1999 SUBARU LEGACY rear

2. COMBINATION OF TRANSMISSION CASE
S3M0190B
(1) Differential ASSY
(2) Drive pinion shim
(3) Drive pinion ASSY
(4) Main shaft ASSY
(5) Main shaft rear plate
(6) Transmission case (LH)
(7) Transmission case (RH)(8) Differential side retainer
(9) O-ring
(10) Oil seal
(11) Retainer lock plate
(12) Release lever
(13) Release bearing(14) Operating cylinder (2500 cc
model)
Tightening torque: N´m (kg-m, ft-lb)
T1:
25 (2.5, 18)
T2:29±3 (3.0±0.3, 21.7±2.2)
1) Alignment marks/numbers on hypoid gear set
The upper number on driven pinion is the match
number for combining it with hypoid driven gear.
The lower number is for shim adjustment. If no
lower number is shown, the value is zero. The
number on hypoid driven gear indicates a number
for combination with drive pinion.
G3M0554
2) Place drive pinion shaft assembly on right hand
transmission main case without shim and tighten
bearing mounting bolts.
22
3-1[W2B2]SERVICE PROCEDURE
2. Transmission Case

IThe drive pinion shim selected before is too thin.
Increase its thickness.
B3M0074
26) After checking the tooth contact of hypoid
gears, remove the lock plate. 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.
NOTE:
Carry out this job on both upper and lower retain-
ers.
Tightening torque:
T: 2 5
±3 N´m (2.5±0.3 kg-m, 18.1±2.2 ft-lb)
S3M0014A
27) 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
NOTE:
Before measuring, tap the end of main shaft with
a plastic hammer lightly in order to make the clear-
ance zero between the main case surface and the
moving flange of bearing.
Dimension (A)
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
B3M0531A
28) Install clutch release lever and bearing. to 2-10 [W3C0].>
B3M0336I
(A) Clutch release lever
(B) Release bearing
28
3-1[W2B2]SERVICE PROCEDURE
2. Transmission Case

5) After installing key on driven shaft, install 3rd-
4th driven gear using ST and press.
NOTE:
Align groove in baulk ring with insert.
ST 499277200 INSTALLER
G3M0615
6) Install a set of roller bearings (42´74´40)
onto the driven shaft using ST and press.
ST 499277200 INSTALLER
G3M0616
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
G3M0617
8) Install lock washer (42´53´2). Install lock nut
(42´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)
G3M0618
NOTE:
IStake lock nut at two points.
IUsing spring balancer, check that starting torque
of roller bearing is 0.1 to 1.5 N´m (0.01 to 0.15
kg-m, 0.07 to 1.1 ft-lb).
B3M0079D
3. DRIVE PINION SHAFT
1) Install roller bearing onto drive pinion. Install
washer (33´50´5) using ST1, ST2 and press.
ST1 499277100 BUSH 1-2 INSTALLER
ST2 499277200 INSTALLER
B3M0080D
32
3-1[W3B3]SERVICE PROCEDURE
3. Drive Pinion Assembly

NOTE:
When installing roller bearing, note its directions
(front and rear) because knock pin hole in outer
race is offset.
B3M0081D
(A) Roller bearing
(B) Knock pin hole
2) Install thrust bearing (33´50´3) and needle
bearing (30´37´23). Install driven shaft assem-
bly.
B3M0082D
3) Install drive pinion collar, needle bearing,
adjusting washer No. 2, thrust bearing, adjusting
washer No. 1 and differential bevel gear sleeve in
that order.
NOTE:
Be careful because spacer must be installed in
proper direction.
B3M0083D
(A) Driven shaft
(B) Drive shaft
(C) Drive pinion collar
(D) Needle bearing (25´30´20)
(E) Washer No. 2 (25´36´4)
(F) Thrust bearing (25´37.5´3)
(G) Washer No. 1 (25´36´t)
(H) Differential bevel gear sleeve
33
[W3B3]3-1SERVICE PROCEDURE
3. Drive Pinion Assembly

B: ASSEMBLY
1. 2200 cc MODEL
1) Assemble sleeve and hub assembly for 3rd-4th
and, 5th synchronizing.
NOTE:
Position open ends of spring 120É apart.
B3M1366A
2) Install 3rd drive gear, baulk ring, and sleeve and
hub assembly for 3rd-4th needle bearing (32´36
´25.7) on transmission main shaft.
NOTE:
Align groove in baulk ring with shifting insert.
3) Install 4th needle bearing race onto transmis-
sion main shaft using ST1, ST2 and a press.
ST1 899714110 REMOVER
ST2 499877000 RACE 4-5 INSTALLER
B3M0543C
4) Install baulk ring, needle bearing (32´30´
25.7), 4th drive gear and 4th gear thrust washer to
transmission main shaft.
S3M0045A
(A) Groove
(B) 4th gear side
5) Drive ball bearing onto the rear section of trans-
mission main shaft using ST1, ST2 and a press.
ST1 899714110 REMOVER
ST2 499877000 RACE 4-5 INSTALLER
B3M0553D
6) Using ST1 and ST2, install the 5th gear thrust
washer and 5th needle bearing race onto the rear
section of transmission main shaft.
NOTE:
Face thrust washer in the correct direction.
ST1 899714110 REMOVER
ST2 499877000 RACE 4-5 INSTALLER
B3M0091D
(A) Face this surface to 5th gear side.
38
3-1[W4B1]SERVICE PROCEDURE
4. Main Shaft Assembly

