1996 SUBARU LEGACY Torque converter install

B: ASSEMBLY OF OVERALL TRANSMISSION
1. TORQUE CONVERTER CLUTCH CASE SECTION
1) Check the appearance of each component and clean.
CAUTION:
Make sure each part is free of harmful cuts, damage
and other faults.
G3M0377
2) Install the washer and snap ring to the speedometer
shaft with ST, and set the oil seal. Then force-fit the shaft
to the torque converter clutch case.
ST 499827000 PRESS
3) Install vehicle speed sensor 2.
CAUTION:
Use new vehicle speed sensor 2, if it has been
removed.
Tightening torque:
5.9±1.5 N⋅m (60±15 kg-cm, 52±13 in-lb)
G3M0378
4) Install the speedometer driven gear to the speedometer
shaft, and secure with a snap ring.
G3M0379
5) Force-fit the oil seal to the torque converter clutch case
with ST.
ST 398437700 DRIFT
G3M0380
6) Install the differential assembly to the case, paying spe-
cial attention not to damage the speedometer gears (drive
and driven) and the inside of the case (particularly, the dif-
ferential side retainer contact surface).
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3-2SERVICE PROCEDURE
4. Overall Transmission

G3M0383
(2) Tighten four bolts to secure the roller bearing.
Tightening torque:
39±3 N⋅m (4.0±0.3 kg-m, 28.9±2.2 ft-lb)
G3M0883
(3) Install the oil pump housing assembly to the torque
converter clutch case, and secure evenly by tightening
four bolts.
Tightening torque:
41±3 N⋅m (4.2±0.3 kg-m, 30.4±2.2 ft-lb)
CAUTION:
Thoroughly remove the liquid gasket from the case
mating surface beforehand.
Use an old gasket or an aluminum washer so as not
to damage the mating surface of the housing.
G3M0384
(4) Rotate the drive pinion several times with ST1 and
ST2.
ST1 498937100 HOLDER
ST2 499787100 WRENCH
G3M0884
(5) Tighten the LH retainer until contact is felt while
rotating the shaft. Then loosen the RH retainer. Keep
tightening the LH retainer and loosening the RH
retainer until the pinion shaft can no longer be turned.
This is the“zero”state.
G3M0885
(6) After the“zero”state is established, back off the LH
retainer 3 notches and secure it with the lock plate.
Then back off the RH retainer and retighten until it
stops. Repeat this procedure several times. Tighten the
RH retainer 1-3/4 notches further. This sets the preload.
Finally, secure the retainer with its lock plate.
NOTE:
Turning the retainer by one tooth changes the backlash
about 0.05 mm (0.0020 in).
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3-2SERVICE PROCEDURE
4. Overall Transmission

G3M0885
(9) If tooth contact is correct, mark the retainer position
and loosen it. After fitting the O-ring, screw in the
retainer to the marked position. Then tighten the lock
plate to the specified torque.
Tightening torque:
25±2 N⋅m (2.5±0.2 kg-m, 18.1±1.4 ft-lb)
G3M0370
12) Install the seal pipe to the torque converter clutch
case.
CAUTION:
Be sure to use a new seal pipe.
G3M0390
13) Install two oil seals to the oil seal retainer with ST.
ST 499247300 INSTALLER
CAUTION:
Always discard old oil seals, and install new ones.
Pay attention to the orientation of the oil seals.
G3M0886
14) Attach the O-ring to the oil seal retainer with vaseline.
Install the seal to the oil pump housing bore.
CAUTION:
Always discard old O-rings and install new ones.
G3M0392
15) Install the oil seal retainer taking care not to damage
the oil seal lips. Then secure with three bolts.
NOTE:
Make sure the O-ring is fitted correctly in position.
Tightening torque:
7±1 N⋅m (0.7±0.1 kg-m, 5.1±0.7 ft-lb)
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3-2SERVICE PROCEDURE
4. Overall Transmission

G3M0393
16) Apply vaseline to the groove on the oil pump cover,
and install two (R) seal rings and two (H) seal rings.
NOTE:
Fit the seal ring after compressing, and rub vaseline into
the seal ring to avoid expansion.
The“R”seal ring has a large diameter, while“H”has
small diameter.
G3M0394
17) Install the rubber seal to the torque converter clutch
case.
CAUTION:
Be careful not to lose the rubber seal.
G3M0395
2. TRANSMISSION CASE SECTION
1) Press-fit the roller bearing to the transmission case with
ST.
ST 398487700 DRIFT
G3M0396
2) Using a plastic hammer, force-fit the oil seal.
G3M0397
3) Install the manual plate and shaft, and secure with a
spring pin.
CAUTION:
Be careful not to damage the oil seal lip.
NOTE:
After installation, make sure of smooth movement.
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3-2SERVICE PROCEDURE
4. Overall Transmission

G3M0424
(4) Secure the housing with two nuts.
Tightening torque:
41±3 N⋅m (4.2±0.3 kg-m, 30.4±2.2 ft-lb)
G3M0394
3. TORQUE CONVERTER CLUTCH CASE AND
TRANSMISSION CASE
1) Apply proper amount of liquid gasket (THREE BOND
Part No. 1215) to the entire torque converter clutch case
mating surface.
NOTE:
Make sure that the rubber seal and seal pipe are fitted in
position.
G3M0335
2) Install the torque converter clutch case assembly to the
transmission case assembly, and secure with six bolts and
four nuts.
Tightening torque:
41±3 N⋅m (4.2±0.3 kg-m, 30.4±2.2 ft-lb)
CAUTION:
When installing, be careful not to damage the torque
converter clutch case bushing and oil seal.
G3M0425
4. CONTROL VALVE AND OIL PAN
1) Install four accumulators with oil pans facing upward.
CAUTION:
Be careful not to confuse the springs and installation
positions.
Spring specification
Unit: mm (in)
Accumulator spring Outer diameter Free length
1—2 28.5 (1.122) 44.5 (1.752)
2—3 20.5 (0.807) 31.0 (1.220)
3—4 17.3 (0.681) 43.7 (1.720)
N—D 17.8 (0.701) 36.5 (1.437)
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3-2SERVICE PROCEDURE
4. Overall Transmission

