check SUBARU LEGACY 1995 Service Repair Manual

C: LINE PRESSURE TEST
1. GENERAL
If the clutch or the brake band shows a sign of slippage or
shifting sensation is not correct, the line pressure should be
checked.
Excessive shocks during upshifting or shifting takes
place at a higher point than under normal circumstances,
may be due to the line pressure being too high.
Slippage or inability to operate the vehicle may, in most
cases, be due to loss of oil pressure for the operation of
the clutch, brake band or control valve.
G3M0869
1) Line pressure measurement (under no load)
CAUTION:
Before measuring line pressure, jack-up front
wheels (front-wheel-drive model) or all wheels (4-wheel
drive model).
Maintain temperature of ATF at approximately 50°C
(122°F) during measurement.
(ATF will reach the above temperature after idling the
engine for approximately 30 minutes with select lever
in“N”or“P”.)
G3M0869
2) Line pressure measurement (under heavy load)
CAUTION:
Before measuring line pressure, apply both foot and
parking brakes with all wheels chocked (Same as for
“stall”test conditions).
Measure line pressure when select lever is in“R”,
“2”with engine under stall conditions.
Measure line pressure within 5 seconds after shift-
ing the select lever to each position. (If line pressure
needs to be measured again, allow the engine to idle
and then stop. Wait for at least one minute before mea-
surement.)
Maintain the temperature of ATF at approximately
50°C (122°F) during measurement. (ATF will reach the
above temperature after idling the engine for approxi-
mately 30 minutes with the select lever in“N”or“P”.)
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3-2SERVICE PROCEDURE
3. Performance Test

G3M0317
2. TEST METHODS
1) Temporarily attach the ST to a suitable place in the
driver’s compartment, remove the blind plug located in
front of the toe board and pass the hose of the ST to the
engine compartment.
ST 498575400 OIL PRESSURE GAUGE ASSY


1Pressure gauge hose


2Hole in toe board (blank cap hole)


3Brake pedal
G3M0869
2) Remove the test plug and install ST1 instead.
3) Connect ST1 with ST2.
ST1 498897200 OIL PRESSURE GAUGE ADAPTER
ST2 498575400 OIL PRESSURE GAUGE ASSY
4) Check for duty ratio changes by opening and closing
throttle valve using select monitor.
5) Check line pressure in accordance with the following
chart.
3. EVALUATION
NOTE:
Under no load:“D”
Under full load:“R”,“2”
(With engine running at stall speed)

Unit: kPa (kg/cm2, psi)
Line pressure
Duty ratio (%)“2”range“R”range“D”range
51,167—1,363
(11.9—13.9, 169—198)1,432—1,569
(14.6—16.0, 208—228)—
22——765—902
(7.8—9.2, 111—131)
100——235—481
(2.4—4.9, 34—70)
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3-2SERVICE PROCEDURE
3. Performance Test

G3M0870
D: TRANSFER CLUTCH PRESSURE TEST
Check transfer clutch pressure in accordance with the fol-
lowing chart in the same manner as with line pressure.
ST 499897700 OIL PRESSURE ADAPTER SET
ST 498575400 OIL PRESSURE GAUGE ASSY
AWD mode:“D”range
FWD mode:“P”range, engine speed 2000 rpm
CAUTION:
Before setting in FWD mode, install spare fuse on FWD
mode switch.
Unit: kPa (kg/cm2, psi)
Duty ratio
(%)AWD mode FWD mode
5667—804
(6.8—8.2, 97—117)667—804
(6.8—8.2, 97—117)
40137—226
(1.4—2.3, 20—33)—
950
(0, 0)—
If oil pressure is not produced or if it does not change in the
AWD mode, the duty solenoid C or transfer valve assem-
bly may be malfunctioning. If oil pressure is produced in the
FWD mode, the problem is similar to that in the AWD
mode.
E: ROAD TEST
1. GENERAL
Road tests should be conducted to properly diagnose the
condition of the automatic transmission.
CAUTION:
When performing test, do not exceed posted speed
limit.
2. CHECKING FOR SHIFT PATTERNS
Check“kick-down”.
D range: 1st
←
→2nd←
→3rd←
→4th
3 range: 1st←
→2nd←
→3rd←4th
2 range: 2nd←3rd←4th
1 range: 1st←2nd←3rd←4th
3. CHECK FOR ENGINE BRAKE OPERATION
Engine brake operation:
D range→4th gear
3 range→3rd gear
2 range→2nd gear
1 range→1st gear
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3-2SERVICE PROCEDURE
3. Performance Test

4. CHECK FOR THE AWD FUNCTION
If“tight-corner braking”occurs when the steering wheel is
fully turned at low speed:
1) Determine the applicable trouble code and check the
corresponding duty solenoid C (transfer) for improper
operation.
2) If the solenoid is operating properly, check transfer
clutch pressure.
3) If oil pressure is normal but“tight-corner braking”
occurs:
Check the transfer control valve for sticking, and the trans-
fer clutch facing for wear.

