SUBARU LEGACY 1996 Service Repair Manual

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)
95
3-2SERVICE PROCEDURE
8. Drive Pinion Shaft

9. Reverse Clutch
G3M0909

1Reverse clutch drum


2Lip seal


3Reverse clutch piston


4Lathe cut seal ring


5Spring


6Spring retainer


7Snap ring

8Dish plate


9Driven plate


10Drive plate


11Retaining plate


12Snap ring


13High clutch drum
A: DISASSEMBLY
1) Remove the snap ring
12, and take out the retaining
plate

11, drive plates
10, driven plates
9, and dish plate
8.
2) Using the ST1, ST2 and ST3, remove the snap ring

7
and take out the spring retainer
6and springs
5.
ST1 398673600 COMPRESSOR
ST2 398177700 INSTALLER
ST3 399893600 PLIERS
3) Take out the piston

3by applying compressed air.
B: INSPECTION
1) Drive plate facing for wear and damage
2) Snap ring for wear, return spring for breakage or setting,
and spring retainer for deformation
3) Lip seal and lathe cut seal ring for damage
4) Piston check ball for operation
96
3-2SERVICE PROCEDURE
9. Reverse Clutch

C: ASSEMBLY
G3M0909

1Reverse clutch drum


2Lip seal


3Reverse clutch piston


4Lathe cut seal ring

5Spring


6Spring retainer


7Snap ring

8Dish plate


9Driven plate


10Drive plate

11Retaining plate


12Snap ring


13High clutch drum
1) Using the ST1, ST2 and ST3 as those used in
disassembling, assemble piston

3the springs
5, spring
retainer

6and snap ring
7.
ST1 398673600 COMPRESSOR
ST2 398177700 INSTALLER
ST3 399893600 PLIERS
2) Assemble the dish plate

8, driven plates
9, drive
plates

10and retaining plate
11in that order and attach the
snap ring

12.
NOTE:
Pay attention to the orientation of the dish plate.
3) Checking operation:
Apply compressed air intermittently to the oil hole, and
check the reverse clutch for smooth operation.
4) Measuring clearance (Retaining plate selection):
Standard value:
0.5—0.8 mm (0.020—0.031 in)
Allowable limit:
1.2 mm (0.047 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)
31567AA350
31567AA360
31567AA370
31567AA380
31567AA390
31567AA4004.6 (0.181)
4.8 (0.189)
5.0 (0.197)
5.2 (0.205)
5.4 (0.213)
5.6 (0.220)
97
3-2SERVICE PROCEDURE
9. Reverse Clutch

10. High Clutch
G3M0469

1High clutch drum


2Lathe cut seal ring


3High clutch piston


4Lathe cut seal ring


5Spring retainer


6Snap ring


7Driven plate (Thinner)

8Drive plate


9Driven plate (Thicker)


10Retaining plate


11Snap ring


12Thrust needle bearing


13High clutch hub
A: DISASSEMBLY
1) Remove the snap ring
11, and take out the retaining
plate

10, drive plates
8, and driven plates
7,
9.
2) Using the ST1, ST2 and ST3, remove the snap ring

6
and take out the spring retainer
5.
ST1 398673600 COMPRESSOR
ST2 398177700 INSTALLER
ST3 399893600 PLIERS
3) Apply compressed air to the clutch drum

1to remove
the piston

3.
B: INSPECTION
1) Drive plate facing for wear and damage
2) Snap ring for wear, return spring for setting and
breakage, and spring retainer for deformation
3) Lathe cut seal rings (large) (small) for damage
4) Piston check ball for smooth operation
98
3-2SERVICE PROCEDURE
10. High Clutch

C: ASSEMBLY
G3M0469

1High clutch drum


2Lathe cut seal ring


3High clutch piston


4Lathe cut seal ring


5Spring retainer


6Snap ring


7Driven plate (Thinner)

8Drive plate


9Driven plate (Thicker)


10Retaining plate


11Snap ring


12Thrust needle bearing


13High clutch hub
1) Using the ST1, ST2 and ST3 as those used in
disassembling, assemble the piston

3, spring retainer
5,
and snap ring

6.
ST1 398673600 COMPRESSOR
ST2 398177700 INSTALLER
ST3 399893600 PLIERS
2) Install the driven plate (thinner)

7, drive plates
8,
driven plates (thicker)

