clutch SUBARU LEGACY 1999 Service Service Manual

IThe drive pinion shim selected before is too thin.
Increase its thickness.
B3M0074
26) After checking the tooth contact of hypoid
gears, remove the lock plate. Then loosen retainer
until the O-ring groove appears. Fit O-ring into the
groove and tighten retainer into the position where
retainer has been tightened in.
Tighten lock plate.
NOTE:
Carry out this job on both upper and lower retain-
ers.
Tightening torque:
T: 2 5
±3 N´m (2.5±0.3 kg-m, 18.1±2.2 ft-lb)
S3M0014A
27) Selecting of main shaft rear plate
Using ST, measure the amount (A) of ball bearing
protrusion from transmission main case surface
and select the proper plate in the following table:
ST 498147000 DEPTH GAUGE
NOTE:
Before measuring, tap the end of main shaft with
a plastic hammer lightly in order to make the clear-
ance zero between the main case surface and the
moving flange of bearing.
Dimension (A)
mm (in)Part No. Mark
4.00 Ð 4.13
(0.1575 Ð 0.1626)32294AA041 1
3.87 Ð 3.99
(0.1524 Ð 0.1571)32294AA051 2
B3M0531A
28) Install clutch release lever and bearing. to 2-10 [W3C0].>
B3M0336I
(A) Clutch release lever
(B) Release bearing
28
3-1[W2B2]SERVICE PROCEDURE
2. Transmission Case

1. Manual Transmission
Symptom Possible cause Remedy
1. Gears are difficult to intermesh.
NOTE:
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 transmis-
sion. 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 gearsReplace.
(c) Worn or scratched bushings Replace.
(d) Incorrect contact between synchro-
nizer ring and gear cone or wearCorrect or replace.
2. Gear slips out.
IGear slips out when coasting on
rough road.
IGear 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 springReplace.
(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 raceReplace.
(h) Worn 2nd driven gear, needle bear-
ing and raceReplace.
(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 transmis-
sion.
NOTE:
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 bear-
ings
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.Replace.
52
3-1[K100]DIAGNOSTICS
1. Manual Transmission

2. Differential
Symptom Possible cause Remedy
1. Broken differential (case, gear,
bearing, etc.)
NOTE:
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 bro-
ken components and at the same time
check other components for any trouble,
and replace if necessary
(b) Use of vehicle under severe condi-
tions such as excessive load and
improper use of clutchReadjust bearing preload and backlash
and face contact of gears.
(c) Improper adjustment of taper roller
bearingAdjust.
(d) Improper adjustment of drive pinion
and hypoid driven gearAdjust.
(e) Excessive backlash due to worn dif-
ferential side gear, washer or differential
pinion vehicle under severe operating
conditions.Add recommended oil to specified level.
Do not use vehicle under severe operat-
ing conditions.
(f) Loose hypoid driven gear clamping
boltsTighten.
2. 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.
IGear noise when driving: If noise
increases as vehicle speed increases it
may be due to insufficient gear oil, incor-
rect gear engagement, damaged gears,
etc.
IGear noise when coasting: Damaged
gears due to maladjusted bearings and
incorrect shim adjustment
IBearing noise when driving or when
coasting: Cracked, broken or damaged
bearings
INoise which mainly occurs when turn-
ing: 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 pinionReplace as a set.
Readjust bearing preload.
(d) Loose roller bearing Readjust hypoid driven gear to drive pin-
ion backlash and check tooth contact.
(e) Distorted hypoid driven gear or differ-
ential caseReplace.
(f) Worn washer and differential pinion
shaftReplace.
53
[K200]3-1DIAGNOSTICS
2. Differential

1. Automatic Transmission and Differential
A: SPECIFICATIONS
Torque
converter
clutchType Symmetric, 3 element, single stage, 2 phase torque converter
Stall torque ratio2200 cc 2.1 Ð 2.3
2500 cc 1.8 Ð 2.0
OUTBACK 2.2 Ð 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 Ð 2,600 rpm
2500 cc 2,200 Ð 2,600 rpm
OUTBACK 2,300 Ð 2,700 rpm
One-way clutch Sprague type one-way clutch
Automatic
transmis-
sionTransmis-
sionType 4-forward, 1-reverse, double-row planetary gears
Control elementMulti-plate clutch 3 sets
Multi-plate brake 2 sets
One-way clutch (sprague type) 1 set
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
2200 cc 37
Rear pinion2200 cc 17
2500 cc 19
Rear internal gear 75
Plate number of high clutch Drive plate & driven plate 4
Plate number of reverse clutch Drive plate & driven plate 2
Plate number of 2-4 brake Drive plate & driven plate 3
Plate number of low clutchDrive plate & driven
plate2200 cc 5
2500 cc 6
Plate number of low & reverse
brakeDrive plate & driven
plate2200 cc 5
2500 cc 6
2
3-2[S1A0]SPECIFICATIONS AND SERVICE DATA
1. Automatic Transmission and Differential

