transmission SUBARU LEGACY 1997 Service Repair Manual

9. BREAKAGE OF HOSES
Pressure hose burstExcessive holding time of relief
statusInstruct customers.
Malfunction of relief valveReplace oil pump.
Poor cold characteristic of fluidReplace fluid.
Forced out return hosePoor connectionCorrect.
Poor holding of clipRetighten.
Poor cold characteristic of fluidReplace fluid.
Fluid bleeding out of hose slightlyWrong layout, tensionedReplace hose.
Excessive play of engine due to
deterioration of engine mounting
rubberReplace defective parts.
Improper stop position of pitching
stopperReplace defective parts.
*11
Crack on hose
Excessive holding time of relief
statusReplace.
Instruct customer.
Excessive tightening torque for
return hose clipReplace.
Power steering fluid, brake fluid,
engine oil, electrolyte adhere on
the hose surfaceReplace.
Pay attention on service work.
Too many times use in extremely
cold weatherReplace.
Instruct customers.
*11 Although surface layer materials of rubber hoses have excellent weathering resistance, heat resistance and resistance for
low temperature brittleness, they are likely to be damaged chemically by brake fluid, battery electrolyte, engine oil and
automatic transmission fluid and their service lives are to be very shortened. It is very important to keep the hoses free
from before mentioned fluids and to wipe out immediately when the hoses are adhered with the fluids.
Since resistances for heat or low temperature brittleness are gradually declining according to time accumulation of hot or
cold conditions for the hoses and their service lives are shortening accordingly, it is necessary to perform careful inspec-
tion frequently when the vehicle is used in hot weather areas, cold weather area and/or a driving condition in which many
steering operations are required in short time. Particularly continuous work of relief valve over 5 seconds causes to reduce
service lives of the hoses, the oil pump, the fluid, etc. due to over heat.
So, avoid to keep this kind of condition when servicing as well as driving.
98
4-3DIAGNOSTICS
1. Power Steering

Model 4 Door Sedan Wagon
Engine (cc) 2200 2200
Driving system FWD AWD FWD AWD
LLLSLLLS
Hill holder—
——
—
Parking
brakeType Mechanical on rear brakes, drum in disc
Effective drum diameter
mm (in)170 (6.69)
Lining dimensions
(length x width x thickness)
mm (in)162.6 x 30.0 x 3.2 (6.40 x 1.181 x 0.126)
Clearance adjustment Manual adjustment
Master
cylinderType Tandem
Effective diameter
mm (in)26.99 (1-1/16)
Reservoir type Sealed type
Brake fluid reservoir capacity
cm
3(cu in)190 (11.59)
Brake
boosterType Vacuum suspended
Effective diameter
mm (in)205 + 230 (8.07 + 9.06)
Proportioning
valveSplit point
kPa (kg/cm
2, psi)2,942 (30.0, 427)
Reducing ratio 0.3
Brake line Dual circuit system
ABS—OP STD—OP STD
ABS/TCS OP—OP—

: Equipped on manual transmission vehicle. (Except TCS model)
4
4-4SPECIFICATIONS AND SERVICE DATA
1. Brakes

Model Sedan Wagon
Engine (cc) 2200
Driving system FWD AWD FWD AWD
L L L POST BRIGHTON L
Hill holder

———

Parking
brakeType Mechanical on rear brakes, drum in disc
Effective drum diameter
mm (in)228.6 (9)
Lining dimensions
(length x width x thickness)
mm (in)218.8 x 35.0 x 4.1 (8.61 x 1.378 x 0.161)
Clearance adjustment Automatic adjustment
Master
cylinderType Tandem
Effective diameter
mm (in)23.81 (15/16)
Reservoir type Sealed type
Brake fluid reservoir capacity
cm
3(cu in)190 (11.59)
Brake
boosterType Vacuum suspended
Effective diameter
mm (in)230 (9.06)
Proportioning
valveSplit point
kPa (kg/cm
2, psi)3,678 (37.5, 533)
Reducing ratio 0.3
Brake line Dual circuit system

: Equipped on manual transmission vehicle.
6
4-4SPECIFICATIONS AND SERVICE DATA
1. Brakes

