1999 SUBARU LEGACY Service Repair Manual

C: ASSEMBLY
B3M1155A
(1) Snap ring
(2) Front planetary carrier
(3) Thrust needle bearing
(4) Rear sun gear
(5) Thrust needle bearing
(6) Rear planetary carrier
(7) Washer
(8) Thrust needle bearing
(9) Rear internal gear(10) Washer
(11) Retaining plate
(12) Drive plate
(13) Driven plate
(14) Dish plate
(15) Snap ring
(16) Cover
(17) Spring retainer
(18) Lathe cut seal ring(19) Low clutch piston
(20) Lathe cut seal ring
(21) Low clutch drum
(22) Needle bearing
(23) Inner snap ring
(24) One-way clutch
(25) Outer snap ring
1) Install lathe cut seal ring to low clutch piston.
2) Fit the low clutch piston to the low clutch drum.
B3M1165A
3) Install spring retainer to low clutch piston.
B3M1166A
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3-2[W18C0]SERVICE PROCEDURE
18. Low Clutch Drum and Planetary Gear

4) Install ST to low clutch drum.
ST 498437100 LOW CLUTCH PISTON
GUIDE
B3M1167A
5) Set the cover on the piston with a press using
ST1 and ST2, and attach the snap ring.
CAUTION:
Be careful not to fold cover seal during instal-
lation.
NOTE:
After installing snap ring, remove ST1, ST2 and
ST3.
ST1 498627100 SEAT
ST2 398673600 COMPRESSOR
ST3 498437100 LOW CLUTCH PISTON
GUIDE
B3M1168A
6) Install the dish plate, driven plates, drive plates,
and retaining plate, and secure with the snap ring.
NOTE:
Pay attention to the orientation of the dish plate.
B3M1169A
7) Check the low clutch for operation.
Set the one-way clutch inner race, and apply com-
pressed air for checking.
B3M0960A
8) Checking low clutch clearance
Measure the gap between the retaining plate and
the operation of the low clutch.
NOTE:
Before measuring clearance, place the same thick-
ness of shim on both sides to prevent retaining
plate from tilting.
If the clearance is out of the specified range, select
a proper retaining plate so that the standard clear-
ance can be obtained.
Standard value:
0.7 Ð 1.1 mm (0.028 Ð 0.043 in)
Allowable limit:
1.6 mm (0.063 in)
B3M0975A
Available retaining plates
Part No. Thickness mm (in)
31567AA830
31567AA840
31567AA850
31567AA860
31567AA8703.8 (0.150)
4.0 (0.157)
4.2 (0.165)
4.4 (0.173)
4.6 (0.181)
95
[W18C0]3-2SERVICE PROCEDURE
18. Low Clutch Drum and Planetary Gear

9) Install washer to rear internal gear.
B3M1170A
10) Install rear internal gear.
B3M1160A
11) Install thrust needle bearing.
CAUTION:
Install thrust needle bearing in the correct
direction.
B3M1171A
12) Install washer to rear planetary carrier.
NOTE:
Make sure washer tooth is inserted into hole on
planetary carrier.
B3M1172A
13) Install rear planetary carrier to low clutch
drum.
B3M1159A
14) Install thrust needle bearing to rear planetary
carrier.
CAUTION:
Install thrust needle bearing in the correct
direction.
B3M1173
96
3-2[W18C0]SERVICE PROCEDURE
18. Low Clutch Drum and Planetary Gear

15) Install rear sun gear.
NOTE:
Pay attention to the orientation of the rear sun
gear.
B3M1158A
16) Install thrust needle bearing to front planetary
carrier.
NOTE:
Pay attention to the orientation of the thrust needle
bearing.
B3M1174A
17) Install front planetary carrier to low clutch
drum.
B3M1157A
18) Install snap ring to low clutch drum.
B3M1156A
19) Install the needle bearing, and secure with the
snap ring.
B3M1164A
20) Install the one-way clutch, one-way clutch
inner race and plate, and secure with the snap ring.
NOTE:
Set the inner race. Make sure that the forward
clutch is free in the clockwise direction and locked
in the counterclockwise direction, as viewed from
the front of the vehicle.
B3M1175A
97
[W18C0]3-2SERVICE PROCEDURE
18. Low Clutch Drum and Planetary Gear

