engine SUBARU LEGACY 1996 Service Repair Manual

G2M0312
9) Remove transmission connector holder bracket.
G2M0313
10) Set ST.
ST 41099AA020 ENGINE SUPPORT ASSY
NOTE:
Also is available Part No. 927670000.
G2M0299
11) Remove bolt which holds right upper side of transmis-
sion to engine.
G2M0290
12) Remove exhaust system.
(1) Lift-up the vehicle.
(2) Remove nuts which install front exhaust pipe onto
engine.
B2M0335
(3) Disconnect connector from rear oxygen sensor.
31
2-11SERVICE PROCEDURE
3. Transmission

G2M0292
20) Remove nuts which hold lower side of transmission to
engine.
G2M0326
21) Place transmission jack under transmission.
CAUTION:
Always support transmission case with a transmis-
sion jack.
On AT model, make sure that the support plates of
transmission jack don’t touch the oil pan.
G2M0831
22) Remove transmission rear crossmember.
MT model
G2M0583
AT model
B2M0035
23) Remove transmission.
CAUTION:
Move transmission jack toward rear until mainshaft
is withdrawn from clutch cover. (MT model)
Move transmission and torque converter as a unit
away from engine. (AT model)
35
2-11SERVICE PROCEDURE
3. Transmission

B: INSTALLATION
1. Install transmission to engine.
2. Install transmission rear crossmember.
3. Take off transmission jack.
4. Tighten nuts which hold lower side of transmission to engine.
5. Tighten bolt which holds right upper side of transmission to
engine.
AT model
6. Install torque converter to drive plate.
7. Remove special tools.
8. Install pitching stopper.
9. Install front drive shafts into transmission.
10. Install stabilizer clamps onto front crossmember.
11. Install gear shift rod and stay.

B










36
2-11SERVICE PROCEDURE
3. Transmission

B2M0035
1) Install transmission onto engine.
(1) Gradually raise transmission with transmission
jack.
(2) Engage them at splines.
CAUTION:
Be careful not to strike mainshaft against clutch cover.
(MT model)
G2M0832
2) Install transmission rear crossmember.
MT model
Tightening torque:
T1: 69±15 N⋅m (7.0±1.5 kg-m, 51±11 ft-lb)
T2: 137±20 N⋅m (14±2 kg-m, 101±14 ft-lb)
G2M0332
AT model
Tightening torque:
T1: 18±5 N⋅m (1.8±0.5 kg-m, 13.0±3.6 ft-lb)
T2: 69±15 N⋅m (7.0±1.5 kg-m, 51±11 ft-lb)
G2M0292
3) Take off transmission jack.
4) Tighten nuts which hold lower side of transmission to
engine.
Tightening torque:
50±4 N⋅m (5.1±0.4 kg-m, 36.9±2.9 ft-lb)
G2M0299
5) Tighten bolt which holds right upper side of transmis-
sion to engine.
Tightening torque:
50±4 N⋅m (5.1±0.4 kg-m, 36.9±2.9 ft-lb)
38
2-11SERVICE PROCEDURE
3. Transmission

G2M0294
6) Install torque converter to drive plate. (AT model)
(1) Tighten bolts which hold torque converter to drive
plate.
(2) Tighten other bolts while rotating the engine by
using ST.
ST 499977000 CRANK PULLEY WRENCH
CAUTION:
Be careful not to drop bolts into torque converter
housing.
Tightening torque:
25±2 N⋅m (2.5±0.2 kg-m, 18.1±1.4 ft-lb)
(3) Clog plug onto service hole.
B2M0017
(4) Install V-belt cover.
G2M0313
7) Remove special tools.
G2M0302
8) Install pitching stopper.
Tightening torque:
T1: 49±5 N⋅m (5.0±0.5 kg-m, 36.2±3.6 ft-lb)
T2: 57±10 N⋅m (5.8±1.0 kg-m, 42±7 ft-lb)
39
2-11SERVICE PROCEDURE
3. Transmission

B2M0032
(3) Install hanger bracket on right side of transmission.
(AWD model)
G2M0290
(4) Install front exhaust pipe onto engine.
Tightening torque:
30±5 N⋅m (3.1±0.5 kg-m, 22.4±3.6 ft-lb)
G2M0291
(5) Install center exhaust pipe to rear exhaust pipe.
Tightening torque:
18±5 N⋅m (1.8±0.5 kg-m, 13.0±3.6 ft-lb)
B2M0313
(6) Tighten bolt which installs center exhaust pipe to
hanger bracket.
Tightening torque:
30±5 N⋅m (3.1±0.5 kg-m, 22.4±3.6 ft-lb)
B2M0335
(7) Connect connector to rear oxygen sensor.
42
2-11SERVICE PROCEDURE
3. Transmission

1. Manual Transmission and
Differential
Symptom and possible cause Remedy
1. Gears are difficult to intermesh.
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 transmission. 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 gears Replace.
(c) Worn or scratched bushings Replace.
(d) Incorrect contact between synchronizer ring and gear
cone or wearCorrect or replace.
2. Gear slips out.
(1) Gear slips out when coasting on rough road.
(2) Gear 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 spring Replace.
(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 race Replace.
(h) Worn 2nd driven gear, needle bearing and race Replace.
(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 transmission.
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 bearings Replace.
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.
69
3-1DIAGNOSTICS
1. Manual Transmission and Differential

