oil change SUBARU LEGACY 1997 Service Repair Manual

BRAKES
IM13-21
4-4
13
.
Anti-lock
Brake
System
(ABS)
[5
.3i
Type]

2
.
FUNCTIONS
OF
SENSORS
AND
ACTUATORS

Name
Function

ABS
control
moduleand
hydraulic
ABSCM-
e
Calculates
and
determine
the
conditionsof
the
wheels
and
body
from
control
unit
(ABSCM&H/U)
section
the
wheel
speedsand
makes
a
proper
decision
suitable
for
the
current
situation
to
control
the
hydraulic
unit
.

In
the
ABS
operation
mode,
the
module
outputs
a
cooperative
control
signal
to
the
AT
control
module
.
(AT
vehicles
only)

Whenever
the
ignition
switch
is
placed
at
ON,
the
module
makes
a
self
diagnosis
.
When
anything
wrong
is
detected,
the
module
cuts
off
the
system
.

Communicates
with
the
Subaru
select
monitor
.

H/U-section
In
the
ABS
operation
mode,
the
H/U
changes
fluid
passages
to
control

the
fluid
pressure
of
the
wheel
cylinders
in
response
to
an
instruction
from
the
ABSCM
.

The
H/U
also
constitutes
thebrake
fluid
passage
from
the
master
cylin-
der
to
the
wheel
cylinders
together
with
pipings
.

Valve
relay-
Serves
asa
power
switch
for
the
solenoid
valve
and
motor
relay
coil
in
section
response
to
an
instruction
from
the
ABSCM
.

Motor
relay-
Serves
as
a
power
switch
for
the
pump
motor
in
response
to
an
instruc-
section
tion
from
the
ABSCM
.

Wheel
speed
sensor
(ABS
sensor)
Detects
the
wheel
speed
in
terms
of
a
change
in
the
magnetic
flux
den-
sity
passingthrough
the
sensor,
converts
it
into
an
electrical
signal,
and
outputs
the
electrical
signal
to
the
ABSCM
.

Tone
wheel
Gives
a
change
in
the
magnetic
flux
density
by
the
teeth
around
the
tone
wheel
to
let
the
ABS
sensor
generate
an
electrical
signal
.

G
sensor
(AWD
vehicle
only)
Detects
a
change
in
G
in
the
longitudinal
direction
of
the
vehicle
and
outputs
it
to
the
ABSCM
in
terms
of
a
change
in
voltage
.

Stop
light
switch
Transmits
the
information
on
whether
the
brakepedal
is
depressed
or
not
to
the
ABSCM
for
use
as
a
condition
in
determining
ABS
operation
.

ABS
warning
light
Alerts
the
driver
to
an
ABS
fault
.
When
the
diagnosis
connector
and
diagnosis
terminal
are
connected,
the
light
flashes
to
indicate
a
trouble
codes
in
response
to
an
instruction
from
the
ABSCM
.

AT
control
module
(TCM)
(AT
vehicles
only)
Provides
shift
controls
(fixing
the
speed
at
3rd
or
changing
front
and
rear
wheel
transmission
characteristics
on
4WD
vehicle)
in
response
to
an
instruction
fromthe
ABSCM
.

Automatic
transmissionOil pumpType Variable-capacity type vane pump
Driving method Driven by engine
Number of vanes 9 pieces
Hydraulic
controlTy p eElectronic/hydraulic control
[Four forward speed changes by electrical signals of car speed
and accelerator (throttle) opening]
Fluid Dexron II or Dexron III type Automatic transmission fluid
Fluid
capacity2200 cc 7.9(8.4 US qt, 7.0 Imp qt)
2500 cc 9.5(10.0 US qt, 8.4 Imp qt)
LubricationLubrication system Forced feed lubrication with oil pump
Oil Automatic transmission fluid (above mentioned.)
Cooling Cooling system Liquid-cooled cooler incorporated in radiator
HarnessInhibitor switch 12 poles
Transmission harnessFWD ... 11 poles
AWD ... 13 poles
TransferTransfer clutch Hydraulic multi-plate clutch
Clutch number of transfer clutch Drive plate & driven plate 5
Control method Electronic, hydraulic type
LubricantThe same Automatic Transmission Fluid used in automatic
transmission.
1st reduction gear ratio 1.000 (53/53)
Final
reductionFinal gear
ratioFront driveFWD 3.900 (39/10)
AWD2200 cc 4.111 (37/9)
2500 cc 4.444 (40/9)
Speedometer gear ratio2200 cc & LSi 0.83 (19/23)
GT 0.80 (20/25)
OUTBACK 0.76 (19/25)
Lubrication oilAPI, GL-5
Oil capacity Front drive 1.2(1.3 US qt, 1.1 Imp qt)
ATF cooling
systemRadiation capacity 1.651 kW (1,420 kcal/h, 5,635 BTU/h)
3
3-2SPECIFICATIONS AND SERVICE DATA
1. Automatic Transmission and Differential

