1999 SUBARU LEGACY rear

6. CONNECTION OF EACH SECTION
1) Install the parking pawl, shaft and return spring.
B3M1062A
2) Install inlet filter to transmission case.
B3M1061A
3) Install transfer valve plate, valve body and duty
solenoid C (transfer) to transmission case.
CAUTION:
IBe sure to install transfer seal lip to transfer
control valve body.
IIf transfer seal lip is damaged, replace seal
with new one.
Tightening torque:
8
±1 N´m (0.8±0.1 kg-m, 5.8±0.7 ft-lb)
B2M2264A
4) Connect connector to duty solenoid C (trans-
fer).5) Install the reduction drive gear assembly.
NOTE:
Insert it fully into position until the bearing shoulder
bottoms.
B3M1113A
6) Using a plastic hammer, install reduction driven
gear assembly, and tighten drive pinion lock nut.
NOTE:
IBe sure to use a new lock nut and a washer.
ISet the select lever in the ªPº range.
IAfter tightening, stake the lock nut securely.
Tightening torque:
98
±5 N´m (10.0±0.5 kg-m, 72.3±3.6 ft-lb)
B3M1058A
7) Measurement and adjustment of extension end
play
(1) Measure distance L from end of extension
case and rear drive shaft with ST.
ST 398643600 GAUGE
L = Measured value þ 15 mm
B3M0985A
69
[W11C6]3-2SERVICE PROCEDURE
11. Overall Transmission

(2) Measure the distance ªº from the transmis-
sion case mating surface to the reduction drive
gear end surface with ST1 and ST2.
= Measured value þ 50 mm
ST1 398643600 GAUGE
ST2 499577000 GAUGE
B3M1114A
(3) Calculation equation:
NOTE:
Add 0.05 mm (0.0020 in) and 0.20 mm (0.0079 in)
thick shims to area ªTº. Calculate formula 2 to
determine ªHº. The calculated ªHº refers to the
shim thickness range. Select shims of suitable
thicknesses within the calculated ªHº range.
T=(L+G)þþH
T : Shim clearance
L : Distance from end of extension case to
end of rear drive shaft
G: Gasket thickness (0.45 mm, 0.0177 in)
: Height from end of transmission case to
end of reduction drive gear
H : Thrust needle bearing thickness
0.05 Ð 0.25 mm (0.0020 Ð 0.0098 in)
Thrust needle bearing
Part No. Thickness mm (in)
806536020
806535030
806535040
806535050
806535060
806535070
8065350903.8 (0.150)
4.0 (0.157)
4.2 (0.165)
4.4 (0.173)
4.6 (0.181)
4.8 (0.189)
5.0 (0.197)
8) Installation of extension case and transmission
case
(1) Attach the selected thrust needle bearing to
the end surface of reduction drive gear with
vaseline.
CAUTION:
Install thrust needle bearing in the correct
direction.
(2) Install the extension case to the transmis-
sion case.
CAUTION:
Be sure to use a new gasket.(3) Tighten bolts to secure the case.
Tightening torque:
25
±2 N´m (2.5±0.2 kg-m, 18.1±1.4 ft-lb)
B3M1057A
9) Install the vehicle speed sensor 1 (rear).
Tightening torque:
7
±1 N´m (0.7±0.1 kg-m, 5.1±0.7 ft-lb)
B3M1056A
70
3-2[W11C6]SERVICE PROCEDURE
11. Overall Transmission

IInstall the oil seal retainer and seal rings. After
adjusting the drive pinion backlash and tooth con-
tact.
B3M1095A
16. Drive Pinion Shaft
A: DISASSEMBLY
1) Straighten the staked portion of the lock nut,
and remove the lock nut while locking the rear
spline portion of the shaft with ST1 and ST2. Then
pull off the drive pinion collar.
ST1 498937100 HOLDER
ST2 499787100 WRENCH
ST3 499757800 ADAPTER
B3M0587A
2) Remove the O-ring.
3) Using a press, separate the rear roller bearing
and outer race from the shaft.
G3M0459
4) Using a press and ST, separate the front roller
bearing from the shaft.
ST 498517000 REPLACER
G3M0460
B: INSPECTION
Make sure that all component parts are free of
harmful cuts, gouges, and other faults.
82
3-2[W16A0]SERVICE PROCEDURE
16. Drive Pinion Shaft

