1999 SUBARU LEGACY clutch

7) Install canister and bracket.
(1) Install power stering pump on bracket, and
tighten bolts.
Tightening torque:
39
±10 N´m (4.0±1.0 kg-m, 29±7 ft-lb)
S2M0086
(2) Install power steering pipe bracket on right
side intake manifold, and install spark plug
codes.
B2M2309
(3) Install front side V-belt, and adjust it.

G2M0286
8) Tighten nuts which hold lower side of transmis-
sion to engine.
Tightening torque:
50
±4 N´m (5.1±0.4 kg-m, 36.9±2.9 ft-lb)
B2M2790
9) Tighten nuts which install front cushion rubber
onto crossmember.
Tightening torque:
69
±15 N´m (7.0±1.5 kg-m, 51±11 ft-lb)
CAUTION:
Be sure to tighten front cushion rubber mount-
ing bolts in the innermost elliptical hole in the
front crossmember.
G2M0303
10) Install front exhaust pipe and center exhaust
pipe.
11) Connect the following hoses.
(1) Fuel delivery hose, return hose and evapo-
ration hose
(2) Heater inlet and outlet hoses
(3) Brake booster vacuum hose
12) Connect the following connectors.
(1) Engine ground terminal
(2) Engine harness connectors
(3) Front oxygen sensor connector
(4) Rear oxygen sensor connector (California
spec. vehicles)
(5) Alternator connector and terminal
(6) A/C compressor connectors (With A/C)
13) Connect the following cables.
(1) Accelerator cable
(2) Cruise control cables (With cruise control)
(3) Clutch cable (2200 cc MT vehicles)
18
2-11[W1C0]SERVICE PROCEDURE
1. Engine

(4) Clutch return spring (Models without hill
holder only)
CAUTION:
After connecting each cable, adjust them.
14) Install chamber stay.
15) Install air intake system.
(1) Install air cleaner element.
(2) Install air intake chamber and air intake duct
with air cleaner upper cover. (Except 2200 cc
California spec. vehicles)
(3) Connect connector to mass air flow sensor.
B2M2018
(4) Install air intake duct with air cleaner case.
(2200 cc California spec. vehicles) [W1A0].> and
16) Install A/C flexible hoses. (With A/C)

CAUTION:
Use new O-rings.
Tightening torque:
25
±7 N´m (2.5±0.7 kg-m, 18.1±5.1 ft-lb)
B2M2774
17) Install cooling system.(1) Attach radiator mounting cushions to body.
B2M0307A
(2) Install radiator while fitting radiator pins to
cushions.
B2M2323
(3) Install radiator brackets and tighten bolts.
Tightening torque:
13.7
±1.5 N´m (1.4±0.15 kg-m, 10.1±1.1
ft-lb)
B2M0320
(4) Connect radiator fan motor connector.
H2M2515
19
[W1C0]2-11SERVICE PROCEDURE
1. Engine

7) Disconnect the following cables.
(1) Clutch return spring (Without hill holder
vehicles)
(2) Clutch cable (2200 cc MT vehicles)
G2M0545
8) Remove starter.
(1) Disconnect connectors and terminal from
starter.
(2) Remove bolt which installs upper side of
starter.
(3) Remove nut which installs lower side of
starter, and remove starter from transmission.
G2M0309
9) Remove pitching stopper.
G2M0295
10) Separate torque converter from drive plate.
(AT vehicles)
(1) Remove service hole plug.(2) Remove bolts which hold torque converter
to drive plate.
S2M0207
(3) While rotating the engine, remove other
bolts using ST.
CAUTION:
Be careful not to drop bolts into torque con-
verter housing.
2200 cc vehicles:
ST 499977300 CRANK PULLEY WRENCH
2500 cc vehicles:
ST 499977100 CRANK PULLEY WRENCH
11) Remove ATF level gauge. (AT vehicles)
CAUTION:
Plug opening to prevent entry of foreign par-
ticles into transmission fluid.
S2M0214
12) Remove operating cylinder. (2500 cc MT
vehicles)
B2M1179B
22
2-11[W2B0]SERVICE PROCEDURE
2. Transmission

