1999 SUBARU LEGACY diff

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

2. Drive Pinion Assembly
B3M0613C
(1) Drive pinion shaft
(2) Roller bearing
(3) Washer
(4) Driven shaft
(5) Key
(6) Woodruff key
(7) Drive pinion collar
(8) Needle bearing
(9) Snap ring (Outer)
(10) Washer
(11) Sub gear
(12) 1st driven gear
(13) Baulk ring(14) 1st-2nd synchronizer hub
(15) Insert key
(16) Reverse driven gear
(17) Outer baulk ring
(18) Synchro cone
(19) Inner baulk ring
(20) 2nd driven gear
(21) 2nd driven gear bush
(22) 3rd-4th driven gear
(23) Driven pinion shim
(24) Roller bearing
(25) 5th driven gear
(26) Lock washer(27) Lock nut
(28) Washer
(29) Thrust bearing
(30) Differential bevel gear sleeve
(31) Washer
(32) Lock washer
(33) Lock nut
Tightening torque: N´m (kg-m, ft-lb)
T1:
29±3 (3.0±0.3, 21.7±2.2)
T2:11 8±8 (12.0±0.8, 86.8±5.8)
T3:265±10 (27±1, 195±7)
7
[C200]3-1COMPONENT PARTS
2. Drive Pinion Assembly

5. Transfer Case and Extension
B3M1358A
(1) Oil guide
(2) Gasket
(3) Transfer case
(4) Ball
(5) Reverse accent spring
(6) Gasket
(7) Plug
(8) Snap ring (Inner)
(9) Reverse check plate
(10) Reverse check spring
(11) Reverse return spring
(12) Reverse check cam
(13) Reverse accent shaft
(14) Return spring cap
(15) Return spring(16) O-ring
(17) Adjusting select shim
(18) Reverse check sleeve
(19) Gasket
(20) Neutral switch
(21) Gasket
(22) Back-up light switch
(23) Ball bearing
(24) Adjusting washer
(25) Ball bearing
(26) Adjusting washer
(27) Ball bearing
(28) Center differential
(29) Adjusting washer
(30) Transfer drive gear(31) Ball bearing
(32) Gasket
(33) Extension
(34) Oil seal
(35) Dust cover
(36) Shift bracket
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)
T4:25±2 (2.5±0.2, 18.1±1.4)
T4:37±3 (3.8±0.3, 27.5±2.2)
11
[C500]3-1COMPONENT PARTS
5. Transfer Case and Extension

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

IIf the gap between the end faces of the ring and
the gear splined part is excessively small when the
ring is pressed against the cone.
Clearance (A):
0.5 Ð 1.0 mm (0.020 Ð 0.040 in)
S3M0188
IWhen the contact surface of the synchronizer
ring insert is scored or abnormally worn down.
5) Shifting insert
Replace the insert if deformed, excessively worn,
or defective in any way.
S3M0189
6) Oil seal
Replace the oil seal if the lip is deformed,
hardened, damaged, worn, or defective in any way.
7) O-ring
Replace the O-ring if the sealing face is deformed,
hardened, damaged, worn, or defective in any way.
8) Gearshift mechanism
Repair or replace the gearshift mechanism if
excessively worn, bent, or defective in any way.9) Differential gear
Repair or replace the differential gear in the follow-
ing cases:
IThe hypoid drive gear and drive pinion shaft
tooth surface are damaged, excessively worn, or
seized.
IThe roller bearing on the drive pinion shaft has
a worn or damaged roller path.
IThere is damage, wear, or seizure of the differ-
ential bevel pinion, differential bevel gear, washer,
pinion shaft, and straight pin.
IThe differential case has worn or damaged slid-
ing surfaces.B3M0558C
(A) Drive pinion shaft
(B) Hypoid driven gear
(C) Pinion shaft
(D) Straight pin
(E) Washer
(F) Differential bevel gear
(G) Differential bevel pinion
(H) Snap ring
(I) Roller bearing
(J) Differential case
14
3-1[W1B0]SERVICE 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

3) Drive out straight pin, and pull out 3-4 fork rod
and shifter fork.
NOTE:
When removing rod, keep other rods in neutral.
Also, when pulling out straight pin, remove it
toward inside of case so that it may not hit against
case.
B3M0523C
(A) Straight pin
(B) 3-4 fork rod
(C) Shifter fork
4) Drive out straight pin, and pull out 1-2 fork rod
and shifter fork.
5) Pull out straight pin, and remove idler gear
shaft, reverse idler gear and washer.
B3M0524C
(A) Straight pin
(B) Idler gear shaft
(C) Idler gear
(D) Washer
6) Remove outer snap ring, and pull out reverse
shifter rod arm from reverse fork rod. Then take out
ball, spring and interlock plunger from rod.
And then remove rod.
NOTE:
When pulling out reverse shifter rod arm, be care-
ful not to let ball pop out of arm.
7) Remove reverse shifter lever.
8) Remove differential side retainers using ST.
ST 499787000 WRENCH ASSY
B3M1360A
9) Remove outer snap ring and pull out speedom-
eter driven gear. Next, remove vehicle speed sen-
sor 2, oil seal, speedometer shaft and washer.
B3M0525C
(A) Outer snap ring
(B) Speedometer driven gear
18
3-1[W2A2]SERVICE PROCEDURE
2. Transmission Case