shift SUBARU LEGACY 1996 Service Owner's Manual

3-2[T7L0]
AUTOMATIC
TRANSMISSION
AND
DIFFERENTIAL

7
.
Diagnostic
Chart
with
Trouble
Code

1
.
Check
harness
connector
between
TCM
and

throttle
position
sensor
.

OK

2
.
Check
throttle
position
sensor
.

OK

1
3
.
Check
input
signal
for
TCM
.

Not
OK

4
.
Check
power
supply
tothrottle
position

sensor
.

OK

9
Repair
TCM
connector
terminal
poor
contact
.

e
Replace
TCM
.

Not
OK
j
Repair
or
replace
harnessconnectors
.

Not
OK
Replace
throttle
position
sensor
.

OK
~
9
Repair
TCM
connector
terminal
poor
contact
.

-~j9
Replace
TCM
.

Not
OK
,1
Repair
or
replace
harnessconnectors
.

E13

884
B84

112
34
U
56
U
78
U
171819
20
212223
24252627
28
2930
454647
48
49
50515253
1
54
1
55
1
5657
7172
73
74
757677787980
8182
83

L
:
TROUBLE
CODE
31

-
THROTTLE
POSITION
SENSOR
-

DIAGNOSIS
:

Input
signal
circuit
ofthrottle
position
sensor
is
open
or

shorted
.

TROUBLE
SYMPTOM
:

Shift
point
too
high
or
too
low
;
engine
brake
not
effected

in
"3"
range
;
excessive
shift
shock
;
excessive
tight
corner

"braking"

~~B56a~B54
821
E13

1234
12345678910
123456
1314151617181920
789101112
5678
9101112
1
23
1112

B2M0613

10

ON-BOARD
DIAGNOSTICS
11
SYSTEM
[T10A0]
2-7

10
.
Diagnostics
Chart
with
Trouble
Code

DTC

No
.

Abbreviation

(Subaru
select
monitor)Item
Page

P0500
VSP
Vehicle
speed
sensor
malfunction
'1

P0505
ISC
Idle
control
system
malfunction
`1

P0506
ISC
-
L
Idle
control
system
RPM
lower
than
expected
'1

P0507
ISC
-
H
Idle
control
system
RPM
higher
than
expected
'1

P0600
-
Serial
communication
link
malfunction
`1

P0601
RAM
Internal
control
module
memory
check
sum
error
'1

P0703
ATBRK
Brake
switch
input
malfunction
'1

P0705
ATRNG
Transmissionrange
sensor
circuit
malfunction
`1

P0710
ATF
Transmission
fluid
temperature
sensor
circuit
malfunction
'1

P0720
ATVSP
Output
speed
sensor
(vehicle
speed
sensor
1)
circuit
malfunction
'1

P0725
ATNE
Engine
speed
input
circuit
malfunction
'1

P0731
ATGR1
Gear
1
incorrect
ratio

P0732
ATGR2
Gear
2
incorrect
ratio
"
1
P0733
ATGR3
Gear
3
incorrect
ratio

P0734
ATGR4
Gear
4
incorrect
ratio

P0740
ATLU
-
F
Torque
converter
clutch
system
malfunction
1

P0743
ATLU
Torque
converter
clutch
system
electrical
*1

P0748
ATPL
Pressure
control
solenoid
electrical
'1

P0753
ATSFTi
Shift
solenoid
A
electrical
`1

P0758
ATSFT2
Shift
solenoid
B
electrical
'1

P0760
ATOVR
-
F
Shift
solenoid
C
malfunction
'1

P0763
ATOVR
Shift
solenoid
C
electrical
'1

P1100
ST-SW
Starter
switch
circuit
malfunction
'1

P1101
N/P
-
SW
Neutral
position
switch
circuit
malfunction
[MT
vehicles]
'1

P1101
N/P
-
SW
Neutral
position
switch
circuit
malfunction
[AT
vehicles]
1

P1102
BR
Pressure
sources
switching
solenoid
valve
circuit
malfunction
'1

P1103
TRQ
Engine
torque
control
signal
circuit
malfunction
`1

P1400
PCVSOL
Fueltank
pressure
control
solenoid
valve
circuit
malfunction
38

P1401
PCV
-
FFueltank
pressure
control
system
function
problem
44

P1402
FIVL
Fuel
level
sensor
circuit
malfunction
46

P1500
FAN
-
1
Radiator
fan
relay
1
circuit
malfunction
'1

P1502
FAN
-
F
Radiator
fan
function
problem
'1

P1700
ATTH
Throttle
position
sensor
circuit
malfunction
for
automatic
transmission
'1

