transmission SUBARU LEGACY 1997 Service Repair Manual

Symptom and possible cause Remedy
5. Noises when cornering


1Damaged differential gear. Replace.


2Excessive wear or damage of thrust washer. Replace.


3Broken pinion mate shaft. Replace.


4Seized or damaged side bearing. Replace.
6. Gear noises
Since noises from engine, muffler, transmission, propeller shaft, wheel bearings, tires, and body are sometimes mistaken for noises
from differential assembly, be careful in checking them. Inspection methods to locate noises include coasting, accelerating, cruising,
and jacking-up all four wheels. Perform these inspections according to condition of trouble. When listening to noises, shift gears into
four wheel drive and fourth speed position, trying to pick up only differential noise.


1Improper tooth contact of hypoid gear. Readjust or replace hypoid gear set.


2Improper backlash for hypoid gear. Readjust.


3Scored or chipped teeth of hypoid gear. Replace hypoid gear set.


4Seized hypoid gear. Replace hypoid gear set.


5Improper preload for front or rear bearings. Readjust.


6Seized, scored, or chipped front or rear bearing. Replace.


7Seized, scored, or chipped side bearing. Replace.


8Vibrating differential carrier. Replace.
2. Propeller Shaft
Symptom and possible cause Remedy
1. Vibration of propeller shaft
Vibration is caused by propeller shaft during operation and is transferred to vehicle body. Generally vibration increase in proportion to
vehicle speed.


1Worn or damaged universal joint. Replace.


2Unbalanced propeller shaft due to bend or dent. Replace.


3Loose installation of propeller shaft. Retighten.


4Worn or damaged center bearing and damaged center mount-
ing rubber.Replace.
2. Tapping when starting and noise while cruising, caused by propeller shaft.


1Worn or damaged universal joint. Replace.


2Worn spline of sleeve yoke. Replace.


3Loose installation of propeller shaft. Retighten.


4Loose installation of joint. Replace.


5Worn or damaged center bearing and damaged center mount-
ing rubber.Replace.
NOTE:
Vibration while cruising may be caused by an unbalanced
tire, improper tire inflation pressure, improper wheel
alignment, etc.
41
3-4DIAGNOSTICS
1. Rear Differential - 2. Propeller Shaft

Symptom and possible cause Remedy
5. Noises when cornering


1Damaged differential gear. Replace.


2Excessive wear or damage of thrust washer. Replace.


3Broken pinion mate shaft. Replace.


4Seized or damaged side bearing. Replace.
6. Gear noises
Since noises from engine, muffler, transmission, propeller shaft, wheel bearings, tires, and body are sometimes mistaken for noises
from differential assembly, be careful in checking them. Inspection methods to locate noises include coasting, accelerating, cruising,
and jacking-up all four wheels. Perform these inspections according to condition of trouble. When listening to noises, shift gears into
four wheel drive and fourth speed position, trying to pick up only differential noise.


1Improper tooth contact of hypoid gear. Readjust or replace hypoid gear set.


2Improper backlash for hypoid gear. Readjust.


3Scored or chipped teeth of hypoid gear. Replace hypoid gear set.


4Seized hypoid gear. Replace hypoid gear set.


5Improper preload for front or rear bearings. Readjust.


6Seized, scored, or chipped front or rear bearing. Replace.


7Seized, scored, or chipped side bearing. Replace.


8Vibrating differential carrier. Replace.
2. Propeller Shaft
Symptom and possible cause Remedy
1. Vibration of propeller shaft
Vibration is caused by propeller shaft during operation and is transferred to vehicle body. Generally vibration increase in proportion to
vehicle speed.


1Worn or damaged universal joint. Replace.


2Unbalanced propeller shaft due to bend or dent. Replace.


3Loose installation of propeller shaft. Retighten.


4Worn or damaged center bearing and damaged center mount-
ing rubber.Replace.
2. Tapping when starting and noise while cruising, caused by propeller shaft.


1Worn or damaged universal joint. Replace.


2Worn spline of sleeve yoke. Replace.


3Loose installation of propeller shaft. Retighten.


4Loose installation of joint. Replace.


