—0.0059 in)
Snap ring (Inner-110)
Part No. Thickness mm (in)
805100061 2.10 (0.0827)
805100062 2.21 (0.0870)
805100063 2.32 (0.0913)
Backlash adjustment axial movement
0.62—0.86 mm (0.0244—0.0339 in)
Adjusting washer (45 x 62 x t)
Part No. Thickness mm (in)
803045041 1.60 (0.0630)
803045042 1.80 (0.0709)
803045043 2.00 (0.0787)
803045044 2.20 (0.0866)
803045045 2.40 (0.0945)
10. FRONT DIFFERENTIAL
Bevel gear to pinion backlash
0.13—0.18 mm (0.0051—0.0071 in)
Washer (38.1 x 50 x t)
Part No.Thickness
mm (in)Part No.Thickness
mm (in)
8030380210.925—
0.950
(0.0364—
0.0374)8030380231.025—
1.050
(0.0404—
0.0413)
8030380220.975—
1.000
(0.0384—
0.0394)
Pinion shaft to axle drive shaft clearance
0—0.2 mm (0—0.008 in)
Snap ring (Outer-28)
Part No.Thickness
mm (in)Part No.Thickness
mm (in)
805028011 1.05 (0.0413) 805028012 1.20 (0.0472)
5
3-1SPECIFICATIONS AND SERVICE DATA
1. Manual Transmission and Differential

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

Symptom and possible cause Remedy
4. Broken differential (case, gear, bearing, etc.)
Abnormal noise will develop and finally it will become impossible to continue to run due to broken pieces obstructing the gear
revolution.
(a) Insufficient or improper oil Disassemble differential and replace broken components and
at the same time check other components for any trouble,
and replace if necessary.
(b) Use of vehicle under severe conditions such as excessive
load and improper use of clutchReadjust bearing preload and backlash and face contact of
gears.
(c) Improper adjustment of taper roller bearing Adjust.
(d) Improper adjustment of drive pinion and hypoid driven
gearAdjust.
(e) Excessive backlash due to worn differential side gear,
washer or differential pinionAdd recommended oil to specified level. Do not use vehicle
under severe operating conditions.
(f) Loose hypoid driven gear clamping bolts Tighten.
5. Differential and hypoid gear noises
Troubles of the differential and hypoid gear always appear as noise problems. Therefore noise is the first indication of the
trouble. However noises from the engine, muffler, tire, exhaust gas, bearing, body, etc. are easily mistaken for the differential
noise. Pay special attention to the hypoid gear noise because it is easily confused with other gear noises. There are the
following four kinds of noises.
(1) Gear noise when driving: If noise increases as vehicle speed increases it may be due to insufficient gear oil, incorrect
gear engagement, damaged gears, etc.
(2) Gear noise when coasting: Damaged gears due to maladjusted bearings and incorrect shim adjustment
(3) Bearing noise when driving or when coasting: Cracked, broken or damaged bearings
(4) Noise which mainly occurs when turning: Unusual noise from differential side gear, differential pinion, differential pinion
shaft, etc.
(a) Insufficient oil Lubricate.
(b) Improper adjustment of hypoid driven gear and drive
pinionCheck tooth contact.
(c) Worn teeth of hypoid driven gear and drive pinion Replace as a set.
Readjust bearing preload.
(d) Loose roller bearing Readjust hypoid driven gear to drive pinion backlash and
check tooth contact.
(e) Distorted hypoid driven gear or differential case Replace.
(f) Worn washer and differential pinion shaft Replace.
70
3-1DIAGNOSTICS
1. Manual Transmission and Differential

71
3-1DIAGNOSTICS
1. Manual Transmission and Differential