1997 SUBARU LEGACY key

G3M0613
3. DRIVEN GEAR ASSEMBLY (2200 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
B3M0078A
1) Install 1st driven gear, 1st-2nd baulk ring and gear and
hub assembly onto driven shaft.
NOTE:
Take care to install gear hub in proper direction.
2) Install 2nd driven gear bushing onto driven shaft using
ST1, ST2 and press.
ST1 499277200 INSTALLER
ST2 499587000 INSTALLER
CAUTION:
Attach a cloth

1to the end of driven shaft to prevent
damage.
G3M0615
3) Install 2nd driven gear, 1st-2nd baulk ring and insert
onto driven shaft. After installing key on driven shaft, install
3rd-4th driven gear using ST and press.
ST 499277200 INSTALLER
Align groove in baulk ring with insert.
G3M0616
4) Install a set of roller bearings (42 x 74 x 40) onto the
driven shaft using ST and press.
ST 499277200 INSTALLER
53
3-1SERVICE PROCEDURE
5. Drive Pinion Assembly (AWD Model)

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)

B3M0078A
1) Install sub gear to 1st driven gear.
2) Install 1st driven gear, 1st baulk ring, gear and hub
assembly onto driven shaft.
NOTE:
Take care to install gear hub in proper direction.
3) Install 2nd driven gear bushing onto driven shaft using
ST1, ST2 and press.
ST1 499277200 INSTALLER
ST2 499587000 INSTALLER
CAUTION:
Attach a cloth

1to the end of driven shaft to prevent
damage.
NOTE:
When press fitting, align oil holes of shaft and bush.
B3M0426A
4) Install 2nd driven gear
1, inner baulk ring
2, synchro
cone

3, outer baulk ring
4and insert onto driven shaft.
G3M0615
5) After installing key on driven shaft, install 3rd-4th driven
gear using ST and press.
ST 499277200 INSTALLER
NOTE:
Align groove in baulk ring with insert.
G3M0616
6) Install a set of roller bearings (42 x 74 x 40) onto the
driven shaft using ST and press.
ST 499277200 INSTALLER
55
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)

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)

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)

5) Measure outside diameter of 1st driven gear bushing to
determine suitable 1st driven gear.
Bushing outside diameter
mm (in)1st driven gear
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
G3M0637
6) Install 1st driven gear, 1st-2nd balk ring and gear and
hub assembly (already assembled in previous step) to
drive pinion shaft by hand.
NOTE:
Align ring groove with insert.
G3M0638
7) Install 1st-2nd driven gear bushing
1to drive pinion
shaft using ST1 and ST2.
ST1 499877000 INSTALLER
ST2 499277100 INSTALLER
G3M0639
8) Install 2nd driven gear
1and 1st-2nd balk ring to drive
pinion shaft by hand.
9) Install key into the groove on drive pinion shaft and
install 3rd-4th driven gear.
NOTE:
Ball bearing may be installed without using the tool. There
should be no problem.
ST 499877000 INSTALLER
61
3-1SERVICE PROCEDURE
6. Drive Pinion Assembly (FWD Model)

G3M0640
10) Install ball bearing (29 x 74 x 38) on drive pinion shaft
with ST.
ST 499277100 INSTALLER
G3M0617
11) Position woodruff key in groove on the rear of drive
pinion shaft. Install 5th driven gear onto drive shaft using
ST and press.
ST 499277100 INSTALLER
CAUTION:
Face 5th driven gear in the correct direction.
Be careful not to dislocate woodruff key while
installing 5th gear.
B3M0353A
G3M0628
12) Install lock washer and tighten lock nut to the specified
torque using ST1 and ST2.
ST1 499987100 or 499987003 or 899984103 SOCKET
WRENCH (35)
ST2 899884100 HOLDER
CAUTION:
Discard old lock nuts, replace with new ones.
Secure lock nut in four places.
Tightening torque:
11 2—124 N⋅m (11.4—12.6 kg-m, 82—91 ft-lb)
62
3-1SERVICE PROCEDURE
6. Drive Pinion Assembly (FWD Model)