1999 SUBARU LEGACY Service Repair Manual

6) Using ST1 and ST2, install snap ring to rear
drive shaft.
NOTE:
After installing snap ring, remove ST1 and ST2.
ST1 499257300 SNAP RING OUTER GUIDE
ST2 499247400 INSTALLER
B3M1181A
7) Install the driven plates, drive plates, pressure
plate and snap ring.
B3M1182A
8) Apply compressed air to see if the assembled
parts move smoothly.
G3M0502
9) Check the clearance.
NOTE:
Before measuring clearance, place the same thick-
ness of shim on both sides to prevent pressure
plate from tilting.
If the clearance is not within the specified range,
select a proper pressure plate.
Standard value:
0.2 Ð 0.6 mm (0.008 Ð 0.024 in)
Allowable limit:
1.6 mm (0.063 in)
G3M0503
Available pressure plates
Part No. Thickness mm (in)
31593AA151
31593AA161
31593AA171
31593AA1813.3 (0.130)
3.7 (0.146)
4.1 (0.161)
4.5 (0.177)
10) Press-fit the ball bearing with ST.
ST 899580100 INSTALLER
G3M0505
101
[W20C0]3-2SERVICE PROCEDURE
20. Transfer Clutch

11) Coat the seal ring with vaseline, and install it
in the seal ring groove of the shaft.
CAUTION:
Do not expand the seal ring excessively when
installing.
ST 899580100 INSTALLER
G3M0493
21. Transfer Valve Body
A: DISASSEMBLY
1) Separate duty solenoid C (transfer) and trans-
fer valve body.
2) Remove the stopper plate and pry out the plug
with a screwdriver. Then extract the spring and
transfer control valve together.
CAUTION:
Be careful not to damage the valve and valve
body.
B3M1183A
(A) Transfer valve body
(B) Return spring
(C) Transfer control valve
(D) Plug
(E) Stopper plate
B: INSPECTION
Check each component for harmful cuts, damage,
or other faults.
C: ASSEMBLY
To assemble, reverse the removal sequence.
NOTE:
Make sure the valve slides smoothly after assem-
bling.
102
3-2[W21A0]SERVICE PROCEDURE
21. Transfer Valve Body

11) Coat the seal ring with vaseline, and install it
in the seal ring groove of the shaft.
CAUTION:
Do not expand the seal ring excessively when
installing.
ST 899580100 INSTALLER
G3M0493
21. Transfer Valve Body
A: DISASSEMBLY
1) Separate duty solenoid C (transfer) and trans-
fer valve body.
2) Remove the stopper plate and pry out the plug
with a screwdriver. Then extract the spring and
transfer control valve together.
CAUTION:
Be careful not to damage the valve and valve
body.
B3M1183A
(A) Transfer valve body
(B) Return spring
(C) Transfer control valve
(D) Plug
(E) Stopper plate
B: INSPECTION
Check each component for harmful cuts, damage,
or other faults.
C: ASSEMBLY
To assemble, reverse the removal sequence.
NOTE:
Make sure the valve slides smoothly after assem-
bling.
102
3-2[W21A0]SERVICE PROCEDURE
21. Transfer Valve Body

22. Transmission Control
Module
A: REMOVAL
1. LHD
1) Disconnect battery ground cable.
G6M0095
2) Remove lower cover and then disconnect con-
nector.
B3M0377A
3) Remove transmission control module.
B3M0443L
(A) Transmission control module
(B) Pedal bracket
4) Disconnect connectors form TCM.
2. RHD
1) Disconnect battery ground cable.
G6M0095
2) Remove lower cover and then disconnect con-
nector.
3) Remove transmission control module.
B3M0445F
(A) Transmission control module
(B) Column shaft
4) Disconnect connectors from transmission con-
trol module.
B: INSTALLATION
1. LHD
1) Connect connectors to TCM.
2) Install TCM to steering support beam.
Tightening torque:
7.4
±2.0 N´m (0.75±0.2 kg-m, 5.4±1.4 ft-lb)
B3M0443L
(A) Transmission control module
(B) Pedal bracket
103
[W22B1]3-2SERVICE PROCEDURE
22. Transmission Control Module

