SUBARU LEGACY 1999 Service Repair Manual

2) Measure backlash between bevel gear and pin-
ion. If it is not within specifications, install a suitable
washer to adjust it.
NOTE:
Be sure the pinion gear tooth contacts adjacent
gear teeth during measurement.
ST1 498247001 MAGNET BASE
ST2 498247100 DIAL GAUGE
Standard backlash:
0.13 Ð 0.18 mm (0.0051 Ð 0.0071 in)
G3M0670
Washer (38.1´50´t)
Part No. Thickness mm (in)
8030380210.925 Ð 0.950
(0.0364 Ð 0.0374)
8030380220.975 Ð 1.000
(0.0384 Ð 0.0394)
8030380231.025 Ð 1.050
(0.0404 Ð 0.0413)
3) Align pinion shaft and differential case at their
holes, and drive straight pin into holes from the
hypoid driven gear side, using ST.
NOTE:
Lock straight pin after installing.
ST 899904100 REMOVER
B3M0609C
(A) Pinion shaft
(B) Differential case
(C) Straight pin
4) Install roller bearing (40´80´19.75) to differ-
ential case.
NOTE:
Be careful because roller bearing outer races are
used as a set.
ST1 499277100 BUSH 1-2 INSTALLER
ST2 398497701 ADAPTER
G3M0671
5) Install hypoid driven gear to differential case
using twelve bolts.
Tightening torque:
T: 6 2
±5 N´m (6.3±0.5 kg-m, 45.6±3.6 ft-lb)
B3M0554C
(A) Hypoid driven gear
(B) Differential case
50
3-1[W6B0]SERVICE PROCEDURE
6. Front Differential

6) Position drive axle shaft in differential case and
hold it with outer snap ring (28). Using a thickness
gauge, measure clearance between the shaft and
case is within specifications.
NOTE:
If it is not within specifications, replace snap ring
with a suitable one.
Clearance:
0 Ð 0.2 mmm (0 Ð 0.008 in)
B3M0100
Snap ring (Outer-28)
Part No. Thickness mm (in)
805028011 1.05 (0.0413)
805028012 1.20 (0.0472)
7. Center Differential
A: DISASSEMBLY AND ASSEMBLY
1) Remove ball bearing using ST.
CAUTION:
Do not reuse ball bearing.
ST 498077300 CENTER DIFFERENTIAL
BEARING REMOVER
B3M1398A
2) Install ball bearing to center differential assem-
bly.
NOTE:
Do not disassemble center differential because it is
a non-disassemble part.
B3M1399A
51
[W7A0]3-1SERVICE PROCEDURE
7. Center Differential

6) Position drive axle shaft in differential case and
hold it with outer snap ring (28). Using a thickness
gauge, measure clearance between the shaft and
case is within specifications.
NOTE:
If it is not within specifications, replace snap ring
with a suitable one.
Clearance:
0 Ð 0.2 mmm (0 Ð 0.008 in)
B3M0100
Snap ring (Outer-28)
Part No. Thickness mm (in)
805028011 1.05 (0.0413)
805028012 1.20 (0.0472)
7. Center Differential
A: DISASSEMBLY AND ASSEMBLY
1) Remove ball bearing using ST.
CAUTION:
Do not reuse ball bearing.
ST 498077300 CENTER DIFFERENTIAL
BEARING REMOVER
B3M1398A
2) Install ball bearing to center differential assem-
bly.
NOTE:
Do not disassemble center differential because it is
a non-disassemble part.
B3M1399A
51
[W7A0]3-1SERVICE PROCEDURE
7. Center Differential