IInstall the oil seal retainer and seal rings. After
adjusting the drive pinion backlash and tooth con-
tact.
B3M1095A
16. Drive Pinion Shaft
A: DISASSEMBLY
1) Straighten the staked portion of the lock nut,
and remove the lock nut while locking the rear
spline portion of the shaft with ST1 and ST2. Then
pull off the drive pinion collar.
ST1 498937100 HOLDER
ST2 499787100 WRENCH
ST3 499757800 ADAPTER
B3M0587A
2) Remove the O-ring.
3) Using a press, separate the rear roller bearing
and outer race from the shaft.
G3M0459
4) Using a press and ST, separate the front roller
bearing from the shaft.
ST 498517000 REPLACER
G3M0460
B: INSPECTION
Make sure that all component parts are free of
harmful cuts, gouges, and other faults.
82
3-2[W16A0]SERVICE PROCEDURE
16. Drive Pinion Shaft

18. Low Clutch Drum and Planetary Gear
A: DISASSEMBLY
B3M1155A
(1) Snap ring
(2) Front planetary carrier
(3) Thrust needle bearing
(4) Rear sun gear
(5) Thrust needle bearing
(6) Rear planetary carrier
(7) Washer
(8) Thrust needle bearing
(9) Rear internal gear(10) Washer
(11) Retaining plate
(12) Drive plate
(13) Driven plate
(14) Dish plate
(15) Snap ring
(16) Cover
(17) Spring retainer
(18) Lathe cut seal ring(19) Low clutch piston
(20) Lathe cut seal ring
(21) Low clutch drum
(22) Needle bearing
(23) Inner snap ring
(24) One-way clutch
(25) Outer snap ring
91
[W18A0]3-2SERVICE PROCEDURE
18. Low Clutch Drum and Planetary Gear

1) Remove snap ring from the low clutch drum.
B3M1156A
2) Take out front planetary carrier and thrust
needle bearing from low clutch drum.
B3M1157A
3) Take out rear sun gear.
B3M1158A
4) Take out rear planetary carrier, washer and
thrust needle bearing.
B3M1159A
5) Take out rear internal gear.
B3M1160A
6) Remove the snap ring from the low clutch drum.
B3M1161A
7) Remove the retaining plate, drive plates, driven
plates and dish plate.
8) Compress the spring retainer, and remove the
snap ring from the low clutch drum, by using ST1
and ST2.
ST1 498627100 SEAT
ST2 398673600 COMPRESSOR
B3M1162A
92
3-2[W18A0]SERVICE PROCEDURE
18. Low Clutch Drum and Planetary Gear

C: ASSEMBLY
B3M1155A
(1) Snap ring
(2) Front planetary carrier
(3) Thrust needle bearing
(4) Rear sun gear
(5) Thrust needle bearing
(6) Rear planetary carrier
(7) Washer
(8) Thrust needle bearing
(9) Rear internal gear(10) Washer
(11) Retaining plate
(12) Drive plate
(13) Driven plate
(14) Dish plate
(15) Snap ring
(16) Cover
(17) Spring retainer
(18) Lathe cut seal ring(19) Low clutch piston
(20) Lathe cut seal ring
(21) Low clutch drum
(22) Needle bearing
(23) Inner snap ring
(24) One-way clutch
(25) Outer snap ring
1) Install lathe cut seal ring to low clutch piston.
2) Fit the low clutch piston to the low clutch drum.
B3M1165A
3) Install spring retainer to low clutch piston.
B3M1166A
94
3-2[W18C0]SERVICE PROCEDURE
18. Low Clutch Drum and Planetary Gear

9) Install washer to rear internal gear.
B3M1170A
10) Install rear internal gear.
B3M1160A
11) Install thrust needle bearing.
CAUTION:
Install thrust needle bearing in the correct
direction.
B3M1171A
12) Install washer to rear planetary carrier.
NOTE:
Make sure washer tooth is inserted into hole on
planetary carrier.
B3M1172A
13) Install rear planetary carrier to low clutch
drum.
B3M1159A
14) Install thrust needle bearing to rear planetary
carrier.
CAUTION:
Install thrust needle bearing in the correct
direction.
B3M1173
96
3-2[W18C0]SERVICE PROCEDURE
18. Low Clutch Drum and Planetary Gear