1997 SUBARU LEGACY check oil

C: ASSEMBLY
G3M0909

1Reverse clutch drum


2Lip seal


3Reverse clutch piston


4Lathe cut seal ring

5Spring


6Spring retainer


7Snap ring

8Dish plate


9Driven plate


10Drive plate

11Retaining plate


12Snap ring


13High clutch drum
1) Using the ST1, ST2 and ST3 as those used in
disassembling, assemble piston

3the springs
5, spring
retainer

6and snap ring
7.
ST1 398673600 COMPRESSOR
ST2 398177700 INSTALLER
ST3 399893600 PLIERS
2) Assemble the dish plate

8, driven plates
9, drive
plates

10and retaining plate
11in that order and attach the
snap ring

12.
NOTE:
Pay attention to the orientation of the dish plate.
3) Checking operation:
Apply compressed air intermittently to the oil hole, and
check the reverse clutch for smooth operation.
4) Measuring clearance (Retaining plate selection):
Standard value:
0.5—0.8 mm (0.020—0.031 in)
Allowable limit:
1.2 mm (0.047 in)
NOTE:
Before measuring clearance, place the same thickness of
shim on both sides to prevent retaining plate from tilting.
Available retaining platesPart No. Thickness mm (in)
31567AA350
31567AA360
31567AA370
31567AA380
31567AA390
31567AA4004.6 (0.181)
4.8 (0.189)
5.0 (0.197)
5.2 (0.205)
5.4 (0.213)
5.6 (0.220)
97
3-2SERVICE PROCEDURE
9. Reverse Clutch

C: ASSEMBLY
G3M0469

1High clutch drum


2Lathe cut seal ring


3High clutch piston


4Lathe cut seal ring


5Spring retainer


6Snap ring


7Driven plate (Thinner)

8Drive plate


9Driven plate (Thicker)


10Retaining plate


11Snap ring


12Thrust needle bearing


13High clutch hub
1) Using the ST1, ST2 and ST3 as those used in
disassembling, assemble the piston

3, spring retainer
5,
and snap ring

6.
ST1 398673600 COMPRESSOR
ST2 398177700 INSTALLER
ST3 399893600 PLIERS
2) Install the driven plate (thinner)

7, drive plates
8,
driven plates (thicker)

9, and retaining plate
10in that order.
Then attach the snap ring

11.
3) Checking operation:
Apply compressed air intermittently to the oil hole, and
check the high clutch for smooth operation.
4) Measuring clearance (Retaining plate selection):
Standard value:
1.8—2.2 mm (0.071—0.087 in)
Allowable limit:
2.6 mm (0.102 in)
NOTE:
Before measuring clearance, place the same thickness of
shim on both sides to prevent retaining plate from tilting.
99
3-2SERVICE PROCEDURE
10. High Clutch

G3M0031
5) Lightly tap the head of front propeller shaft with a cop-
per hammer until center bearing is removed.
CAUTION:
Be careful not to damage the thread portion.
D: INSPECTION
NOTE:
Do not disassemble propeller shaft. Check the following
and replace if necessary.
1) Tube surfaces for dents or cracks
2) Splines for deformation or abnormal wear
3) Joints for non-smooth operation or abnormal noise
4) Center bearing for free play, noise or non-smooth
operation
5) Oil seals for abnormal wear or damage
6) Center bearing for breakage
G3M0030
E: ASSEMBLY
1) Install center bearing onto front propeller shaft.
2) Align marks and install companion flange.
G3M0029
3) Tighten stake nut until center bearing is set in position.
CAUTION:
Be sure to install new stake nut.
Tightening torque:
270±25 N⋅m (27.5±2.5 kg-m, 199±18 ft-lb)
NOTE:
Stake the nut after tightening.
12
3-4SERVICE PROCEDURE
1. Propeller Shaft

E: ASSEMBLY
1) Precautions for assembling
(1) Assemble in the reverse order of disassembling.
(2) Check and adjust each part during assembly.
(3) Keep the shims and washers in order, so that they
are not misinstalled.
(4) Thoroughly clean the surfaces on which the shims,
washers and bearings are to be installed.
(5) Apply gear oil when installing the bearings and
thrust washers.
(6) Be careful not to mix up the right and left hand cups
of the bearings.
G3M0079
(7) Replace the oil seal with new one at every disas-
sembly. Apply chassis grease between the lips when
installing the oil seal.
G3M1037
2) Adjusting preload for front and rear bearings
Adjust the bearing preload with spacer and washer
between front and rear bearings. Pinion height adjusting
washer are not affected by this adjustment. The adjustment
must be carried out without oil seal inserted.
(1) Press rear bearing race into differential carrier with
ST1 and ST2.
ST1 398477701 HANDLE
ST2 398427703 DRIFT 2
G3M0081
(2) Insert ST1 into case with pinion height adjusting
washer and rear bearing cone fitted onto it.
CAUTION:
Re-use the used washer if not deformed.
Use a new rear bearing cone.
(3) Then install preload adjusting spacer and washer,
front bearing cone, ST2, companion flange, and washer
and drive pinion nut.
ST1 398507702 DUMMY SHAFT
ST2 398507703 DUMMY COLLAR
27
3-4SERVICE PROCEDURE
2. Rear Differential

1. Rear Differential
Symptom and possible cause Remedy
1. Oil leakage


1Worn, scratched, or incorrectly seated front or side oil seal.
Scored, battered, or excessively worn sliding surface of com-
panion flange.Repair or replace.


2Clogged or damaged air breather. Clean, repair or replace.


