SUBARU LEGACY 1996 Service Repair Manual

G3M0367
2) Install and route the transmission harness.
CAUTION:
Be careful not to damage the harness.
B3M0418A
3) Install the control valve assembly.
(1) Set the select lever in range“2”.
(2) Install the two brackets, ATF temperature sensor
and the control valve by engaging the manual valve and
manual lever, then tighten the 17 bolts.
Tightening torque:
8±1 N⋅m (0.8±0.1 kg-m, 5.8±0.7 ft-lb)
CAUTION:
Be careful not to pinch the harness roll the gasket.
Tighten the control valve mounting bolts evenly.
B3M0419A
4) Install the oil strainer to the control valve. Be careful not
to cut or break the O-ring. Then tighten four bolts.
Tightening torque:
8±1 N⋅m (0.8±0.1 kg-m, 5.8±0.7 ft-lb)
B3M0420A
5) Secure four connectors.
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3-2SERVICE PROCEDURE
4. Overall Transmission

G3M0345
6) Install the oil cooler outlet pipe, and secure with two
bolts.
Tightening torque:
8±1 N⋅m (0.8±0.1 kg-m, 5.8±0.7 ft-lb)
CAUTION:
Fit the pipe into position. Be careful to avoid twisting.
G3M0427
7) Install the oil pan.
(1) Attach the magnet at the specified position.
G3M0428
(2) With gasket inserted, secure the oil pan by tighten-
ing 20 bolts.
Tightening torque:
4.9±0.5 N⋅m (0.50±0.05 kg-m, 3.6±0.4 ft-lb)
NOTE:
Tighten the bolts evenly.
G3M0867
5. EXTENSION SECTION
NOTE:
When installing new oil seal into extension case, press it
with ST.
ST 498057300 INSTALLER
1) Install the filter in the extension case.
NOTE:
Pay attention to the orientation of the filter.
2) Install the transfer clutch valve assembly, transfer pipe,
and the stay then secure with five bolts.
Tightening torque:
8±1 N⋅m (0.8±0.1 kg-m, 5.8±0.7 ft-lb)
CAUTION:
Be sure to tighten the going lead with one of these
bolts.
Be sure to use a new gasket.
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3-2SERVICE PROCEDURE
4. Overall Transmission

G3M0894
3) Install the transfer clutch assembly to the case.
CAUTION:
Be careful not to damage the seal rings.
NOTE:
Insert the clutch assembly fully into position until the bear-
ing shoulder bottoms.
G3M0429
6. CONNECTION OF EACH SECTION
1) Install vehicle speed sensor 1 on transmission case.
[FWD only]
Tightening torque:
7±1 N⋅m (0.7±0.1 kg-m, 5.1±0.7 ft-lb)
2) Install oil pipe.
G3M0339
3) Install the reduction driven gear.
4) Install the parking pawl and shaft, set the select lever in
the“P”range and tighten the drive pinion lock nut.
Tightening torque:
98±5 N⋅m (10.0±0.5 kg-m, 72.3±3.6 ft-lb)
NOTE:
After tightening, stake the lock nut securely.
G3M0895
5) Install the reduction drive gear assembly.
CAUTION:
Align mark on reduction drive gear with mark on driven
gear during installation.
NOTE:
Insert it fully into position until the bearing shoulder bot-
toms.
G3M0430
6) Measurement and adjustment of extension end play
(1) Measure distance L from end of extension case and
rear drive shaft with ST. (On FWD models, measure
distance from end of case to point at bearing location.)
ST 398643600 GAUGE
Unit: mm
L = Measured value15
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3-2SERVICE PROCEDURE
4. Overall Transmission

