3-1 SUBARU LEGACY 1997 Service Repair Manual

4-4
LM13-1]
BRAKES
13
.
Anti-lock
Brake
System
(ABS)
[5
.3i
Type]

13
.
Anti-lock
Brake
System
(ABS)
[5
.3i
Type]

1
.
FEATURE

*
This
ABS
5
.3i
type
incorporates
the
hydraulic
control
unit,
ABS
control
module,
valve
relay
and

motor
relay
in
one
unit
for
betterproductivity
and
lightweight
.

*
The
ABS
(Anti-lock
brake
system)
electrically
controls
brake
fluid
pressure
to
prevent
wheel

"lock"
during
braking
on
slippery
road
surfaces,
thereby
improving
directional/steering
stability
as

well
as
shortening
the
braking
distance
.

*
If
the
ABS
becomes
inoperative,
the
fail-safe
system
activates
to
ensure
it
acts
asa
conventional

brake
system
.
The
warning
light
also
comes
on
to
indicate
that
the
ABS
is
malfunctioning
.

"
The
front-and-rear
wheels
utilize
a
4-sensor,
4-channel
control
design
:
the
front
wheels
havean

independent
control
design*1
and
the
rear
wheels
have
a
select
low
control
design*2
.

*1
:
A
system
which
independently
controls
fluid
pressure
to
left
and
right
front
wheels
.

*2
:
A
system
which
provides
the
same
fluid
pressure
control
for
the
two
rear
wheels
if
either
wheel

starts
to"lock
."

10
ABS
control
moduleand
hydraulic
control
unit
(ABSCM&H/U)
Proportioning
valve
OO
Diagnosisconnector
OO
ABS
warning
light

OO
Data
link
connector
(for
SUBARU
select
monitor)
OO
Transmission
control
module
(only
AT
vehicle)
Tone
wheel

OO
ABS
sensor
09
Wheel
cylinder
O
G
sensor
(only
AWD
vehicle)
>>
Brake
switch
D
Master
cylinder

?15A

2

TABLE
OFCONTENTS

2-1
~************

2-2
*********~k**

2-3
tE**tE*ylr****t1~~t

2-3b
*******tlr~~ylr**

2-4
~t~~t~t1E7E~t~lr~lr~t~t~t~t

2-5
*yt***********
ENGINE
SECTION
2-6
*~~**********

2-7
*************

2-8
*****yt**ytyt*~*

2-9
*******~t*~*~*

2-10
**It~**yt**~*yt*

2-11
**~**********

3-1
**~t******~k*yt*

TRANSMISSION
AND
DIFFERENTIAL
3'2
**********'k**

SECTION
3-3
tf*~yt*yt*ytyt~t*yt~t

3-4
*yttt~*~~******

4-1
~t***~~~yt~k*~~*

4-2
~t*~t~**yttt***~k*

4-3
~**~k**~**~~~~

MECHANICAL
COMPONENTS
4-4
Brakes
SECTION

4-5
**~t~t~t~~~t**~~r*

4-6
*************

4-7
*tt**7f~*~k*****

5-1
*******~*****

5-2
*************

5-3
***********ytyt
BODY
SECTION
5-4
*skateboards*
с*

5-5
y1r*******~****

5-5b
**~t**********

6-1
**~~****yt****
ELECTRICAL
SECTION
6-2
~****~t**~t**1f~

All
right
reserved
.
This
book
may
not
bereproduced

or
copied,
in
whole
or
in
part,
withoutthe
written

permission
of
FUJI
HEAVY
INDUSTRIES
LTD
.,

TOKYO
JAPAN
.

SUBARU,
++
and
O
are
trademarks
of

FUJI
HEAVY
INDUSTRIES
LTD
.

@
Copyright
1996
FUJI
HEAVY
INDUSTRIES
LTD
.

