SUBARU LEGACY 1999 Service Repair Manual

(1) Using a press and ST1, install the needle
bearing to the inner race.
ST1 398497701 INSTALLER
NOTE:
Use the following ST when removing.
ST 398527700 PULLER ASSY
B3M1409A
(2) Install two seal rings to one-way clutch inner
race.
NOTE:
Apply vaseline to the groove of the inner race and
to the seal ring after installation, so that the seal
ring will not expand.
B3M1100A
(3) Tighten eight socket head bolts from the
rear side of the transmission case.
Tightening torque:
25
±2 N´m (2.5±0.2 kg-m, 18.1±1.4 ft-lb)
CAUTION:
Be sure to tighten evenly.
B3M0958
(4) Install thrust needle bearing.NOTE:
Place transmission case with the front facing up.
12) Installation of the low & reverse brake:
(1) Install dish plate, driven plates, drive plates,
and a retaining plate, and secure with a snap
ring.
NOTE:
Pay attention to the orientation of the dish plate.
B3M1081A
(2) Apply compressed air intermittently to
check for operation.
B3M0957
(3) Check the clearance. (Selection of retaining
plate)
NOTE:
Before measuring clearance, place the same thick-
ness of shim on both sides to prevent retaining
plate from tilting.
Standard value:
0.7 Ð 1.2 mm (0.028 Ð 0.047 in)
Allowable limit:
2.2 mm (0.087 in)
B3M0977
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3-2[W11C2]SERVICE PROCEDURE
11. Overall Transmission

Available retaining plates
Part No. Thickness mm (in)
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)
13) Install leaf spring of low and reverse brake.
CAUTION:
Pay attention to the direction and position of
leaf spring during installation.
B3M0956A
14) Install O-ring to 2-4 brake piston.
CAUTION:
IIf O-ring breaks or damage is noted, replace
with new O-ring.
IApply a coat of vaseline to inner side of
O-ring before installation.
15) Install 2-4 brake piston to 2-4 brake piston
retainer.
B3M1080A
16) Install 2-4 brake piston and retainer to trans-
mission case.
CAUTION:
Align the hole in the 2-4 brake seal of transmis-
sion case with the hole in 2-4 brake piston
retainer during installation.
B3M1079A
17) Install 2-4 brake piston return spring to trans-
mission case.
B3M1078A
18) Position snap ring in transmission. Using ST,
press the snap ring into place.
ST 498677100 COMPRESSOR
B3M1101A
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[W11C2]3-2SERVICE PROCEDURE
11. Overall Transmission

19) Install planetary gear and low clutch assembly
to transmission case.
Install carefully while rotating the low clutch and
planetary gear assembly slowly paying special
attention not to damage the seal ring.
B3M1076A
20) Installation of the 2-4 brake:
(1) Install pressure plate, drive plate, driven
plate, retaining plate and snap ring.
B3M1075
(2) Install 2-4 brake oil seal to transmission
case.
NOTE:
Be sure to use a new one.
B3M1102A
(3) After all 2-4 brake component parts have
been installed, blow in air intermittently and con-
firm the operation of the brake.
B3M1103
(4) Measure the clearance between the retain-
ing plate and the snap ring.
NOTE:
Select a retaining plate with a suitable value from
the following table, so that the clearance becomes
the standard value.
Standard value:
0.8 Ð 1.2 mm (0.031 Ð 0.047 in)
Allowable limit:
1.5 mm (0.059 in)
B3M0980
Available retaining plates
Part No. Thickness mm (in)
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)
64
3-2[W11C2]SERVICE PROCEDURE
11. Overall Transmission

21) Install leaf spring of 2-4 brake.
NOTE:
Be careful not to mistake the location of the leaf
spring to be inserted.
B3M1104A
22) Install thrust needle bearing.
CAUTION:
Install thrust needle bearing in the correct
direction.
B3M1075
23) Install front sun gear and thrust needle bear-
ing.
CAUTION:
Install thrust needle bearing in the correct
direction.
B3M1072A
24) Install the high clutch hub and thrust needle
bearing.
Attach the thrust needle bearing to the hub with
vaseline and install the hub by correctly engaging
the splines of the front planetary carrier.
CAUTION:
Install thrust needle bearing in the correct
direction.
B3M1071A
25) Install the high clutch assembly.
NOTE:
Correctly engage the high clutch hub and clutch
splines.
B3M1070A
26) Adjustment of total end play:
(1) Using ST, measure the distance from the
transmission case mating surface to the
recessed portion of the high clutch drum ªLº.
ST 398643600 GAUGE
B3M0982A
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[W11C2]3-2SERVICE PROCEDURE
11. Overall Transmission