5Worn or damaged center bearing and damaged center mount-
ing rubber.Replace.
NOTE:
Vibration while cruising may be caused by an unbalanced
tire, improper tire inflation pressure, improper wheel
alignment, etc.
41
3-4DIAGNOSTICS
1. Rear Differential - 2. Propeller Shaft

G4M0529
1. FWD MODEL
1) Loosen wheel nuts. Lift-up vehicle and remove wheel.
2) Remove rear exhaust pipe and muffler.
3) Remove stabilizer link from rear lateral link.
4) Scribe an aligning mark on adjusting bolt, adjusting
wheel and crossmember.
5) Remove bolts securing lateral links to housing.
6) Turn cap (lateral link) counterclockwise until it contacts
stopper, then remove cap.
7) While holding adjusting bolt’s head with a wrench,
loosen self-locking nut.
CAUTION:
Always loosen self-locking nut before turning adjust-
ing bolt.
8) Lateral link removal
(1) Left lateral links
Remove adjusting bolt and front and rear lateral links.
(2) Right lateral links
Support crossmember with transmission jack.
Remove bolts securing crossmember to vehicle body.
Lower transmission jack until adjusting bolt can be
removed. Remove adjusting bolt, front and rear lateral
links.
2. AWD MODEL
1) Loosen wheel nuts. Lift-up vehicle and remove wheel.
2) Remove stabilizers link from lateral link.
3) Remove A.B.S. sensor harness from trailing link.
(A.B.S. equipped models.)
B4M0573A
4) Remove bolt securing trailing link to housing.
5) Remove DOJ from differential.
6) Scribe an alignment mark on rear lateral link adjusting
bolt and crossmember.
7) Remove bolt securing lateral link to housing.
8) Remove bolts securing front and rear lateral links to
crossmember, detach lateral links.
CAUTION:
To loosen adjusting bolt, always loosen nut while hold-
ing the head of adjusting bolt.
35
4-1SERVICE PROCEDURE
8. Lateral Link

G4M0544
5) Place transmission jack under rear crossmember.
G4M0545
6) Remove bolts securing crossmember to vehicle body,
and remove crossmember.
7) Scribe an alignment mark on rear lateral link cam bolt
and crossmember.
8) Remove four bolts securing front and rear lateral links
to crossmember by loosening nuts.
B: INSPECTION
Check removed parts for damage and cracks, and correct
or replace if defective.
C: INSTALLATION
1) Install in reverse order of removal.
2) For installation and tightening torque of rear differential,
refer to 3-4 [W2F0].
CAUTION:
Always tighten rubber bushing when wheels are in full
contact with the ground and vehicle is at curb weight
condition.
NOTE:
Check wheel alignment and adjust if necessary.
46
4-1SERVICE PROCEDURE
11. Rear Crossmember (AWD Model)

1. Front Axle
A: REMOVAL
1) Disconnect ground cable from battery.
2) Jack-up vehicle, support it with safety stands, and
remove front wheels.
G4M0214
3) Unlock axle nut.
4) Remove axle nut using a socket wrench.
CAUTION:
Be sure to loose and retighten axle nut after removing
wheel from vehicle. Failure to follow this rule may dam-
age wheel bearings.
G4M0215
5) Remove stabilizer link.
G4M0216
6) Remove DOJ from transmission spindle.
7) Remove front drive shaft assembly from hub. If it is hard
to remove, use STs.
ST1 926470000 AXLE SHAFT PULLER
ST2 927140000 PLATE
CAUTION:
Be careful not to damage oil seal lip when removing
front drive shaft.
When replacing front drive shaft, also replace inner
oil seal.
8) Remove disc brake caliper from housing, and suspend
it from strut using a wire.
9
4-2SERVICE PROCEDURE
1. Front Axle

Tightening torque:
186±20 N⋅m (19±2 kg-m, 137±14 ft-lb)
CAUTION:
Use a new axle nut.
Always tighten axle nut before installing wheel on
vehicle. If wheel is installed and comes in contact with
ground when axle nut is loose, wheel bearings may be
damaged.
Be sure to tighten axle nut to specified torque. Do
not overtighten it as this may damage wheel bearing.
12) Install O-ring to hub cap flange, and install hub cap by
lightly tapping it with a plastic-faced hammer.
13) Install wheel and tighten wheel nuts to specified
torque.
Tightening torque (Wheel nut):
88±10 N⋅m (9±1 kg-m, 65±7 ft-lb)
4. Front and Rear Drive Shafts
A: REMOVAL
1. FRONT DRIVE SHAFT
1) Disconnect ground cable from battery.
2) Jack-up vehicle, support it with safety stands (rigid
racks), and remove front wheel cap and wheels.
3) Unlock axle nut.
4) While depressing brake pedal, remove axle nut using a
socket wrench.
CAUTION:
Be sure to loosen and retighten axle nut after remov-
ing wheel from vehicle. Failure to follow this rule may
damage wheel bearings.
5) Disconnect stabilizer link from transverse link.
6) Disconnect transverse link from housing.
G4M0279
7) Remove spring pin which secures transmission spindle
to DOJ.
CAUTION:
Use a new spring pin.
28
4-2SERVICE PROCEDURE
3. Rear Axle (FWD) - 4. Front and Rear Drive Shafts