Automatic
transmis-
sionTransmis-
sionSelector positionP (Park)Transmission in
neutral, output mem-
ber 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 pos-
sible 4th®3rd®
2nd)
1 (1st)1st gear locked
(Deceleration pos-
sible 4th®3rd®
2nd®1st)
Control method Hydraulic remote control
Oil pumpType Trochoid constant-displacement pump
Driving method Driven by engine
Number of teethInner rotor 9
Outer rotor 10
Hydraulic
controlTypeElectronic/hydraulic control [Four forward speed changes by electri-
cal signals of vehicle speed and accelerator (throttle) opening]
Fluid Dexron II or Dexron III type Automatic transmission fluid
Fluid capacity2200 cc 8.4 Ð 8.7(8.9 Ð 9.2 US qt, 7.4 Ð 7.7 Imp qt)
2500 cc 9.3 Ð 9.6(9.8 Ð 10.1 US qt, 8.2 Ð 8.4 Imp qt)
Lubrica-
tionLubrication 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 harness 17 poles
TransferTransfer clutch Hydraulic multi-plate clutch
Plate number of transfer clutchDrive plate & driven
plate2200 cc 4
2500 cc 5
Control method Electronic, hydraulic type
LubricantThe same Automatic Transmission
Fluid used in automatic transmission.
1st reduction gear ratio 1.000 (53/53)
3
[S1A0]3-2SPECIFICATIONS AND SERVICE DATA
1. Automatic Transmission and Differential

No. Part Name Part Number Dimension mm (in) Application
1 Rotor (Oil pump)15008AA060
15008AA070
15008AA08011.37 Ð 11.38 (0.4476 Ð 0.4480)
11.38 Ð 11.39 (0.4480 Ð 0.4484)
11.39 Ð 11.40 (0.4484 Ð 0.4488)Adjusting side clearance of oil
pump
2 Thrust bearing806528050
806528060
806528070
806528080
806528090
8065281004.11 (0.1618)
4.3 (0.169)
4.5 (0.177)
4.7 (0.185)
4.9 (0.193)
5.1 (0.201)Adjusting total end play
3Retaining plate
(High clutch)31567AA710
31567AA720
31567AA730
31567AA740
31567AA670
31567AA680
31567AA690
31567AA7004.7 (0.185)
4.8 (0.189)
4.9 (0.193)
5.0 (0.197)
5.1 (0.201)
5.2 (0.205)
5.3 (0.209)
5.4 (0.213)Adjusting clearance of high
clutch
4Retaining plate
(Reverse clutch)31567AA750
31567AA760
31567AA770
31567AA780
31567AA790
31567AA800
31567AA810
31567AA8203.8 (0.150)
4.0 (0.157)
4.2 (0.165)
4.4 (0.173)
4.6 (0.181)
4.8 (0.189)
5.0 (0.197)
5.2 (0.205)Adjusting clearance of reverse
clutch
5Retaining plate
(2-4 brake)31567AA610
31567AA620
31567AA630
31567AA640
31567AA650
31567AA6605.6 (0.220)
5.8 (0.228)
6.0 (0.236)
6.2 (0.244)
6.4 (0.252)
6.6 (0.260)Adjusting clearance of 2-4
brake
6Retaining plate
(Low clutch)31567AA830
31567AA840
31567AA850
31567AA860
31567AA8703.8 (0.150)
4.0 (0.157)
4.2 (0.165)
4.4 (0.173)
4.6 (0.181)Adjusting clearance of low
clutch
7Retaining plate
(Low and reverse
brake)31667AA320
31667AA330
31667AA340
31667AA350
31667AA360
31667AA370
31667AA3804.2 (0.165)
4.5 (0.177)
4.8 (0.189)
5.1 (0.201)
5.4 (0.213)
5.7 (0.224)
6.0 (0.236)Adjusting clearance of low
and reverse brake
8Pressure plate
(Transfer clutch)31593AA151
31593AA161
31593AA171
31593AA1813.3 (0.130)
3.7 (0.146)
4.1 (0.161)
4.5 (0.177)Adjusting clearance of transfer
clutch
9Thrust bearing
(Transfer clutch)806536020
806535030
806535040
806535050
806535060
806535070
8065350903.8 (0.150)
4.0 (0.157)
4.2 (0.165)
4.4 (0.173)
4.6 (0.181)
4.8 (0.189)
5.0 (0.197)Adjusting end play of transfer
clutch
10Washer
(Front differential)803038021
803038022
8030380230.95 (0.0374)
1.00 (0.0394)
1.05 (0.0413)Adjusting backlash of differen-
tial bevel gear
7
[S1B0]3-2SPECIFICATIONS AND SERVICE DATA
1. Automatic Transmission and Differential