(2) Using ST, measure the distance from the oil
pump housing mating surface to the top surface
of the oil pump cover with thrust needle bearing.
ST 398643600 GAUGE
B3M0983A
(3) Calculation of total end play
Select suitable bearing race from among those
listed in this table so that clearance C is in the
0.25 Ð 0.55 mm (0.0098 Ð 0.0217 in) range.
C=(L+G)þ
CClearance between concave portion of high clutch
and end of clutch drum support
LLength from case mating surface to concave por-
tion of high clutch
G Gasket thickness (0.28 mm, 0.0110 in)
Height from housing mating surface to upper sur-
face of clutch drum support
B3M0984A
Thrust needle bearing
Part No. Thickness mm (in)
806528050
806528060
806528070
806528080
806528090
8065281004.1 (0.161)
4.3 (0.169)
4.5 (0.177)
4.7 (0.185)
4.9 (0.193)
5.1 (0.201)
27) Install the oil pump housing assembly.
(1) After completing end play adjustment, insert
the bearing race in the recess of the high clutch.
Attach the thrust needle bearing to the oil pump
cover with vaseline.(2) After correctly installing the gasket to the
case mating surface, carefully install the oil
pump housing assembly. Be careful to avoid hit-
ting the drive pinion against the inside of the
case.
CAUTION:
IBe careful not to damage the seal ring.
IBe sure to use a new gasket.
(3) Install both parts with dowel pins aligned.
Make sure no clearance exists at the mating
surface.
NOTE:
Any clearance suggests a damaged seal ring.
(4) Secure the housing with two nuts.
Tightening torque:
T: 4 1
±3 N´m (4.2±0.3 kg-m, 30.4±2.2 ft-lb)
B3M1068A
3. TORQUE CONVERTER CLUTCH CASE
AND TRANSMISSION CASE
1) Apply proper amount of liquid gasket (THREE
BOND Part No. 1215) to the entire torque con-
verter clutch case mating surface.
NOTE:
Make sure that the rubber seal and seal pipe are
fitted in position.
G3M0394
66
3-2[W11C3]SERVICE PROCEDURE
11. Overall Transmission

2) Install the torque converter clutch case assem-
bly to the transmission case assembly, and secure
with six bolts and four nuts.
CAUTION:
When installing, be careful not to damage the
torque converter clutch case bushing and oil
seal.
Tightening torque:
41
±3 N´m (4.2±0.3 kg-m, 30.4±2.2 ft-lb)
B3M1055A
4. CONTROL VALVE AND OIL PAN
1) Install and route the transmission harness.
CAUTION:
Be careful not to damage the harness.
B3M1067A
2) Install the control valve assembly.
(1) Set the select lever in range ªNº.(2) Install the control valve by engaging the
manual valve and manual lever, then tighten the
17 bolts.
CAUTION:
Tighten the control valve mounting bolts
evenly.
Tightening torque:
8
±1 N´m (0.8±0.1 kg-m, 5.8±0.7 ft-lb)
B3M1037A
(A) Short bolts
(B) Long bolts
3) Connect all connectors.
B2M2263C
(A) Lock-up duty solenoid (Blue)
(B) Low clutch timing solenoid (Gray)
(C) Line pressure duty solenoid (Red)
(D) Shift solenoid 2 (Yellow)
(E) Shift solenoid 1 (Green)
(F) 2-4 brake timing solenoid (Black)
(G) 2-4 brake duty solenoid (Red)
(H) ATF temperature sensor
4) Install the oil pan.
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[W11C4]3-2SERVICE PROCEDURE
11. Overall Transmission

(1) Attach the magnet at the specified position.
B3M1105A
(2) Apply proper amount of liquid gasket
(THREE BOND Part No. 1217B) to the entire oil
pan mating surace.
B3M1040A
(3) Install the oil pan to the transmission case
assembly, and secure with 20 bolts.
NOTE:
Tighten the bolts evenly.
Tightening torque:
4.9
±0.5 N´m (0.50±0.05 kg-m, 3.6±0.4 ft-lb)
B3M1065A
5) Install torque converter turbine speed sensor
and vehicle speed sensor 2 (front).
Tightening torque:
7
±1 N´m (0.7±0.1 kg-m, 5.1±0.7 ft-lb)
B3M1066A
5. EXTENSION SECTION
NOTE:
When installing new oil seal into extension case,
press it with ST.
ST 498057300 INSTALLER
1) Install the transfer pipe to extension case.
B3M1090A
2) Install the transfer clutch assembly to the case.
CAUTION:
Be careful not to damage the seal rings.
NOTE:
Insert the clutch assembly fully into position until
the bearing shoulder bottoms.
B3M1106A
68
3-2[W11C5]SERVICE PROCEDURE
11. Overall Transmission