P1701
ATCRS
Cruise
control
set
signal
circuit
malfunction
for
automatic
transmission
'1

P1702
ATDIAG
Automatic
transmission
diagnosis
inputsignal
circuit
malfunction
'1

P0461'2
EXERR22
Fuel
level
sensor
circuit
range/performance
problem
56

"1
:
<
Ref
.
to
2-7
[T11A0]
.*4
>

'2
:
Only
OBD-II
general
scan
tool
displays
DTC
.

6-3
IDso21
WIRING
DIAGRAM

6
.
Wiring
Diagram

6
.
Wiring
Diagram

2
.
GROUND
DISTRIBUTION

i26
Radio
Front
turn
signal
F3

and
sidemarker
z
light
RH

Cigarette
lighter
8~7
Mode
Flb
~
actuator

Subfan
motor
i
GR

f17

Main
fan
motor
11

Front
turn
signs
F~
and
sidemarker
light
LH

Turn
&
hazard
B32

module

Power
wind
relay

AT
shift
lock
control
module

B64
Seat
belt
timer[5
:ji

D66
Bleck>

2

(Brown)
i19
i1B

(B
I
e
C
K)
843

1
2
3456

B57
(g
I
ac
k)

123456
71319461111121

13

'D
2
box
iiio1vuemination
light
=
0
1
agnos
1
a
---B=
term
!
na
I

CD
E
T
B
Fan
switch

GB-7
L
+~
~
3
(9)Illumination
control
module

i
17
s
Mode
control
a
panel
-
om
FGS
L
O
oc
~
B71
3
e
Comb
i
nat
i
on

i18
C~'
sw
i
tch

Rear
defoggro0
switch

870
e
Combination
a
Cruise
control`-'switch
main
switch

b
:
i12
Combination
meter
emote
control
~
830
Combination
rearview
mirror
,
,switch
"J
switch

m
B39
B47
Mainrela
y

(B
r
own>

(B
r
own)
(~D(B
I
ack)

F1721
123
F1
f2T3-1
F1
r2
M
G31
M-
4
MS6
141516

(~~
(Brown)
(D

j

24
3
q
S6
1
23
F45T6
7
1
234
S678
PM
1
2
30
78

CD
(~D(Light
gray)
ill
Bleck>
F45
i4
(Blue)

123
456
12345678
234
6789
1
~~
7891011121314
12345678910111213141516
910111213141516
11
(21314151617181920

BUR04-03A

2

WIRING
DIAGRAM
[oso2i
6-3

6
.
Wiring
Diagram

GB-3

B3B
i3
i13
Comb
ination
'L~J
meter

B31
SRS
harness

BB
E
E
Frontwiper
[Uf
motor

4-6
GB-4
B9
FWD
sw
I
tch
CI
:~

816
Brakefluid
level
switch

Rear
Rear
finisherfinisher
light
LH
light
RH
049
8
D42
D4G
Lisence
plate
Iight
RH

D45
Lisence
plate
11ght
LH

043
Rearwipe
r
motor

048
Rear
defogge
r

R26
Rear
combination
LM
light
RH

R28
Rear
combination
LM
I(ght
LH

D46
Reargate
klatch
switch

R7
033R67

(B
I
ac
k)R6
i23
(BrowN
(B
I
ec
k)
B9
R25
(B
I
ec
k)
B16
(G
rey)
DB
(Gray)
D44045

21
2
12
1212

FI6
(B
I
ac
k)
B62D63R26
(B
I
ac
k)

039

12

BBB
(Black)

123

Fl7
(B
I
ac
k)
D49D42R2B
(B
I
ac
k)
(K)
(Y
e
11
ow)
(E)(9)
12
34
M1_2T3741
13141516
1
o23
N4
;5677
1
234
1
234
5
M67
8
R56
;7iR8

(B
I
8C
k)
(B
I
ac
K)
(Brown)

