1996 SUBARU LEGACY clutch

Problem parts
Inhibitor switch
Control module
Vehicle speed sensor 1
Vehicle speed sensor 2
Select cable
Select lever
FWD switch
Starter motor and harness
Throttle position sensor
Diagnosis switch
Accumulator (“N”—“D”)
Accumulator (2A)
Accumulator (4A)
Accumulator (3R)
ATF temperature sensor
Strainer
Duty solenoid A
Duty solenoid B
Shift solenoid 1
Shift solenoid 2
Shift solenoid 3
Control valve
Detent spring
Manual plate
Transfer clutch
Transfer valve
Transfer pipe
Duty solenoid C
Forward clutch
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Engine brake is not effected when select
lever is in“3”or“2”range.
Engine brake is not effected when select
lever is in“1”range.X
Shift characteristics are erroneous.XXXX X X
No lock-up occurs. X X X X
Vehicle cannot be set in“D”range power
mode.XX
“D”range power mode cannot be released. X X X
Parking brake is not effected. X X
Shift lever cannot be moved or is hard to
move from“P”range.XX
Select lever is hard to move. X X X X
Select lever is too light to move (unreason-
able resistance).XX
ATF spurts out.
Differential oil spurts out.
Differential oil level changes excessively.
Odor is produced from oil supply pipe.XX
Shock occurs when select lever is moved
from“1”to“2”range.X XXXX X
Slippage occurs when select lever is moved
from“1”to“2”range.X XXXX X
Shock occurs when select lever is moved
from“2”to“3”range.XXXXXX
Slippage occurs when select lever is moved
from“2”to“3”range.XXXXXX
Shock occurs when select lever is moved
from“3”to“4”range.X X XXX X
Slippage occurs when select lever is moved
from“3”to“4”range.X X XXX X
Shock occurs when select lever is moved
from“3”to“2”range.XXXXX
Shock occurs when select lever is moved
from“D”to“1”range.XXXXX
Shock occurs when select lever is moved
from“2”to“1”range.XXXXX
Shock occurs when accelerator pedal is
released at medium speeds.XXXXX
Vibration occurs during straight-forward
operation.XX
Select lever slips out of position during
acceleration or while driving on rough terrain.XX XX
Vibration occurs during turns (tight corner
“braking”phenomenon).XXX X X XX X
Front wheel slippage occurs during standing
starts.X X X X X X XXXX
Vehicle is not set in FWD mode. X XXX X
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69
3-2AUTOMATIC TRANSMISSION AND DIFFERENTIAL
9. General Diagnostic Table

Overrunning clutch
Drive pinion
Crown gear
Axle shaft
Differential gear
Final gear
Seal pipe
Oil pump
High clutch
Band brake
Low & reverse clutch
Reverse clutch
One-way clutch (1-2)
One-way clutch (3-4)
Double oil seal
Input shaft
Output shaft
Planetary gear
Reduction gear
Drive plate
Torque converter one-way clutch
Lock-up facing
Lock-up damper
ATF deterioration
ATF level too high or too low
Differential gear oil level too high or too low
Engine performance
Engine speed signal
Parking brake mechanism
Problem parts
30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 Symptom
XEngine brake is not effected when select
lever is in“3”or“2”range.
XEngine brake is not effected when select
lever is in“1”range.
Shift characteristics are erroneous.
X X No lock-up occurs.
Vehicle cannot be set in“D”range power
mode.
“D”range power mode cannot be released.
X Parking brake is not effected.
XShift lever cannot be moved or is hard to
move from“P”range.
Select lever is hard to move.
Select lever is too light to move (unreason-
able resistance).
X ATF spurts out.
X Differential oil spurts out.
X X Differential oil level changes excessively.
X XXXX X XOdor is produced from oil supply pipe.
XXXShock occurs when select lever is moved
from“1”to“2”range.
XSlippage occurs when select lever is moved
from“1”to“2”range.
XX X XShock occurs when select lever is moved
from“2”to“3”range.
XXSlippage occurs when select lever is moved
from“2”to“3”range.
XX XXShock occurs when select lever is moved
from“3”to“4”range.
XSlippage occurs when select lever is moved
from“3”to“4”range.
XX XShock occurs when select lever is moved
from“3”to“2”range.
XShock occurs when select lever is moved
from“D”to“1”range.
XXShock occurs when select lever is moved
from“2”to“1”range.
XXShock occurs when accelerator pedal is
released at medium speeds.
XXVibration occurs during straight-forward
operation.
Select lever slips out of position during
acceleration or while driving on rough terrain.
XVibration occurs during turns (tight corner
“braking”phenomenon).
Front wheel slippage occurs during standing
starts.
Vehicle is not set in FWD mode.
30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58
70
3-2AUTOMATIC TRANSMISSION AND DIFFERENTIAL
9. General Diagnostic Table

