SUBARU LEGACY 1996 Service Repair Manual

G3M0307
(6) Remove vehicle speed sensor 1.
G3M0308
(7) Remove extension and gasket.
Remove gear select cable nut.
Move gear select cable so that extension bolts can
be removed.
G3M0309
Remove bolts.
Remove extension and disconnect duty solenoid C
connector.
CAUTION:
Do not force extension back before disconnecting
solenoid connector. Otherwise, harness may be dam-
aged.
NOTE:
Use a container to catch oil flowing from extension.
G3M0310
(8) Remove duty solenoid C and transfer valve body
from extension.
Remove transfer clutch drum.
G3M0867
Remove clamp which secures pipe.
Remove bolts.
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2. On-Car Services

G3M0867
2) Installation
(1) Install duty solenoid C and transfer valve body.
Install duty solenoid C and transfer valve body.
Install pipe and clamp.
Tightening torque:
8±1 N⋅m (0.8±0.1 kg-m, 5.8±0.7 ft-lb)
Install clutch drum.
G3M0309
(2) Install extension.
Connect connector.
Tighten 11 bolts.
Tightening torque:
25±2 N⋅m (2.5±0.2 kg-m, 18.1±1.4 ft-lb)
G3M0308
Install gear select cable.
Tightening torque:
14±4 N⋅m (1.4±0.4 kg-m, 10.1±2.9 ft-lb)
G3M0307
(3) Install vehicle speed sensor 1.
Tightening torque:
7±1 N⋅m (0.7±0.1 kg-m, 5.1±0.7 ft-lb)
G3M0306
(4) Install rear crossmember.
Tighten bolts.
Tightening torque:
Crossmember to body
69±15 N⋅m (7.0±1.5 kg-m, 51±11 ft-lb)
Crossmember to cushion
18±5 N⋅m (1.8±0.5 kg-m, 13.0±3.6 ft-lb)
Lower and remove transmission jack.
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G3M0782
(5) Install propeller shaft.
Tightening torque:
At rear differential
23±5 N⋅m (2.3±0.5 kg-m, 16.6±3.6 ft-lb)
At center bearing
39±5 N⋅m (4.0±0.5 kg-m, 28.9±3.6 ft-lb)
NOTE:
Align matching marks on propeller shaft and rear differen-
tial coupling.
G3M0305
(6) Install front exhaust pipe
Tightening torque:
At engine
29±5 N⋅m (3.0±0.5 kg-m, 21.7±3.6 ft-lb)
At hanger
29±5 N⋅m (3.0±0.5 kg-m, 21.7±3.6 ft-lb)
At front and rear connections
18±5 N⋅m (1.8±0.5 kg-m, 13.0±3.6 ft-lb)
G3M0313
(7) Lower and remove jack.
(8) Connect the following parts:
Oxygen sensor connector
Multi-connector
G3M0304
(9) Install pitching stopper.
Tightening torque:
Body side
57±10 N⋅m (5.8±1.0 kg-m, 42±7 ft-lb)
Engine side
49±5 N⋅m (5.0±0.5 kg-m, 36.2±3.6 ft-lb)
G3M0282
(10) Replenish ATF and check oil level. Check for
leaks.
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2. On-Car Services

3. Performance Test
A: STALL TEST
1. GENERAL
The stall test is of extreme importance in diagnosing the
condition of the automatic transmission and the engine. It
should be conducted to measure the engine stall speeds in
all shift ranges except the P and N ranges.
Purposes of the stall test:
1) To check the operation of the automatic transmission
clutch.
2) To check the operation of the torque converter clutch.
3) To check engine performance.
2. TEST METHODS
Preparations before test:


1Check that throttle valve opens fully.


2Check that engine oil level is correct.


3Check that coolant level is correct.


4Check that ATF level is correct.


5Check that differential gear oil level is correct.