3Loose bolts on differential spindle or side retainer, or incor-
rectly fitted O-ring.Tighten bolts to specified torque. Replace O-ring.


4Loose rear cover attaching bolts or damaged gasket. Tighten bolts to specified torque. Replace gasket and apply liquid
packing.


5Loose oil filler or drain plug. Retighten and apply liquid packing.


6Wear, damage or incorrectly fitting for spindle, side retainer
and oil seal.Repair or replace.
2. Seizure
Seized or damaged parts should be replaced, and also other parts should be thoroughly checked for any defect and should be
repaired or replaced as required.


1Insufficient backlash for hypoid gear. Readjust or replace.


2Excessive preload for side, rear, or front bearing. Readjust or replace.


3Insufficient or improper oil used. Replace seized part and fill with specified oil to specified level.
3. Damage
Damaged parts should be replaced, and also other parts should be thoroughly checked for any defect and should be repaired or
replaced as required.


1Improper backlash for hypoid gear. Replace.


2Insufficient or excessive preload for side, rear, or front bear-
ing.Readjust or replace.


3Excessive backlash for differential gear. Replace gear or thrust washer.


4Loose bolts and nuts such as crown gear bolt. Retighten.


5Damage due to overloading. Replace.
4. Noises when starting or shifting gears
Noises may be caused by differential assembly, universal joint, wheel bearing, etc. Find out what is actually making noise before dis-
assembly.


1Excessive backlash for hypoid gear. Readjust.


2Excessive backlash for differential gear. Replace gear or thrust washer.


3Insufficient preload for front or rear bearing. Readjust.


4Loose drive pinion nut. Tighten to specified torque.


5Loose bolts and nuts such as side bearing retainer attaching
bolt.Tighten to specified torque.
40
3-4DIAGNOSTICS
1. Rear Differential

G4M0492
3) Remove nut (do not remove bolt.) securing transverse
link to crossmember.
4) Remove two bolts securing bushing bracket of trans-
verse link to vehicle body at rear bushing location.
G4M0493
5) Extract ball joint from housing.
6) Remove bolt securing transverse link to crossmember
and extract transverse link from crossmember.
G4M0494
B: DISASSEMBLY
1. FRONT BUSHING
Using ST, press front bushing out of place.
ST 927680000 INSTALLER & REMOVER SET
G4M0495
2. REAR BUSHING
1) Scribe an aligning mark on transverse link and rear
bushing.
2) Loosen nut and remove rear bushing.
C: INSPECTION
1) Check transverse link for wear, damage and cracks,
and correct or replace if defective.
2) Check bushings for cracks, wear,damage and creeping.
3) Check rear bushing for oil leaks.
4) If defective, replace with new one.
17
4-1SERVICE PROCEDURE
2. Front Transverse Link

C: INSPECTION
Check the disassembled parts for cracks, damage and
wear, and replace with new parts if defective.
G4M0508
1. DAMPER STRUT
1) Check for oil leakage.
2) Move the piston rod up and down to check its operates
smoothly without any binding.
3) Play of piston rod
Measure the play as follows:
Fix outer shell and fully extend the rod. Set a dial gauge at
the end of the rod: L [10 mm (0.39 in)], then apply a force
of W [20 N (2 kg, 4 lb)] to threaded portion. With the force
of 20 N (2 kg, 4 lb) applied, read dial gauge indication: P
1.
Apply a force of 20 N (2 kg, 4 lb) in the opposite direction
of“W”, then read dial gauge indication: P
2. The free play
is determined by the following equation:
Play = P
1,P2
Limit of play:
Less than 0.8 mm (0.031 in)
If the play is greater, replace the strut with new one.
2. STRUT MOUNT
Check rubber part for wear, cracks and deterioration, and
replace it with new one if defective.
3. DUST COVER
If any cracks or damage are found, replace it with new one.
4. COIL SPRING
When vehicle posture is uneven, although there are no
considerable reasons like tire puncture, uneven loading,
etc., check coil spring and spring seats for cracks,
deformation, etc., and replace it with a new one if defective.
5. HELPER
Replace it with new one if cracked or damaged.
23
4-1SERVICE PROCEDURE
4. Front Strut

D: ASSEMBLY
1) Before installing coil spring, strut mount, etc., on the
strut, check for the presence of air in the dampening force
generating mechanism of the strut since air prevents
proper dampening force from being produced.
2) Checking for the presence of air
(1) Place the strut vertically with the piston rod facing
upward.
(2) Move the piston rod to the center of its entire
stroke.
(3) While holding the piston rod end with finger-tips,
move the rod up and down.
(4) If the piston rod moves at least 10 mm (0.39 in) in
step (3), purge air from the strut.
3) Air purging procedure
(1) Place the strut vertically with the piston rod facing
upward.
(2) Fully extend the piston rod.
(3) With the piston rod fully extended, place the piston
rod side down. The strut must stand vertically.
(4) Fully contract the piston rod.
(5) Repeat 3 or 4 times steps (1) through (4) above.
NOTE:
After completely purging air from the strut, be sure to place
the strut with the piston rod facing upward. If it is laid down,
check for entry of air in the strut as outlined under item 2)
above.
B4M0568A
4) Using a coil spring compressor, compress the coil
spring.
NOTE:
Make sure that the vertical installing direction of coil spring
is as shown in figure.
G4M0510
5) Set the coil spring correctly so that its end face fits well
into the spring seat as shown.
6) Install helper and dust cover to the piston rod.
24
4-1SERVICE PROCEDURE
4. Front Strut