3. Electrical Components Location
B6M0273A
1Actuator

2Vacuum pump and valve

3Inhibitor switch (AT)

4Cruise control main switch
5Cruise control command switch

6Cruise control module

7Stop and brake switch

8Clutch switch (MT)
5
6-2BODY ELECTRICAL SYSTEM
3. Electrical Components Location

5. Control Module I/O Signal
G6M0015
ContentTerminal
No.Measuring conditions and I/O signals (ignition switch ON and engine idling)
Main power supply 2
Battery voltage is present when main power is turned ON.

“0”volt is present when main power is turned OFF.
Inhibitor switch (AT) (U.S.A.)
N position switch (AT) (CANADA)4
“0”volt is present when selector lever is set to P or N position (CANADA: N position only).

Battery voltage is present when selector lever is other than P or N position (CANADA: N
position only).
Air valve 5
“0”volt is present when vehicle is stopped.

ON-and-OFF (“0”-and-battery voltage) operation is alternately repeated while cruise control
is operating.
GND 6—
Vacuum pump motor 7
“0”volt is present when vehicle is stopped.

ON-and-OFF (“0”-and-battery voltage) operation is alternately repeated while cruise control
is operating.
Data link connector 8—
RESUME/ACCEL switch 9
Battery voltage is present when switch is turned ON.

“0”volt is present when switch is turned OFF.
SET/COAST switch 10
Battery voltage is present when switch is turned ON.

“0”volt is present when switch is turned OFF.
Ignition switch 12
Battery voltage is present when ignition switch is turned ON.

“0”volt is present when ignition switch is turned OFF.
Release valve 13
“0”volt is present when vehicle is stopped.

ON-and-OFF (“0”-and-battery voltage) operation is alternately repeated while cruise control
is operating.
Power supply to vacuum pump
motor, air valve, release valve14
“0”volt is present when vehicle is stopped.

Battery voltage is present while cruise control is operating.
Cruise main switch 15
Battery voltage is present during pressing the main switch, and then approx. 12 V is
present while switch is turned ON.

“0”volt is present when switch is turned OFF.
Brake switch 16Turn the cruise main switch to ON and leave clutch pedal released (MT).
Then check that;

“0”volt is present when brake pedal is depressed.

Battery voltage is present when brake pedal is released.
Additionally only in MT vehicle, keep the cruise main switch to ON and leave brake pedal
released.
Then check that;

“0”volt is present when clutch pedal is depressed.

Battery voltage is present when clutch pedal is released.
Data link connector 17—
Data link connector 18—
Vehicle speed sensor 2 19Lift-up the vehicle until all four wheels are raised off ground, and then rotate any wheel manu-
ally.
Approx. 5 and 0 volt pulse signals are alternately input to cruise control module.
Stop light switch 20Turn ignition switch to OFF.
Then check that;

Battery voltage is present when brake pedal is depressed.

“0”volt is present when brake pedal is released.
NOTE:
Voltage at terminals 5, 7, 13 and 14 cannot be checked unless vehicle is driving by cruise control operation.
7
6-2BODY ELECTRICAL SYSTEM
5. Control Module I/O Signal

6. Diagnostics Chart for On-board
Diagnosis System
A: BASIC DIAGNOSTICS PROCEDURE
Trouble occurs.
Pre-inspection
Check if cruise control main switch turns ON prop-
erly.
OK
Not OK
Diagnostics Chart for Power Line [T700].>
(Main switch fails when turning to ON.)
Check if cruise speed is properly set while driving at
minimum of 40 km/h (25 MPH).
OK
Not OK
Diagnostics Chart with Trouble Code [T800].> (When cruise control cannot be set.)
Check if cruise control is properly released during
operation.
OK
Not OK
Check if cruise speed is held within set speed ±3
km/h (±2 MPH).
OK
Not OK
Basic inspection of actuator, vacuum pump and
valve (When is not running
at a fixed speed.)
Check if RESUME/ACCEL switch functions properly.
OK
Not OK
Diagnostics Chart with Trouble Code [T800].> (When cruise control cannot be set.)
Check if SET/COAST switch functions properly.
OK
Not OK
Check if CANCEL switch functions properly. (Airbag
equipped model)
OK
Not OK
Check if cruise speed is released when brake pedal
is depressed.
OK
Not OK
Set cruise speed again. Check if cruise speed is
released when clutch pedal is depressed (MT
model) or when select lever is moved to“Neutral.”
OK
Not OK
Cruise control system is in good order.











