Subaru Legacy BN/BS (2015-2019) Service Manual: Installation
1. Clean the mating surfaces of the transmission case, transfer case and extension case. 2. Apply a coat of grease to the taper roller bearing (transfer case side) of transfer driven gear and the roller rolling surface of the taper roller bearing (extension case side). Grease: NICHIMOLY N-130 or equivalent 3. Install the center differential and the transfer driven gear.
4. Install the taper roller bearing (extension case side) outer race to the transfer driven gear. 5. While pressing the taper roller bearing (extension case side) outer race horizontally, rotate the transfer driven gear for ten turns. 6. Measure the height “W” between transfer case and taper roller bearing (transfer case side) on the transfer driven gear.
7. Measure the depth “X” of taper roller bearing insertion part of the extension case. NOTE: Measure while the taper roller bearing (extension case side) outer race and the adjusting washer are removed.
8. Calculate the adjusting washer thickness “t” using the following calculation. t = X − W + (0.15 — 0.2 mm (0.006 — 0.008 in)) X: Depth of taper roller bearing insertion part of extension case W: Height between transfer case and taper roller bearing (transfer case side) on transfer driven gear 0.15 — 0.20 mm (0.006 — 0.008 in): Amount of standard protrusion 9. Select the adjusting washer with the nearest value in the following table. NOTE: Be sure that it is always within the preload. Preload of taper roller bearing (extension case side) (amount of standard protrusion): 0.15 — 0.20 mm (0.006 — 0.008 in)
10. Install the selected adjusting washer and taper roller bearing (extension case side) outer race.
11. Measure the depth “S” between the transfer case + ST and the center differential.
12. Measure the height “T” between the extension case + ST and the transfer drive gear.
13. Calculate the adjusting washer thickness “U” using the following calculation. U = S + T − 30 mm (1.18 in) − (0.15 — 0.35 mm (0.0059 — 0.0138 in)) S: Depth between the transfer case + ST and the center differential T: Depth between the extension case + ST and the transfer drive gear 30 mm (1.18 in): Thickness of ST (- 2 pieces) 0.15 — 0.35 mm (0.0059 — 0.0138 in): Clearance 14. Select a suitable adjusting washer in the following table. Clearance: 0.15 — 0.35 mm (0.0059 — 0.0138 in)
15. Install the adjusting washer to center differential. 16. Apply liquid gasket seamlessly. Liquid gasket: THREE BOND 1215B or equivalent
17. Install the extension case assembly. Tightening torque: 40 N·m (4.1 kgf-m, 29.5 ft-lb)
18. Temporarily install the gasket to the transmission case side. NOTE: Use a new gasket. 19. Install the transfer case together with the extension case assembly. (1) While moving the HANDLE to align the spline position, press in the transfer case assembly until the knock pin comes slightly out of transfer case.
(2) Set and hold the selector lever COMPL to the 1st-2nd side, and install the transfer case assembly so that the shifter arm edge and fork rod does not contact.
20. Temporarily install the transfer case assembly. 21. Install the shift lever COMPL, then insert the remover or similar tool instead of straight pin.
22. Operate the selector arm and remover to confirm the correct shifting into each gear is possible. 23. Install the transfer case assembly. Tightening torque: 24.5 N·m (2.5 kgf-m, 18.1 ft-lb)
24. Install the shift lever COMPL and secure it with the straight pin. NOTE: Use a new straight pin.
25. Apply liquid gasket seamlessly. Liquid gasket: THREE BOND 1215B or equivalent
26. Install the transmission cover. Tightening torque: 25 N·m (2.5 kgf-m, 18.4 ft-lb)
27. Install the back-up light switch and the neutral position switch. Switches and Harness > INSTALLATION 28. Install the manual transmission assembly to the vehicle. Manual Transmission Assembly > INSTALLATION | ||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||
Assembly
1. TRANSFER CASE1. Install the shift link assembly to the transfer case. Shift Link Assembly > INSTALLATION2. Install the interlock plate.NOTE:• Use a new bolt and gasket.• Clean the bolt ...
Disassembly
1. TRANSFER CASE1. Remove the interlock plate.NOTE:Do not remove the precoat bolt (B) if the parts are assembled as a transmission assembly.(A)Interlock plate(B)Precoat bolt2. Remove the shift link as ...
Other materials:
Removal
1. Disconnect the ground terminal from battery sensor. NOTE2. Remove the V-belts. V-belt > REMOVAL3. Disconnect the connector (A) and terminal (B) from the generator, and remove the clip (C).4. Remove the V-belt cover bracket.5. Remove the generator from the generator bracket.6. Remove the V-belt ...