2

1. Manual Transmission and
Differential
A: SPECIFICATIONS
ItemModel
2200 cc 2500 cc OUTBACK
Type 5-forward speeds with synchromesh and 1-reverse
Transmission gear ratio1st 3.545
2nd 2.111
3rd 1.448
4th 1.088
5th 0.780 0.871
Reverse 3.416
Front
reduction
gearFinalType of gear Hypoid
Gear ratio 3.900 4.111
Rear
reduction
gearTransferType of gear Helical
Gear ratio 1.000
FinalType of gear Hypoid
Gear ratio 3.900 4.111
Front
differentialType and number of gear Straight bevel gear (Bevel pinion: 2, Bevel gear: 2)
Center
differentialType and number of gear Straight bevel gear (Bevel pinion: 2, Bevel gear: 2 and viscous coupling)
Transmission gear oil GL-5
Transmission oil capacity 3.5
(3.7 US qt, 3.1 Imp qt)
2
3-1SPECIFICATIONS AND SERVICE DATA
1. Manual Transmission and Differential

B: SERVICE DATA
1. EXTENSION (AWD Model)
Snap ring (Inner-72) to ball bearing side clearance
0 — 0.15 mm (0 — 0.0059 in)
Snap ring (Inner-72)
Part No. Thickness mm (in)
805172071 1.78 (0.0701)
805172072 1.90 (0.0748)
805172073 2.02 (0.0795)
Snap ring (Outer-30) to ball bearing side clearance
0 — 0.15 mm (0 — 0.0059 in)
Snap ring (Outer-30)
Part No. Thickness mm (in)
805030041 1.53 (0.0602)
805030042 1.65 (0.0650)
805030043 1.77 (0.0697)
2. EXTENSION ASSEMBLY (AWD Model)
Thrust washer (52 x 61 x t) to ball bearing side clearance
0.05 — 0.30 mm (0.0020 — 0.0118 in)
Thrust washer (52 x 61 x t)
Part No. Thickness mm (in)
803052021 0.50 (0.0197)
803052022 0.75 (0.0295)
803052023 1.00 (0.0394)
3. TRANSFER CASE OR REAR CASE
Neutral position adjustment
Adjustment shim
Part No. Thickness mm (in)
32190AA000 0.15 (0.0059)
32190AA010 0.30 (0.0118)
Reverse accent shaft
Part No. Mark Remarks
32188AA040 1Neutral position is closer to
1st.
32188AA011 No mark or 2 Standard
32188AA050 3Neutral position is closer to
reverse gear.
Reverse check plate adjustment
Reverse check plate
Part No. Mark AngleθRemarks
32189AA000 0 28°Arm stops closer to
5th gear.
32189AA010 1 31°Arm stops closer to
5th gear.
33189AA020 2 34°Arm stops in the
center.
32189AA030 3 37°Arm stops closer to
reverse gear.
32189AA040 4 40°Arm stops closer to
reverse gear.
4. REVERSE IDLER GEAR
Adjustment of reverse idler gear position
Reverse idler gear to transmission case (LH) wall clearance
6.0 — 7.5 mm (0.236 — 0.295 in)
Reverse shifter lever
Part No. Mark Remarks
32820AA000 0 Further from case wall
32820AA010 No mark Standard
32820AA020 2 Closer to the case wall
After installing a suitable reverse shifter lever, adjust reverse idler
gear to transmission case wall clearance to within 0 to 0.5 mm (0
to 0.020 in) using washers.
Washer (20.5 x 26 x t)
Part No.Thickness
mm (in)Part No.Thickness
mm (in)
803020151 0.4 (0.016) 803020154 1.9 (0.075)
803020152 1.1 (0.043) 803020155 2.3 (0.091)
803020153 1.5 (0.059)
3
3-1SPECIFICATIONS AND SERVICE DATA
1. Manual Transmission and Differential

