1996 SUBARU LEGACY clutch

G3M0473
2) Set the retainer on the piston with a press using ST1
and ST2, and attach the snap ring.
ST1 498627000 SEAT
ST2 398673600 COMPRESSOR
G3M0479
3) Install the dish plate, driven plates, drive plates, and
retaining plate, and secure with the snap ring. (Overrun-
ning clutch)
NOTE:
Pay attention to the orientation of the dish plate.
G3M0480
4) Install the dish plates, driven plates, drive plates, and
retaining plate, and secure with the snap ring. (Forward
clutch)
NOTE:
Pay attention to the orientation of the dish plate.
G3M0481
5) Install the snap ring (for front planetary carrier).
G3M0474
6) Check the forward clutch and overrunning clutch for
operation.
Set the one-way clutch inner race, and apply compressed
air for checking.
103
3-2SERVICE PROCEDURE
11. Forward Clutch Drum

G3M0482
7) Checking clearance:
Forward clutch
Standard value:
0.45—0.85 mm (0.0177—0.0335 in)
Allowable limit:
1.6 mm (0.063 in)
Overrunning clutch
Standard value:
1.0—1.4 mm (0.039—0.055 in)
Allowable limit:
2.0 mm (0.079 in)
NOTE:
Before measuring clearance, place the same thickness of
shim on both sides to prevent retaining plate from tilting.
If the clearance is out of the specified range, select a
proper retaining plate so that the standard clearance can
be obtained.
Forward clutchPart No. Thickness mm (in)
31567AA270
31567AA280
31567AA290
31567AA300
31567AA310
31567AA320
31567AA3304.0 (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)
Overrunning clutchPart No. Thickness mm (in)
31567AA120
31567AA130
31567AA140
31567AA150
31567AA160
31567AA170
31567AA1808.0 (0.315)
8.2 (0.323)
8.4 (0.331)
8.6 (0.339)
8.8 (0.346)
9.0 (0.354)
9.2 (0.362)
G3M0476
8) Install the needle bearing, and secure with the snap
ring.
104
3-2SERVICE PROCEDURE
11. Forward Clutch Drum

G3M0484
9) Install the one-way clutch (1-2) and plate, and secure
with the snap ring.
NOTE:
Set the inner race. Make sure that the forward clutch is free
in the clockwise direction and locked in the counterclock-
wise direction, as viewed from the front of the vehicle.
G3M0911
12. One-way Clutch Outer Race
A: DISASSEMBLY
Remove the snap ring. Then remove the one-way clutch
(3-4).
B: INSPECTION
Check the sliding surface and one-way clutch (3-4) for any
harmful cuts, damage, or other faults.
G3M0486
C: ASSEMBLY
1) Assemble the one-way clutch (3-4), and secure with the
snap ring.
NOTE:
Pay attention to the orientation of the one-way clutch (3-4).
2) Assemble the rear internal gear, and secure the outer
race. Make sure that the internal gear is locked in the
clockwise direction, and free to rotate in the counterclock-
wise direction.
105
3-2SERVICE PROCEDURE
11. Forward Clutch Drum - 12. One-Way Clutch Outer Race

G3M0484
9) Install the one-way clutch (1-2) and plate, and secure
with the snap ring.
NOTE:
Set the inner race. Make sure that the forward clutch is free
in the clockwise direction and locked in the counterclock-
wise direction, as viewed from the front of the vehicle.
G3M0911
12. One-way Clutch Outer Race
A: DISASSEMBLY
Remove the snap ring. Then remove the one-way clutch
(3-4).
B: INSPECTION
Check the sliding surface and one-way clutch (3-4) for any
harmful cuts, damage, or other faults.
G3M0486
C: ASSEMBLY
1) Assemble the one-way clutch (3-4), and secure with the
snap ring.
NOTE:
Pay attention to the orientation of the one-way clutch (3-4).
2) Assemble the rear internal gear, and secure the outer
race. Make sure that the internal gear is locked in the
clockwise direction, and free to rotate in the counterclock-
wise direction.
105
3-2SERVICE PROCEDURE
11. Forward Clutch Drum - 12. One-Way Clutch Outer Race