(3) Remove spring pins and separate front
drive shafts from each side of the transmission.
CAUTION:
Discard removing spring pin. Replace with a
new one.
G2M0325
23) Remove nuts which hold lower side of trans-
mission to engine.
B2M2790
24) Place transmission jack under transmission.
CAUTION:
IAlways support transmission case with a
transmission jack.
IOn AT vehicles, make sure that the support
plates of transmission jack don't touch the oil
pan.
G2M0326
25) Remove transmission rear crossmember.
IMT vehicles
G2M0831
IAT vehicles
S2M0221
26) Remove transmission.
CAUTION:
IMove transmission jack toward rear until
mainshaft is withdrawn from clutch cover. (MT
vehicles)
IMove transmission and torque converter as
a unit away from engine. (AT vehicles)
B2M0035
26
2-11[W2B0]SERVICE PROCEDURE
2. Transmission

C: INSTALLATION
1) Install ST to torque converter clutch case. (AT
vehicles)
ST 498277200 STOPPER SET
H2M1961A
2) Install transmission to engine.
(1) Gradually raise transmission with transmis-
sion jack.
B2M0035
(2) Engage them at splines.
CAUTION:
Be careful not to strike mainshaft against
clutch cover. (MT vehicles)
3) Install transmission rear crossmember.
IMT vehicles
Tightening torque:
T1: 69
±15 N´m (7.0±1.5 kg-m, 51±11 ft-lb)
T2: 137
±20 N´m (14±2 kg-m, 101±14 ft-lb)
G2M0832
IAT vehicles
Tightening torque:
T1: 37
±10 N´m (3.8±1.0 kg-m, 27±7 ft-lb)
T2: 69
±15 N´m (7.0±1.5 kg-m, 51±11 ft-lb)
S2M0221A
4) Take off transmission jack.
5) Tighten nuts which hold lower side of transmis-
sion to engine.
Tightening torque:
50
±4 N´m (5.1±0.4 kg-m, 36.9±2.9 ft-lb)
B2M2790
6) Tighten bolt which holds upper side of transmis-
sion to engine.
Tightening torque:
50
±4 N´m (5.1±0.4 kg-m, 36.9±2.9 ft-lb)
B2M2791
7) Install torque converter to drive plate. (AT
vehicles)
27
[W2C0]2-11SERVICE PROCEDURE
2. Transmission

18) Install ATF level gauge. (AT vehicles)
S2M0214
19) Connect the following connectors.
(1) Transmission harness connectors (AT
vehicles)
(2) Transmission ground terminal
(3) Front oxygen sensor connector
(4) Rear oxygen sensor connector (California
spec. vehicles)
(5) Neutral position switch connector (MT
vehicles)
(6) Back-up light switch connector (MT
vehicles)
20) Connect the following cables.
(1) Cruise control cable
(With cruise control vehicles)
(2) Clutch cable (2200 cc MT vehicles)
21) Install return spring.
(Without hill holder vehicles)
22) Install starter.
(1) Install starter onto transmission case, and
connect connectors and terminals.
(2) Tighten bolt and nut which install starter
onto transmission.
Tightening torque:
40
±4 N´m (4.1±0.4 kg-m, 29.7±2.9 ft-lb)
G2M0309
23) Install chamber stay.
IMT vehicles
S2M0210
IAT vehicles
S6M0023
24) Install air intake duct and chamber. (Except
2200 cc California spec. vehicles) [W1A0].>
25) Install air intake duct with air cleaner case.
(2200 cc California spec. vehicles) [W1A0].> and
26) Connect battery ground cable.
27) Fill ATF and differential gear oil. (AT vehicles)

28) Check selector lever operation. (AT vehicles)

29) Take off vehicle from lift arms.
30) Check the vehicle on road tester. (AT vehicles)

31
[W2C0]2-11SERVICE PROCEDURE
2. Transmission

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