1999 SUBARU LEGACY rear

1. Manual Transmission and Differential
ItemModel
AWD
2200 cc 2500 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 3.333
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 differential Type and number of gear Straight bevel gear (Bevel pinion: 2, Bevel gear: 2)
Center differential Type and number of gearStraight bevel gear (Bevel pinion: 2, Bevel gear: 2 and vis-
cous coupling)
Transmission gear oilGL-5
Transmission oil capacity 3.5(3.7 US qt, 3.1 Imp qt)
2. Transmission Gear Oil
Recommended oil
B1H0024
3. 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 Ð 0.18 mm (0.0051 Ð 0.0071 in)
Selection of main shaft rear plate
Main shaft rear plate
Dimension ªAº mm
(in)Part No. Mark
4.00 Ð 4.13
(0.1575 Ð 0.1626)32294AA041 1
3.87 Ð 3.99
(0.1524 Ð 0.1571)32294AA051 2
2
3-1[S100]SPECIFICATIONS AND SERVICE DATA
1. Manual Transmission and Differential

3. Main Shaft Assembly
A: 2200 cc MODEL
B3M1404A
(1) Oil seal
(2) Needle bearing
(3) Transmission main shaft
(4) Needle bearing
(5) 3rd drive gear
(6) Inner baulk ring
(7) Synchro cone
(8) Outer baulk ring
(9) Coupling sleeve (3rd-4th)
(10) Synchronizer hub (3rd-4th)
(11) Shifting insert key (3rd-4th)
(12) Baulk ring (4th)(13) 4th drive gear
(14) 4th needle bearing race
(15) Needle bearing
(16) 4th gear thrust washer
(17) Ball bearing
(18) 5th gear thrust washer
(19) 5th needle bearing race
(20) Needle bearing
(21) Main shaft rear plate
(22) 5th drive gear
(23) Baulk ring (5th)
(24) Shifting insert key (5th-Rev)(25) Synchronizer hub (5th-Rev)
(26) Coupling sleeve (5th-Rev)
(27) Insert stopper plate
(28) Lock washer
(29) Lock nut
(30) Straight pin
(31) Reverse idler gear shaft
(32) Reverse idler gear
(33) Washer
Tightening torque: N´m (kg-m, ft-lb)
T:
11 8±6 (12.0±0.6, 86.8±4.3)
8
3-1[C3A0]COMPONENT PARTS
3. Main Shaft Assembly

B: 2500 cc MODEL
B3M1357A
(1) Oil seal
(2) Needle bearing
(3) Transmission main shaft
(4) Needle bearing
(5) 3rd drive gear
(6) Inner baulk ring
(7) Synchro cone (3rd)
(8) Outer baulk ring
(9) Coupling sleeve (3rd-4th)
(10) Synchronizer hub (3rd-4th)
(11) Shift insert key (3rd-4th)
(12) 4th baulk ring
(13) 4th drive gear
(14) 4th needle bearing race(15) Needle bearing
(16) 4th gear thrust washer
(17) Ball bearing
(18) 5th gear thrust washer
(19) 5th needle bearing race
(20) Needle bearing
(21) Main shaft rear plate
(22) 5th drive gear
(23) 5th baulk ring
(24) Shift insert key (5th-Rev)
(25) Synchronizer hub (5th-Rev)
(26) Coupling sleeve
(27) Rev baulk ring
(28) Synchro cone (Rev)(29) Ball bearing
(30) Synchro cone stopper
(31) Snap ring
(32) Lock washer
(33) Lock nut
(34) Straight pin
(35) Reverse idler gear shaft
(36) Reverse idler gear
(37) Washer
Tightening torque: N´m (kg-m, ft-lb)
T:
11 8±6 (12.0±0.6, 86.8±4.3)
9
[C3B0]3-1COMPONENT PARTS
3. Main Shaft Assembly

1. General
A: PRECAUTIONS
1) Clean oil, grease, dirt and dust from transmis-
sion.
2) Remove drain plug to drain oil. After draining,
retighten it as before.
CAUTION:
Replace gasket with a new one.
Tightening torque:
44
±3 N´m (4.5±0.3 kg-m, 32.5±2.2 ft-lb)
B3M0037D
3) Attach transmission to ST.
ST 499937100 TRANSMISSION STAND SET
G3M0517
4) Rotating parts should be coated with oil prior to
assembly.
5) All disassembled parts, if to be reused, should
be reinstalled in the original positions and direc-
tions.
6) Gaskets and lock washers must be replaced
with new ones.
7) Liquid gasket should be used where specified
to prevent leakage.
8) Fill transmission gear oil through the oil level
gauge hole up to upper point level gauge. 1-5 [G9A1].>
B: INSPECTION
Disassembled parts should be washed clean first
and then inspected carefully.
1) Bearings
Replace bearings in the following cases:IBearings whose balls, outer races and inner
races are broken or rusty.
IWorn bearings
IBearings that fail to turn smoothly or make
abnormal noise when turned after gear oil lubrica-
tion.
IThe ball bearing on the rear side of the drive
pinion shaft should be checked for smooth rotation
before the drive pinion assembly is disassembled.
In this case, because a preload is working on the
bearing, its rotation feels like it is slightly dragging
unlike the other bearings.
B3M0038E
(A) Drive pinion shaft
(B) Ball bearing
IBearings having other defects
2) Bushing (each gear)
Replace the bushing in the following cases:
IWhen the sliding surface is damaged or abnor-
mally worn.
IWhen the inner wall is abnormally worn.
3) Gears
IReplace gears with new ones if their tooth sur-
faces are broken, damaged, or excessively worn.
ICorrect or replace if the cone that contacts the
baulk ring is rough or damaged.
ICorrect or replace if the inner surface or end
face is damaged.
4) Baulk ring
Replace the ring in the following cases:
IWhen the inner surface and end face are dam-
aged.
IWhen the ring inner surface is abnormally or
partially worn down.
13
[W1B0]3-1SERVICE PROCEDURE
1. General