B: INSPECTION
1) Check connected and fixed condition of connector.
2) Check valve relay and motor relay for discontinuity or
short circuits.
Condition Terminal number Standard Diagram Terminal location
Valve relayTurning off
electricity.85—86 103±10Ω
G4M0456G4M0457
30—87a less than 0.5Ω
30—87 less than 1 MΩ
Turning on
electricity between
85 and 86.
(DC 12 V)30—87a more than 1 MΩ
30—87 less than 0.5Ω
Motor relayTurning off
electricity.85—86 80±8Ω
G4M0458G4M0459
30—87 more than 1 MΩ
Turning on
electricity between
85 and 86.
(DC 12 V)30—87 less than 0.5Ω
C: CHECKING THE HYDRAULIC UNIT ABS
OPERATION
1. CHECKING THE HYDRAULIC UNIT ABS
OPERATION BY PRESSURE GAUGE
1) Lift-up vehicle and remove wheels.
2) Disconnect the air bleeder screws from the FL and FR
caliper bodies.
B4M0633A
3) Connect two pressure gauges to the FL and FR caliper
bodies.
CAUTION:

Pressure gauges used exclusively for brake fluid
must be used.

Do not employ pressure gauge previously used for
transmission since the piston seal is expanded which
may lead to malfunction of the brake.
NOTE:
Wrap sealing tape around the pressure gauge.
80
4-4SERVICE PROCEDURE
15. Hydraulic Unit for ABS System (ABS 5.3 Type)

C: CHECKING THE HYDRAULIC UNIT ABS
OPERATION
1. CHECKING THE HYDRAULIC UNIT ABS
OPERATION BY PRESSURE GAUGE
1) Lift-up vehicle and remove wheels.
2) Disconnect the air bleeder screws from the FL and FR
caliper bodies.
B4M0633A
3) Connect two pressure gauges to the FL and FR caliper
bodies.
CAUTION:

Pressure gauges used exclusively for brake fluid
must be used.

Do not employ pressure gauge previously used for
transmission since the piston seal is expanded which
may lead to malfunction of the brake.
NOTE:
Wrap sealing tape around the pressure gauge.
4) Bleed air from the pressure gauges.
5) Perform ABS sequence control.
6) When the hydraulic unit begins to work, and first the FL
side performs decompression, holding, and compression,
and then the FR side performs decompression, holding,
and compression.
7) Read values indicated on the pressure gauge and
check if the fluctuation of the values between decompres-
sion and compression meets the standard values. Also
check if any irregular brake pedal tightness is felt.
Initial value When decompressed When compressed
Front wheel 3,432 kPa (35 kg/cm
2, 498 psi)490 kPa (5 kg/cm2, 71 psi)
or less981 kPa (10 kg/cm2, 142 psi)
or more
Rear wheel 3,432 kPa (35 kg/cm
2, 498 psi)490 kPa (5 kg/cm2, 71 psi)
or less981 kPa (10 kg/cm2, 142 psi)
or more
8) Remove pressure gauges and air bleeder screws from
the RL and RR caliper bodies.
9) Connect the air bleeder screws hose to the FL and FR
caliper bodies.
10) Connect two pressure gauges to the RL and RR cali-
per bodies.
11) Bleed air from the pressure gauges and the FL and FR
caliper bodies.
12) Perform ABS sequence control. [W20D0].>
13) When the hydraulic unit begins to work, at first the RR
side performs decompression, holding, and compression,
and then the RL side performs decompression, holding,
and compression.
14) Read values indicated on the pressure gauges and
check if they meet the standard value.
107
4-4SERVICE PROCEDURE
20. Hydraulic Unit for ABS/TCS System

E: CHECKING THE HYDRAULIC UNIT TCS
OPERATION
1. CHECKING THE HYDRAULIC UNIT TCS
OPERATION BY PRESSURE GAUGE
1) Lift-up vehicle and remove wheels.
2) Disconnect the air bleeder screws from the FL and FR
caliper bodies.
B4M0633A
3) Connect two pressure gauges to the FL and FR caliper
bodies.
CAUTION:

Pressure gauges used exclusively for brake fluid
must be used.

Do not employ pressure gauge previously used for
transmission since the piston seal is expanded which
may lead to malfunction of the brake.
NOTE:
Wrap sealing tape around the pressure gauge.
4) Bleed air from the pressure gauges.
5) Perform sequence control.
6) When the hydraulic unit begins to work, and first the FL
side performs compression, holding, and decompression,
and then the FR side performs compression, holding, and
decompression.
7) Read values indicated on the pressure gauge and
check if the fluctuation of the values between compression
and decompression meets the standard values. Also check
if any irregular brake pedal tightness is felt.
Initial value When compressed When decompressed
Front left wheel490 kPa (5 kg/cm
2, 71 psi)
or less1,471 kPa (15 kg/cm2, 213 psi)
or more490 kPa (5 kg/cm2, 71 psi)
or less
Front right wheel490 kPa (5 kg/cm
2, 71 psi)
or less1,471 kPa (15 kg/cm2, 213 psi)
or more490 kPa (5 kg/cm2, 71 psi)
or less
8) After checking, remove the pressure gauges from the
caliper bodies.
9) Connect the air bleeder screws to the FL and FR cali-
per bodies.
10) Bleed air from brake line.
11 3
4-4SERVICE PROCEDURE
20. Hydraulic Unit for ABS/TCS System