7) Install the following parts to the rear section of
transmission main shaft.
NOTE:
IAlign groove in baulk ring with shifting insert.
IBe sure to fit pawl of insert stopper plate into 4
mm (0.16 in) dia. hole in the boss section of syn-
chronizer hub.
B3M1367A
(A) Needle bearing (32´36´25.7)
(B) 5th drive gear
(C) Baulk ring
(D) Sleeve and hub assembly
(E) Insert stopper plate
(F) Lock washer (22´38´2)
(G) Lock nut
8) Tighten lock nuts (22´13) to the specified
torque using ST1 and ST2.
NOTE:
Secure lock nuts in two places after tightening.
ST1 499987003 SOCKET WRENCH (35)
ST2 498937000 TRANSMISSION HOLDER
Tightening torque:
11 8
±6 N´m (12.0±0.6 kg-m, 86.8±4.3 ft-lb)
2. 2500 cc MODEL
1) Assemble sleeve and hub assembly for 3rd-4th
and, 5th synchronizing.
NOTE:
Position open ends of spring 120É apart.
B3M1366A
2) Install 3rd drive gear, outer baulk ring, synchro
cone, inner baulk ring, sleeve and hub assembly
for 3rd needle bearing on transmission main shaft.
NOTE:
Align groove in baulk ring with insert key.
B3M0837A
(A) 3rd needle bearing (32´36´25.7)
(B) 3rd drive gear
(C) Inner baulk ring
(D) Synchro cone
(E) Outer baulk ring
(F) Sleeve and hub ASSY
39
[W4B2]3-1SERVICE PROCEDURE
4. Main Shaft Assembly

3) Install 4th needle bearing race onto transmis-
sion main shaft using ST1, ST2 and a press.
ST1 899714110 REMOVER
ST2 499877000 RACE 4-5 INSTALLER
B3M0543C
4) Install baulk ring, needle bearing (32´30´
25.7), 4th drive gear and 4th gear thrust washer to
transmission main shaft.
S3M0045A
(A) Groove
(B) 4th gear side
5) Drive ball bearing onto the rear section of trans-
mission main shaft using ST1, ST2 and a press.
ST1 899714110 REMOVER
ST2 499877000 RACE 4-5 INSTALLER
B3M0553D
6) Using ST1 and ST2, install the 5th gear thrust
washer and 5th needle bearing race onto the rear
section of transmission main shaft.
NOTE:
Face thrust washer in the correct direction.
ST1 899714110 REMOVER
ST2 499877000 RACE 4-5 INSTALLER
B3M0091D
(A) Face this surface to 5th gear side.
7) Install bearing onto synchro cone.
8) Install baulk ring and synchro cone onto 5th-
Rev sleeve and hub assembly using ST and a
oress.
NOTE:
IUsing new ball bearing.
IAfter press fitting, make sure synchro cone
rotates freely.
ST 499757002 SNAP RING PRESS
B3M1370A
(A) Baulk ring
(B) Synchro cone
(C) Ball bearing
40
3-1[W4B2]SERVICE PROCEDURE
4. Main Shaft Assembly

9) Install synchro cone stopper and snap ring to
5th-Rev sleeve and hub assembly.
B3M0435B
(A) Synchro cone stopper
(B) Snap ring
10) Install the rest parts to the rear section of
transmission main shft.
NOTE:
After groove in baulk ring with shifting insert.
ST 499987003 SOCKET WRENCH
ST 498937000 TRANSMISSION HOLDER
B3M1371A
(A) Needle bearing (32 x 36 x 25.7)
(B) 5th drive gear
(C) Baulk ring
(D) 5th-Rev sleeve and hub ASSY
(E) Lock washer (22 x 38 x 2)
(F) Lock nuts (22 x 13)
11) Tighten lock nuts to the specified torque using
ST1 and ST2.
NOTE:
Secure lock nuts in two places after tightening.
ST1 499987000 SOCKET WRENCH
ST2 498937000 TRANSMISSION HOLDER
Tightening torque:
11 8
±6 N´m (12.0±0.6 kg-m, 86.8±4.3 ft-lb)
41
[W4B2]3-1SERVICE PROCEDURE
4. Main Shaft Assembly