5. SHIFTER FORK AND ROD
Select suitable shifter forks so that both coupling sleeve and
reverse driven gear are positioned in the center of their synchro-
mesh mechanisms.
1st-2nd shifter fork
Part No. Mark Remarks
32804AA060 1Approach to 1st gear by
0.2 mm (0.008 in)
32804AA070 No mark Standard
32804AA080 3Approach to 2nd gear by
0.2 mm (0.008 in)
3rd-4th shifter fork
Part No. Mark Remarks
32810AA060 1Approach to 4th gear by
0.2 mm (0.008 in)
32810AA070 No mark Standard
32810AA100 3Approach to 3rd gear by
0.2 mm (0.008 in)
5th shifter fork
Part No. Mark Remarks
32812AA200 4Approach to 5th gear by
0.2 mm (0.008 in)
32812AA210 No mark Standard
32812AA220 6Become distant from 5th
gear by 0.2 mm (0.008 in)
Rod end clearance
A: 1st-2nd—3rd-4th
0.5—1.5 mm (0.020—0.059 in)
B: 3rd-4th—5th
0.6—1.4 mm (0.024—0.055 in)
6. TRANSMISSION CASE ASSEMBLY
Drive pinion shim adjustment
Drive pinion shim
Part No.Thickness
mm (in)Part No.Thickness
mm (in)
32295AA0310.150
(0.0059)32295AA0710.250
(0.0098)
32295AA0410.175
(0.0069)32295AA0810.275
(0.0108)
32295AA0510.200
(0.0079)32295AA0910.300
(0.0118)
32295AA0610.225
(0.0089)32295AA1010.500
(0.0197)
Hypoid gear backlash
0.13—0.18 mm (0.0051—0.0071 in)Selection of main shaft rear plate
Main shaft rear plate
Dimension“A”mm (in) Part No. Mark
4.00—4.13 (0.1575—0.1626) 32294AA041 1
3.87—3.99 (0.1524—0.1571) 32294AA051 2
7. DRIVE PINION ASSEMBLY
Preload adjustment of thrust bearing
Starting torque
0.3—0.8 N⋅m(3—8 kg-cm, 2.6—6.9 in-lb)
Adjusting washer No. 1
Part No. Thickness mm (in)
803025051 3.925 (0.1545)
803025052 3.950 (0.1555)
803025053 3.975 (0.1565)
803025054 4.000 (0.1575)
803025055 4.025 (0.1585)
803025056 4.050 (0.1594)
803025057 4.075 (0.1604)
Adjusting washer No. 2
Part No. Thickness mm (in)
803025059 3.850 (0.1516)
803025054 4.000 (0.1575)
803025058 4.150 (0.1634)
Assemble a driven shaft and 1st driven gear that are selected for
the proper radial clearance adjustment.
Driven shaft 1st driven gear
Part No.Diameter A
mm (in)Part No.
32229AA15049.959—49.966
(1.9669—
1.9672)32231AA290
32229AA14049.967—49.975
(1.9672—
1.9675)32231AA280
8. DRIVE PINION ASSEMBLY (FWD Model)
Selection of 1st driven gear:
1st driven gear
Outer diameter of bushing mm (in) Part No.
41.983—41.996 (1.6529—1.6534) 32231AA320
41.968—41.982 (1.6523—1.6528) 32231AA330
41.954—41.967 (1.6517—1.6522) 32231AA340
4
3-1SPECIFICATIONS AND SERVICE DATA
1. Manual Transmission and Differential

9. CENTER DIFFERENTIAL (AWD Model)
Snap ring (Inner-110) to center differential case clearance
0—0.15 mm (0—0.0059 in)
Snap ring (Inner-110)
Part No. Thickness mm (in)
805100061 2.10 (0.0827)
805100062 2.21 (0.0870)
805100063 2.32 (0.0913)
Backlash adjustment axial movement
0.62—0.86 mm (0.0244—0.0339 in)
Adjusting washer (45 x 62 x t)
Part No. Thickness mm (in)
803045041 1.60 (0.0630)
803045042 1.80 (0.0709)
803045043 2.00 (0.0787)
803045044 2.20 (0.0866)
803045045 2.40 (0.0945)
10. FRONT DIFFERENTIAL
Bevel gear to pinion backlash
0.13—0.18 mm (0.0051—0.0071 in)
Washer (38.1 x 50 x t)
Part No.Thickness
mm (in)Part No.Thickness
mm (in)
8030380210.925—
0.950
(0.0364—
0.0374)8030380231.025—
1.050
(0.0404—
0.0413)
8030380220.975—
1.000
(0.0384—
0.0394)
Pinion shaft to axle drive shaft clearance
0—0.2 mm (0—0.008 in)
Snap ring (Outer-28)
Part No.Thickness
mm (in)Part No.Thickness
mm (in)
805028011 1.05 (0.0413) 805028012 1.20 (0.0472)
5
3-1SPECIFICATIONS AND SERVICE DATA
1. Manual Transmission and Differential