16) Cut off band with an allowance of about 10 mm (0.39
in) left from the clip and bend this allowance over the clip.
CAUTION:
Be careful to that the end of the band is in close con-
tact with clip.
17) Fix up boot on BJ in the same manner.
NOTE:
Extend and retract FTJ to provide equal grease coating.
G4M0291
E: INSTALLATION
1. FRONT DRIVE SHAFT
1) Insert UFJ (Under cut Free Joint) into hub splines.
CAUTION:
Be careful not to damage inner oil seal lip.
2) Using ST1 and ST2, pull drive shaft into place.
ST1 922431000 AXLE SHAFT INSTALLER
ST2 927390000 ADAPTER
CAUTION:
Do not hammer drive shaft when installing it.
3) Tighten axle nut temporarily.
G4M0279
4) Install DOJ on transmission spindle and drive spring pin
into place.
CAUTION:
Always use a new spring pin.
43
4-2SERVICE PROCEDURE
4. Front and Rear Drive Shafts

5. Replacement of Front DOJ and UFJ
Boots
A: REMOVAL
1) Disconnect ground cable from battery.
2) Jack-up vehicle, support it with safety stands (rigid
rocks), and remove front wheel cap and wheels.
NOTE:
Do not remove axle nut.
3) Remove stabilizer link.
4) Disconnect transverse link from housing.
G4M0279
5) Remove spring pin which secures transmission spindle
to DOJ.
CAUTION:
Use a new spring pin.
6) Remove DOJ and UFJ boot from drive shaft.

B: INSTALLATION
1) Install DOJ and UFJ boots to drive shaft.

G4M0279
2) Install DOJ on transmission spindle and drive spring pin
into place.
CAUTION:
Always use a new spring pin.
3) Connect transverse link to housing.
4) Install stabilizer link.
46
4-2SERVICE PROCEDURE
5. Replacement of Front DOJ and UFJ Boots

14. Replacement of Front FTJ and BJ
Boots
A: REMOVAL
1) Disconnect ground cable from battery.
2) Jack-up vehicle, support it with safety stands (rigid
rocks), and remove front wheel cap and wheels.
NOTE:
Do not remove axle nut.
3) Remove stabilizer link.
4) Disconnect transverse link from housing.
G4M0279
5) Remove spring pin which secures transmission spindle
to FTJ.
CAUTION:
Use a new spring pin.
6) Remove FTJ and BJ boot from drive shaft.

B: INSTALLATION
1) Install FTJ and BJ boots to drive shaft.

G4M0279
2) Install FTJ on transmission spindle and drive spring pin
into place.
CAUTION:
Always use a new spring pin.
3) Connect transverse link to housing.
4) Install stabilizer link.
53
4-2SERVICE PROCEDURE
14. Replacement of Front FTJ and BJ Boots

Whine or growl (continuous or
intermittent)
While engine is running with/
without steering turned.Loosened installation of oil pump,
oil pump bracketRetighten.
*8
Abnormal inside of oil pump, hoseReplace oil pump, hose, if the
noise can be heard when running
as well as stand still.
Torque converter growl
air conditioner compression growlRemove power steering pulley
belt and confirm.
Creaking noise (intermittent)
While engine is running with
steering turned.Abnormal inside of gearboxReplace bad parts of gearbox.
Abnormal bearing for steering
shaftApply grease or replace.
*9
Generates when turning steering
wheel with brake (service or park-
ing) applied.If the noise goes off when brake
is released, it is normal.
*10
Vibration
While engine is running with/
without steering turned.
Too low engine speed at startAdjust and instruct customers.
Vane pump aerationFix wrong part.
Vent air.
Damaged valve in oil pump, gear-
boxReplace oil pump, bad parts of
gearbox.
Looseness of play of steering,
suspension partsRetighten.
*8 Oil pump makes whine or growl noise slightly due to its mechanism. Even if the noise can be heard when steering wheel
is turned at stand still there is no abnormal function in the system provided that the noise eliminates when the vehicle is
running.
*9 When stopping with service brake and/or parking brake applied, power steering can be operated easily due to its light
steering effort. If doing so, the disk rotates slightly and makes creaking noise. The noise is generated by creaking between
the disk and pads. If the noise goes off when the brake is released, there is no abnormal function in the system.
*10 There may be a little vibration around the steering devices when turning steering wheel at standstill, even though the com-
ponent parts are properly adjusted and have no defects.
Hydraulic systems are likely to generate this kind of vibration as well as working noise and fluid noise because of com-
bined conditions, i.e., road surface and tire surface, engine speed and turning speed of steering wheel, fluid temperature
and braking condition.
This phenomena does not indicate there is some abnormal function in the system.
The vibration can be known when steering wheel is turned repeatedly at various speeds from slow to rapid step by step
with parking brake applied on concrete road and in“D”range for automatic transmission vehicle.
95
4-3DIAGNOSTICS
1. Power Steering