G3M0325
10) Tighten the drain plugs.
Tightening torque:
Diff.
44±3 N⋅m (4.5±0.3 kg-m, 32.5±2.2 ft-lb)
AT F
25±2 N⋅m (2.5±0.2 kg-m, 18.1±1.4 ft-lb)
G3M0437
11) Insert the input shaft while turning lightly by hand.
CAUTION:
Be careful not to damage the bushing.
G3M0327
12) Install the torque converter clutch assembly.
(1) Install the oil pump shaft to the torque converter
clutch.
NOTE:
Make sure the clip fits securely in its groove.
(2) Holding the torque converter clutch assembly by
hand, carefully install it to the torque converter clutch
case. Be careful not to damage the bushing. Also avoid
undue contact between the oil pump shaft bushing and
stator shaft portion of the oil pump cover.
(3) Rotate the shaft lightly by hand to engage the
splines securely.
13) Fill ATF and differential gear oil.

Oil capacity:
Diff.
1.1—1.3(1.2—1.4 US qt, 1.0—1.1 Imp qt)
AT F
7.9—8.2(8.4—8.7 US qt, 7.0—7.2 Imp qt)
NOTE:
After filling oil, insert the oil level gauge into the oil inlet.
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3-2SERVICE PROCEDURE
4. Overall Transmission

6. Control Valve Body
The control valve is composed of parts which are accu-
rately machined to a high degree and should be handled
carefully during disassembly and assembly. As these parts
are similar in shape, they should be arranged in neat order
on a table after disassembly so that they can be easily
installed to their original positions. Spring loaded parts
should be also handled carefully, as springs may jump out
of place when the parts are disassembled or removed.
Extreme care should be taken so as not to drop valves on
the floor. Before assembling, the parts and valves should
be dipped in a container filled with the ATF. Make sure that
the valves are clean and free from any foreign material
before assembly. Torque specifications should also be
observed.
G3M0899

1Lock-up control sleeve


2Lock-up control plug


3Lock-up control valve


4Pilot valve


5Pressure regulator valve


6Pressure regulator plug


7Torque converter regulation valve


8Pressure regulator sleeve plug


9Accumulator control sleeve


10Accumulator control plug


11Shuttle duty shift valve


124-2 sequence valve


13Pressure modifier valve


14Shift valve B


154-2 relay valve


16Shift valve A


17Overrunning clutch control valve

18Overrunning clutch reducing valve


19Shuttle shift valve


20Manual valve


21Forward clutch control valve


221st reducing valve


233-2 timing valve


24Servo charger valve


25Pressure regulator spring


26Pressure modifier spring


27Modifier accumulator spring


28Pilot spring


29Accumulator control spring


30Shift B spring


31Shift A spring


32Shuttle shift spring


33Overrunning clutch control spring


344-2 sequence spring

354-2 relay spring


36Servo charger spring


373-2 timing spring


381st reducing spring


39Overrunning clutch reducing spring


40Torque converter regulator spring


41Lock-up control spring


42Shuttle duty shift spring
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3-2SERVICE PROCEDURE
6. Control Valve Body

Whine or growl (continuous or
intermittent)
While engine is running with/
without steering turned.Loosened installation of oil pump,
oil pump bracketRetighten.
*8
Abnormal inside of oil pump, hoseReplace oil pump, hose, if the
noise can be heard when running
as well as stand still.
Torque converter growl
air conditioner compression growlRemove power steering pulley
belt and confirm.
Creaking noise (intermittent)
While engine is running with
steering turned.Abnormal inside of gearboxReplace bad parts of gearbox.
Abnormal bearing for steering
shaftApply grease or replace.
*9
Generates when turning steering
wheel with brake (service or park-
ing) applied.If the noise goes off when brake
is released, it is normal.
*10
Vibration
While engine is running with/
without steering turned.
Too low engine speed at startAdjust and instruct customers.
Vane pump aerationFix wrong part.
Vent air.
Damaged valve in oil pump, gear-
boxReplace oil pump, bad parts of
gearbox.
Looseness of play of steering,
suspension partsRetighten.
*8 Oil pump makes whine or growl noise slightly due to its mechanism. Even if the noise can be heard when steering wheel
is turned at stand still there is no abnormal function in the system provided that the noise eliminates when the vehicle is
running.
*9 When stopping with service brake and/or parking brake applied, power steering can be operated easily due to its light
steering effort. If doing so, the disk rotates slightly and makes creaking noise. The noise is generated by creaking between
the disk and pads. If the noise goes off when the brake is released, there is no abnormal function in the system.
*10 There may be a little vibration around the steering devices when turning steering wheel at standstill, even though the com-
ponent parts are properly adjusted and have no defects.
Hydraulic systems are likely to generate this kind of vibration as well as working noise and fluid noise because of com-
bined conditions, i.e., road surface and tire surface, engine speed and turning speed of steering wheel, fluid temperature
and braking condition.
This phenomena does not indicate there is some abnormal function in the system.
The vibration can be known when steering wheel is turned repeatedly at various speeds from slow to rapid step by step
with parking brake applied on concrete road and in“D”range for automatic transmission vehicle.
96
4-3DIAGNOSTICS
1. Power Steering