1. Manual Transmission
Symptom Possible cause Remedy
1. Gears are difficult to intermesh.
NOTE:
The cause for difficulty in shifting gears
can be classified into two kinds: one is
malfunction of the gear shift system and
the other is malfunction of the transmis-
sion. However, if the operation is heavy
and engagement of the gears is difficult,
defective clutch disengagement may
also be responsible. Check whether the
clutch is correctly functioning, before
checking the gear shift system and
transmission.(a) Worn, damaged or burred chamfer of
internal spline of sleeve and reverse
driven gearReplace.
(b) Worn, damaged or burred chamfer of
spline of gearsReplace.
(c) Worn or scratched bushings Replace.
(d) Incorrect contact between synchro-
nizer ring and gear cone or wearCorrect or replace.
2. Gear slips out.
IGear slips out when coasting on
rough road.
IGear slips out during acceleration.(a) Defective pitching stopper adjustment Adjust
(b) Loose engine mounting bolts Tighten or replace.
(c) Worn fork shifter, broken shifter fork
rail springReplace.
(d) Worn or damaged ball bearing Replace.
(e) Excessive clearance between splines
of synchronizer hub and synchronizer
sleeveReplace.
(f) Worn tooth step of synchronizer hub
(responsible for slip- out of 3rd gear)Replace.
(g) Worn 1st driven gear, needle bearing
and raceReplace.
(h) Worn 2nd driven gear, needle bear-
ing and raceReplace.
(i) Worn 3rd drive gear and bushing Replace.
(j) Worn 4th drive gear and bushing Replace.
(k) Worn reverse idler gear and bushing Replace.
3. Unusual noise comes from transmis-
sion.
NOTE:
If an unusual noise is heard when the
vehicle is parked with its engine idling
and if the noise ceases when the clutch
is disengaged, it may be considered that
the noise comes from the transmission.(a) Insufficient or improper lubrication Lubricate or replace with specified oil.
(b) Worn or damaged gears and bear-
ings
NOTE:
If the trouble is only wear of the tooth
surfaces, merely a high roaring noise will
occur at high speeds, but if any part is
broken, rhythmical knocking sound will
be heard even at low speeds.Replace.
52
3-1[K100]DIAGNOSTICS
1. Manual Transmission

2. Differential
Symptom Possible cause Remedy
1. Broken differential (case, gear,
bearing, etc.)
NOTE:
Abnormal noise will develop and finally it
will become impossible to continue to
run due to broken pieces obstructing the
gear revolution.(a) Insufficient or improper oil Disassemble differential and replace bro-
ken components and at the same time
check other components for any trouble,
and replace if necessary
(b) Use of vehicle under severe condi-
tions such as excessive load and
improper use of clutchReadjust bearing preload and backlash
and face contact of gears.
(c) Improper adjustment of taper roller
bearingAdjust.
(d) Improper adjustment of drive pinion
and hypoid driven gearAdjust.
(e) Excessive backlash due to worn dif-
ferential side gear, washer or differential
pinion vehicle under severe operating
conditions.Add recommended oil to specified level.
Do not use vehicle under severe operat-
ing conditions.
(f) Loose hypoid driven gear clamping
boltsTighten.
2. Differential and hypoid gear noises
Troubles of the differential and hypoid
gear always appear as noise problems.
Therefore noise is the first indication of
the trouble. However noises from the
engine, muffler, tire, exhaust gas,
bearing, body, etc. are easily mistaken
for the differential noise. Pay special
attention to the hypoid gear noise
because it is easily confused with other
gear noises. There are the following four
kinds of noises.
IGear noise when driving: If noise
increases as vehicle speed increases it
may be due to insufficient gear oil, incor-
rect gear engagement, damaged gears,
etc.
IGear noise when coasting: Damaged
gears due to maladjusted bearings and
incorrect shim adjustment
IBearing noise when driving or when
coasting: Cracked, broken or damaged
bearings
INoise which mainly occurs when turn-
ing: Unusual noise from differential side
gear, differential pinion, differential pinion
shaft, etc.(a) Insufficient oil Lubricate.
(b) Improper adjustment of hypoid driven
gear and drive pinionCheck tooth contact.
(c) Worn teeth of hypoid driven gear and
drive pinionReplace as a set.
Readjust bearing preload.
(d) Loose roller bearing Readjust hypoid driven gear to drive pin-
ion backlash and check tooth contact.
(e) Distorted hypoid driven gear or differ-
ential caseReplace.
(f) Worn washer and differential pinion
shaftReplace.
53
[K200]3-1DIAGNOSTICS
2. Differential

