1996 SUBARU LEGACY Torque converter install

G2M0294
15) Separate torque converter from drive plate. (AT model)
(1) Lower the vehicle.
(2) Remove service hole plug.
(3) Remove bolts which hold torque converter to drive
plate.
(4) Remove other bolts while rotating the engine using
ST.
ST 499977000 CRANK PULLEY WRENCH
G2M0295
16) Remove pitching stopper.
B2M0336
17) Disconnect fuel delivery hose, return hose and evapo-
ration hose.
CAUTION:
Disconnect hose with its end wrapped with cloth to
prevent fuel from splashing.
Catch fuel from hose into container.
G2M0297
18) Support engine with a lifting device and wire ropes.
G2M0298
19) Support transmission with a garage jack.
CAUTION:
Before moving engine away from transmission, check
to be sure no work has been overlooked. Doing this is
very important in order to facilitate re-installation and
because transmission lowers under its own weight.
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2-11SERVICE PROCEDURE
2. Engine

B: INSTALLATION
1. Install engine to transmission.
2. Tighten bolts which hold upper side of transmission to engine.
3. Remove lifting device and wire rope.
4. Remove garage jack.
5. Install pitching stopper.
AT model
6. Install torque converter onto drive plate.
7. Install canister and bracket.
8. Install power steering pump on bracket.
9. Tighten nuts which hold lower side of transmission to engine.
10. Tighten nuts which install front cushion rubber onto cross-
member.
11. Install front exhaust pipe and center exhaust pipe.
12. Connect hoses, connectors and cables.
13. Install air intake system.
Air intake duct
Air cleaner element and upper cover.
With A/C
14. Install A/C pressure hoses.
15. Install cooling system.
16. Install battery onto the vehicle, and connect cables.
17. Fill coolant.
18. Check ATF level, and connect if necessary. [AT]
19. Correct power steering oil, and bleed air.
20. Remove front hood stay, and close front hood.
21. Take off the vehicle from lift arms.












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2-11SERVICE PROCEDURE
2. Engine

G2M0302
5) Install pitching stopper.
Tightening torque:
T1: 49±5 N⋅m (5.0±0.5 kg-m, 36.2±3.6 ft-lb)
T2: 57±10 N⋅m (5.8±1.0 kg-m, 42±7 ft-lb)
G2M0294
6) Install torque converter onto drive plate. (AT model)
(1) Tighten bolts which hold torque converter to drive
plate.
(2) Tighten other bolts while rotating the engine by
using ST.
ST 499977000 CRANK PULLEY WRENCH
CAUTION:
Be careful not to drop bolts into torque converter
housing.
Tightening torque:
25±2 N⋅m (2.5±0.2 kg-m, 18.1±1.4 ft-lb)
(3) Clog plug onto service hole.
G2M0272
7) Install canister and bracket.
B2M0334
8) Install power steering pump on bracket.
(1) Install power steering pump on bracket, and tighten
bolts.
Tightening torque:
39±10 N⋅m (4.0±1.0 kg-m, 29±7 ft-lb)
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2-11SERVICE PROCEDURE
2. Engine

G2M0545
(2) Disconnect the following cables.
Clutch release spring (MT model)
Clutch cable (MT model)
G2M0309
5) Remove starter.
(1) Disconnect connectors and terminal from starter.
(2) Remove bolt which installs upper side of starter.
(3) Remove nut which installs lower side of starter, and
remove starter from transmission.
G2M0295
6) Remove pitching stopper.
G2M0294
7) Separate torque converter from drive plate. (AT model)
(1) Remove service hole plug.
(2) Remove bolts which hold torque converter to drive
plate.
(3) While rotating the engine, remove other bolts using
ST.
ST 499977000 CRANK PULLEY WRENCH
CAUTION:
Be careful not to drop bolts into torque converter
housing.
B2M0031
8) Remove ATF level gauge. (AT model)
CAUTION:
Plug opening to prevent entry of foreign particles into
transmission fluid.
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2-11SERVICE PROCEDURE
3. Transmission

B: INSTALLATION
1. Install transmission to engine.
2. Install transmission rear crossmember.
3. Take off transmission jack.
4. Tighten nuts which hold lower side of transmission to engine.
5. Tighten bolt which holds right upper side of transmission to
engine.
AT model
6. Install torque converter to drive plate.
7. Remove special tools.
8. Install pitching stopper.
9. Install front drive shafts into transmission.
10. Install stabilizer clamps onto front crossmember.
11. Install gear shift rod and stay.

