1997 SUBARU LEGACY torque

B3M0043A
4) Remove reverse check sleeve
5.
Disassembly procedure is as follows:
(1) Using a standard screwdriver, remove snap ring

A
(Inner-28).
NOTE:
Replace snap ring with a new one if deformed or weak-
ened.
(2) Remove reverse check plate

B.
(3) Remove reverse check spring

Cwith cam
D.
(4) Remove reverse return spring

E.
(5) Remove reverse accent shaft

F.
(6) Remove O-ring

G.
NOTE:
Reverse check sleeve assembly uses an O-ring which
should not be scratched.
Be careful not to break adjustment shim placed between
reverse check sleeve assembly and case.
B3M0042A
5) Remove back-up light switch
7.
6) Remove oil guide

9.
Tightening torque:
T1: 6.4±0.5 N⋅m (0.65±0.05 kg-m, 4.7±0.4 ft-lb)
T2: 10±1 N⋅m (1.0±0.1 kg-m, 7.2±0.7 ft-lb)
T3: 19.6±1.5 N⋅m (2.00±0.15 kg-m, 14.5±1.1 ft-lb)
T4: 25±2 N⋅m (2.5±0.2 kg-m, 18.1±1.4 ft-lb)
21
3-1SERVICE PROCEDURE
2. Transfer Case and Extension (AWD Model)

C: ASSEMBLY
1. EXTENSION
G3M0953
Tightening torque: N⋅m (kg-m, ft-lb)
T: 25±2 (2.5±0.2, 18.1±1.4)
1) Installation of ball bearing
1and selection of snap ring


2(Inner-72)
(1) Attach ball bearing

1(30 x 72 x 17) to extension
and install snap ring

2.
B3M0044A
(2) Measure clearance between snap ring
2and outer
race of ball bearing

1with a thickness gauge.
CAUTION:
Replace ball bearing with a new one.
Clearance:
0—0.15 mm (0—0.0059 in)
(3) If the measurement is not within the specification,
select suitable snap ring

2.
Snap ring (Inner-72)
Part No. Thickness mm (in)
805172071 1.78 (0.0701)
805172072 1.90 (0.0748)
805172073 2.02 (0.0795)
23
3-1SERVICE PROCEDURE
2. Transfer Case and Extension (AWD Model)

B3M0042A
2) Installation of shifter arm
1and selector arm
8
Install shifter arm into the partition from the front while
inserting selector arm into the opening in reverse check
sleeve. Pass shaft through hole in selector arm until its end
comes out of the rear of transfer case.
NOTE:
Apply a coat of gear oil to shifter arm. Also make sure oil
seal is positioned properly.
Tightening torque:
T1: 6.4±0.5 N⋅m (0.65±0.05 kg-m, 4.7±0.4 ft-lb)
T2: 10±1 N⋅m (1.0±0.1 kg-m, 7.2±0.7 ft-lb)
T3: 19.6±1.5 N⋅m (2.00±0.15 kg-m, 14.5±1.1 ft-lb)
T4: 25±2 N⋅m (2.5±0.2 kg-m, 18.1±1.4 ft-lb)
B3M0049A
3. COMBINATION OF TRANSFER CASE AND
EXTENSION ASSEMBLY
1) Install center differential

1and transfer driven gear
2
into transfer case.
Tightening torque:
T: 37±3 N⋅m (3.8±0.3 kg-m, 27.5±2.2 ft-lb)
B3M0050A
2) Selection of thrust washer (52 x 61 x t)
(1) Measure height“W”between transfer case and ball
bearing on the transfer driven gear

3.
26
3-1SERVICE PROCEDURE
2. Transfer Case and Extension (AWD Model)

D: INSTALLATION
B3M0053A
Tightening torque: N⋅m (kg-m, ft-lb)
T1: 15.7±1.5 (1.6±0.15, 11.6±1.1)
T2: 19.6±1.5 (2.00±0.15, 14.5±1.1)
T3: 24.5±2.0 (2.50±0.20, 18.1±1.4)
1) Install transfer case
2with extension assembly
1.
2) Secure selector arm to shifter arm with shifter fork
screw

3. Shifter arm should be caught by pawl of rod.
Selector arm must be engaged with reverse check sleeve
assembly.
3) Adjustment of neutral position
(1) Shift gear into 3rd gear position.
(2) Shifter arm turns lightly toward the 1st/2nd gear
side but heavily toward the reverse gear side because
of the function of the return spring, until arm contacts
the stopper.
(3) Make adjustment so that the heavy stroke (reverse
side) is a little more than the light stroke (1st/2nd side).
(4) To adjust, remove bolts holding reverse check
sleeve assembly

4to the case, move sleeve assem-
bly outward, and place adjustment shim (0 to 1 ea.)
between sleeve assembly and case to adjust the clear-
ance.
28
3-1SERVICE PROCEDURE
2. Transfer Case and Extension (AWD Model)

3. Rear Case (FWD Model)
A: DISASSEMBLY
G3M0952
Tightening torque: N⋅m (kg-m, ft-lb)
T1: 6.4±0.5 (0.65±0.05, 4.7±0.4)
T2: 10±1 (1.0±0.1, 7.2±0.7)
T3: 25±2 (2.5±0.2, 18.1±1.4)
1) Remove rear case
1.
2) Remove plug

2, spring
3and reverse check ball
4.
3) Remove neutral switch

5.
4) Pull out shifter arm

6.
5) Remove reverse check sleeve

7.
NOTE:
The disassembly procedure is the same as for AWD model.
B3M0056A
6) Remove back-up light switch
8.
7) Remove oil seal

9.
CAUTION:
Do not reuse oil seal.
30
3-1SERVICE PROCEDURE
3. Rear Case (FWD Model)

B: ASSEMBLY
1) Assembly of rear case is in the reverse order of disas-
sembly.
G3M0952
Tightening torque: N⋅m (kg-m, ft-lb)
T1: 6.4±0.5 (0.65±0.05, 4.7±0.4)
T2: 10±1 (1.0±0.1, 7.2±0.7)
T3: 25±5 (2.5±0.5, 18.1±3.6)
2) Installation of shifter arm
6
Install shifter arm into the partition from the front while
inserting selector arm into the opening in reverse check
sleeve. Pass shaft through hole in selector arm until its end
comes out of the rear of transmission case assembly.
CAUTION:
Apply a coat of gear oil to shifter arm. Also make sure
oil seal is positioned properly.
3) Adjustment of neutral position
NOTE:
After assembling and installing rear case, adjust neutral
position.
(1) Shift gear into 3rd gear position.
(2) Shifter arm turns lightly toward the 1st/2nd gear
side but heavily toward the reverse gear side because
of the function of the return spring, until arm contacts
the stopper.
(3) Make adjustment so that the heavy stroke (reverse
side) is a little more than the light stroke (1st/2nd side).
(4) To adjust, remove bolts holding reverse check
sleeve assembly to the case, move sleeve assembly
outward, and place adjustment shim (0 to 1 ea.)
between sleeve assembly and case to adjust the clear-
ance.
31
3-1SERVICE PROCEDURE
3. Rear Case (FWD Model)

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.
37
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.
40
3-1SERVICE PROCEDURE
4. Transmission Case