SUBARU LEGACY 1995 Service Repair Manual

G3M0864
A: DISASSEMBLY
1) Remove the following parts from the upper valve body.
(1) Solenoid assembly (shift 1-2-3)
(2) Duty solenoid A (line pressure)
B3M0405A
2) Remove the following parts from the lower valve body.
(1) Duty solenoid B (lock-up)
(2) Bracket
3) Separate the upper valve body and lower valve body.
G3M0901
CAUTION:
Do not lose the nine (9) steel balls contained in the
upper valve body.
Do not lose an orifice and a strainer contained in the
lower valve body.
NOTE:
Remove the upper-lower valve body tightening bolts. Then
remove two locating bolts. (
)
During ordinary servicing, clean the control valve bodies in
this condition, without further disassembly.
In the event of a seized clutch or other problem, disas-
semble the control valve bodies further, and clean the com-
ponent parts.
B: INSPECTION
Make sure that each component is free of harmful gouges,
cuts, or dust.
87
3-2SERVICE PROCEDURE
6. Control Valve Body

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.
88
3-2SERVICE PROCEDURE
6. Control Valve Body

G3M0906
5) Temporarily assemble lower valve body to upper valve
body.
CAUTION:
Be careful not to drop the upper body interior steel
ball, or the lower body interior filter, orifice check
spring, or orifice check valve.
B3M0406A
6) Install the duty solenoid B and the four brackets.
7) Tighten twenty seven bolts & washers and two reamer
bolts.
Tightening torque:
T1: 8±1 N⋅m (0.8±0.1 kg-m, 5.8±0.7 ft-lb)
T2: 11.3±1.5 N⋅m (1.15±0.15 kg-m, 8.3±1.1 ft-lb)
Unit: mm (in)
abcde
Length 70 (2.76) 50 (1.97) 33 (1.30) 27 (1.06) 28 (1.10)
Numbers 2 6 16 1 2
G3M0864
8) Install the shift solenoid and duty solenoid A.
a length : 16 mm (0.63 in)
b length : 27 mm (1.06 in)
Tightening torque:
8±1 N⋅m (0.8±0.1 kg-m, 5.8±0.7 ft-lb)
G3M0445
7. Oil Pump Assembly
A: DISASSEMBLY
1) Remove the oil seal retainer.
Also remove the O-ring and oil seal (air breather).
89
3-2SERVICE PROCEDURE
6. Control Valve Body - 7. Oil Pump Assembly

G3M0906
5) Temporarily assemble lower valve body to upper valve
body.
CAUTION:
Be careful not to drop the upper body interior steel
ball, or the lower body interior filter, orifice check
spring, or orifice check valve.
B3M0406A
6) Install the duty solenoid B and the four brackets.
7) Tighten twenty seven bolts & washers and two reamer
bolts.
Tightening torque:
T1: 8±1 N⋅m (0.8±0.1 kg-m, 5.8±0.7 ft-lb)
T2: 11.3±1.5 N⋅m (1.15±0.15 kg-m, 8.3±1.1 ft-lb)
Unit: mm (in)
abcde
Length 70 (2.76) 50 (1.97) 33 (1.30) 27 (1.06) 28 (1.10)
Numbers 2 6 16 1 2
G3M0864
8) Install the shift solenoid and duty solenoid A.
a length : 16 mm (0.63 in)
b length : 27 mm (1.06 in)
Tightening torque:
8±1 N⋅m (0.8±0.1 kg-m, 5.8±0.7 ft-lb)
G3M0445
7. Oil Pump Assembly
A: DISASSEMBLY
1) Remove the oil seal retainer.
Also remove the O-ring and oil seal (air breather).
89
3-2SERVICE PROCEDURE
6. Control Valve Body - 7. Oil Pump Assembly

G3M0446
2) Remove the oil pump cover.
NOTE:
Lightly tap the end of the stator shaft to remove the cover.
G3M0447
3) Remove the retainer and return spring. Then remove
the rotor, two vane rings and nine vanes.
G3M0448
4) Remove the cam ring and control piston.
Also remove the O-ring, friction ring, two side seals, and
plain seal.
G3M0449
5) Remove two seal rings (R) and two seal rings (H).
B: INSPECTION
1) Make sure that each component is free of harmful
gouges, cuts, and dust.
90
3-2SERVICE PROCEDURE
7. Oil Pump Assembly