MEMO:
54
3-1DIAGNOSTICS

1. Automatic Transmission and Differential
A: SPECIFICATIONS
Torque
converter
clutchType Symmetric, 3 element, single stage, 2 phase torque converter
Stall torque ratio2200 cc 2.1 Ð 2.3
2500 cc 1.8 Ð 2.0
OUTBACK 2.2 Ð 2.4
Nominal diameter2200 cc 236 mm (9.29 in)
2500 cc 246 mm (9.69 in)
Stall speed (at sea
level)2200 cc 2,200 Ð 2,600 rpm
2500 cc 2,200 Ð 2,600 rpm
OUTBACK 2,300 Ð 2,700 rpm
One-way clutch Sprague type one-way clutch
Automatic
transmis-
sionTransmis-
sionType 4-forward, 1-reverse, double-row planetary gears
Control elementMulti-plate clutch 3 sets
Multi-plate brake 2 sets
One-way clutch (sprague type) 1 set
Gear ratio1st2200 cc 2.785
2500 cc 3.027
2nd2200 cc 1.545
2500 cc 1.619
3rd 1.000
4th 0.694
Reverse 2.272
Tooth number of planetary gearFront sun gear 33
Front pinion 21
Front internal gear 75
Rear sun gear2200 cc 42
2200 cc 37
Rear pinion2200 cc 17
2500 cc 19
Rear internal gear 75
Plate number of high clutch Drive plate & driven plate 4
Plate number of reverse clutch Drive plate & driven plate 2
Plate number of 2-4 brake Drive plate & driven plate 3
Plate number of low clutchDrive plate & driven
plate2200 cc 5
2500 cc 6
Plate number of low & reverse
brakeDrive plate & driven
plate2200 cc 5
2500 cc 6
2
3-2[S1A0]SPECIFICATIONS AND SERVICE DATA
1. Automatic Transmission and Differential

Automatic
transmis-
sionTransmis-
sionSelector positionP (Park)Transmission in
neutral, output mem-
ber immovable, and
engine start possible
R (Reverse)Transmission in
reverse for backing
N (Neutral)Transmission in
neutral, and engine
start possible
D (Drive)Automatic gear
change
1st
¬
®2nd¬
®3rd¬
®4th
3 (3rd)Automatic gear
change
1st
¬
®2nd¬
®3rd
¬4th
2 (2nd)2nd gear locked
(Deceleration pos-
sible 4th®3rd®
2nd)
1 (1st)1st gear locked
(Deceleration pos-
sible 4th®3rd®
2nd®1st)
Control method Hydraulic remote control
Oil pumpType Trochoid constant-displacement pump
Driving method Driven by engine
Number of teethInner rotor 9
Outer rotor 10
Hydraulic
controlTypeElectronic/hydraulic control [Four forward speed changes by electri-
cal signals of vehicle speed and accelerator (throttle) opening]
Fluid Dexron II or Dexron III type Automatic transmission fluid
Fluid capacity2200 cc 8.4 Ð 8.7(8.9 Ð 9.2 US qt, 7.4 Ð 7.7 Imp qt)
2500 cc 9.3 Ð 9.6(9.8 Ð 10.1 US qt, 8.2 Ð 8.4 Imp qt)
Lubrica-
tionLubrication system Forced feed lubrication with oil pump
Oil Automatic transmission fluid (above mentioned.)
Cooling Cooling system Liquid-cooled cooler incorporated in radiator
HarnessInhibitor switch 12 poles
Transmission harness 17 poles
TransferTransfer clutch Hydraulic multi-plate clutch
Plate number of transfer clutchDrive plate & driven
plate2200 cc 4
2500 cc 5
Control method Electronic, hydraulic type
LubricantThe same Automatic Transmission
Fluid used in automatic transmission.
1st reduction gear ratio 1.000 (53/53)
3
[S1A0]3-2SPECIFICATIONS AND SERVICE DATA
1. Automatic Transmission and Differential

Final
reductionFinal gear
ratioFront drive2200 cc 4.111 (37/9)
2500 cc 4.444 (40/9)
Lubrication oil
H3M1235A
Oil capacity Front drive 1.2(1.3 US qt, 1.1 Imp qt)
ATF cooling system Radiation capacity 1.977 kW (1,700 kcal/h, 6,746 BTU/h)
4
3-2[S1A0]SPECIFICATIONS AND SERVICE DATA
1. Automatic Transmission and Differential

MEMO:
5
[S1A0]3-2SPECIFICATIONS AND SERVICE DATA
1. Automatic Transmission and Differential