P
3141
56
789
1
F273
F1
4
6789
0151
7
89
1
2
34

161
2
314
0
1121314E
69
7181
1
11
1
12
1
314
51617
A
920

12

11112
314(51617
B4
02122
78

I
F1
34

161718
212223py

56

2~14

BUR04-03B

5
.
M
.
J
.
[Referto
foldout
page
.]
-
-
z~

B97
Rl

B92
Door
lock
module

B94
GB-8
Cruise
control
module

888
L=]
Evaporator
thermoswitch

R7

P
position
switch

R6

C
Shift
lock
solenoid

R46R67R58
Fuel
gauge
-e-C~umodule
&
fuel
pump

R25
LEE
Reardefogger
condenser

R23
-riPower
antenna
s1
-
~_5
GB-9

High-mounted
stop
light
D39
-12
m

R37

m4
D33

3

8
.
Electrical
Wiring
Harness
and
Ground
Point

Connector
Connecting
to

No
.
Pole
Color
Area
No
.
Name

R156
B-2
B97
Bulkhead
wiring
harness
(S
.M
.J
.)

R4
1
Black
B-2
Parking
brake
switch

R5
2B-2
Select
lever
illumination
light

R6
2
Black
B-2
Shift
lock
solenoid

R7
2B-2P
position
switch

RS
2B-2
Seat
belt
switch

R9
1
Brown
B-3Front
door
switch
LH

R11
8
B-4D21
Rear
doorcord
LH
R12
1
Brown
B-2
Front
door
switch
RH

R14
8
B-2
D27
Rear
door
cord
RH

R15
8B-3
R57
Fueltank
cord

R16
1
Brown
A-3
Rear
door
switch
RH

R30
2
Black
B-2
Diode
(Rear
gale
latch
switch)

R46
2
B3
R67
Fuel
lankcord

R50
2
Green
B-2
890
Bulkhead
wiring
harness

R52
2
A-3
Room
light

R57
S
B-3
R15
Rear
wiring
harness

R58
6
A-3
Fuel
gaugemodule
&
fuel
pump

R59
2
B-4
Fuel
gauge
submodule
R67
2
B-3
R46
Rear
wiring
harness

R68
2B-3
Pressure
control
solenoid
valve

R69
I
2
A-3
Vent
control
solenoid
valve

non-coiorea

A

B

C
n

6
.
REAR
WIRING
HARNESS
AND
GROUND
POINT

1
I
2
I
3
I
4
2
~S
4
[D806]

B6M0695A

A

B

C

u

8
.
Electrical
Wiring
Harness
and
Ground
Point

Connector
Connecting
to

No
.
Pole
Color
Area
No
.
Name

R156
B-2
B97
Bulkhead
wiring
harness
(S
.M
.J
.)

R4
1
Black
B-2
Parking
brake
switch

R5
2B-2
Select
lever
illumination
light

R6
2
Black
B-2
Shift
lock
solenoid

R7
2B-2P
position
switch

RS
2B-2
Seat
belt
switch

R9
1
Brown
B-3Front
door
switch
LH

R11
8
B-4D21
Rear
doorcord
LH
R12
1
Brown
B-2
Front
door
switch
RH

R14
8
B-2
D27
Rear
door
cord
RH

R15
8B-3
R57
Fueltank
cord

R16
1
Brown
A-3
Rear
door
switch
RH

R30
2
Black
B-2
Diode
(Rear
gale
latch
switch)

