1997 SUBARU LEGACY Service Repair Manual

oil filter fuse keyless entry service indicator fuel consumption tire pressure

Load previous 8 pages

Page 633 of 3342

SUBARU LEGACY 1997 Service Repair Manual 20) Connect connectors and cables.
(1) Connect the following connectors.
Transmission harness connectors
Transmission ground terminal
Front oxygen sensor connector
Vehicle speed sensor 2
Neutral

Page 634 of 3342

SUBARU LEGACY 1997 Service Repair Manual 1. Manual Transmission and
Differential
A: SPECIFICATIONS
ItemModel
2200 cc 2500 cc OUTBACK
Type 5-forward speeds with synchromesh and 1-reverse
Transmission gear ratio1st 3.545
2nd 2.111
3rd 1.448
4t

Page 635 of 3342

SUBARU LEGACY 1997 Service Repair Manual B: SERVICE DATA
1. EXTENSION (AWD Model)
Snap ring (Inner-72) to ball bearing side clearance
0 — 0.15 mm (0 — 0.0059 in)
Snap ring (Inner-72)
Part No. Thickness mm (in)
805172071 1.78 (0.0701)
805

B: SERVICE DATA
1. EXTENSION (AWD Model)
Snap ring (Inner-72) to ball bearing side clearance
0 — 0.15 mm (0 — 0.0059 in)
Snap ring (Inner-72)
Part No. Thickness mm (in)
805172071 1.78 (0.0701)
805172072 1.90 (0.0748)
805172073 2.02 (0.0795)
Snap ring (Outer-30) to ball bearing side clearance
0 — 0.15 mm (0 — 0.0059 in)
Snap ring (Outer-30)
Part No. Thickness mm (in)
805030041 1.53 (0.0602)
805030042 1.65 (0.0650)
805030043 1.77 (0.0697)
2. EXTENSION ASSEMBLY (AWD Model)
Thrust washer (52 x 61 x t) to ball bearing side clearance
0.05 — 0.30 mm (0.0020 — 0.0118 in)
Thrust washer (52 x 61 x t)
Part No. Thickness mm (in)
803052021 0.50 (0.0197)
803052022 0.75 (0.0295)
803052023 1.00 (0.0394)
3. TRANSFER CASE OR REAR CASE
Neutral position adjustment
Adjustment shim
Part No. Thickness mm (in)
32190AA000 0.15 (0.0059)
32190AA010 0.30 (0.0118)
Reverse accent shaft
Part No. Mark Remarks
32188AA040 1Neutral position is closer to
1st.
32188AA011 No mark or 2 Standard
32188AA050 3Neutral position is closer to
reverse gear.
Reverse check plate adjustment
Reverse check plate
Part No. Mark AngleθRemarks
32189AA000 0 28°Arm stops closer to
5th gear.
32189AA010 1 31°Arm stops closer to
5th gear.
33189AA020 2 34°Arm stops in the
center.
32189AA030 3 37°Arm stops closer to
reverse gear.
32189AA040 4 40°Arm stops closer to
reverse gear.
4. REVERSE IDLER GEAR
Adjustment of reverse idler gear position
Reverse idler gear to transmission case (LH) wall clearance
6.0 — 7.5 mm (0.236 — 0.295 in)
Reverse shifter lever
Part No. Mark Remarks
32820AA000 0 Further from case wall
32820AA010 No mark Standard
32820AA020 2 Closer to the case wall
After installing a suitable reverse shifter lever, adjust reverse idler
gear to transmission case wall clearance to within 0 to 0.5 mm (0
to 0.020 in) using washers.
Washer (20.5 x 26 x t)
Part No.Thickness
mm (in)Part No.Thickness
mm (in)
803020151 0.4 (0.016) 803020154 1.9 (0.075)
803020152 1.1 (0.043) 803020155 2.3 (0.091)
803020153 1.5 (0.059)
3
3-1SPECIFICATIONS AND SERVICE DATA
1. Manual Transmission and Differential

Page 636 of 3342

SUBARU LEGACY 1997 Service Repair Manual 5. SHIFTER FORK AND ROD
Select suitable shifter forks so that both coupling sleeve and
reverse driven gear are positioned in the center of their synchro-
mesh mechanisms.
1st-2nd shifter fork
Part No.

