1999 SUBARU LEGACY Service Repair Manual

3. Drive Pinion Assembly
A: DISASSEMBLY
1. DRIVE PINION SHAFT
1) Straighten lock nut at staked portion. Remove
the lock nut using ST1, ST2 and ST3.
ST1 899884100 HOLDER
ST2 498427100 STOPPER
ST3 899988608 SOCKET WRENCH
G3M0595
2) Withdraw drive pinion from driven shaft.
Remove differential bevel gear sleeve, adjusting
washer No. 1, adjusting washer No. 2, thrust
bearing, needle bearing, drive pinion collar, needle
bearing and thrust bearing.
B3M0536G
(A) Differential bevel gear sleeve
(B) Washer No. 1 (25´37.5´t)
(C) Thrust bearing (25´37.5´3)
(D) Washer No. 2 (25´37.5´4)
(E) Needle bearing (25´30´20)
(F) Drive pinion collar
(G) Needle bearing (30´37´23)
(H) Thrust bearing (33´50´3)
3) Remove roller bearing and washer (33´50´
5) using ST and press.
CAUTION:
Do not reuse roller bearing.
ST 498077000 REMOVER
G3M0607
2. DRIVEN GEAR ASSEMBLY
CAUTION:
Attach a cloth to the end of driven shaft (on the
frictional side of thrust needle bearing) during
disassembly or reassembly to prevent damage.
1) Straighten lock nut at staked portion. Remove
the lock nut using ST1 and ST2.
ST1 499987300 SOCKET WRENCH (50)
ST2 899884100 HOLDER
G3M0608
2) Remove 5th driven gear using ST.
ST 499857000 5TH DRIVEN GEAR
REMOVER
G3M0609
3) Remove woodruff key.
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[W3A2]3-1SERVICE PROCEDURE
3. Drive Pinion Assembly

4) Remove roller bearing (42´74´40), 3rd-4th
driven gear using ST1 and ST2.
ST1 499757002 SNAP RING PRESS
ST2 899714110 REMOVER
G3M0610
5) Remove the key.
6) Remove 2nd driven gear, inner baulk ring, syn-
chro cone and outer baulk ring.
B3M0426C
(A) 2nd driven gear
(B) Inner baulk ring
(C) Synchro coner
(D) Outer baulk ring
7) Remove 1st driven gear, 2nd gear bushing,
gear and hub using ST1 and ST2.
NOTE:
Replace gear and hub if necessary. Do not attempt
to disassemble if at all possible because they must
engage at a specified point. If they have to be
disassembled, mark the engaging point before-
hand.
ST1 499757002 SNAP RING PRESS
ST2 899714110 REMOVER
G3M0611
8) Remove sub gears for 1st and 2nd driven gear.
B: ASSEMBLY
1. GEAR AND HUB ASSEMBLY
Assemble gear and hub assembly.
NOTE:
IUse new gear and hub assembly, if gear or hub
have been replaced.
IBe sure the insert keys are correctly located in
the insert key grooves inside the reverse driven
gear.
B3M0431B
(A) Key grooves
(B) Reverse driven gear
30
3-1[W3B1]SERVICE PROCEDURE
3. Drive Pinion Assembly

B3M0077E
(A) 1st gear side
(B) 2nd gear side
(C) Flush surface
(D) Stepped surface
2. DRIVEN GEAR ASSEMBLY
Assemble a driven shaft and 1st driven gear that
select for adjustment the proper radial clearance.
Driven shaft 1st driven gear
Part No.Diameter (A)
mm (in)Part No.
32229AA15049.959 Ð 49.966
(1.9669 Ð 1.9672)32231AA730
32229AA14049.967 Ð 49.975
(1.9672 Ð 1.9675)32231AA720
B3M0537A
1) Install sub gear to 1st driven gear.
2) Install 1st driven gear, 1st baulk ring, gear and
hub assembly onto driven shaft.
NOTE:
Take care to install gear hub in proper direction.3) Install 2nd driven gear bushing onto driven
shaft using ST1, ST2 and press.
ST1 499277200 INSTALLER
ST2 499587000 INSTALLER
CAUTION:
Attach a cloth to the end of driven shaft to pre-
vent damage.
NOTE:
When press ftting, align oil holes of shaft and bush.
B3M0078D
4) Install 2nd driven gear, inner baulk ring, syn-
chro cone, outer baulk ring and insert onto driven
shaft.
B3M0426C
(A) 2nd driven gear
(B) Inner baulk ring
(C) Synchro cone
(D) Outer baulk ring
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[W3B2]3-1SERVICE PROCEDURE
3. Drive Pinion Assembly