R46
2
B3
R67
Fuel
lankcord

R50
2
Green
B-2
890
Bulkhead
wiring
harness

R52
2
A-3
Room
light

R57
S
B-3
R15
Rear
wiring
harness

R58
6
A-3
Fuel
gaugemodule
&
fuel
pump

R59
2
B-4
Fuel
gauge
submodule
R67
2
B-3
R46
Rear
wiring
harness

R68
2B-3
Pressure
control
solenoid
valve

R69
I
2
A-3
Vent
control
solenoid
valve

non-coiorea

A

B

C
n

6
.
REAR
WIRING
HARNESS
AND
GROUND
POINT

1
I
2
I
3
I
4
2
~S
4
[D806]

B6M0695A

A

B

C

u

1. Clutch System
Condition Possible cause and testing Corrective action
1. Clutch slip-
pageIt is hard to perceive clutch slippage in the early stage, but pay attention to the following symptoms.
(a) Engine revs up when shifting.
(b) High speed driving is impossible; especially rapid acceleration impossible and vehicle speed does not increase in
proportion to an increase in engine speed.
(c) Power falls, particularly when ascending a slope, and there is a smell of burning of the clutch facing.
Method of testing: Put the vehicle in stationary condition with parking brake fully applied. Disengage the clutch and
shift the transmission gear into the first. Gradually allow the clutch to engage while gradually increasing the engine
speed. The clutch function is satisfactory if the engine stalls. However, the clutch is slipping if the vehicle does not
start off and the engine does not stall.
(a) No clutch pedal play Readjust.
(b) No release lever end play Readjust.
(c) Clutch facing smeared by oil Replace.
(d) Worn clutch facing Replace.
(e) Deteriorated diaphragm spring Replace.
(f ) Distorted pressure plate or flywheel Correct or replace.
(g) Defective release bearing holder Correct or replace.
(h) Defective pedal and cable system Correct or replace.
2. Clutch
drags.As a symptom of this trouble, a harsh scratching noise develops and control becomes quite difficult when shifting
gears. The symptom becomes more apparent when shifting into the first gear. However, because much trouble of the
this sort is due to defective synchronization mechanism, carry out the test as described after.
Method of testing: Refer to DIAGNOSTIC DIAGRAM on page after.
It may be judged as insufficient disengagement of clutch if any noise occurs during this test.
(a) Excessive clutch pedal play Readjust.
(b) Excessive clutch release lever play Readjust.
(c) Worn or rusty clutch disc hub spline Replace clutch disc.
(d) Excessive deflection of clutch disc facing Correct or replace.
(e) Seized crankshaft pilot needle bearing Replace.
(f ) Malfunction of pedal and cable system Correct or replace.
(g) Cracked clutch disc facing Replace.
(h) Sticked clutch disc (smeared by oil or water) Replace.
3. Clutch chat-
ters.Clutch chattering is an unpleasant vibration to the whole body when the vehicle is just started with clutch partially
engaged.
(a) Improper clutch cable routing Correct.
(b) Adhesion of oil on the facing Replace clutch disc.
(c) Weak or broken torsion spring Replace clutch disc.
(d) Defective facing contact or excessive disc Replace clutch disc defection.
(e) Warped pressure plate or flywheel Correct or replace.
(f ) Loose disc rivets Replace clutch disc.
(g) Loose engine mounting Retighten or replace mounting.
(h) Improper adjustment of pitching stopper Adjustment.
11
2-10DIAGNOSTICS
1. Clutch System

1. DIAGNOSTIC DIAGRAM OF CLUTCH DRAG
Test (1)
Disengage the clutch and shift quickly from neutral to reverse in idling condition.
Gear noise
Ye s
No
Sufficient disengagement of clutch
Test (2)
Shift to reverse after 0.5 to 1.0 sec of clutch disengagement.
Gear noise
Ye s
No
Defective transmission
or excessive clutch drag torque
[Cause]
1. Defective pilot bearing
2. Excessive disc deflection
3. Defective transmission
4. Defective clutch disc hub spline
Test (3)
Shift the gear N,R several times during disengaging clutch as test (2).
Gear noise
Ye s
No
Sticked clutch disc
[Cause]
1. Clutch disc smeared by oil
2. Clutch disc smeared by rust
3. Defective clutch disc hub spline
Clutch drags.
[Cause]
1. Cracked clutch disc facing
2. Damaged or worn clutch cover
3. Malfunction of clutch release system
4. Insufficient clutch release amount
5. Excessive clutch pedal play






13
2-10DIAGNOSTICS
1. Clutch System

A
16. Remove gear shift rod and stay from transmission.
17. Remove shift selector cable.
18. Remove bolts which install stabilizer clamp onto
crossmember.
19. Remove front drive shaft from transmission.
20. Remove nuts which hold lower side of transmission to
engine.
21. Place transmission jack under transmission.
22. Remove transmission rear crossmember.
23. Remove transmission.








28
2-11SERVICE PROCEDURE
3. Transmission

G3M0697
16) Remove gear shift rod and stay from transmission.
(MT model)
(1) Remove spring.
(2) Disconnect stay from transmission.
(3) Disconnect rod from transmission.
B2M0033A
17) Remove shift selector cable. (AT model)
(1) Disconnect shift selector cable from selector
lever.
(2) Remove cable bracket from body.
G2M0323
18) Remove bolts which install stabilizer clamps onto
crossmember.
G2M0324
19) Remove front drive shafts from transmission.
(1) Remove transverse link from housing.
(2) Lower transverse link.
G2M0325
(3) Remove spring pins and separate front drive shafts
from each side of the transmission.
CAUTION:
Discard removing spring pin. Replace with a new one.
34
2-11SERVICE PROCEDURE
3. Transmission