1999 SUBARU LEGACY front differential

8. Extension Assembly
Thrust washer (52´61´t) to ball bearing side
clearance
0.05 Ð 0.30 mm (0.0020 Ð 0.0118 in)
Thrust washer (52´61´t)
Part No. Thickness mm (in)
803052021 0.50 (0.0197)
803052022 0.75 (0.0295)
803052023 1.00 (0.0394)
Thrust washer to center differential side clearance
0.15 Ð 0.35 mm (0.0059 Ð 0.0138 in)
Thrust washer (52´61´t)
Part No. Thickness mm (in)
803036050 0.9 (0.035)
803036054 1.0 (0.039)
803036051 1.1 (0.043)
803036055 1.2 (0.047)
803036052 1.3 (0.051)
803036056 1.4 (0.055)
803036053 1.5 (0.059)
803036057 1.6 (0.063)
803036058 1.7 (0.067)
9. Front Differential
Bevel gear to pinion backlash
0.13 Ð 0.18 mm (0.0051 Ð 0.0071 in)
Washer (38.1´50´t)
Part No.Thickness
mm (in)Part No.Thickness
mm (in)
8030380210.925 Ð
0.950
(0.0364 Ð
0.0374)8030380231.025 Ð
1.050
(0.0404 Ð
0.0413)
8030380220.975 Ð
1.000
(0.0384 Ð
0.0394)ÐÐ
Pinion shaft to axle drive shaft clearance
0 Ð 0.2 mm (0 Ð 0.008 in)
Snap ring (Outer-28)
Part No.Thickness
mm (in)Part No.Thickness
mm (in)
805028011 1.05 (0.0413) 805028012 1.20 (0.0472)
5
[S900]3-1SPECIFICATIONS AND SERVICE DATA
9. Front Differential

6. Front Differential
B3M0521B
(1) Drive pinion shaft
(2) Hypoid driven gear
(3) Pinion shaft
(4) Straight pin
(5) Washer
(6) Differential bevel gear
(7) Differential bevel pinion(8) Snap ring (Outer)
(9) Roller bearing
(10) Differential case
(11) Oil seal
(12) Differential side retainer
(13) O-ring
(14) Axle drive shaft(15) Retainer lock plate
Tightening torque: N´m (kg-m, ft-lb)
T1:
25±5 (2.5±0.5, 18.1±3.6)
T2:62±5 (6.3±0.5, 45.6±3.6)
12
3-1[C600]COMPONENT PARTS
6. Front Differential

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

3) Inspection and adjustment of ST
NOTE:
ILoosen the two bolts and adjust so that the scale
indicates 0.5 correctly when the plate end and the
scale end are on the same level.
ITighten the two bolts.
ST 499917500 DRIVE PINION GAUGE ASSY
B3M0064B
(A) Plate
(B) Scale
4) Position the ST by inserting the knock pin of ST
into the knock hole in the transmission case.
ST 499917500 DRIVE PINION GAUGE ASSY
5) Slide the drive pinion gauge scale with finger tip
and read the value at the point where it matches
with the end face of drive pinion.
ST 499917500 DRIVE PINION GAUGE ASSY
B3M0065C
(A) Adjust clearance to zero without shim.
6) The thickness of shim shall be determined by
adding the value indicated on drive pinion to the
value indicated on the ST. (Add if the number on
drive pinion is prefixed by + and subtract if the
number is prefixed by þ.)
ST 499917500 DRIVE PINION GAUGE ASSY7) Select one to three shims from the next table for
the value determined as described above and take
a shim thickness which is closest to the said value.
Drive pinion shim
Part No. Thickness mm (in)
32295AA031 0.150 (0.0059)
32295AA041 0.175 (0.0069)
32295AA051 0.200 (0.0079)
32295AA061 0.225 (0.0089)
32295AA071 0.250 (0.0098)
32295AA081 0.275 (0.0108)
32295AA091 0.300 (0.0118)
32295AA101 0.500 (0.0197)
8) Install differential assembly on left hand trans-
mission case.
CAUTION:
Be careful not to fold the sealing lip of oil seal.
NOTE:
Wrap the left and right splined sections of axle
shaft with vinyl tape to prevent scratches.
G3M0557
9) Install needle bearing and oil seal onto the front
of transmission main shaft assembly, and position
in left side transmission case.
CAUTION:
IWrap clutch splined section with vinyl tape
to prevent damage to oil seal.
IApply grease (Unilube #2 or equivalent) to
the sealing lip of oil seal.
IUse a new oil seal.
23
[W2B2]3-1SERVICE PROCEDURE
2. Transmission Case