G3M0317
2. TEST METHODS
1) Temporarily attach the ST to a suitable place in the
driver’s compartment, remove the blind plug located in
front of the toe board and pass the hose of the ST to the
engine compartment.
ST 498575400 OIL PRESSURE GAUGE ASSY


1Pressure gauge hose


2Hole in toe board (blank cap hole)


3Brake pedal
G3M0869
2) Remove the test plug and install ST1 instead.
3) Connect ST1 with ST2.
ST1 498897200 OIL PRESSURE GAUGE ADAPTER
ST2 498575400 OIL PRESSURE GAUGE ASSY
4) Check for duty ratio changes by opening and closing
throttle valve using select monitor.
5) Check line pressure in accordance with the following
chart.
3. EVALUATION
NOTE:
Under no load:“D”
Under full load:“R”,“2”
(With engine running at stall speed)

Unit: kPa (kg/cm2, psi)
Line pressure
Duty ratio (%)“2”range“R”range“D”range
2200 cc 2500 cc
51,147—1,344
(11.7—13.1, 166—195)1,275—1,569
(13.0—16.0, 185—228)—
22——765—902
(7.8—9.2, 111—131)
100——235—481
(2.4—4.9, 34—70)392—490
(4.0—5.0, 57—71)
42
3-2SERVICE PROCEDURE
3. Performance Test

G3M0870
D: TRANSFER CLUTCH PRESSURE TEST
Check transfer clutch pressure in accordance with the fol-
lowing chart in the same manner as with line pressure.
ST 499897700 OIL PRESSURE ADAPTER SET
ST 498575400 OIL PRESSURE GAUGE ASSY
AWD mode:“D”range
FWD mode:“P”range, engine speed 2000 rpm
CAUTION:
Before setting in FWD mode, install spare fuse on FWD
mode switch.
Unit: kPa (kg/cm2, psi)
Duty ratio
(%)AWD mode FWD mode
5667—804
(6.8—8.2, 97—117)667—804
(6.8—8.2, 97—117)
40137—226
(1.4—2.3, 20—33)—
950
(0, 0)—
If oil pressure is not produced or if it does not change in the
AWD mode, the duty solenoid C or transfer valve assem-
bly may be malfunctioning. If oil pressure is produced in the
FWD mode, the problem is similar to that in the AWD
mode.
E: ROAD TEST
1. GENERAL
Road tests should be conducted to properly diagnose the
condition of the automatic transmission.
CAUTION:
When performing test, do not exceed posted speed
limit.
2. CHECKING FOR SHIFT PATTERNS
Check“kick-down”.
D range: 1st
←
→2nd←
→3rd←
→4th
3 range: 1st←
→2nd←
→3rd←4th
2 range: 2nd←3rd←4th
1 range: 1st←2nd←3rd←4th
3. CHECK FOR ENGINE BRAKE OPERATION
Engine brake operation:
D range→4th gear
3 range→3rd gear
2 range→2nd gear
1 range→1st gear
43
3-2SERVICE PROCEDURE
3. Performance Test