B: INSPECTION
1) Check connected and fixed condition of connector.
B4M1248A
2) Check specifications of the mark with ABSCM&H/U.
Mark Model
C3 AWD AT
C4 AWD MT
C: CHECKING THE HYDRAULIC UNIT ABS
OPERATION
1. CHECKING THE HYDRAULIC UNIT ABS
OPERATION BY PRESSURE GAUGE
1) Lift-up vehicle and remove wheels.
2) Disconnect the air bleeder screws from the FL and FR
caliper bodies.
B4M0633A
3) Connect two pressure gauges to the FL and FR caliper
bodies.
CAUTION:

Pressure gauges used exclusively for brake fluid
must be used.

Do not employ pressure gauge previously used for
transmission since the piston seal is expanded which
may lead to malfunction of the brake.
NOTE:
Wrap sealing tape around the pressure gauge.
123
4-4SERVICE PROCEDURE
22. ABS Control Module and Hydraulic Control Unit (ABSCM&H/U) (ABS 5.3i Type)

4. UNDERBODY
B5M0190A
10Radiator panel (LWR) frame gauge hole 10 mm (0.39 in) dia.

11Front side frame front lower surface 20 mm (0.79 in) dia.

12Front side frame center lower surface 20 mm (0.79 in) dia.

13Front suspension attaching hole M14

14Suspension attaching bracket M14

15Front side frame rear lower center surface 20 mm (0.79 in) dia.

16Transmission mount attaching hole M10

17Front side frame rear lower surface 15 mm (0.59 in) dia.

18Rear frame front M12

19Rear frame front hole 25 mm (0.98 in) dia.

20Rear crossmember attaching hole M12

21Rear frame center hole 7 mm (0.28 in) dia.

22Rear frame rear concave part 15 mm (0.59 in) dia.
6
5-1SERVICE DATA
2. Body Datum Points

G6M0095
1. Starter
A: REMOVAL AND INSTALLATION
1) Disconnect battery ground cable.
G2M0309
2) Disconnect connector and terminal from starter.
3) Remove starter from transmission.
4) Installation is in the reverse order of removal.
Tightening torque:
50±4 N⋅m (5.1±0.4 kg-m, 36.9±2.9 ft-lb)
B: TEST
1. MAGNETIC SWITCH
CAUTION:
The following magnetic switch tests should be per-
formed with specified voltage applied.
Each test should be conducted within 3 to 5 sec-
onds. Power to be furnished should be one-half the
rated voltage.
B6M0415A
1) Pull-in test
Connect two battery negative leads onto magnetic switch
body and terminal C respectively. Then connect battery
positive lead onto terminal 50. Pinion should extend when
lead connections are made.
B6M0416A
2) Holding-in test
Disconnect lead from terminal C with pinion extended. Pin-
ion should be held in the extended position.
7
6-1SERVICE PROCEDURE
1. Starter

C: INSTALLATION
CAUTION:

Ensure sensor mounting hole is clean and free of
foreign matter.

Apply grease to tip end of key to prevent key from
falling off sensor.

Align tip end of key with key groove on end of
speedometer shaft during installation.
1) Hand tighten vehicle speed sensor 2, then tighten it
using suitable tool.
Tightening torque required for sensor to reach bottom of
transmission is as follows:
Tightening torque:
0.39—0.88 N⋅m (4.0—9.0 kg-cm, 3.5—7.8 in-lb)
CAUTION:

When torque must be applied that exceeds 0.88 N⋅m
(9.0 kg-cm, 7.8 in-lb), the key and key groove on end of
speedometer may not be aligned properly. Remove the
key, align it correctly and reassemble.

Sensor threads are secured by Locktite. The reas-
sembly must be completed within 5 minutes before
Locktite dries.
2) Tighten vehicle speed sensor 2 further to specified
torque.
Tightening torque:
5.9±1.5 N⋅m (60±15 kg-cm, 52±13 in-lb)
36
6-2SERVICE PROCEDURE
14. Vehicle Speed Sensor 2