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
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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

C: ADJUSTMENT
1. THRUST BEARING PRELOAD
1) After completing the preceding steps 1) through
3), select adjusting washer No. 2 so that dimension
(H) is zero through visual check. Position washer
(18.3´30´4) and lock washer (18´30´2) and
install lock nut (18´13.5).
B3M0538A
2) Using ST1, ST2 and ST3, tighten lock nut to the
specified torque.
ST1 899884100 HOLDER
ST2 498427100 STOPPER
ST3 899988608 SOCKET WRENCH (27)
Tightening torque:
11 8
±8 N´m (12±0.8 kg-m, 86.8±5.8 ft-lb)
G3M0626
3) After removing ST2, measure starting torque
using torque driver.
ST1 899884100 HOLDER
ST3 899988608 SOCKET WRENCH (27)
Starting torque:
54
±25 N´m (5.5±2.5 kg-m, 40±18 ft-lb)
B3M0085A
4) If starting torque is not within specified limit,
select new adjusting washer No. 1 and recheck
starting torque.
B3M0536H
Adjusting washer No. 1
Part No. Thickness mm (in)
803025051 3.925 (0.1545)
803025052 3.950 (0.1555)
803025053 3.975 (0.1565)
803025054 4.000 (0.1575)
803025055 4.025 (0.1585)
803025056 4.050 (0.1594)
803025057 4.075 (0.1604)
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3-1[W3C1]SERVICE PROCEDURE
3. Drive Pinion Assembly

5) If specified starting torque range cannot be
obtained when a No. 1 adjusting washer is used,
then select a suitable No. 2 adjusting washer from
those listed in the following table. Repeat steps 1)
through 4) to adjust starting torque.
B3M0536I
(A) Adjusting washer No. 1
(B) Adjusting washer No. 2
Starting torque Dimension H Washer No. 2
Low Small Select thicker one.
High Large Select thinner one.
Adjusting washer No. 2
Part No. Thickness mm (in)
803025059 3.850 (0.1516)
803025054 4.000 (0.1575)
803025058 4.150 (0.1634)
6) Recheck that starting torque is within specified
range, then clinch lock nut at four positions.
4. Main Shaft Assembly
A: DISASSEMBLY
1. 2200 cc MODEL
1) Put vinyl tape around main shaft splines to pro-
tect oil seal from damage. Then pull out oil seal
and needle bearing by hand.
2) Remove lock nut from transmission main shaft
assembly.
NOTE:
Remove caulking before taking off lock nut.
ST1 498937000 TRANSMISSION HOLDER
ST2 499987003 SOCKET WRENCH (35)
B3M0087A
3) Remove insert stopper plate, sleeve and hub
assembly No. 2, baulk ring, 5th drive gear, and
needle bearing.
B3M1364A
(A) Insert stopper plate
(B) Sleeve and hub assembly No. 2
(C) Baulk ring
(D) 5th drive gear
(E) Needle bearing (32´36´25.7)
35
[W4A1]3-1SERVICE PROCEDURE
4. Main Shaft Assembly

4) Using ST1 and ST2, remove the rest of parts.
NOTE:
Replace sleeve and hub with new ones. Do not
attempt to disassemble because they must engage
at a specified point. If they should be
disassembled, marking engagement point on
splines beforehand.
ST1 899864100 REMOVER
ST2 899714110 REMOVER
B3M0834A
2. 2500 cc MODEL
1) Put vinyl tape around main shaft splines to pro-
tect oil seal from damage. Then pull out oil seal
and needle bearing by hand.
2) Remove lock nut from transmission main shaft
assembly.
NOTE:
Remove caulking before taking off lock nut.
ST1 498937000 TRANSMISSION HOLDER
ST2 499987003 SOCKET WRENCH (35)
B3M0439A
3) Remove 5th-Rev sleeve and hub assembly,
baulk ring, 5th drive gear and needle bearing (32
x 36 x 25.7).
B3M0437B
(A) 5th-Rev sleeve and hub ASSY
(B) Baulk ring
(C) 5th drive gear
4) Remove snap ring and synchro cone stopper
from 5th-Rev sleeve and hub assembly.
B3M0435B
(A) Synchro cone
(B) Snap ring
36
3-1[W4A2]SERVICE PROCEDURE
4. Main Shaft Assembly