sensor SUBARU LEGACY 1997 Service Repair Manual

G3M0367
2) Install and route the transmission harness.
CAUTION:
Be careful not to damage the harness.
B3M0418A
3) Install the control valve assembly.
(1) Set the select lever in range“2”.
(2) Install the two brackets, ATF temperature sensor
and the control valve by engaging the manual valve and
manual lever, then tighten the 17 bolts.
Tightening torque:
8±1 N⋅m (0.8±0.1 kg-m, 5.8±0.7 ft-lb)
CAUTION:
Be careful not to pinch the harness roll the gasket.
Tighten the control valve mounting bolts evenly.
B3M0419A
4) Install the oil strainer to the control valve. Be careful not
to cut or break the O-ring. Then tighten four bolts.
Tightening torque:
8±1 N⋅m (0.8±0.1 kg-m, 5.8±0.7 ft-lb)
B3M0420A
5) Secure four connectors.
75
3-2SERVICE PROCEDURE
4. Overall Transmission

G3M0894
3) Install the transfer clutch assembly to the case.
CAUTION:
Be careful not to damage the seal rings.
NOTE:
Insert the clutch assembly fully into position until the bear-
ing shoulder bottoms.
G3M0429
6. CONNECTION OF EACH SECTION
1) Install vehicle speed sensor 1 on transmission case.
[FWD only]
Tightening torque:
7±1 N⋅m (0.7±0.1 kg-m, 5.1±0.7 ft-lb)
2) Install oil pipe.
G3M0339
3) Install the reduction driven gear.
4) Install the parking pawl and shaft, set the select lever in
the“P”range and tighten the drive pinion lock nut.
Tightening torque:
98±5 N⋅m (10.0±0.5 kg-m, 72.3±3.6 ft-lb)
NOTE:
After tightening, stake the lock nut securely.
G3M0895
5) Install the reduction drive gear assembly.
CAUTION:
Align mark on reduction drive gear with mark on driven
gear during installation.
NOTE:
Insert it fully into position until the bearing shoulder bot-
toms.
G3M0430
6) Measurement and adjustment of extension end play
(1) Measure distance L from end of extension case and
rear drive shaft with ST. (On FWD models, measure
distance from end of case to point at bearing location.)
ST 398643600 GAUGE
Unit: mm
L = Measured value15
77
3-2SERVICE PROCEDURE
4. Overall Transmission

G3M0896
7) Installation of extension case (AWD), transmission
cover (FWD) and transmission case.
AWD model:
(1) Attach the selected thrust needle bearing to the end
surface of reduction drive gear with vaseline.
(2) Set the parking return spring.
(3) Remove the transfer clutch from the extension
case.
Set the needle bearing on the reduction drive shaft and
then install transfer clutch to the transfer clutch hub.
NOTE:
Be sure to engage the spline teeth correctly.
(4) With gasket inserted between them, install the
extension case to the transmission case.
CAUTION:
Be sure to use a new gasket.
After inserting the extension case halfway, connect
the connector for duty solenoid C. Be careful not to
jam the cord in the case.
Be careful not to damage the rear drive shaft seal
ring.
(5) Tighten bolts to secure the case.
Tightening torque:
25±2 N⋅m (2.5±0.2 kg-m, 18.1±1.4 ft-lb)
FWD model:
(1) Attach selected shim to transmission cover using
vaseline.
(2) Set the parking return spring.
(3) After positioning gasket, assemble transmission
cover and transmission case.
NOTE:
While aligning bearings, parking shaft, reduction driven
gear, etc. assemble the two cases.
(4) Tighten bolts.
Tightening torque:
25±2 N⋅m (2.5±0.2 kg-m, 18.1±1.4 ft-lb)
G3M0336
7. EXTERNAL PARTS
1) Install the vehicle speed sensor 1. (AWD only)
Tightening torque:
7±1 N⋅m (0.7±0.1 kg-m, 5.1±0.7 ft-lb)
79
3-2SERVICE PROCEDURE
4. Overall Transmission

4. Control Valve and Harness Routing
B3M0106A

1Stay


2Oil strainer


3Transmission harness


4O-ring


5Duty sol. A (Line pressure)


6Sol. ASSY


7Upper valve body


8Ball


9Upper separator gasket


10Lower separator gasket


11Lower valve body


12Duty sol. B (Lock-up)

13Pipe


14Bracket


15Bracket


16O-ring


17Vehicle speed sensor 1 (FWD only)