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3-2SERVICE PROCEDURE
3. Performance Test

B: ASSEMBLY OF OVERALL TRANSMISSION
1. TORQUE CONVERTER CLUTCH CASE SECTION
1) Check the appearance of each component and clean.
CAUTION:
Make sure each part is free of harmful cuts, damage
and other faults.
G3M0377
2) Install the washer and snap ring to the speedometer
shaft with ST, and set the oil seal. Then force-fit the shaft
to the torque converter clutch case.
ST 499827000 PRESS
3) Install vehicle speed sensor 2.
CAUTION:
Use new vehicle speed sensor 2, if it has been
removed.
Tightening torque:
5.9±1.5 N⋅m (60±15 kg-cm, 52±13 in-lb)
G3M0378
4) Install the speedometer driven gear to the speedometer
shaft, and secure with a snap ring.
G3M0379
5) Force-fit the oil seal to the torque converter clutch case
with ST.
ST 398437700 DRIFT
G3M0380
6) Install the differential assembly to the case, paying spe-
cial attention not to damage the speedometer gears (drive
and driven) and the inside of the case (particularly, the dif-
ferential side retainer contact surface).
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3-2SERVICE PROCEDURE
4. Overall Transmission

7) Install the circlip to the axle shaft, insert the shaft into
the differential assembly, and tap it into position with a
plastic hammer.
Thrust play:
Approx. 0.3—0.5 mm (0.012—0.020 in)
CAUTION:
If no play is felt, check whether the shaft is fully
inserted. If shaft insertion is correct, replace the axle
shaft.
Be sure to use a new circlip.
G3M0368
8) Wrap vinyl tape around the splined portion of the axle
shaft.
9) Install the oil seal and outer race (taper roller bearing)
to the differential side retainer. Then screw in the retainer
and the O-ring after coating the threads with oil.
CAUTION:
Pay attention not to damage the oil seal lips.
Do not confuse the RH and LH oil seals.
Keep the O-ring removed from the retainer.
B3M0352A
10) Using the ST, screw in the retainer until light contact
is felt.
ST 499787000 WRENCH ASSY
NOTE:
Screw in the RH side slightly deeper than the LH side.
G3M0382
11) Hypoid gear backlash adjustment and tooth contact
check
(1) Assemble the drive pinion assembly to the oil pump
housing.
CAUTION:
Be careful not to bend the shims. [W8C0].>
Be careful not to force the pinion against the hous-
ing bore.
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3-2SERVICE PROCEDURE
4. Overall Transmission

G3M0387
(7) Turn the drive pinion several rotations with ST1 and
check to see if the backlash is within the standard value
with ST2 and ST3.
ST1 499787100 WRENCH
ST2 498247001 MAGNET BASE
ST3 498247100 DIAL GAUGE
Backlash:
0.13—0.18 mm (0.0051—0.0071 in)
After confirming that the backlash is correct, check the
tooth contact.
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3-2SERVICE PROCEDURE
4. Overall Transmission

(8) Apply red lead evenly to the surfaces of three or
four teeth of the crown gear. Rotate the drive pinion in
the forward and reverse directions several times. Then
remove the oil pump housing, and check the tooth con-
tact pattern.
If tooth contact is improper, readjust the backlash or
shim thickness.
Checking item Contact pattern Corrective action
Tooth contact
Tooth contact pattern is slightly shifted
toward to under no-load rotation.
[When loaded, contact pattern moves
toward heel.]
B3M0317A
Face contact
Backlash is too large.This may cause noise and chipping at
tooth ends.
B3M0319
Increase thickness of drive pinion height
adjusting shim in order to bring drive pinion
close to crown gear.
B3M0323
Flank contact
Backlash is too small.This may cause noise and stepped wear
on surfaces.
B3M0320
Reduce thickness of drive pinion height
adjusting shim in order to move drive pin-
ion away from crown gear.
B3M0324
Toe contact
(Inside end contact)
Contact areas is small.This may cause chipping at toe ends.
B3M0321
Adjust as for flank contact.
B3M0324
Heel contact
(Outside end contact)
Contact area is small.This may cause chipping at heel ends.
B3M0322
Adjust as for face contact.
B3M0323
: Adjusting direction of drive pinion
: Adjusting direction of crown gear
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3-2SERVICE PROCEDURE
4. Overall Transmission

G3M0405
(2) Apply compressed air intermittently to check for
operation.
G3M0406
(3) Check the clearance. (Selection of retaining plate)
Standard value:
1.1—1.7 mm (0.043—0.067 in)
Allowable limit:
2.7 mm (0.106 in)
NOTE:
Before measuring clearance, place the same thickness of
shim on both sides to prevent retaining plate from tilting.
Available retaining platesPart No. Thickness mm (in)
31667AA180
31667AA190
31667AA200
31667AA210
31667AA220
31667AA230
31667AA240
31667AA2506.5 (0.256)
6.8 (0.268)
7.1 (0.280)
7.4 (0.291)
7.7 (0.303)
8.0 (0.315)
8.2 (0.323)
8.4 (0.331)
B3M0404A
11) Install the forward clutch drum.
(1) Install carefully while rotating the drum slowly pay-
ing special attention not to damage the seal ring.
(2) Installation is complete when the drum recedes 2.5
mm (0.098 in) from the inner race surface.
G3M0408
12) Assemble the overrunning clutch hub.
CAUTION:
Install thrust needle bearing in the correct direction.

NOTE:
Join the thrust needle bearing and thrust washer with
vaseline, and then install them together.
Make sure that the splines are engaged correctly.
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3-2SERVICE PROCEDURE
4. Overall Transmission

G3M0902
C: ASSEMBLY
1) Install the nine steel balls to the upper valve body.
G3M0903
2) From under upper valve body, install two bolts using
washers and position upper separator gasket.
G3M0904
3) Install the orifice check valve, orifice check spring and
filter to the lower valve body.
G3M0905
4) Install lower separate gasket and separate plate on
lower body in that order, then temporarily tighten three
support plates and two brackets.
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3-2SERVICE PROCEDURE
6. Control Valve Body