9, and retaining plate
10in that order.
Then attach the snap ring

11.
3) Checking operation:
Apply compressed air intermittently to the oil hole, and
check the high clutch for smooth operation.
4) Measuring clearance (Retaining plate selection):
Standard value:
1.8—2.2 mm (0.071—0.087 in)
Allowable limit:
2.6 mm (0.102 in)
NOTE:
Before measuring clearance, place the same thickness of
shim on both sides to prevent retaining plate from tilting.
99
3-2SERVICE PROCEDURE
10. High Clutch

Available retaining platesPart No. Thickness mm (in)
31567AA190
31567AA200
31567AA210
31567AA220
31567AA230
31567AA240
31567AA250
31567AA2603.6 (0.142)
3.8 (0.150)
4.0 (0.157)
4.2 (0.165)
4.4 (0.173)
4.6 (0.181)
4.8 (0.189)
5.0 (0.197)
G3M0471
11. Forward Clutch Drum
A: DISASSEMBLY
1) Remove two snap rings from the forward clutch drum.
2) Remove the retaining plate, drive plates, driven plates
and dish plate. (Forward clutch)
G3M0472
3) Remove the snap ring from the forward clutch drum.
4) Remove the retaining plate, drive plates, driven plates
and dish plate. (Overrunning clutch)
G3M0473
5) Compress the spring retainer, and remove the snap ring
from the forward clutch, by using ST1 and ST2.
ST1 498627100 SEAT
ST2 398673600 COMPRESSOR
G3M0474
6) Install the one-way clutch inner race to the forward
clutch drum, and apply compressed air to remove the over-
running piston and forward piston.
100
3-2SERVICE PROCEDURE
10. High Clutch - 11. Forward Clutch Drum

Available retaining platesPart No. Thickness mm (in)
31567AA190
31567AA200
31567AA210
31567AA220
31567AA230
31567AA240
31567AA250
31567AA2603.6 (0.142)
3.8 (0.150)
4.0 (0.157)
4.2 (0.165)
4.4 (0.173)
4.6 (0.181)
4.8 (0.189)
5.0 (0.197)
G3M0471
11. Forward Clutch Drum
A: DISASSEMBLY
1) Remove two snap rings from the forward clutch drum.
2) Remove the retaining plate, drive plates, driven plates
and dish plate. (Forward clutch)
G3M0472
3) Remove the snap ring from the forward clutch drum.
4) Remove the retaining plate, drive plates, driven plates
and dish plate. (Overrunning clutch)
G3M0473
5) Compress the spring retainer, and remove the snap ring
from the forward clutch, by using ST1 and ST2.
ST1 498627100 SEAT
ST2 398673600 COMPRESSOR
G3M0474
6) Install the one-way clutch inner race to the forward
clutch drum, and apply compressed air to remove the over-
running piston and forward piston.
100
3-2SERVICE PROCEDURE
10. High Clutch - 11. Forward Clutch Drum

G3M0475
7) Remove the one-way clutch after taking out the snap
ring.
G3M0476
8) Remove the needle bearing after taking out the snap
ring.
B: INSPECTION
1) Drive plate facing for wear and damage
2) Snap ring for wear, return spring for setting and
breakage, and snap ring retainer for deformation
3) Lip seal and lathe cut ring for damage
4) Piston and drum check ball for operation
101
3-2SERVICE PROCEDURE
11. Forward Clutch Drum

C: ASSEMBLY
B3H0014

1Snap ring


2Retainer


3Lathe cut seal ring


4Dish plate


5Snap ring


6Snap ring


7Retaining plate


8Dish plate


9Snap ring


10Retaining plate

11Forward clutch piston


12Lathe cut seal ring


13Drift ball


14Forward clutch drum


15Overrunning clutch piston


16Snap ring


17Plate


18O.W.C. (1-2)


19Needle bearing


20Lathe cut seal ring

21Snap ring


22Outer race


23Driven plate


24Driven plate (Thicker)


25Driven plate (Thinner)


26Drive plate


27Drive plate


28Sleeve


29Bushing
G3M0478
1) Fit the forward piston and overrunning piston to the for-
ward clutch drum.
NOTE:
Align the forward piston cut-out portion with the spline of
the drum.
102
3-2SERVICE PROCEDURE
11. Forward Clutch Drum