1997 SUBARU LEGACY service

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

G3M0564
(1) Place the transmission with case left side facing
downward and put ST1 on bearing cup.
(2) Screw retainer assembly into left case from the bot-
tom with ST2. Fit ST3 on the transmission main shaft.
Shift gear into 4th or 5th and turn the shaft several
times. Screw in the retainer while turning ST3 until a
slight resistance is felt on ST2.
This is the contact point of hypoid gear and drive pin-
ion shaft. Repeat the above sequence several times to
ensure the contact point.
ST1 399780104 WEIGHT
ST2 499787000 WRENCH ASSY
ST3 499927100 HANDLE
B3M0340A
(3) Remove weight and screw in retainer without
O-ring on the upper side and stop at the point where
slight resistance is felt.
NOTE:
At this point, the backlash between the hypoid gear and
drive pinion shaft is zero.
ST 499787000 WRENCH ASSY
B3M0334A
(4) Fit lock plate
11. Loosen the retainer on the lower
side by 1-1/2 notches of lock plate and turn in the
retainer on the upper side by the same amount in order
to obtain the backlash.
NOTE:
The notch on the lock plate moves by 1/2 notch if the plate
is turned upside down.
(5) Turn in the retainer on the upper side additionally
by 1 notch in order to apply preload on taper roller
bearing.
(6) Tighten temporarily both the upper and lower lock
plates and mark both holder and lock plate for later
readjustment.
(7) Turn transmission main shaft several times while
tapping around retainer lightly with plastic hammer.
(8) Set ST1 and ST2. Insert the needle through trans-
mission oil drain plug hole so that the needle comes in
contact with the tooth surface at a right angle and check
the backlash.
46
3-1SERVICE PROCEDURE
4. Transmission Case

B3M0335A
ST1 498247001 MAGNET BASE
ST2 498247100 DIAL GAUGE
Backlash:
0.13—0.18 mm (0.0051—0.0071 in)
NOTE:
If backlash is outside specified range, adjust it by turn-
ing holder in right side case.
Each time holder rotates one tooth, backlash changes
by 0.05 mm (0.0020 in).
(9) Check tooth contact of hypoid gear as follows:
Apply a uniform thin coat of red lead on both tooth sur-
faces of 3 or 4 teeth of the hypoid gear. Move the
hypoid gear back and forth by turning the transmission
main shaft until a definite contact pattern is developed
on hypoid gear, and judge whether face contact is cor-
rect. If it is incorrect, make the following correction.
B3M0070A
Tooth contact is correct.


1To e


2Coast side


3Heel


4Drive side
B3M0071
Backlash is excessive.
To reduce backlash, loosen holder on the upper side
(case right side) and turn in the holder on the lower side
(case left side) by the same amount.
B3M0072
Backlash is insufficient.
To increase backlash, loosen holder on the lower side
(case left side) and turn in the holder on the upper side
(case right side) by the same amount.
47
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

G3M0573
12) Selecting of main shaft rear plate
Using ST, measure the amount A of ball bearing protrusion
from transmission main case surface and select the proper
plate in the following table:
ST 498147000 DEPTH GAUGE
Dimension“A”
mm (in)Part No. Mark
4.00—4.13
(0.1575—0.1626)32294AA041 1
3.87—3.99
(0.1524—0.1571)32294AA051 2
NOTE:
Before measuring, tap the end of main shaft with a plastic
hammer lightly in order to make the clearance zero
between the main case surface and the moving flange of
bearing.
B3M0336D
13) Install clutch release lever
1and operating cylinder
(hydraulic application type)

2. [W3C2], [W5A0].>
G3M0595
5. Drive Pinion Assembly (AWD Model)
A: DISASSEMBLY
1. DRIVE PINION SHAFT
1) Straighten lock nut at staked portion. Remove the lock
nut using ST1, ST2 and ST3.
ST1 899884100 HOLDER
ST2 498427100 STOPPER
ST3 899988608 SOCKET WRENCH
G3M0606
2) Withdraw drive pinion from driven shaft.
Remove differential bevel gear sleeve