18Separator plate
Tightening torque: N⋅m (kg-m, ft-lb)
T1: 7±1 (0.7±0.1, 5.1±0.7)
T2: 8±1 (0.8±0.1, 5.8±0.7)
T3: 11.3±1.5 (1.15±0.15, 8.3±1.1)
13
3-2COMPONENT PARTS
4. Control Valve and Harness Routing

10. Transfer and Extension
B3M0375A

1Snap ring


2Pressure plate


3Drive plate


4Driven plate


5Thrust needle bearing


6Snap ring


7Spring retainer


8Lathe cut seal ring


9Transfer clutch piston


10Lathe cut seal ring


11Needle bearing


12Rear drive shaft


13Ball bearing

14Seal ring


15Vehicle speed sensor 1 (AWD only)


16Transfer clutch pipe


17Duty sol. C (Transfer clutch)


18Gasket


19Plate


20Filter


21Gasket


22Roller bearing


23Extension case


24Oil seal


25Dust seal


26Seal transfer piston

27O-ring


28Test plug


29O-ring


30Clip


31Transfer valve body


32Clip


33Stay
Tightening torque: N⋅m (kg-m, ft-lb)
T1: 7±1 (0.7±0.1, 5.1±0.7)
T2: 8±1 (0.8±0.1, 5.8±0.7)
T3: 13±1 (1.3±0.1, 9.4±0.7)
T4: 25±2 (2.5±0.2, 18.1±1.4)
20
3-2COMPONENT PARTS
10. Transfer and Extension

G3M0856
Oil pump housing
Oil pump housing (Defective casting)
O-ring on the test plugs
Checking blind plugs
Differential gear breather
G3M0857
Automatic transmission case
Transmission case (Defective casting)
Mating surface of oil pan
O-ring on the test plugs
Checking blind plugs (Steel balls)
Oil supply pipe connector
ATF cooler pipe connector and gasket
Oil pan drain plug
O-ring on the transmission harness holder
Oil pump plugs
ATF breather
Shift lever oil seal
G3M0858
Extension case
Extension case (Defective casting)
O-ring on the vehicle speed sensor
Rear drive shaft oil seal
Checking blind plugs (Steel ball)
O-ring on the test plugs
25
3-2SERVICE PROCEDURE
2. On-Car Service

G3M0293
(4) Check if there is continuity at equal points when the
select lever is turned 1.5°in both directions from the N
range.
If there is continuity in one direction and the continuity
in the other or if there is continuity at unequal points,
adjust the inhibitor switch.
G3M0294

(1) Loosen the three inhibitor switch securing bolts.
(2) Shift the select lever to the N range.
(3) Insert ST as vertical as possible into the holes in
the inhibitor switch lever and switch body.
ST 499267300 STOPPER PIN
(4) Tighten the three inhibitor switch bolts.
Tightening torque:
3.4±0.5 N⋅m (0.35±0.05 kg-m, 2.5±0.4 ft-lb)
(5) Repeat the above checks. If the inhibitor switch is
determined to be“faulty”, replace it.
G3M0295
3. SENSOR (IN TRANSMISSION)
Check each sensor, solenoid and ground system for short
circuits.
29
3-2SERVICE PROCEDURE
2. On-Car Service

Standard values
Part name Terminal Resistance (Ω)
Vehicle speed sensor 1 9—16 450—720
ATF temperature sensor 5—12 [2,100—2,900/20°C (68°F) 275—375/80°C (176°F)]
Duty solenoid A
(Line pressure solenoid)7—4, 8 1.5—4.5
Duty solenoid B
(Lock-up solenoid)6—4, 8 9—17
Shift solenoid 1 3—4, 8 20—32
Shift solenoid 2 2—4, 8 20—32
Shift solenoid 3 1—4, 8 20—32
Duty solenoid C (AWD only)
(Transfer clutch solenoid)11—4, 8 9—17
NOTE:
If part is faulty, its resistance value will be different from the
standard value indicated above.
B3M0112A
30
3-2SERVICE PROCEDURE
2. On-Car Service

G3M0304
2. DUTY SOLENOID C AND TRANSFER VALVE BODY
1) Removal
(1) Remove pitching stopper.
G3M0297
(2) Raise vehicle and drain ATF.
G3M0305
(3) Remove front exhaust pipe.
Disconnect oxygen sensor connector, and remove
exhaust pipe.
G3M0782
(4) Remove propeller shaft.
NOTE:
Before removing propeller shaft, scribe matching marks on
propeller shaft and rear differential coupling.
G3M0306
(5) Remove rear crossmember.
Support transmission using a transmission jack and
raise slightly.
Remove bolts and nuts as shown in Figure.
34
3-2SERVICE PROCEDURE
2. On-Car Service

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.
35
3-2SERVICE PROCEDURE
2. On-Car Service