1999 SUBARU LEGACY Service Repair Manual

5. Transfer Case and Extension
A: REMOVAL
1) Remove back-up light switch and neutral
switch.
B3M1372A
2) Remove transfer case with extension assembly.
B3M1373
3) Remove shifter arm.
B: DISASSEMBLY
1. SEPARATION OF TRANSFER CASE
AND EXTENSION ASSEMBLY
1) Separate transfer case and extension assem-
bly.
B3M1374A
2) Remove transfer driven gear and center differ-
ential as a set.
B3M1375A
3) Remove thrust washer.
2. TRANSFER CASE
1) Remove plug, spring and reverse check ball.
B3M1376
2) Remove reverse check assembly.
B3M1377
3) Remove oil guide.
B3M1378
42
3-1[W5A0]SERVICE PROCEDURE
5. Transfer Case and Extension

3. EXTENSION
1) Remove transfer drive gear assembly.
B3M1380
2) Remove shift bracket.
B3M1381
3) Using ST, remove ball bearing from transfer
drive gear.
ST 498077100 REMOVER
B3M1382A
4) Remove oil seal from extension case.
4. REVERSE CHECK SLEEVE
1) Using a standard screwdriver, remove snap
ring.
NOTE:
Replace snap ring with a new one if deformed or
weakened.
B3M1383A
2) Remove reverse check plate, reverse check
spring, reverse check cam, return spring (5th-Rev),
reverse accent shaft, return spring cap and return
spring (1st-2nd).
B3M1384A
(A) Reverse check plate
(B) Reverse check spring
(C) Return spring (5th-Rev)
(D) Reverse check cam
(E) Reverse accent shaft
(F) Return spring cap
(G) Return spring (1st-2nd)
43
[W5B4]3-1SERVICE PROCEDURE
5. Transfer Case and Extension

3) Remove O-ring.
NOTE:
IReverse check sleeve assembly uses an O-ring
which should not be scratched.
IBe careful not to break adjustment shim placed
between reverse check sleeve assembly and case.
5. TRANSFER DRIVEN GEAR
1) Using ST, remove ball bearing from transfer
driven gear
ST 498077000 REMOVER
B3M1385A
2) Using ST, remove ball bearing from transfer
driven gear
ST 899864100 REMOVER
B3M1386A
C: ASSEMBLY
1. EXTENSION
1) Install ball bearing to transfer drive gear.
B3M1387A
2) Using ST, install oil seal to extension caset.
CAUTION:
Use new oil seal.
ST 498057300 INSTALLER
3) Install shift bracket to extension case.
Tightening torque:
25
±2 N´m (2.5±0.2 kg-m, 18.1±1.4 ft-lb)
B3M1381
4) Install transfer drive gear to extension case.
B3M1380
44
3-1[W5B5]SERVICE PROCEDURE
5. Transfer Case and Extension

2. REVERSE CHECK SLEEVE
1) Install return spring (1st-2nd), return spring cap,
reverse accent shaft, check cam, return spring and
check spring onto reverse check sleeve.
NOTE:
Be sure the bent section of reverse check spring is
positioned in the groove in check cam.
B3M1388A
(A) Reverse check sleeve
(B) Return spring (1st-2nd)
(C) Return spring cap
(D) Reverse accent shaft
(E) Return spring (5th-Rev)
(F) Reverse check cam
(G) Reverse check spring
2) Hook the bent section of reverse check spring
over reverse check plate.
3) Rotate cam so that the protrusion of reverse
check cam is at the opening in plate.
4) With cam held in that position, install plate onto
reverse check sleeve and hold with snap ring.
5) Position O-ring in groove in sleeve.CAUTION:
IMake sure the cutout section of reverse
accent shaft is aligned with the opening in
reverse check sleeve.
ISpin cam by hand for smooth rotation.
IMove cam and shaft all the way toward plate
and release.
If cam does not return properly, replace reverse
check spring; if shaft does not, check for
scratches on the inner surface of sleeve. If
sleeve is in good order, replace spring.
B3M0048D
(A) Snap ring
(B) Reverse check plate
(C) Check spring
(D) Check cam
ISelect a suitable reverse accent shaft and
reverse check plate.
3. TRANSFER CASE
1) Install oil guide to transfer case.
Tightening torque:
6.4
±0.5 N´m (0.65±0.05 kg-m, 4.7±0.4 ft-lb)
B3M1378
45
[W5C3]3-1SERVICE PROCEDURE
5. Transfer Case and Extension