G3M0383
(2) Tighten four bolts to secure the roller bearing.
Tightening torque:
39±3 N⋅m (4.0±0.3 kg-m, 28.9±2.2 ft-lb)
G3M0883
(3) Install the oil pump housing assembly to the torque
converter clutch case, and secure evenly by tightening
four bolts.
Tightening torque:
41±3 N⋅m (4.2±0.3 kg-m, 30.4±2.2 ft-lb)
CAUTION:
Thoroughly remove the liquid gasket from the case
mating surface beforehand.
Use an old gasket or an aluminum washer so as not
to damage the mating surface of the housing.
G3M0384
(4) Rotate the drive pinion several times with ST1 and
ST2.
ST1 498937100 HOLDER
ST2 499787100 WRENCH
G3M0884
(5) Tighten the LH retainer until contact is felt while
rotating the shaft. Then loosen the RH retainer. Keep
tightening the LH retainer and loosening the RH
retainer until the pinion shaft can no longer be turned.
This is the“zero”state.
G3M0885
(6) After the“zero”state is established, back off the LH
retainer 3 notches and secure it with the lock plate.
Then back off the RH retainer and retighten until it
stops. Repeat this procedure several times. Tighten the
RH retainer 1-3/4 notches further. This sets the preload.
Finally, secure the retainer with its lock plate.
NOTE:
Turning the retainer by one tooth changes the backlash
about 0.05 mm (0.0020 in).
61
3-2SERVICE PROCEDURE
4. Overall Transmission

G3M0317
2. TEST METHODS
1) Temporarily attach the ST to a suitable place in the
driver’s compartment, remove the blind plug located in
front of the toe board and pass the hose of the ST to the
engine compartment.
ST 498575400 OIL PRESSURE GAUGE ASSY


1Pressure gauge hose


2Hole in toe board (blank cap hole)


3Brake pedal
G3M0869
2) Remove the test plug and install ST1 instead.
3) Connect ST1 with ST2.
ST1 498897200 OIL PRESSURE GAUGE ADAPTER
ST2 498575400 OIL PRESSURE GAUGE ASSY
4) Check for duty ratio changes by opening and closing
throttle valve using select monitor.
5) Check line pressure in accordance with the following
chart.
3. EVALUATION
NOTE:
Under no load:“D”
Under full load:“R”,“2”
(With engine running at stall speed)

Unit: kPa (kg/cm2, psi)
Line pressure
Duty ratio (%)“2”range“R”range“D”range
2200 cc 2500 cc
51,147—1,344
(11.7—13.1, 166—195)1,275—1,569
(13.0—16.0, 185—228)—
22——765—902
(7.8—9.2, 111—131)
100——235—481
(2.4—4.9, 34—70)392—490
(4.0—5.0, 57—71)
42
3-2SERVICE PROCEDURE
3. Performance Test

G3M0870
D: TRANSFER CLUTCH PRESSURE TEST
Check transfer clutch pressure in accordance with the fol-
lowing chart in the same manner as with line pressure.
ST 499897700 OIL PRESSURE ADAPTER SET
ST 498575400 OIL PRESSURE GAUGE ASSY
AWD mode:“D”range
FWD mode:“P”range, engine speed 2000 rpm
CAUTION:
Before setting in FWD mode, install spare fuse on FWD
mode switch.
Unit: kPa (kg/cm2, psi)
Duty ratio
(%)AWD mode FWD mode
5667—804
(6.8—8.2, 97—117)667—804
(6.8—8.2, 97—117)
40137—226
(1.4—2.3, 20—33)—
950
(0, 0)—
If oil pressure is not produced or if it does not change in the
AWD mode, the duty solenoid C or transfer valve assem-
bly may be malfunctioning. If oil pressure is produced in the
FWD mode, the problem is similar to that in the AWD
mode.
E: ROAD TEST
1. GENERAL
Road tests should be conducted to properly diagnose the
condition of the automatic transmission.
CAUTION:
When performing test, do not exceed posted speed
limit.
2. CHECKING FOR SHIFT PATTERNS
Check“kick-down”.
D range: 1st
←
→2nd←
→3rd←
→4th
3 range: 1st←
→2nd←
→3rd←4th
2 range: 2nd←3rd←4th
1 range: 1st←2nd←3rd←4th
3. CHECK FOR ENGINE BRAKE OPERATION
Engine brake operation:
D range→4th gear
3 range→3rd gear
2 range→2nd gear
1 range→1st gear
43
3-2SERVICE PROCEDURE
3. Performance Test

