1997 SUBARU LEGACY Transfer

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
4th 1.088
5th 0.780 0.871
Reverse 3.416
Front
reduction
gearFinalType of gear Hypoid
Gear ratio 3.900 4.111
Rear
reduction
gearTransferType of gear Helical
Gear ratio 1.000
FinalType of gear Hypoid
Gear ratio 3.900 4.111
Front
differentialType and number of gear Straight bevel gear (Bevel pinion: 2, Bevel gear: 2)
Center
differentialType and number of gear Straight bevel gear (Bevel pinion: 2, Bevel gear: 2 and viscous coupling)
Transmission gear oil GL-5
Transmission oil capacity 3.5
(3.7 US qt, 3.1 Imp qt)
2
3-1SPECIFICATIONS AND SERVICE DATA
1. Manual Transmission and Differential

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

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


11Reverse accent spring


12Gasket


13Plug


14Snap ring (Inner)


15Reverse check plate

16Reverse check spring


17Reverse return spring


18Reverse check cam


19Reverse accent shaft


20O-ring


21Adjusting select shim


22Reverse check sleeve


23Adjusting washer


24Ball bearing


25Transfer driven gear


26Ball bearing


27Oil seal


28Shift bracket


29Extension cover


30Gasket

31Snap ring (Outer-30)


32Gasket


33Ball bearing


34Snap ring (Inner-72)


35Transfer drive gear


36Extension
Tightening torque: N⋅m (kg-m, ft-lb)
T1: 5±1 (0.5±0.1, 3.6±0.7)
T2: 10±1 (1.0±0.1, 7.2±0.7)
T3: 15.7±1.5
(1.6±0.15, 11.6±1.1)
T4: 25±2 (2.5±0.2, 18.1±1.4)
T5: 37±3 (3.8±0.3, 27.5±2.2)
6
3-1COMPONENT PARTS
1. Transfer Case and Extension (AWD Model)

1. General
A: APPLICATION
Large titleModel
AWD FWD
1 General


2Transfer Case and Extension
(AWD Model)

3 Rear Case (FWD Model)

4 Transmission Case


5 Drive Pinion Assembly (AWD Model)

6 Drive Pinion Assembly (FWD Model)

7 Main Shaft Assembly


8 Center Differential (AWD Model)

9 Front Differential


The table above shows the titles of the main sections in
Service Procedures and the applicable vehicle models.
Carry out service operations by referring to the sections
applicable to the vehicle to be serviced.
15
3-1SERVICE PROCEDURE
1. General

2. Transfer Case and Extension (AWD
Model)
A: REMOVAL
B3M0041A
1) Remove transfer cover
1.
2) Remove shifter fork screw

2which secures selector
arm to shifter arm.
3) Remove transfer case

4with extension assembly
3.
19
3-1SERVICE PROCEDURE
2. Transfer Case and Extension (AWD Model)

B: DISASSEMBLY
1. SEPARATION OF TRANSFER CASE AND
EXTENSION ASSEMBLY
G3M0523
1) Separate transfer case
1and extension assembly
2.
2) Remove transfer driven gear

3and center differential


4as a set.
3) Remove thrust washer

5(52x61xt).
B3M0042A
2. TRANSFER CASE
1) Remove neutral switch

6.
NOTE:
Before removing shifter arm, disconnect neutral switch.
2) Draw out shifter arm

1and remove selector arm
8.
3) Remove plug

2, spring
3and reverse check ball
4.
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)
20
3-1SERVICE PROCEDURE
2. Transfer Case and Extension (AWD Model)

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)

3. EXTENSION
G3M0526
1) Remove extension cover
2and shift bracket
1.
2) Remove snap ring

4(Outer-30).
3) Remove transfer drive gear

5.
CAUTION:
Do not remove ball bearing unless replacing.
4) Remove snap ring

6(Inner-72).
5) Remove ball bearing

7.
CAUTION:
Do not reuse ball bearing.
6) Remove oil seal

8.
CAUTION:
Do not reuse oil seal.
22
3-1SERVICE PROCEDURE
2. Transfer Case and Extension (AWD Model)