G3M0431
(2) Measure the distance“”from the transmission
case mating surface to the reduction drive gear end
surface with ST1 and ST2. (On FWD models, measure
distance from end of case to end of bearing.)
Unit: mm
= Measured value50
ST1 398643600 GAUGE
ST2 499577000 GAUGE
(3) Calculation equation:
Unit: mm
T = (L + 0.4)
T : Clearance between end of reduction drive gear
and end of rear drive shaft. (Clearance between
end of reduction drive gear and end of bearing on
FWD model)
L : Distance from end of extension case to end of
rear drive shaft. (Distance from end of case to
point at bearing location)
0.4: Gasket thickness
: Height from end of transmission case to end of
reduction drive gear. (Height from end of case to
end of bearing on FWD models)
Select suitable thrust needle bearing from among those
listed in the following table to adjust clearance in the
0.05—0.20 mm (0.0020—0.0079 in) range.
AWD: Thrust needle bearingPart No. Thickness mm (in)
806536020
806535030
806535040
806535050
806535060
806535070
8065350903.8 (0.150)
4.0 (0.157)
4.2 (0.165)
4.4 (0.173)
4.6 (0.181)
4.8 (0.189)
5.0 (0.197)
FWD: Reduction gear shimPart No. Thickness mm (in)
31288AA000 0.15 (0.0059)
Select from one to five shims so that clearance is within
specifications.
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3-2SERVICE PROCEDURE
4. Overall Transmission

G3M0896
7) Installation of extension case (AWD), transmission
cover (FWD) and transmission case.
AWD model:
(1) Attach the selected thrust needle bearing to the end
surface of reduction drive gear with vaseline.
(2) Set the parking return spring.
(3) Remove the transfer clutch from the extension
case.
Set the needle bearing on the reduction drive shaft and
then install transfer clutch to the transfer clutch hub.
NOTE:
Be sure to engage the spline teeth correctly.
(4) With gasket inserted between them, install the
extension case to the transmission case.
CAUTION:
Be sure to use a new gasket.
After inserting the extension case halfway, connect
the connector for duty solenoid C. Be careful not to
jam the cord in the case.
Be careful not to damage the rear drive shaft seal
ring.
(5) Tighten bolts to secure the case.
Tightening torque:
25±2 N⋅m (2.5±0.2 kg-m, 18.1±1.4 ft-lb)
FWD model:
(1) Attach selected shim to transmission cover using
vaseline.
(2) Set the parking return spring.
(3) After positioning gasket, assemble transmission
cover and transmission case.
NOTE:
While aligning bearings, parking shaft, reduction driven
gear, etc. assemble the two cases.
(4) Tighten bolts.
Tightening torque:
25±2 N⋅m (2.5±0.2 kg-m, 18.1±1.4 ft-lb)
G3M0336
7. EXTERNAL PARTS
1) Install the vehicle speed sensor 1. (AWD only)
Tightening torque:
7±1 N⋅m (0.7±0.1 kg-m, 5.1±0.7 ft-lb)
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4. Overall Transmission

G3M0434
2) Installation and adjustment of inhibitor switch
(1) Install the inhibitor switch to the transmission case.
Fit the projecting portion of the switch in the recessed
portion of the case, and tighten three bolts temporarily.
(2) Insert the range select lever into the shaft, and
tighten the nut.
Tightening torque:
47±5 N⋅m (4.8±0.5 kg-m, 34.7±3.6 ft-lb)
G3M0435
(3) With the selector lever set to“N”adjust the inhibi-
tor switch so that the hole of range select lever is
aligned with the inhibitor switch hole with ST.
ST 499267300 STOPPER PIN
NOTE:
Ensure that gauge moves properly.
(4) With hole aligned, tighten three bolts to secure the
inhibitor switch.
Tightening torque:
3.4±0.5 N⋅m (0.35±0.05 kg-m, 2.5±0.4 ft-lb)
B3M0115
3) Clip the following cords and harness.
(1) Transmission harness
(2) Inhibitor switch cord
G3M0333
4) Install the oil cooler outlet pipe.
Tightening torque:
34±3 N⋅m (3.5±0.3 kg-m, 25.3±2.2 ft-lb)
5) Install the oil cooler inlet pipe.
Tightening torque:
25±2 N⋅m (2.5±0.2 kg-m, 18.1±1.4 ft-lb)
CAUTION:
Be sure to use a new aluminum washer.
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3-2SERVICE PROCEDURE
4. Overall Transmission