B










36
2-11SERVICE PROCEDURE
3. Transmission

G2M0294
6) Install torque converter to drive plate. (AT model)
(1) Tighten bolts which hold torque converter to drive
plate.
(2) Tighten other bolts while rotating the engine by
using ST.
ST 499977000 CRANK PULLEY WRENCH
CAUTION:
Be careful not to drop bolts into torque converter
housing.
Tightening torque:
25±2 N⋅m (2.5±0.2 kg-m, 18.1±1.4 ft-lb)
(3) Clog plug onto service hole.
B2M0017
(4) Install V-belt cover.
G2M0313
7) Remove special tools.
G2M0302
8) Install pitching stopper.
Tightening torque:
T1: 49±5 N⋅m (5.0±0.5 kg-m, 36.2±3.6 ft-lb)
T2: 57±10 N⋅m (5.8±1.0 kg-m, 42±7 ft-lb)
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2-11SERVICE PROCEDURE
3. Transmission

3. Performance Test
A: STALL TEST
1. GENERAL
The stall test is of extreme importance in diagnosing the
condition of the automatic transmission and the engine. It
should be conducted to measure the engine stall speeds in
all shift ranges except the P and N ranges.
Purposes of the stall test:
1) To check the operation of the automatic transmission
clutch.
2) To check the operation of the torque converter clutch.
3) To check engine performance.
2. TEST METHODS
Preparations before test:


1Check that throttle valve opens fully.


2Check that engine oil level is correct.


3Check that coolant level is correct.


4Check that ATF level is correct.


5Check that differential gear oil level is correct.


6Increase ATF temperature to 50 to 80°C (122 to 176°F)
by idling the engine for approximately 30 minutes (with
select lever set to“N”or“P”).
1) Install an engine tachometer at a location visible from
the driver’s compartment and mark the stall speed range
on the tachometer scale.
2) Place the wheel chocks at the front and rear of all
wheels and engage the parking brake.
3) Move the manual linkage to ensure it operates properly,
and shift the select lever to the 2 range.
B3M0286B
4) While forcibly depressing the foot brake pedal, gradu-
ally depress the accelerator pedal until the engine operates
at full throttle.
5) When the engine speed is stabilized, read that speed
quickly and release the accelerator pedal.
6) Shift the select lever to Neutral, and cool down the
engine by idling it for more than one minute.
7) Record the stall speed.
8) If stall speed in 2 range is higher than specifications,
forward clutch slipping on brake band slipping may occur.
To identify it, conduct the same test as above in D range.
9) Perform the stall tests with the select lever in the R
range.
CAUTION:
Do not continue the stall test for MORE THAN FIVE
SECONDS at a time (from closed throttle, fully open
throttle to stall speed reading). Failure to follow this
instruction causes the engine oil and ATF to deterio-
rate and the clutch and brake band to be adversely
affected.
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3-2SERVICE PROCEDURE
3. Performance Test

G3M0366
30) Remove the inhibitor switch.
G3M0367
31) Remove the transmission harness.
CAUTION:
Be careful not to damage the cord insulation.
G3M0368
4. TORQUE CONVERTER CLUTCH CASE SECTION
1) Wrap the axle shaft serration with vinyl tape.
2) Remove the differential side retainer with ST.
ST 499787000 WRENCH ASSY
CAUTION:
Hold the differential case assembly by hand to avoid
damaging retainer mounting hole of the torque con-
verter clutch case and speedometer gears.
G3M0956
3) Extract the axle shaft with ST1 and ST2.
ST1 499095500 REMOVER
ST2 499247300 INSTALLER
CAUTION:
Do not reuse the circlip.
G3M0370
4) Remove the differential case assembly.
CAUTION:
Remove the seal pipe if it is attached. (Reusing is
not allowed.)
Be careful not to damage the retainer mounting hole
of the torque converter clutch case and the speedom-
eter gears.
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3-2SERVICE PROCEDURE
4. Overall Transmission