G3M0493
15. Transfer Clutch
A: DISASSEMBLY
1) Remove the seal ring.
CAUTION:
Be careful not to damage the seal ring.
G3M0494
2) Using a press and ST, remove the ball bearing.
ST 498077000 REMOVER
CAUTION:
Do not reuse the bearing.
G3M0495
3) Remove the snap ring, and take out the pressure plate,
drive plates, and driven plates.
G3M0496
4) Remove the snap ring with ST1, ST2 and ST3, and take
out the spring retainer.
ST1 399893600 PLIERS
ST2 398673600 COMPRESSOR
ST3 498627000 SEAT
G3M0497
5) Apply compressed air to the rear drive shaft to remove
the piston.
109
3-2SERVICE PROCEDURE
15. Transfer Clutch

B: INSPECTION
1) Check the drive plate facing for wear and damage.
2) Check the snap ring for wear, return spring for perma-
nent set and breakage, and spring retainer for deformation.
3) Check the lathe cut ring for damage.
G3M0498
C: ASSEMBLY
1) Install the lathe cut seal ring to the I.D./O.D. of the
transfer clutch piston.
G3M0499
2) Install piston.
(1) Connect piston to rear drive shaft (until it reaches
hole in valve body).
(2) Install spring retainer to piston.
(3) Using ST1, ST2 and ST3, attach transfer piston
seal to ST2.
ST1 499247400 INSTALLER
ST2 499257400 PISTON GUIDE
ST3 498267400 TABLE
CAUTION:
Be careful not to tilt transfer piston seal.
G3M0500
(4) Place ST3 onto rear drive shaft so that spring can
be inserted into hole in transfer piston seal.
(5) Attach ST2 to rear drive shaft. Using ST1, press
into place.
ST1 499247400 INSTALLER
ST2 499257300 SNAP RING OUTER GUIDE
ST3 499257400 PISTON GUIDE
CAUTION:
Do not allow lip of transfer piston seal to fold back.
11 0
3-2SERVICE PROCEDURE
15. Transfer Clutch

G3M0501
3) Install the driven plates, drive plates, and pressure
plate, and secure with a snap ring with ST1, ST2 and a
press.
ST1 398673600 COMPRESSOR
ST2 498627000 SEAT
G3M0502
4) Apply compressed air to see if the assembled parts
move smoothly.
G3M0503
5) Check the clearance.
Standard value:
0.2—0.6 mm (0.008—0.024 in)
Allowable limit:
1.6 mm (0.063 in)
If the clearance is not within the specified range, select a
proper pressure plate.
NOTE:
Before measuring clearance, place the same thickness of
shim on both sides to prevent pressure plate from tilting.
Available pressure platesPart No. Thickness mm (in)
31593AA151
31593AA161
31593AA171
31593AA1813.3 (0.130)
3.7 (0.146)
4.1 (0.161)
4.5 (0.177)
G3M0505
6) Press-fit the ball bearing with ST.
ST 899580100 INSTALLER
111
3-2SERVICE PROCEDURE
15. Transfer Clutch

G3M0505
7) Coat the seal ring with vaseline, and install it in the seal
ring groove of the shaft.
CAUTION:
Do not expand the seal ring excessively when install-
ing.
ST 899580100 INSTALLER
G3M0913
16. Transfer Valve Body
A: DISASSEMBLY
1) Remove the plate. Then remove the spring and pilot
valve together.
2) Remove the straight pin and pry out the plug with a
screwdriver. Then extract the spring and transfer clutch
valve together.
CAUTION:
Be careful not to damage the valve and valve body.
B: INSPECTION
Check each component for harmful cuts, damage, or other
faults.
C: ASSEMBLY
To assemble, reverse the removal sequence.
NOTE:
Make sure the valve slides smoothly after assembling.
11 2
3-2SERVICE PROCEDURE
15. Transfer Clutch - 16. Transfer Valve Body