G3M0332
6) Install the oil charge pipe.
Tightening torque:
Upper
41±3 N⋅m (4.2±0.3 kg-m, 30.4±2.2 ft-lb)
Lower
6.4±0.5 N⋅m (0.65±0.05 kg-m, 4.7±0.4 ft-lb)
CAUTION:
Be careful not to damage the O-ring.
G3M0348
7) Adjustment of brake band
(1) After tightening the brake band adjusting screw
with ST to 9 N⋅m (0.9 kg-m, 6.5 ft-lb) torque, back it off
three turns. Then secure with a lock nut.
ST 398603610 SOCKET WRENCH
Tightening torque:
26±2 N⋅m (2.7±0.2 kg-m, 19.5±1.4 ft-lb)
NOTE:
When tightening the lock nut, be careful not to turn the
adjusting screw.
B3M0114A
8) Install the air breather hose.


1Air breather hose (Transmission case)


2Air breather hose (Oil pump housing)
B3M0113
9) Install the pitching stopper bracket.
Tightening torque:
41±3 N⋅m (4.2±0.3 kg-m, 30.4±2.2 ft-lb)
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3-2SERVICE PROCEDURE
4. Overall Transmission

G3M0325
10) Tighten the drain plugs.
Tightening torque:
Diff.
44±3 N⋅m (4.5±0.3 kg-m, 32.5±2.2 ft-lb)
AT F
25±2 N⋅m (2.5±0.2 kg-m, 18.1±1.4 ft-lb)
G3M0437
11) Insert the input shaft while turning lightly by hand.
CAUTION:
Be careful not to damage the bushing.
G3M0327
12) Install the torque converter clutch assembly.
(1) Install the oil pump shaft to the torque converter
clutch.
NOTE:
Make sure the clip fits securely in its groove.
(2) Holding the torque converter clutch assembly by
hand, carefully install it to the torque converter clutch
case. Be careful not to damage the bushing. Also avoid
undue contact between the oil pump shaft bushing and
stator shaft portion of the oil pump cover.
(3) Rotate the shaft lightly by hand to engage the
splines securely.
13) Fill ATF and differential gear oil.
<Ref. to 1-5 [09A2], [010A0].>
Oil capacity:
Diff.
1.1—1.3(1.2—1.4 US qt, 1.0—1.1 Imp qt)
AT F
7.9—8.2(8.4—8.7 US qt, 7.0—7.2 Imp qt)
NOTE:
After filling oil, insert the oil level gauge into the oil inlet.
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3-2SERVICE PROCEDURE
4. Overall Transmission

G3M0438
5. Reduction Drive Gear Assembly
A: DISASSEMBLY
1) Take out the seal rings.
CAUTION:
Be careful not to damage the seal rings.
B3M0107A
2) Take out the snap ring (outer
1).
CAUTION:
Be careful not to damage the splines.
3) Using a press, remove the ball bearing

2from shaft
3.
(FWD only)
G3M0440
4) Using a press, remove the reduction drive gear.
G3M0441
5) Using a press, remove the ball bearing.
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3-2SERVICE PROCEDURE
5. Reduction Drive Gear Assembly

B: INSPECTION
Make sure that each component is free of harmful gouges,
cuts, or dust.
G3M0442
C: ASSEMBLY
1) Press-fit the ball bearing and reduction drive gear to the
shaft.
B3M0107A
2) AWD: Fit the snap ring
1securely in the snap ring
groove on the shaft

3.
FWD: Press ball bearing

2into place and secure snap
ring

1to groove in shaft
3.
G3M0438
3) Attach two seal rings.
NOTE:
To make subsequent assembly easier, apply vaseline to
the grooves of the shaft and to the exterior of the seal ring.
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3-2SERVICE PROCEDURE
5. Reduction Drive Gear Assembly