19. Differential Case Assembly
A: DISASSEMBLY
1) Using a press and ST, remove the taper roller
bearing.
ST 498077000 REMOVER
G3M0488
2) Secure the case in a vise and remove the
crown gear tightening bolts, then separate the
crown gear, case (RH) and case (LH).
G3M0489
3) Pull out the straight pin and shaft, and remove
the differential bevel gear, washer, and differential
bevel pinion.
G3M0490
B: INSPECTION
Check each component for harmful cuts, damage
and other faults.
C: ASSEMBLY
1) Install the washer, differential bevel gear and
differential bevel pinion in the differential case
(RH). Insert the pinion shaft, and fit the straight pin.
NOTE:
Install straight pin from reverse direction.
G3M0490
2) Install the washer and differential bevel gear to
the differential case (LH). Then put the case over
the differential case (RH), and connect both cases.
3) Install the crown gear and secure by tightening
the bolt.
Standard tightening torque:
62
±5 N´m (6.3±0.5 kg-m, 45.6±3.6 ft-lb)
G3M0489
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3-2[W19A0]SERVICE PROCEDURE
19. Differential Case Assembly

4) Measurement of backlash (Selection of washer)
Measure the gear backlash with ST1 and ST2, and
insert ST2 through the access window of the case.
ST1 498247001 MAGNET BASE
ST2 498247100 DIAL GAUGE
NOTE:
Measure the backlash by applying a pinion tooth
between two bevel gear teeth.
Standard value:
0.13 Ð 0.18 mm (0.0051 Ð 0.0071 in)
G3M0491
5) Using ST, install taper roller bearing.
ST 398487700 DRIFT
G3M0492
20. Transfer Clutch
A: DISASSEMBLY
1) Remove the seal ring.
CAUTION:
Be careful not to damage the seal ring.
G3M0493
2) Using a press and ST, remove the ball bearing.
CAUTION:
Do not reuse the bearing.
ST 498077600 REMOVER
G3M0494
3) Remove the snap ring, and take out the pres-
sure plate, drive plates, and driven plates.
G3M0495
99
[W20A0]3-2SERVICE PROCEDURE
20. Transfer Clutch

4) Measurement of backlash (Selection of washer)
Measure the gear backlash with ST1 and ST2, and
insert ST2 through the access window of the case.
ST1 498247001 MAGNET BASE
ST2 498247100 DIAL GAUGE
NOTE:
Measure the backlash by applying a pinion tooth
between two bevel gear teeth.
Standard value:
0.13 Ð 0.18 mm (0.0051 Ð 0.0071 in)
G3M0491
5) Using ST, install taper roller bearing.
ST 398487700 DRIFT
G3M0492
20. Transfer Clutch
A: DISASSEMBLY
1) Remove the seal ring.
CAUTION:
Be careful not to damage the seal ring.
G3M0493
2) Using a press and ST, remove the ball bearing.
CAUTION:
Do not reuse the bearing.
ST 498077600 REMOVER
G3M0494
3) Remove the snap ring, and take out the pres-
sure plate, drive plates, and driven plates.
G3M0495
99
[W20A0]3-2SERVICE PROCEDURE
20. Transfer Clutch

4) Remove the snap ring with ST1, ST2 and ST3,
and take out the return spring and transfer clutch
piston seal.
ST1 399893600 PLIERS
ST2 398673600 COMPRESSOR
ST3 398623600 SEAT
B3M1415A
5) Apply compressed air to the rear drive shaft to
remove the piston.
G3M0497
B: INSPECTION
1) Check the drive plate facing for wear and dam-
age.
2) Check the snap ring for wear, return spring for
permanent set and breakage, and return spring for
deformation.
3) Check the lathe cut ring for damage.
C: ASSEMBLY
1) Install the transfer clutch piston.
B3M1400A
2) Install return spring to transfer piston.
B3M1177A
3) Install transfer clutch piston seal.
B3M1401A
4) Install ST to rear drive shaft.
ST 499257300 SNAP RING OUTER GUIDE
B3M1402A
5) Install snap ring to ST.
ST 499257300 SNAP RING OUTER GUIDE
B3M1180A
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3-2[W20B0]SERVICE PROCEDURE
20. Transfer Clutch