1996 SUBARU LEGACY torque

G3M0640
10) Install ball bearing (29 x 74 x 38) on drive pinion shaft
with ST.
ST 499277100 INSTALLER
G3M0617
11) Position woodruff key in groove on the rear of drive
pinion shaft. Install 5th driven gear onto drive shaft using
ST and press.
ST 499277100 INSTALLER
CAUTION:
Face 5th driven gear in the correct direction.
Be careful not to dislocate woodruff key while
installing 5th gear.
B3M0353A
G3M0628
12) Install lock washer and tighten lock nut to the specified
torque using ST1 and ST2.
ST1 499987100 or 499987003 or 899984103 SOCKET
WRENCH (35)
ST2 899884100 HOLDER
CAUTION:
Discard old lock nuts, replace with new ones.
Secure lock nut in four places.
Tightening torque:
11 2—124 N⋅m (11.4—12.6 kg-m, 82—91 ft-lb)
59
3-1SERVICE PROCEDURE
6. Drive Pinion Assembly (FWD Model)

G3M0650
5) Drive ball bearing
1onto the rear section of transmis-
sion main shaft using ST1, ST2 and a press.
ST1 899714110 REMOVER
ST2 499877000 RACE 4-5 INSTALLER
B3M0091A
6) Using the same tools as in step 5) above, install the
following parts onto the rear section of transmission main
shaft.
5th gear thrust washer
NOTE:
Face thrust washer in the correct direction.


c: Face this surface to 5th gear side.
ST1 899714110 REMOVER
ST2 499877000 RACE 4-5 INSTALLER
5th needle bearing race
B3M0092A
7) Install the following parts to the rear section of transmis-
sion main shaft.
Needle bearing (32 x 36 x 25.7)
5th drive gear
Baulk ring
Sleeve

Aand hub assembly
Insert stopper plate

B
Lock washer
C(22x38x2)
Tighten lock nuts

D(22 x 13) to the specified torque
using ST1 and ST2.
ST1 499987003 SOCKET WRENCH (35)
ST2 498937000 TRANSMISSION HOLDER
NOTE:
Align groove

Ein baulk ring with shifting insert.
Be sure to fit pawl

Fof insert stopper plate into 4 mm
(0.16 in) dia. hole in the boss section of synchronizer hub.
Secure lock nuts in two places after tightening.
Tightening torque:
118±6 N⋅m (12.0±0.6 kg-m, 86.8±4.3 ft-lb)
62
3-1SERVICE PROCEDURE
7. Main Shaft Assembly

G3M0666
3) Align pinion shaft and differential case at their holes,
and drive straight pin

5into holes from the hypoid driven
gear side, using ST.
ST 899904100 REMOVER
NOTE:
Lock straight pin after installing.
G3M0671
4) Install roller bearing (40 x 80 x 19.75) to differential
case.
NOTE:
Be careful because roller bearing outer races are used as
a set.
ST1 499277100 BUSH 1-2 INSTALLER
ST2 398497701 ADAPTER
G3M0666
5) Install hypoid driven gear
4to differential case
10using
twelve bolts

3.
Tightening torque:
62±5 N⋅m (6.3±0.5 kg-m, 45.6±3.6 ft-lb)
67
3-1SERVICE PROCEDURE
9. Front Differential

1. Automatic Transmission and
Differential
A: SPECIFICATIONS
Torque
converter
clutchType Symmetric, 3 element, single stage, 2 phase torque converter clutch coupling
Stall torque ratio2200 cc 2.1 — 2.3
2500 cc 1.8 — 2.0
2500 cc
OUTBACK2.2—2.4
Nominal diameter2200 cc 236 mm (9.29 in)
2500 cc 246 mm (9.69 in)
Stall speed (at sea level)2200 cc 2,300 — 2,700 rpm
2500 cc 2,200 — 2,600 rpm
2500 cc
OUTBACK2,400 — 2,800 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 4 sets
Multi-plate brake 1 set
Band brake 1 set
One-way clutch (sprague type) 2 sets
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
2500 cc 37
Rear pinion2200 cc 17
2500 cc 19
Rear internal gear 75
Clutch number of reverse clutch Drive plate & driven plate 2
Clutch number of high clutch Drive plate & driven plate2200 cc ... 4
2500 cc ... 5
Clutch number of forward clutch Drive plate & driven plate 5
Clutch number of overrunning
clutchDrive plate & driven plate 3
Clutch number of low & reverse
brakeDrive plate & driven plateExcept 2500 cc OUTBACK ...
5
2500 cc OUTBACK ... 6
Selector positionP (Park)Transmission in neutral, output
member 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 possible
4th,3rd,2nd)
1 (1st)1st gear locked
(Deceleration possible
4th,3rd,2nd,1st)
Control method Hydraulic remote control
2
3-2SPECIFICATIONS AND SERVICE DATA
1. Automatic Transmission and Differential