2. Transmission Case
A: DISASSEMBLY
1. SEPARATION OF TRANSMISSION
S3M0190A
(1) Operating cylinder
(2) Release lever
(3) Release bearing
(4) Release lever sealing(5) Bolt
(6) Main shaft rear plate
(7) Transmission case
(8) Drive pinion ASSY(9) Main shaft ASSY
(10) Front differential
1) Remove clutch release lever. [W3A0].>
B3M0336I
(A) Clutch release lever
(B) Release bearing
2) Remove transfer case assembly. [W5A0].>3) Remove bearing mounting bolts.
S3M0099
15
[W2A1]3-1SERVICE PROCEDURE
2. Transmission Case

4) Remove main shaft rear plate.
S3M0100B
5) Put vinyl tape around splines of right and left
axle drive shafts to prevent damage to oil seals.
B3M1405A
6) Separate transmission case into right and left
cases by loosening seventeen coupling bolts and
nuts.
B3M1359
7) Remove drive pinion shaft assembly from left
side transmission case.
NOTE:
Use a hammer handle, etc. to remove if too tight.
B3M0101G
8) Remove main shaft assembly.
9) Remove differential assembly.
CAUTION:
IBe careful not to confuse right and left roller
bearing outer races.
IBe careful not to damage retainer oil seal.
G3M0557
16
3-1[W2A1]SERVICE PROCEDURE
2. Transmission Case

2) Install reverse shifter lever, reverse idler gear
and reverse idler gear shaft, and secure with
straight pin.
NOTE:
Be sure to install reverse idler shaft from the rear
side.
B3M0526C
(A) Reverse shifter lever
(B) Reverse idler gear
(C) Reverse idler gear shaft
(D) Straight pin
3) Install reverse arm fork spring, ball and inter-
lock plunger (5.56´19.6) to reverse fork rod arm.
Insert reverse fork rod into hole in reverse fork rod
arm, and hold it with outer snap ring using ST.
CAUTION:
Apply grease to plunger to prevent it from fall-
ing.
ST 399411700 ACCENT BALL INSTALLER
4) Position ball (7.1438), spring and gasket in
reverse shifter rod hole, on left side transmission
case, and tighten checking ball plug.
CAUTION:
Replace gasket with a new one.5) Move reverse shifter rod toward REV side.
Adjust clearance between reverse idler gear and
transmission case wall, using reverse shifter lever.
Clearance A:
6.0 Ð 7.5 mm (0.236 Ð 0.295 in)
G3M0796
Reverse shifter lever
Part No. No. Remarks
32820AA070 7 Further from case wall
32820AA080 8 Standard
32820AA090 9 Closer to case wall
6) After installing a suitable reverse shifter lever,
shift into neutral. Using a thickness gauge, mea-
sure clearance between reverse idler gear and
transmission case wall and adjust with washer(s).
Clearance:
0 Ð 0.5 mm (0 Ð 0.020 in)
B3M0063
Washer (20.5´26´t)
Part No. Thickness mm (in)
803020151 0.4 (0.016)
803020152 1.1 (0.043)
803020153 1.5 (0.059)
803020154 1.9 (0.075)
803020155 2.3 (0.091)
7) Install 1-2 fork rod into 1-2 shifter fork via the
hole on the rear of transmission case.
8) Align the holes in rod and fork, and drive
straight pin (6´22) into these holes using ST.
ST 398791700 STRAIGHT PIN REMOVER
20
3-1[W2B1]SERVICE PROCEDURE
2. Transmission Case

CAUTION:
Replace straight pin with a new one.
NOTE:
ISet other rods to neutral.
IMake sure interlock plunger (5.56´19.6) is on
the 3-4 fork rod side.
9) Install interlock plunger (3´11.9) onto 3-4 fork
rod.
CAUTION:
Apply a coat of grease to plunger to prevent it
from falling.
10) Install 3-4 fork rod into 3-4 shifter fork via the
hole on the rear of transmission case.
11) Align the holes in rod and fork, and drive
straight pin (6´22) into these holes.
ST 398791700 STRAIGHT PIN REMOVER
CAUTION:
Replace straight pin with a new one.
NOTE:
ISet reverse fork rod to neutral.
IMake sure interlock plunger (installed before) is
on the reverse fork rod side.
12) Install 5th shifter fork onto the rear of reverse
fork rod. Align holes in the two parts and drive
straight pin into place.
CAUTION:
Replace straight pin with a new one.
ST 398791700 STRAIGHT PIN REMOVER
B3M0333J
(A) 5th shifter fork
(B) Reverse fork rod
(C) Straight pin
13) Position balls, checking ball springs and gas-
kets into 3-4 and 1-2 rod holes, and install plugs.
CAUTION:
Replace gasket with a new one.
G3M0552
14) Install washer and speedometer shaft, and
press fit oil seal with ST.
CAUTION:
Use new oil seal, if it has been removed.
ST 899824100 or 499827000 PRESS
15) Install vehicle speed sensor 2.
CAUTION:
Use new vehicle speed sensor 2, if it has been
removed.
Tightening torque:
5.9
±1.5 N´m (60±15 kg-cm, 52±13 in-lb)
16) Install speedometer driven gear and snap
ring.
CAUTION:
Use a new snap ring, if it has been removed.
B3M0527C
(A) Speedometer driven gear
(B) Snap ring
21
[W2B1]3-1SERVICE PROCEDURE
2. Transmission Case