G3M0450
2) Selection of oil pump components (rotor, vanes, control
piston and cam ring)
(1) Using a micrometer, measure the height of the
rotor, vanes, control piston and cam ring in at least four
positions. (Measure the height at one place for each of
the nine vanes.)
NOTE:
Remove the control piston seals when measuring.
Remove the friction ring from the cam ring when mea-
suring.
G3M0451
(2) Using a depth gauge, measure the depth of the oil
pump housing from the contact/sliding surface of the
above mentioned component parts in the same manner
as above.
G3M0452
(3) Make sure that the clearances are within the speci-
fied wear limits. If the wear limit is exceeded, select
pump components so that the standard clearance can
be obtained.
Unit: mm (in)
Part name Wear limit Standard value
Rotor, control piston,
vanes0.054
(0.0021)0.030—0.044
(0.0012—0.0017)
Cam ring0.034
(0.0013)0.010—0.024
(0.0004—0.0009)
NOTE:
Select vanes which are the same height as the rotor.
G3M0453
C: ASSEMBLY
1) Coat both the O-ring and friction ring with vaseline and
attach to the cam ring. Then fit them into the oil pump
housing.
91
3-2SERVICE PROCEDURE
7. Oil Pump Assembly

G3M0454
2) Install the vane ring, rotor and vanes into the housing
in this sequence.
G3M0455
3) Install the return spring and retainer between the hous-
ing and cam ring.
G3M0456
4) Install the control piston to the oil pump housing.
NOTE:
Fit the seal in the piston groove, with the red seals facing
the top side. (Two side seals and one plain seal are
attached.)
5) Set the rotor at the center of the housing bore. Apply
ATF abundantly to each rotary portion.
G3M0446
6) Install the oil pump cover.
Tightening torque:
25±2 N⋅m (2.5±0.2 kg-m, 18.1±1.4 ft-lb)
NOTE:
Align both pivots with the pivot holes of the cover, and
install the cover being careful not to apply undue force to
the pivots.
After assembling, turn the oil pump shaft to check for
smooth rotation of the rotor.
G3M0449
NOTE:
Install the oil seal retainer and seal rings (R) and (H)
after adjusting the drive pinion backlash and tooth contact.
92
3-2SERVICE PROCEDURE
7. Oil Pump Assembly

G3M0458
8. Drive Pinion Shaft
A: DISASSEMBLY
1) Straighten the staked portion of the lock nut, and
remove the lock nut while locking the rear spline portion of
the shaft with ST1 and ST2. Then pull off the drive pinion
collar.
ST1 498937100 HOLDER
ST2 499787100 WRENCH
NOTE:
Remove the O-ring
G3M0459
2) Using a press, separate the rear roller bearing and
outer race from the shaft.
G3M0460
3) Using a press and ST, separate the front roller bearing
from the shaft.
ST 498517000 REPLACER
B: INSPECTION
Make sure that all component parts are free of harmful
cuts, gouges, and other faults.
93
3-2SERVICE PROCEDURE
8. Drive Pinion Shaft

G3M0461
C: ASSEMBLY
1) Measure dimension“A”of the drive pinion shaft.
G3M0462
2) Using a press, force-fit the roller bearing in position.
CAUTION:
Do not change the relative positions of the outer race
and bearing cone.
3) After fitting the O-ring to the shaft, attach the drive pin-
ion collar to the shaft.
CAUTION:
Be careful not to damage the O-ring.
G3M0908
4) Tighten the lock washer and lock nut with ST1.
ST1 498937100 HOLDER
Actual tightening torque:
113±5 N⋅m (11.5±0.5 kg-m, 83.2±3.6 ft-lb)
NOTE:
Pay attention to the orientation of lock washer.
Tightening torque using torque wrench is determined by
the following equation:
T
1=72.2L + 72.2xT
T: Actual tightening torque
Install ST2 to torque wrench as straight as possible.
ST2 499787100 WRENCH
G3M0464
5) Measure the starting torque of the bearing.
Make sure the starting torque is within the specified range.
If out of the allowable range, replace the roller bearing.
Starting torque:
0.3—2.0 N⋅m(3—20 kg-cm, 2.6—17.4 ft-lb)
94
3-2SERVICE PROCEDURE
8. Drive Pinion Shaft

G3M0465
6) Stake the lock nut securely at two places.
7) Measure dimension“B”of the drive pinion shaft.
8) Determine the thickness t (mm) of the drive pinion shim.
t = 6.5±0.0625 (B A)
NOTE:
The number of shims must be three or less.
Available drive pinion shimsPart No. Thickness mm (in)
31451AA050
31451AA060
31451AA070
31451AA080
31451AA090
31451AA1000.150 (0.0059)
0.175 (0.0069)
0.200 (0.0079)
0.225 (0.0089)
0.250 (0.0098)
0.275 (0.0108)
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3-2SERVICE PROCEDURE
8. Drive Pinion Shaft