6. CONNECTION OF EACH SECTION
1) Install the parking pawl, shaft and return spring.
B3M1062A
2) Install inlet filter to transmission case.
B3M1061A
3) Install transfer valve plate, valve body and duty
solenoid C (transfer) to transmission case.
CAUTION:
IBe sure to install transfer seal lip to transfer
control valve body.
IIf transfer seal lip is damaged, replace seal
with new one.
Tightening torque:
8
±1 N´m (0.8±0.1 kg-m, 5.8±0.7 ft-lb)
B2M2264A
4) Connect connector to duty solenoid C (trans-
fer).5) Install the reduction drive gear assembly.
NOTE:
Insert it fully into position until the bearing shoulder
bottoms.
B3M1113A
6) Using a plastic hammer, install reduction driven
gear assembly, and tighten drive pinion lock nut.
NOTE:
IBe sure to use a new lock nut and a washer.
ISet the select lever in the ªPº range.
IAfter tightening, stake the lock nut securely.
Tightening torque:
98
±5 N´m (10.0±0.5 kg-m, 72.3±3.6 ft-lb)
B3M1058A
7) Measurement and adjustment of extension end
play
(1) Measure distance L from end of extension
case and rear drive shaft with ST.
ST 398643600 GAUGE
L = Measured value þ 15 mm
B3M0985A
69
[W11C6]3-2SERVICE PROCEDURE
11. Overall Transmission

(2) Measure the distance ªº from the transmis-
sion case mating surface to the reduction drive
gear end surface with ST1 and ST2.
= Measured value þ 50 mm
ST1 398643600 GAUGE
ST2 499577000 GAUGE
B3M1114A
(3) Calculation equation:
NOTE:
Add 0.05 mm (0.0020 in) and 0.20 mm (0.0079 in)
thick shims to area ªTº. Calculate formula 2 to
determine ªHº. The calculated ªHº refers to the
shim thickness range. Select shims of suitable
thicknesses within the calculated ªHº range.
T=(L+G)þþH
T : Shim clearance
L : Distance from end of extension case to
end of rear drive shaft
G: Gasket thickness (0.45 mm, 0.0177 in)
: Height from end of transmission case to
end of reduction drive gear
H : Thrust needle bearing thickness
0.05 Ð 0.25 mm (0.0020 Ð 0.0098 in)
Thrust needle bearing
Part No. Thickness mm (in)
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)
8) Installation of extension case and transmission
case
(1) Attach the selected thrust needle bearing to
the end surface of reduction drive gear with
vaseline.
CAUTION:
Install thrust needle bearing in the correct
direction.
(2) Install the extension case to the transmis-
sion case.
CAUTION:
Be sure to use a new gasket.(3) Tighten bolts to secure the case.
Tightening torque:
25
±2 N´m (2.5±0.2 kg-m, 18.1±1.4 ft-lb)
B3M1057A
9) Install the vehicle speed sensor 1 (rear).
Tightening torque:
7
±1 N´m (0.7±0.1 kg-m, 5.1±0.7 ft-lb)
B3M1056A
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3-2[W11C6]SERVICE PROCEDURE
11. Overall Transmission

7. EXTERNAL PARTS
1) Using ST, install ATF filter to transmission case.
Calculate ATF filter torque specifications using the
following formula.
T
2=L2/(L1+L2)´T1T1:14±2 N´m (1.4±0.2 kg-m, 10.1±1.4 ft-lb)
[Required torque setting]
T
2: Tightening torque
L
1: ST length 0.078 m (3.07 in)
L
2: Torque wrench length
CAUTION:
Align ST with torque wrench while tightening
AFT filter.
ST 498545400 OIL FILTER WRENCH
B3M1084A
2) Adjustment of inhibitor switch
(1) With the select lever set to ªNº adjust the
inhibitor switch so that the hole of range select
lever is aligned with the inhibitor switch hole
with ST.
NOTE:
Ensure that gauge moves properly.
ST 499267300 STOPPER PIN
B3M1115A
(2) With hole aligned, tighten three bolts to
secure the inhibitor switch.
Tightening torque:
3.4
±0.5 N´m (0.35±0.05 kg-m, 2.5±0.4 ft-lb)
3) Install air breather hose.
B3M1051A
(A) Air breather hose (Transmission case)
(B) Air breather hose (Oil pump housing)
4) Clip the following cords and harness.
B3M1054A
(A) Transmission harness
(B) Inhibitor switch harness
5) Install the oil cooler outlet pipe.
CAUTION:
Be sure to use a new aluminum washer.
Tightening torque:
34
±3 N´m (3.5±0.3 kg-m, 25.3±2.2 ft-lb)
6) Install the oil cooler inlet pipe.
CAUTION:
Be sure to use a new aluminum washer.
Tightening torque:
25
±2 N´m (2.5±0.2 kg-m, 18.1±1.4 ft-lb)
B3M1053A
71
[W11C7]3-2SERVICE PROCEDURE
11. Overall Transmission