Symptom and possible cause Remedy
4. Broken differential (case, gear, bearing, etc.)
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 broken components and
at the same time check other components for any trouble,
and replace if necessary.
(b) Use of vehicle under severe conditions such as excessive
load and improper use of clutchReadjust bearing preload and backlash and face contact of
gears.
(c) Improper adjustment of taper roller bearing Adjust.
(d) Improper adjustment of drive pinion and hypoid driven
gearAdjust.
(e) Excessive backlash due to worn differential side gear,
washer or differential pinionAdd recommended oil to specified level. Do not use vehicle
under severe operating conditions.
(f) Loose hypoid driven gear clamping bolts Tighten.
5. 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.
(1) Gear noise when driving: If noise increases as vehicle speed increases it may be due to insufficient gear oil, incorrect
gear engagement, damaged gears, etc.
(2) Gear noise when coasting: Damaged gears due to maladjusted bearings and incorrect shim adjustment
(3) Bearing noise when driving or when coasting: Cracked, broken or damaged bearings
(4) Noise which mainly occurs when turning: 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 pinion Replace as a set.
Readjust bearing preload.
(d) Loose roller bearing Readjust hypoid driven gear to drive pinion backlash and
check tooth contact.
(e) Distorted hypoid driven gear or differential case Replace.
(f) Worn washer and differential pinion shaft Replace.
70
3-1DIAGNOSTICS
1. Manual Transmission and Differential

1. Automatic Transmission and
Differential
A: SPECIFICATIONS
Torque
converter
clutchType Symmetric, 3 element, single stage, 2 phase torque converter clutch coupling
Stall torque ratio2200 cc 2.1 — 2.3
2500 cc 1.8 — 2.0
2500 cc
OUTBACK2.2—2.4
Nominal diameter2200 cc 236 mm (9.29 in)
2500 cc 246 mm (9.69 in)
Stall speed (at sea level)2200 cc 2,300 — 2,700 rpm
2500 cc 2,200 — 2,600 rpm
2500 cc
OUTBACK2,400 — 2,800 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 4 sets
Multi-plate brake 1 set
Band brake 1 set
One-way clutch (sprague type) 2 sets
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
2500 cc 37
Rear pinion2200 cc 17
2500 cc 19
Rear internal gear 75
Clutch number of reverse clutch Drive plate & driven plate 2
Clutch number of high clutch Drive plate & driven plate2200 cc ... 4
2500 cc ... 5
Clutch number of forward clutch Drive plate & driven plate 5
Clutch number of overrunning
clutchDrive plate & driven plate 3
Clutch number of low & reverse
brakeDrive plate & driven plateExcept 2500 cc OUTBACK ...
5
2500 cc OUTBACK ... 6
Selector positionP (Park)Transmission in neutral, output
member 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 possible
4th,3rd,2nd)
1 (1st)1st gear locked
(Deceleration possible
4th,3rd,2nd,1st)
Control method Hydraulic remote control
2
3-2SPECIFICATIONS AND SERVICE DATA
1. Automatic Transmission and Differential

Automatic
transmis-
sionOil pumpType Variable-capacity type vane pump
Driving method Driven by engine
Number of vanes 9 pieces
Hydraulic
controlTypeElectronic/hydraulic control
[Four forward speed changes by
electrical signals of car speed and
accelerator (throttle) opening]
FluidDexron II or Dexron III type Automatic
transmission fluid
Fluid capacity2200 cc 7.9(8.4 US qt, 7.0 Imp qt)
2500 cc 9.5(10.0 US qt, 8.4 Imp qt)
LubricationLubrication system Forced feed lubrication with oil pump
OilAutomatic transmission fluid (above
mentioned.)
Cooling Cooling systemLiquid-cooled cooler incorporated in
radiator
HarnessInhibitor switch 12 poles
Transmission harnessFWD ... 11 poles
AWD ... 13 poles
TransferTransfer clutch Hydraulic multi-plate clutch
Clutch number of transfer clutchDrive plate &
driven plate5
Control method Electronic, hydraulic type
LubricantThe same Automatic Transmission
Fluid used in automatic transmission.
1st reduction gear ratio 1.000 (53/53)
Final
reductionFinal gear
ratioFront driveFWD 3.900 (39/10)
AWD2200 cc 4.111 (37/9)
2500 cc 4.444 (40/9)
Speedometer gear ratio2200 cc & 2500 cc 0.83 (19/23)
2500 cc OUTBACK 0.76 (19/25)
Lubrication oilAPI, GL-5
Oil
capacityFront drive 1.2(1.3 US qt, 1.1 Imp qt)
AT F
cooling
systemRadiation capacity 1.651 kW (1,420 kcal/h, 5,635 BTU/h)
3
3-2SPECIFICATIONS AND SERVICE DATA
1. Automatic Transmission and Differential