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

6. Front Differential
A: DISASSEMBLY
1) Remove right and left snap rings from
differential, and then remove two axle drive shafts.
NOTE:
During reassembly, reinstall each axle drive shaft
in the same place from which it was removed.
2) Loosen twelve bolts and remove hypoid drive
gear.
B3M0551C
(A) Snap ring
(B) Axle drive shaft
(C) Hypoid drive gear
3) Drive out straight pin from differential assembly
toward hypoid driven gear.
ST 899904100 REMOVER
G3M0667
4) Pull out pinion shaft, and remove differential
bevel pinion and gear and washer.
B3M0552C
(A) Pinion shaft
(B) Bevel pinion
(C) Bevel gear
(D) Washer
5) Remove roller bearing using ST.
ST 399527700 PULLER SET
G3M0668
B: ASSEMBLY
1) Install bevel gear and bevel pinion together with
washers, and insert pinion shaft.
NOTE:
Face the chamfered side of washer toward gear.
B3M0099D
(A) Bevel pinion
(B) Bevel gear
(C) Pinion shaft
49
[W6B0]3-1SERVICE PROCEDURE
6. Front Differential

2) Measure backlash between bevel gear and pin-
ion. If it is not within specifications, install a suitable
washer to adjust it.
NOTE:
Be sure the pinion gear tooth contacts adjacent
gear teeth during measurement.
ST1 498247001 MAGNET BASE
ST2 498247100 DIAL GAUGE
Standard backlash:
0.13 Ð 0.18 mm (0.0051 Ð 0.0071 in)
G3M0670
Washer (38.1´50´t)
Part No. Thickness mm (in)
8030380210.925 Ð 0.950
(0.0364 Ð 0.0374)
8030380220.975 Ð 1.000
(0.0384 Ð 0.0394)
8030380231.025 Ð 1.050
(0.0404 Ð 0.0413)
3) Align pinion shaft and differential case at their
holes, and drive straight pin into holes from the
hypoid driven gear side, using ST.
NOTE:
Lock straight pin after installing.
ST 899904100 REMOVER
B3M0609C
(A) Pinion shaft
(B) Differential case
(C) Straight pin
4) Install roller bearing (40´80´19.75) to differ-
ential case.
NOTE:
Be careful because roller bearing outer races are
used as a set.
ST1 499277100 BUSH 1-2 INSTALLER
ST2 398497701 ADAPTER
G3M0671
5) Install hypoid driven gear to differential case
using twelve bolts.
Tightening torque:
T: 6 2
±5 N´m (6.3±0.5 kg-m, 45.6±3.6 ft-lb)
B3M0554C
(A) Hypoid driven gear
(B) Differential case
50
3-1[W6B0]SERVICE PROCEDURE
6. Front Differential

1. Automatic Transmission and Differential
A: SPECIFICATIONS
Torque
converter
clutchType Symmetric, 3 element, single stage, 2 phase torque converter
Stall torque ratio2200 cc 2.1 Ð 2.3
2500 cc 1.8 Ð 2.0
OUTBACK 2.2 Ð 2.4
Nominal diameter2200 cc 236 mm (9.29 in)
2500 cc 246 mm (9.69 in)
Stall speed (at sea
level)2200 cc 2,200 Ð 2,600 rpm
2500 cc 2,200 Ð 2,600 rpm
OUTBACK 2,300 Ð 2,700 rpm
One-way clutch Sprague type one-way clutch
Automatic
transmis-
sionTransmis-
sionType 4-forward, 1-reverse, double-row planetary gears
Control elementMulti-plate clutch 3 sets
Multi-plate brake 2 sets
One-way clutch (sprague type) 1 set
Gear ratio1st2200 cc 2.785
2500 cc 3.027
2nd2200 cc 1.545
2500 cc 1.619
3rd 1.000
4th 0.694
Reverse 2.272
Tooth number of planetary gearFront sun gear 33
Front pinion 21
Front internal gear 75
Rear sun gear2200 cc 42
2200 cc 37
Rear pinion2200 cc 17
2500 cc 19
Rear internal gear 75
Plate number of high clutch Drive plate & driven plate 4
Plate number of reverse clutch Drive plate & driven plate 2
Plate number of 2-4 brake Drive plate & driven plate 3
Plate number of low clutchDrive plate & driven
plate2200 cc 5
2500 cc 6
Plate number of low & reverse
brakeDrive plate & driven
plate2200 cc 5
2500 cc 6
2
3-2[S1A0]SPECIFICATIONS AND SERVICE DATA
1. Automatic Transmission and Differential