1997 SUBARU LEGACY torque

2. COMBINATION OF TRANSMISSION CASE
B3M0614B
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.
41
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.
48
3-1SERVICE PROCEDURE
4. Transmission Case

G3M0617
5) Position woodruff key in groove on the rear of driven
shaft. Install 5th driven gear onto drive shaft using ST and
press.
ST 499277200 INSTALLER
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:
265±10 N⋅m (27±1 kg-m, 195±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).
G3M0613
4. DRIVEN GEAR ASSEMBLY (2500 cc MODEL)
Assemble a driven shaft and 1st driven gear that select for
adjustment the proper radial clearance.
Driven shaft 1st driven gear
Part No. Diameter A mm (in) Part No.
32229AA15049.959—49.966
(1.9669—1.9672)32231AA290
32229AA14049.967—49.975
(1.9672—1.9675)32231AA280
54
3-1SERVICE PROCEDURE
5. Drive Pinion Assembly (AWD Model)

G3M0617
7) Position woodruff key in groove on the rear of driven
shaft. Install 5th driven gear onto drive shaft using ST and
press.
ST 499277200 INSTALLER
G3M0618
8) 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:
265±10 N⋅m (27±1 kg-m, 195±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
5. 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.
56
3-1SERVICE PROCEDURE
5. Drive Pinion Assembly (AWD Model)

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

4.
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
6. 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)
57
3-1SERVICE PROCEDURE
5. Drive Pinion Assembly (AWD Model)

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)
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)
58
3-1SERVICE PROCEDURE
5. Drive Pinion Assembly (AWD Model)

6) Recheck that starting torque is within specified range,
then clinch lock nut at four positions.
G3M0628
6. Drive Pinion Assembly (FWD Model)
A: DISASSEMBLY
1) Loosen lock nut using ST1 and ST2.
ST1 499987100 or 499987003 or 899984103 SOCKET
WRENCH (35)
ST2 899884100 HOLDER
NOTE:
Remove caulking before taking off lock nut.
B3M0341A
2) Remove 5th driven gear using a press.
ST 498077000 5TH DRIVEN GEAR REMOVER
G3M0610
3) Remove woodruff key.
4) Remove roller bearing (29 x 74 x 38) and 3rd-4th driven
gear using ST1 and ST2.
ST1 899714110 REMOVER
ST2 499757002 SNAP RING PRESS
G3M0611
5) Remove 2nd driven gear assembly.
6) Remove 3rd-4th driven gear key.
7) Remove 1st driven gear, 2nd gear bushing, and gear &
hub assembly using ST1 and ST2.
Replace gear and hub if necessary. Do not attempt to dis-
assemble if at all possible because they must engage at a
specified point. If they have to be disassembled, mark the
engaging point beforehand.
ST1 499757002 SNAP RING PRESS
ST2 899714110 REMOVER
59
3-1SERVICE PROCEDURE
6. Drive Pinion Assembly (FWD Model)