G3M0383
(2) Tighten four bolts to secure the roller bearing.
Tightening torque:
39±3 N⋅m (4.0±0.3 kg-m, 28.9±2.2 ft-lb)
G3M0883
(3) Install the oil pump housing assembly to the torque
converter clutch case, and secure evenly by tightening
four bolts.
Tightening torque:
41±3 N⋅m (4.2±0.3 kg-m, 30.4±2.2 ft-lb)
CAUTION:
Thoroughly remove the liquid gasket from the case
mating surface beforehand.
Use an old gasket or an aluminum washer so as not
to damage the mating surface of the housing.
G3M0384
(4) Rotate the drive pinion several times with ST1 and
ST2.
ST1 498937100 HOLDER
ST2 499787100 WRENCH
G3M0884
(5) Tighten the LH retainer until contact is felt while
rotating the shaft. Then loosen the RH retainer. Keep
tightening the LH retainer and loosening the RH
retainer until the pinion shaft can no longer be turned.
This is the“zero”state.
G3M0885
(6) After the“zero”state is established, back off the LH
retainer 3 notches and secure it with the lock plate.
Then back off the RH retainer and retighten until it
stops. Repeat this procedure several times. Tighten the
RH retainer 1-3/4 notches further. This sets the preload.
Finally, secure the retainer with its lock plate.
NOTE:
Turning the retainer by one tooth changes the backlash
about 0.05 mm (0.0020 in).
61
3-2SERVICE PROCEDURE
4. Overall Transmission

G3M0317
2. TEST METHODS
1) Temporarily attach the ST to a suitable place in the
driver’s compartment, remove the blind plug located in
front of the toe board and pass the hose of the ST to the
engine compartment.
ST 498575400 OIL PRESSURE GAUGE ASSY


1Pressure gauge hose


2Hole in toe board (blank cap hole)


3Brake pedal
G3M0869
2) Remove the test plug and install ST1 instead.
3) Connect ST1 with ST2.
ST1 498897200 OIL PRESSURE GAUGE ADAPTER
ST2 498575400 OIL PRESSURE GAUGE ASSY
4) Check for duty ratio changes by opening and closing
throttle valve using select monitor.
5) Check line pressure in accordance with the following
chart.
3. EVALUATION
NOTE:
Under no load:“D”
Under full load:“R”,“2”
(With engine running at stall speed)

Unit: kPa (kg/cm2, psi)
Line pressure
Duty ratio (%)“2”range“R”range“D”range
2200 cc 2500 cc
51,147—1,344
(11.7—13.1, 166—195)1,275—1,569
(13.0—16.0, 185—228)—
22——765—902
(7.8—9.2, 111—131)
100——235—481
(2.4—4.9, 34—70)392—490
(4.0—5.0, 57—71)
42
3-2SERVICE PROCEDURE
3. Performance Test

G3M0870
D: TRANSFER CLUTCH PRESSURE TEST
Check transfer clutch pressure in accordance with the fol-
lowing chart in the same manner as with line pressure.
ST 499897700 OIL PRESSURE ADAPTER SET
ST 498575400 OIL PRESSURE GAUGE ASSY
AWD mode:“D”range
FWD mode:“P”range, engine speed 2000 rpm
CAUTION:
Before setting in FWD mode, install spare fuse on FWD
mode switch.
Unit: kPa (kg/cm2, psi)
Duty ratio
(%)AWD mode FWD mode
5667—804
(6.8—8.2, 97—117)667—804
(6.8—8.2, 97—117)
40137—226
(1.4—2.3, 20—33)—
950
(0, 0)—
If oil pressure is not produced or if it does not change in the
AWD mode, the duty solenoid C or transfer valve assem-
bly may be malfunctioning. If oil pressure is produced in the
FWD mode, the problem is similar to that in the AWD
mode.
E: ROAD TEST
1. GENERAL
Road tests should be conducted to properly diagnose the
condition of the automatic transmission.
CAUTION:
When performing test, do not exceed posted speed
limit.
2. CHECKING FOR SHIFT PATTERNS
Check“kick-down”.
D range: 1st
←
→2nd←
→3rd←
→4th
3 range: 1st←
→2nd←
→3rd←4th
2 range: 2nd←3rd←4th
1 range: 1st←2nd←3rd←4th
3. CHECK FOR ENGINE BRAKE OPERATION
Engine brake operation:
D range→4th gear
3 range→3rd gear
2 range→2nd gear
1 range→1st gear
43
3-2SERVICE PROCEDURE
3. Performance Test