8
6-2BODY ELECTRICAL SYSTEM
6. Diagnostics Chart for On-board Diagnosis System

2. CRUISE CANCEL CONDITIONS DIAGNOSIS
1) Connect select monitor.
2) Start the engine and turn cruise control main switch to
ON.
3) Set select monitor in“FB0”mode.
4) Drive vehicle at least 40 km/h (25 MPH) with cruise
speed set.
5) If cruise speed is canceled itself (without doing any
cancel operations), a trouble code will appear on select
monitor display.
CAUTION:

A trouble code will also appear when cruise cancel
is effected by driver. Do not confuse.

Have a co-worker ride in vehicle to assist in diagno-
sis during driving.
NOTE:
Trouble code will be cleared by turning ignition switch or
cruise control main switch to OFF.
3. REAL-TIME DIAGNOSIS
1) Connect select monitor.
2) Turn ignition switch and cruise control main switch to
ON.
3) Set select monitor in“FA 0”mode.
4) Ensure that normal indication is displayed when con-
trols are operated as indicated below:

When SET/COAST switch is pressed.

When RESUME/ACCEL switch is pressed.

When brake pedal is depressed. (Stop and brake switch
turns ON.)

When clutch pedal is depressed. (MT model)

When select lever is set to N position. (AT model)
10
6-2BODY ELECTRICAL SYSTEM
6. Diagnostics Chart for On-board Diagnosis System

8. Diagnostics Chart with Trouble Code
A: TROUBLE CODE
Trouble code Item Contents of diagnosis Page
10 OK Normal 18
11 BRAKE/ST/CL or N
Input signals from brake switch“OFF”, stop light
switch“ON”(Brake pedal is in depressed condi-
tion.)

Input signals from clutch switch“OFF”, or inhibi-
tor switch is in“N”position.
[Clutch pedal is depressed (MT), or select lever
is set to N position (AT).]20
12 NOT SET SP Out of cruise speed range 22
13 LOW SP LIM Low-speed control limiter 22
14 CANCEL SW Input signal from cancel switch 26
15 NO MEMORY No memorized cruise speed—
21 SP SENS NG Faulty vehicle speed sensor 2 22
22 COM SW NGFaulty SET/COAST switch or RESUME/ACCEL
switch26
23 RELAY NG Faulty safety relay included in cruise control module 29
24 CPU RAM NG Faulty CPU RAM included in cruise control module 29
31 MOTOR NG Faulty vacuum motor or motor drive system 30
32 AIR VAL NG Faulty air valve or valve drive system 30
33 REL VAL NG Faulty release valve or valve drive system 30
16
6-2BODY ELECTRICAL SYSTEM
8. Diagnostics Chart with Trouble Code

LED No. Signal name Display
1 SET/COAST switch SE
2 RESUME/ACCEL switch RE
3 Stop light switch ST
4
Brake switch

Clutch switch (MT)BR
5 Inhibitor switch (AT) N
6——
7——
8——
9——
10——
SE RE ST BR N
—————
1
2345
678910
1. CHECK THE SIGNAL USING A SELECT MONITOR.
1) Turn ignition switch to ON.
2) Turn cruise control main switch to ON.
3) Set select monitor in“FA 0”mode.
4) Check signals for proper operation.
(1) When pushing the SET switch:
LED No. 1 goes out—lights.
(2) When pushing the RESUME switch:
LED No. 2 goes out—lights.
B6M0533
B6M0527
2. CHECK THE CRUISE CONTROL COMMAND
SWITCH.
1) Disconnect connector from command switch.
2) Measure voltage between connector (S1) and body.
Connector & terminal / Specified voltage:
(S1) No. 1—Body / 10 V, or more
3) Check for harness short circuit between command
switch and body.
Terminals / Specified resistance:
No. 2—Body / 1 MΩ, min.
No. 3—Body / 1 MΩ, min.
B6M0534
4) Measure resistance between each terminal of switch
side connector to check the switch operation.
Terminals:
No. 1—No. 2 (SET/COAST SWITCH)
No. 1—No. 3 (RESUME/ACCEL SWITCH)
Specified resistance:
10Ω, max. (ON)
1MΩ, min. (OFF)
18
6-2BODY ELECTRICAL SYSTEM
8. Diagnostics Chart with Trouble Code