1, adjusting washer
No. 1

2(25 x 37.5 x t), adjusting washer No. 2
3(25 x
37.5 x 4), thrust bearing

4(25 x 37.5 x 3), needle bearing


5(25 x 30 x 20), drive pinion collar
6, needle bearing
7
(30 x 37 x 23) and thrust bearing
8(33x50x3).
49
3-1SERVICE PROCEDURE
5. Drive Pinion Assembly (AWD Model)

G3M0573
12) Selecting of main shaft rear plate
Using ST, measure the amount A of ball bearing protrusion
from transmission main case surface and select the proper
plate in the following table:
ST 498147000 DEPTH GAUGE
Dimension“A”
mm (in)Part No. Mark
4.00—4.13
(0.1575—0.1626)32294AA041 1
3.87—3.99
(0.1524—0.1571)32294AA051 2
NOTE:
Before measuring, tap the end of main shaft with a plastic
hammer lightly in order to make the clearance zero
between the main case surface and the moving flange of
bearing.
B3M0336D
13) Install clutch release lever
1and operating cylinder
(hydraulic application type)

2. [W3C2], [W5A0].>
G3M0595
5. Drive Pinion Assembly (AWD Model)
A: DISASSEMBLY
1. DRIVE PINION SHAFT
1) Straighten lock nut at staked portion. Remove the lock
nut using ST1, ST2 and ST3.
ST1 899884100 HOLDER
ST2 498427100 STOPPER
ST3 899988608 SOCKET WRENCH
G3M0606
2) Withdraw drive pinion from driven shaft.
Remove differential bevel gear sleeve

1, adjusting washer
No. 1

2(25 x 37.5 x t), adjusting washer No. 2
3(25 x
37.5 x 4), thrust bearing

4(25 x 37.5 x 3), needle bearing


5(25 x 30 x 20), drive pinion collar
6, needle bearing
7
(30 x 37 x 23) and thrust bearing
8(33x50x3).
49
3-1SERVICE PROCEDURE
5. Drive Pinion Assembly (AWD Model)

G3M0607
3) Remove roller bearing and washer (33 x 50 x 5) using
ST and press.
ST 498077000 REMOVER
CAUTION:
Do not reuse roller bearing.
G3M0608
2. DRIVEN GEAR ASSEMBLY (2200 cc MODEL)
CAUTION:
Attach a cloth to the end of driven shaft (on the fric-
tional side of thrust needle bearing) during disassem-
bly or reassembly to prevent damage.
1) Straighten lock nut at staked portion. Remove the lock
nut using ST1 and ST2.
ST1 499987300 SOCKET WRENCH (50)
ST2 899884100 HOLDER
G3M0609
2) Remove 5th driven gear using ST.
ST 499857000 5TH DRIVEN GEAR REMOVER
G3M0610
3) Remove woodruff key.
4) Remove roller bearing (42 x 74 x 40), 3rd and 4th driven
gear using ST1 and ST2.
ST1 499757002 SNAP RING PRESS
ST2 899714110 REMOVER
G3M0611
5) Remove the key.
6) Remove 2nd driven gear assembly.
7) Remove 1st driven gear, 2nd gear bushing, gear and
hub 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
50
3-1SERVICE PROCEDURE
5. Drive Pinion Assembly (AWD Model)

8) Remove sub gears for 1st and 2nd driven gear.
G3M0608
3. DRIVEN GEAR ASSEMBLY (2500 cc MODEL)
CAUTION:
Attach a cloth to the end of driven shaft (on the fric-
tional side of thrust needle bearing) during disassem-
bly or reassembly to prevent damage.
1) Straighten lock nut at staked portion. Remove the lock
nut using ST1 and ST2.
ST1 499987300 SOCKET WRENCH (50)
ST2 899884100 HOLDER
G3M0609
2) Remove 5th driven gear using ST.
ST 499857000 5TH DRIVEN GEAR REMOVER
G3M0610
3) Remove woodruff key.
4) Remove roller bearing (42 x 74 x 40), 3rd-4th driven
gear using ST1 and ST2.
ST1 499757002 SNAP RING PRESS
ST2 899714110 REMOVER
B3M0426A
5) Remove the key.
6) Remove 2nd driven gear

1, inner baulk ring
2, synchro
cone

3and outer baulk ring
4.
51
3-1SERVICE PROCEDURE
5. Drive Pinion Assembly (AWD Model)