engine SUBARU LEGACY 1997 Service Repair Manual

G2M0290
14) Remove exhaust system.
(1) Remove nuts which install front exhaust pipe onto
engine.
B2M0335
(2) Disconnect connector from rear oxygen sensor.
G2M0291
(3) Separate center exhaust pipe from rear exhaust
pipe.
B2M0313
(4) Remove bolt which installs center exhaust pipe to
hanger bracket.
(5) Take off front and center exhaust pipes.
G2M0315
(6) Remove rear exhaust pipe. (AWD model)
CAUTION:
When removing exhaust pipes, be careful each
exhaust pipe does not drop out.
32
2-11SERVICE PROCEDURE
3. Transmission

G2M0324
21) 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.
G2M0292
22) Remove nuts which hold lower side of transmission to
engine.
G2M0326
23) 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
24) Remove transmission rear crossmember.
MT model
35
2-11SERVICE PROCEDURE
3. Transmission

B2M1171
AT model
B2M0035
25) 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is withdrawn from clutch cover.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)
36
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.
Hydraulic clutch model
7. Install operating cylinder.
8. Remove special tools.
9. Install pitching stopper.
10. Install front drive shafts into transmission.
11. Install stabilizer clamps onto front crossmember.
12. Install gear shift rod and stay.

B











37
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)
B2M1172A
AT model
Tightening torque:
T1: 37±10 N⋅m (3.8±1.0 kg-m, 27±7 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)
39
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.
B2M1179B
7) Install operating cylinder. (Hydraulic clutch model)
Tightening torque:
37±3 N⋅m (3.8±0.3 kg-m, 27.5±2.2 ft-lb)
G2M0313
8) Remove special tools.
40
2-11SERVICE PROCEDURE
3. Transmission

G2M0382
(2) Install rear exhaust pipe to muffler. (AWD model)
Tightening torque:
48±9 N⋅m (4.9±0.9 kg-m, 35.4±6.5 ft-lb)
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)
43
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.
72
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.
73
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
OUTBACK 2.2 — 2.4
Nominal diameter2200 cc 236 mm (9.29 in)
2500 cc 246 mm (9.69 in)
Stall speed (at sea level)2200 cc 2,200 — 2,600 rpm
2500 cc 2,200 — 2,600 rpm
OUTBACK 2,300 — 2,700 rpm
One-way clutch Sprague type one-way clutch
Automatic
transmissionTransmissionType 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
clutchDrive plate & driven plate 2
Clutch number of
high clutchDrive plate & driven plate2200 cc ... 4
2500 cc ... 5
Clutch number of forward
clutchDrive plate & driven plate 5
Clutch number of
overrunning clutchDrive plate & driven plate 3
Clutch number of low &
reverse brakeDrive plate & driven plateExcept OUTBACK ... 5
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