6Increase ATF temperature to 50 to 80°C (122 to 176°F)
by idling the engine for approximately 30 minutes (with
select lever set to“N”or“P”).
1) Install an engine tachometer at a location visible from
the driver’s compartment and mark the stall speed range
on the tachometer scale.
2) Place the wheel chocks at the front and rear of all
wheels and engage the parking brake.
3) Move the manual linkage to ensure it operates properly,
and shift the select lever to the 2 range.
B3M0286B
4) While forcibly depressing the foot brake pedal, gradu-
ally depress the accelerator pedal until the engine operates
at full throttle.
5) When the engine speed is stabilized, read that speed
quickly and release the accelerator pedal.
6) Shift the select lever to Neutral, and cool down the
engine by idling it for more than one minute.
7) Record the stall speed.
8) If stall speed in 2 range is higher than specifications,
forward clutch slipping on brake band slipping may occur.
To identify it, conduct the same test as above in D range.
9) Perform the stall tests with the select lever in the R
range.
CAUTION:
Do not continue the stall test for MORE THAN FIVE
SECONDS at a time (from closed throttle, fully open
throttle to stall speed reading). Failure to follow this
instruction causes the engine oil and ATF to deterio-
rate and the clutch and brake band to be adversely
affected.
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3-2SERVICE PROCEDURE
3. Performance Test

Be sure to cool down the engine for at least one minute
after each stall test with the select lever set in the P or
N range and with the idle speed lower than 1,200 rpm.
If the stall speed is higher than the specified range,
attempt to finish the stall test in as short a time as
possible, in order to prevent the automatic transmis-
sion from sustaining damage.
Specifications
Stall speed (at sea level):
2200 cc 2,300 — 2,700 rpm
2500 cc 2,200 — 2,600 rpm
2500 cc OUTBACK 2,400 — 2,800 rpm
3. EVALUATION
Stall speed
(at sea level)Position Cause
Less than specifications2
RThrottle valve not fully open
Erroneous engine operation
Torque converter clutch’s one-way clutch slipping
Greater than specificationsDForward clutch slipping
One-way clutch (1-2) malfunctioning
RLine pressure too low
Reverse clutch slipping
Low & reverse brake slipping
2Line pressure too low
Forward clutch slipping
Brake band slipping
One-way clutch (3-4) malfunctioning
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3. Performance Test

B: TIME LAG TEST
1. GENERAL
If the shift lever is shifted while the engine is idling, there
will be a certain time elapse or lag before the shock can be
felt. This is used for checking the condition of the forward
clutch, reverse clutch, low & reverse brake, forward one-
way clutch and low one-way clutch.
CAUTION:
Perform the test at normal operation fluid tempera-
ture 60 to 80°C (140 to 176°F).
Be sure to allow a one minute interval between tests.
Make three measurements and take the average
value.
2. TEST METHODS
1) Fully apply the parking brake.
2) Start the engine.
Check idling speed (A/C OFF).
“N”range: 800±100 rpm
3) Shift the shift lever from“N”to“D”range.
Using a stop watch, measure the time it takes from shift-
ing the lever until the shock is felt.
Time lag: Less than 1.2 seconds
4) In same manner, measure the time lag for“N”,“R”.
Time lag: Less than 1.5 seconds
3. EVALUATION
1) If“N”,“D”time lag is longer than specified:
Line pressure too low
Forward clutch worn
Low one-way clutch not operating properly
2) If“N”,“R”time lag is longer than specified:
Line pressure too low
Reverse clutch worn
Low & reverse brake worn
Forward one-way clutch not operating properly
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3. Performance Test

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. 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
2200 cc 2500 cc
51,147—1,344
(11.7—13.1, 166—195)1,275—1,569
(13.0—16.0, 185—228)—
22——765—902
(7.8—9.2, 111—131)
100——235—481
(2.4—4.9, 34—70)392—490
(4.0—5.0, 57—71)
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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. 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. Performance Test