3) Remove TCM from steering support beam.
2. RHD
1) Connect connectors to transmission control
module.
2) Install transmission control module.
Tightening torque:
25
±5 N´m (2.5±0.5 kg-m, 18.1±3.6 ft-lb)
B3M0445F
(A) Transmission control module
(B) Column shaft
3) Installing procedure hereafter is in the reverse
order of removal.
23. Dropping Resistor
A: REMOVAL AND INSTALLATION
1) Disconnect battery ground cable.
G6M0095
2) Remove air intake duct.
3) Disconnect connector from dropping resistor.
4) Remove dropping resistor from bracket.
B3M1408A
5) Installation is in the reverse order of removal.
Tightening torque:
6.4
±0.5 N´m (0.65±0.05 kg-m, 4.7±0.4 ft-lb)
B3M1408A
104
3-2[W22B2]SERVICE PROCEDURE
23. Dropping Resistor

3) Remove TCM from steering support beam.
2. RHD
1) Connect connectors to transmission control
module.
2) Install transmission control module.
Tightening torque:
25
±5 N´m (2.5±0.5 kg-m, 18.1±3.6 ft-lb)
B3M0445F
(A) Transmission control module
(B) Column shaft
3) Installing procedure hereafter is in the reverse
order of removal.
23. Dropping Resistor
A: REMOVAL AND INSTALLATION
1) Disconnect battery ground cable.
G6M0095
2) Remove air intake duct.
3) Disconnect connector from dropping resistor.
4) Remove dropping resistor from bracket.
B3M1408A
5) Installation is in the reverse order of removal.
Tightening torque:
6.4
±0.5 N´m (0.65±0.05 kg-m, 4.7±0.4 ft-lb)
B3M1408A
104
3-2[W22B2]SERVICE PROCEDURE
23. Dropping Resistor

1. Manual Transmission
A: AWD MODEL
B3M0607B
(1) Gear shift knob
(2) Console boot
(3) Boot plate
(4) Gear shift lever
(5) Bush
(6) Spacer
(7) Locking wire
(8) Boot
(9) Snap ring
(10) O-ring(11) Bush (Shift lever)
(12) Cushion rubber
(13) Bush (Stay rear)
(14) Joint
(15) Rod
(16) Bracket
(17) Spring
(18) Washer
(19) Stay
(20) Bush (Stay front)Tightening torque: N´m (kg-m, ft-lb)
T1:
4.4±1.5 (0.45±0.15, 3.3±1.1)
T2:5 (0.51, 3.7)
T3:12±3 (1.2±0.3, 8.7±2.2)
T4:18±5 (1.8±0.5, 13.0±3.6)
T5:24.5±2 (2.50±0.20,
18.07
±1.48)
2
3-3[C1A0]COMPONENT PARTS
1. Manual Transmission

B: FWD MODEL
B3M0606B
(1) Gear shift knob
(2) Console boot
(3) Boot plate
(4) Gear shift lever
(5) Bush
(6) Spacer
(7) Locking wire
(8) Boot
(9) Snap ring(10) O-ring
(11) Bush (Shift lever)
(12) Cushion rubber
(13) Bush (Stay rear)
(14) Joint
(15) Rod
(16) Bracket
(17) Spring
(18) Stay(19) Bush (Stay front)
Tightening torque: N´m (kg-m, ft-lb)
T1:
4.4±1.5 (0.45±0.15, 3.3±1.1)
T2:5 (0.51, 3.7)
T3:12±3 (1.2±0.3, 8.7±2.2)
T4:18±5 (1.8±0.5, 13.0±3.6)
T5:29±5 (3.0±0.5, 21.7±3.6)
3
[C1B0]3-3COMPONENT PARTS
1. Manual Transmission