2) Install reverse check sleeve assembly to trans-
fer case.
Tightening torque:
6.4
±0.5 N´m (0.65±0.05 kg-m, 4.7±0.4 ft-lb)
B3M1377
3) Install ball, reverse accent spring, washer and
plug to transfer case.
Tightening torque:
10
±1 N´m (1.0±0.1 kg-m, 7.2±0.7 ft-lb)
B3M1376
4. TRANSFER DRIVEN GEAR
1) Install ball bearing to transfer driven gear.
B3M1389A
2) Install ball bearing to transfer driven gear.
B3M1390A
5. COMBINATION OF TRANSFER CASE
AND EXTENSION ASSEMBLY
1) Install center differential and transfer driven
gear into transfer case.
B3M1375A
2) Measure height ªWº between transfer case and
ball bearing on the transfer driven gear.
B3M1392A
3) Measure depth ªXº.
B3M1406A
46
3-1[W5C4]SERVICE PROCEDURE
5. Transfer Case and Extension

4) Calculate space ªYº using the following equa-
tion: Y=XþW+0.24 mm (0.0094 in) [Thickness
of gasket]
5) Select suitable washer in the following table:
Standard clearance between thrust washer
and ball bearing:
0.05 Ð 0.30 mm (0.0020 Ð 0.0118 in)
Space ªYº mm (in)Thrust washer (52´61´t)
Part No.Thickness
mm (in)
0.55 Ð 0.79
(0.0217 Ð 0.0311)803052021 0.50 (0.0197)
0.80 Ð 1.04
(0.0315 Ð 0.0409)803052022 0.75 (0.0295)
1.05 Ð 1.30
(0.0413 Ð 0.0512)803052023 1.00 (0.0394)
6) Fit thrust washers on transfer drive shaft.
7) Measure depth ªSº between transfer case and
center differential.
ST 398643600 GAUGE
B3M1407A
8) Measure depth ªTº between extension case
and transfer drive grar.
ST 398643600 GAUGE
B3M1395A
9) Calculate space ªUº using the following equa-
tion:U=S+T-0.24 mm (0.0094 in) [Thickness
of gasket]
10) Select suitable washer inthe following table:
Standard clearance:
0.15 Ð 0.35 mm (0.0059 Ð 0.0138 in)
Thrust washer
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)
11) Fit thrust washer on center differential.
12) Install extension assembly into transfer case.
Tightening torque:
37
±3 N´m (3.8±0.3 kg-m, 27.5±2.2 ft-lb)
B3M0052A
D: INSTALLATION
1) Install shifter arm to transfer case.
B3M1396
2) Hang the shifter arm on the 3rd-4th fork rod.
B3M1397A
47
[W5D0]3-1SERVICE PROCEDURE
5. Transfer Case and Extension

3) Install transfer case with extension assembly to
transmission case.
Tightening torque:
24.5
±2.0 N´m (2.50±0.20 kg-m, 18.1±1.4
ft-lb)
B3M1373
E: ADJUSTMENT
1. NEUTRAL POSITION ADJUSTMENT
1) Shift gear into 3rd gear position.
2) Shifter arm turns lightly toward the 1st/2nd gear
side but heavily toward the reverse gear side
because of the function of the return spring, until
arm contacts the stopper.
3) Make adjustment so that the heavy stroke
(reverse side) is a little more than the light stroke
(1st/2nd side).
4) To adjust, remove bolts holding reverse check
sleeve assembly to the case, move sleeve assem-
bly outward, and place adjustment shim (0 to 1 ea.)
between sleeve assembly and case to adjust the
clearance.
CAUTION:
Be careful not to break O-ring when placing
shim(s).
NOTE:
IWhen shim is removed, the neutral position will
move closer to reverse; when shim is added, the
neutral position will move closer to 1st gear.
IIf shims alone cannot adjust the clearance,
replace reverse accent shaft and re-adjust.
Adjustment shim
Part No. Thickness mm (in)
32190AA000 0.15 (0.0059)
32190AA010 0.30 (0.0118)
Reverse accent shaft
Part No. Mark Remarks
32188AA090 XNeutral position is
closer to 1st gear.
32188AA100 Y Standard
32188AA110 ZNeutral position is
closer to reverse gear.
2. REVERSE CHECK PLATE
ADJUSTMENT
1) Shift shifter arm to ª5thº and then to reverse to
see if reverse check mechanism operates properly.
2) Also check to see if arm returns to neutral when
released from the reverse position. If arm does not
return properly, replace reverse check plate.
Reverse check plate
Part No. (A): No. AngleqRemarks
32189AA000 0 28ÉArm stops closer to
5th gear.
32189AA010 1 31ÉArm stops closer to
5th gear.
32189AA020 2 34ÉArm stops in the cen-
ter.
32189AA030 3 37ÉArm stops closer to
reverse gear.
32189AA040 4 40ÉArm stops closer to
reverse gear.
B3M0054B
3) Install neutral position switch and back-up light
switch to transfer case.
Tightening torque:
24.5
±2.0 N´m (2.50±0.20 kg-m, 18.1±1.4
ft-lb)
B3M1372A
48
3-1[W5E1]SERVICE PROCEDURE
5. Transfer Case and Extension

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