5. SHIFTER FORK AND ROD
Select suitable shifter forks so that both coupling sleeve and
reverse driven gear are positioned in the center of their synchro-
mesh mechanisms.
1st-2nd shifter fork
Part No. Mark Remarks
32804AA060 1Approach to 1st gear by
0.2 mm (0.008 in)
32804AA070 No mark Standard
32804AA080 3Approach to 2nd gear by
0.2 mm (0.008 in)
3rd-4th shifter fork
Part No. Mark Remarks
32810AA060 1Approach to 4th gear by
0.2 mm (0.008 in)
32810AA070 No mark Standard
32810AA100 3Approach to 3rd gear by
0.2 mm (0.008 in)
5th shifter fork
Part No. Mark Remarks
32812AA200 4Approach to 5th gear by
0.2 mm (0.008 in)
32812AA210 No mark Standard
32812AA220 6Become distant from 5th
gear by 0.2 mm (0.008 in)
Rod end clearance
A: 1st-2nd—3rd-4th
0.5—1.5 mm (0.020—0.059 in)
B: 3rd-4th—5th
0.6—1.4 mm (0.024—0.055 in)
6. TRANSMISSION CASE ASSEMBLY
Drive pinion shim adjustment
Drive pinion shim
Part No.Thickness
mm (in)Part No.Thickness
mm (in)
32295AA0310.150
(0.0059)32295AA0710.250
(0.0098)
32295AA0410.175
(0.0069)32295AA0810.275
(0.0108)
32295AA0510.200
(0.0079)32295AA0910.300
(0.0118)
32295AA0610.225
(0.0089)32295AA1010.500
(0.0197)
Hypoid gear backlash
0.13—0.18 mm (0.0051—0.0071 in)Selection of main shaft rear plate
Main shaft rear plate
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
7. DRIVE PINION ASSEMBLY
Preload adjustment of thrust bearing
Starting torque
0.3—0.8 N⋅m(3—8 kg-cm, 2.6—6.9 in-lb)
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)
Adjusting washer No. 2
Part No. Thickness mm (in)
803025059 3.850 (0.1516)
803025054 4.000 (0.1575)
803025058 4.150 (0.1634)
Assemble a driven shaft and 1st driven gear that are selected for
the proper radial clearance adjustment.
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
8. DRIVE PINION ASSEMBLY (FWD Model)
Selection of 1st driven gear:
1st driven gear
Outer diameter of bushing mm (in) Part No.
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
4
3-1SPECIFICATIONS AND SERVICE DATA
1. Manual Transmission and Differential

Page 637 of 3342

SUBARU LEGACY 1997 Service Repair Manual 9. CENTER DIFFERENTIAL (AWD Model)
Snap ring (Inner-110) to center differential case clearance
0—0.15 mm (0—0.0059 in)
Snap ring (Inner-110)
Part No. Thickness mm (in)
805100061 2.10 (0.0827)
8051

Page 638 of 3342

SUBARU LEGACY 1997 Service Repair Manual 1. Transfer Case and Extension (AWD
Model)
B3M0326A
1Transfer cover

2Cover gasket

3Oil seal

4Gasket

5Neutral switch

6Back-up light switch

7Transfer case

8Gasket

9Oil guide

10Ball

Page 639 of 3342

SUBARU LEGACY 1997 Service Repair Manual 2. Rear Case (FWD Model)
G3M0265
1Rear case

2Case gasket

3Back-up light switch

4Neutral switch

5Reverse check sleeve ASSY

6Gasket

7Adjusting shim
8O-ring

9Oil seal
Tightening torque: N

Page 640 of 3342

SUBARU LEGACY 1997 Service Repair Manual 3. Transmission Case
B3M0327A
1Transmission case ASSY

2Gasket

3Drain plug

4Snap ring (Outer)

5Speedometer driven gear

6Washer

7Speedometer shaft

8Snap ring (Outer)

9Oil seal

10Oil l

Load next 8 pages

Page: < prev 1-10 ... 601-608 609-616 617-624 625-632 633-640 641-648 649-656 657-664 665-672 ... 3344 next >

oil reset lights fuses bolt pattern engine coolant compression ratio