No. Part Name Part NumberInside diameter
mm (in)Outside diameter
mm (in)Dimension
mm (in)Application
(1)Thrust needle
bearing806528050
806528060
806528070
806528080
806528090
80652810028.5 (1.122) 48 (1.89)4.1 (0.161)
4.3 (0.169)
4.5 (0.177)
4.7 (0.185)
4.9 (0.193)
5.1 (0.201)Adjusting total
end play
(2)Thrust needle
bearing806530040 30 (1.18) 47 (1.85) 3.8 (0.150)Place of high
clutch
(3)Thrust needle
bearing806551020 51 (2.01) 71 (2.80) 3.3 (0.130)Place of front sun
gear
(4)Thrust needle
bearing806535120 35 (1.38) 53 (2.09) 4.8 (0.189)Place of rear sun
gear
(5)Thrust needle
bearing806534060 35 (1.38) 53 (2.09) 3.3 (0.130)Place of rear sun
gear
(6)Thrust needle
bearing806558030 58 (2.28) 78 (3.07) 2.8 (0.110)Place of rear
internal gear
(7)Thrust needle
bearing806541020 39.7 (1.563) 54 (2.13) 3.6 (0.142)Place of one-way
clutch
(8)Thrust needle
bearing806536020
806535030
806535040
806535050
806535060
806535070
80653509036 (1.42) 53 (2.09)3.8 (0.150)
4.0 (0.157)
4.2 (0.165)
4.4 (0.173)
4.6 (0.181)
4.8 (0.189)
5.0 (0.197)Adjusting end play
of transfer clutch
D: FLUID PASSAGES
1. TRANSMISSION CASE (FRONT SIDE)
B3M0987A
(1) Low clutch pressure (2) Oil cooler inlet pressure (3) Low & reverse brake pressure
11
[S1D1]3-2SPECIFICATIONS AND SERVICE DATA
1. Automatic Transmission and Differential

2. TRANSMISSION CASE (LH SIDE)
B3M0988A
(1) Oil cooler outlet pressure
(2) Low & reverse brake pressure(3) Oil cooler inlet pressure
(4) Low clutch pressure(5) 2-4 brake pressure
3. TRANSMISSION CASE (REAR SIDE)
B3M0989A
(1) Pilot pressure (2) Line pressure
12
3-2[S1D2]SPECIFICATIONS AND SERVICE DATA
1. Automatic Transmission and Differential

4. OIL PUMP COVER
B3M0990A
(1) High clutch pressure
(2) Lock-up release pressure(3) Front lubricating hole
(4) Lock-up apply pressure(5) Reverse clutch pressure
5. OIL PUMP HOUSING
B3M0991A
(1) Oil pump outlet pressure
(2) Lock-up apply pressure
(3) Lock-up release pressure(4) High clutch pressure
(5) Drain
(6) Air breather(7) Reverse clutch pressure
13
[S1D5]3-2SPECIFICATIONS AND SERVICE DATA
1. Automatic Transmission and Differential

6. TRANSMISSION CASE
B3M0992A
(1) Oil pump inlet port
(2) Reverse clutch pressure
(3) Oil pump outlet port
(4) Lock-up apply pressure(5) Lock-up release pressure
(6) High clutch pressure
(7) Oil cooler outlet pressure
(8) Line pressure(9) Pilot pressure
(10) Low & reverse brake pressure
(11) Low clutch pressure
(12) 2-4 brake pressure
7. EXTENSION CASE
B3M0993A
14
3-2[S1D6]SPECIFICATIONS AND SERVICE DATA
1. Automatic Transmission and Differential