1. Transfer Case and Extension (AWD
Model)
B3M0326A

1Transfer cover


2Cover gasket


3Oil seal


4Gasket


5Neutral switch


6Back-up light switch


7Transfer case


8Gasket


9Oil guide


10Ball


11Reverse accent spring


12Gasket


13Plug


14Snap ring (Inner)


15Reverse check plate

16Reverse check spring


17Reverse return spring


18Reverse check cam


19Reverse accent shaft


20O-ring


21Adjusting select shim


22Reverse check sleeve


23Adjusting washer


24Ball bearing


25Transfer driven gear


26Ball bearing


27Oil seal


28Shift bracket


29Extension cover


30Gasket

31Snap ring (Outer-30)


32Gasket


33Ball bearing


34Snap ring (Inner-72)


35Transfer drive gear


36Extension
Tightening torque: N⋅m (kg-m, ft-lb)
T1: 5±1 (0.5±0.1, 3.6±0.7)
T2: 10±1 (1.0±0.1, 7.2±0.7)
T3: 15.7±1.5
(1.6±0.15, 11.6±1.1)
T4: 25±2 (2.5±0.2, 18.1±1.4)
T5: 37±3 (3.8±0.3, 27.5±2.2)
6
3-1COMPONENT PARTS
1. Transfer Case and Extension (AWD Model)

2. Rear Case (FWD Model)
G3M0265

1Rear case


2Case gasket


3Back-up light switch


4Neutral switch


5Reverse check sleeve ASSY


6Gasket


7Adjusting shim

8O-ring


9Oil seal
Tightening torque: N⋅m (kg-m, ft-lb)
T1: 6.4±0.5 (0.65±0.05, 4.7±0.4)
T2: 25±2 (2.5±0.2, 18.1±1.4)
7
3-1COMPONENT PARTS
2. Rear Case (FWD Model)

3. Transmission Case
B3M0327A

1Transmission case ASSY


2Gasket


3Drain plug


4Snap ring (Outer)


5Speedometer driven gear


6Washer


7Speedometer shaft


8Snap ring (Outer)


9Oil seal


10Oil level gauge


11Pitching stopper bracket


12Clamp


13Clip
Tightening torque: N⋅m (kg-m, ft-lb)
T: 44±3 (4.5±0.3, 32.5±2.2)
Size All models Torque
8 mm bolt

5—
15
25±2 N⋅m
(2.5±0.2 kg-m,
18.1±1.4 ft-lb)
10 mm bolt

1—
4

16—
17
39±2 N⋅m
(4.0±0.2 kg-m,
28.9±1.4 ft-lb)
8
3-1COMPONENT PARTS
3. Transmission Case

4. Shifter Fork and Shifter Rod
B3M0338A

1Plug


2Gasket


3Reverse accent spring


4Ball


5Snap ring (Inner)


6Reverse check plate


7Reverse check spring


8Reverse return spring


9Reverse check cam


10Reverse accent shaft


11O-ring


12Adjusting select shim


13Reverse check sleeve

14Selector arm (AWD model)


15Shifter arm (AWD model)


16Reverse shifter lever


17Reverse fork rod arm


18Snap ring (Outer)


19Spring


20Ball


213rd-4th shifter fork


221st-2nd shifter fork


23Straight pin


24Reverse fork rod


255th shifter fork


26Interlock plunger

273rd-4th fork rod


281st-2nd fork rod


29Ball


30Checking ball spring


31Gasket


32Checking ball plug


33Shifter arm (FWD model)
Tightening torque: N⋅m (kg-m, ft-lb)
T1: 6.4±0.5 (0.65±0.05, 4.7±0.4)
T2: 10±1 (1.0±0.1, 7.2±0.7)
T3: 19.6±1.5
(2.00±0.15, 14.5±1.1)
9
3-1COMPONENT PARTS
4. Shifter Fork and Shifter Rod