1. Torque Converter Clutch and Case
B3M0104A

1Pitching stopper bracket


2Oil level gauge


3O-ring


4Oil seal


5Snap ring


6Washer


7Speedometer shaft


8Clip


9Oil pump shaft


10Seal ring


11Seal pipe


12Speedometer driven gear


13Snap ring


14Drain plug

15Oil seal


16Harness clip


17Torque converter clutch case


18Torque converter clutch


19O-ring


20Input shaft


21Gasket


22Oil drain pipe
Tightening torque: N⋅m (kg-m, ft-lb)
T1: 18±5 (1.8±0.5, 13.0±3.6)
T2: 41±3 (4.2±0.3, 30.4±2.2)
T3: 44±3 (4.5±0.3, 32.5±2.2)
10
3-2COMPONENT PARTS
1. Torque Converter Clutch and Case

2. Differential Case
G3M0846

1Crown gear


2Straight pin


3Pinion shaft


4Differential case (RH)


5Differential case (LH)


6Taper roller bearing


7Oil seal (LH)


8O-ring


9Differential side retainer


10Circlip


11Axle shaft

12Oil seal (RH)


13Speedometer drive gear


14Washer


15Differential bevel pinion


16Differential bevel gear


17Lock plate
Tightening torque: N⋅m (kg-m, ft-lb)
T1: 25±2 (2.5±0.2, 18.1±1.4)
T2: 62±5 (6.3±0.5, 45.6±3.6)
11
3-2COMPONENT PARTS
2. Differential Case

3. Oil Pump
B3M0354A

1Retainer


2Return spring


3Pin


4Friction ring


5O-ring


6Cam ring


7Vane ring


8Vane


9Rotor


10Oil pump cover


11Thrust washer


12Seal ring (R)


13Seal ring (H)


14Thrust needle bearing


15Thrust washer

16Air breather hose


17Drive pinion shaft


18Roller bearing


19Shim


20Test plug


21Oil pump housing


22Pin


23Side seal


24Control piston


25Plane seal


26Gasket


27O-ring


28Oil seal


29Oil seal retainer


30Drive pinion collar

31Lock washer


32Lock nut


33O-ring


34O-ring


35Nipple


36Stud bolt
Tightening torque: N⋅m (kg-m, ft-lb)
T1: 7±1 (0.7±0.1, 5.1±0.7)
T2: 13±1 (1.3±0.1, 9.4±0.7)
T3: 18±5 (1.8±0.5, 13.0±3.6)
T4: 25±2 (2.5±0.2, 18.1±1.4)
T5: 39±3 (4.0±0.3, 28.9±2.2)
T6: 41±3 (4.2±0.3, 30.4±2.2)
T7: 113±5 (11.5±0.5, 83.2±3.6)
12
3-2COMPONENT PARTS
3. Oil Pump

4. Control Valve and Harness Routing
B3M0106A

1Stay


2Oil strainer


3Transmission harness


4O-ring


5Duty sol. A (Line pressure)


6Sol. ASSY


7Upper valve body


8Ball


9Upper separator gasket


10Lower separator gasket


11Lower valve body


12Duty sol. B (Lock-up)

13Pipe


14Bracket


15Bracket


16O-ring


17Vehicle speed sensor 1 (FWD only)


18Separator plate
Tightening torque: N⋅m (kg-m, ft-lb)
T1: 7±1 (0.7±0.1, 5.1±0.7)
T2: 8±1 (0.8±0.1, 5.8±0.7)
T3: 11.3±1.5 (1.15±0.15, 8.3±1.1)
13
3-2COMPONENT PARTS
4. Control Valve and Harness Routing