1996 SUBARU LEGACY low oil pressure

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.












20
2-11SERVICE PROCEDURE
2. Engine

No. Part Name Part Number Dimension mm (in) Application
1 Control piston2500 cc 31235AA000—030
13.5
0.030
0.037(0.53150.0012
0.0015), 13.50.023
0.030(0.53150.0009
0.0012),
13.50.016
0.023(0.53150.0006
0.0009), 13.50.009
0.016(0.53150.0004
0.0006)Adjusting side clear-
ance of oil pump
2200 cc 31235AA040 — 070
2 Cam ring 31241AA001 — 03117
0.010
0.017(0.66930.0004
0.0007), 170.003
0.010(0.66930.0001
0.0004),
17+0.004
0.003(0.6693+0.0002
0.0001), 17+0.011
+0.004(0.6693+0.0004
+0.0002)Adjusting side clear-
ance of oil pump
3 Vane (Oil pump) 31243AA000 — 03017
0.030
0.037(0.66930.0012
0.0015), 170.023
0.030(0.66930.0009
0.0012),
170.016
0.023(0.66930.0006
0.0009), 17+0.009
+0.016(0.6693+0.0004
+0.0006)Adjusting side clear-
ance of oil pump
4 Rotor (Oil pump) 31240AA000 — 03017
0.030
0.037(0.66930.0012
0.0015), 170.023
0.030(0.66930.0009
0.0012),
170.016
0.023(0.66930.0006
0.0009), 17+0.009
+0.016(0.6693+0.0004
+0.0006)Adjusting side clear-
ance of oil pump
5Thrust washer
(Reverse clutch)31299AA000 — 0600.7, 0.9, 1.1, 1.3, 1.5, 1.7, 1.9
(0.028, 0.035, 0.043, 0.051, 0.059, 0.067, 0.075)Adjusting end play of
reverse clutch drum
6 Bearing race 803031021 — 0270.8, 1.0, 1.2, 1.4, 1.6, 1.8, 2.0
(0.031, 0.039, 0.047, 0.055, 0.063, 0.071, 0.079)Adjusting total end
play
7 Retaining plate 31567AA350 — 4004.6, 4.8, 5.0, 5.2, 5.4, 5.6 (0.181, 0.189, 0.197, 0.205,
0.213, 0.220)Adjusting clearance
of reverse clutch
8 Retaining plate31567AA340,
31567AA190 — 2603.4, 3.6, 3.8, 4.0, 4.2, 4.4, 4.6, 4.8, 5.0
(0.134, 0.142, 0.150, 0.157, 0.165, 0.173, 0.181, 0.189,
0.197)Adjusting clearance
of high clutch
9 Retaining plate31567AA010,
31567AA060 — 1104.0, 4.2, 4.4, 4.6, 4.8, 5.0, 5.2
(0.157, 0.165, 0.173, 0.181, 0.189, 0.197, 0.205)Adjusting clearance
of forward clutch
10 Retaining plate 31567AA410 — 4708.0, 8.2, 8.4, 8.6, 8.8, 9.0, 9.2
(0.315, 0.323, 0.331, 0.339, 0.346, 0.354, 0.362)Adjusting clearance
of overrunning clutch
11Retaining plate
No. 231667AA180 — 2506.5, 6.8, 7.1, 7.4, 7.7, 8.0, 8.2, 8.4
(0.256, 0.268, 0.280, 0.291, 0.303, 0.315, 0.323, 0.331)Adjusting clearance
of low and reverse
brake
12Pressure plate
(Front)31593AA151 — 1813.3, 3.7, 4.1, 4.5
(0.130, 0.146, 0.161, 0.177)Adjusting clearance
of transfer clutch
13Thrust bearing
(35x53xT)806536020,
806535030 — 070,
0903.8, 4.0, 4.2, 4.4, 4.6, 4.8, 5.0
(0.150, 0.157, 0.165, 0.173, 0.181, 0.189, 0.197)Adjusting end play of
transfer clutch
14Washer
(38.1 x 50 x T)803038021 — 0230.95, 1.00, 1.05
(0.0374, 0.0394, 0.0413)Adjusting backlash
of differential bevel
gear
15 Drive pinion shim 31451AA050 — 1000.150, 0.175, 0.200, 0.225, 0.250, 0.275
(0.0059, 0.0069, 0.0079, 0.0089, 0.0098, 0.0108)Adjusting drive pin-
ion height
5
3-2SPECIFICATIONS AND SERVICE DATA
1. Automatic Transmission and Differential

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

G3M0859
Transmission cover
Transmission cover (Defective casting)
The point listed above should be checked for fluid leak.
Checking method is as follows:
(1) Place the vehicle in the pit, and check whether the
leaking oil is ATF or not. The ATF is wine red in color,
and can be discriminated easily from engine oil and
gear oil.
(2) Wipe clean the leaking oil and dust from a suspect-
able area, using a non-inflammable organic solvent
such as carbon tetrachloride.
(3) Run the engine to raise the fluid temperature, and
set the selector lever to“D”in order to increase the fluid
pressure and quickly detect a leaking point. Also check
for fluid leaks while shifting select lever to“R”,“2”, and
“1”.
G3M0289
B: ADJUSTMENT
1. BRAKE BAND
If the following abnormal shifting conditions are noted in a
road test, the brake band must be adjusted.
Improper brake band clearances and their symptoms
Clearance Problem
1. Too wide Upshift from 1st directly to 3rd gear occurs.
2. WideEngine rpm increases abruptly while upshifting from 1st
to 2nd gear or 3rd to 4th gear.
Time lag of at least one second occurs during kickdown
operation from 3rd to 2nd gear.
3. Small“Braking”symptom occurs while upshifting from 2nd to 3rd
gear.
4. Too smallUpshifts from 2nd to 4th gear and downshifts from 4th to
2nd gear occur repeatedly.
26
3-2SERVICE PROCEDURE
2. On-Car Services

G3M0863
(6) Remove control valve body and two brackets.
Remove 6 long bolts (Black) and 11 short bolts (Yellow).
NOTE:
Be careful because oil flows from valve body.
Be careful not to damage accumulator spring at rear of
control valve.
G3M0864
(7) Remove shift solenoids 1, 2, and 3, and duty sole-
noid A.
a length : 16 mm (0.63 in)
b length : 27 mm (1.06 in)
(8) Remove duty solenoid B.
G3M0302
2) Installation
(1) Install duty solenoid B (lock-up).
Tightening torque:
11.3±1.5 N⋅m (1.15±0.15 kg-m, 8.3±1.1 ft-lb)
G3M0864
(2) Install solenoid valves.
Shift solenoids, 1, 2 and 3, and duty solenoid A (line
pressure).
Tightening torque:
8±1 N⋅m (0.8±0.1 kg-m, 5.8±0.7 ft-lb)
32
3-2SERVICE PROCEDURE
2. On-Car Services

C: LINE PRESSURE TEST
1. GENERAL
If the clutch or the brake band shows a sign of slippage or
shifting sensation is not correct, the line pressure should be
checked.
Excessive shocks during upshifting or shifting takes
place at a higher point than under normal circumstances,
may be due to the line pressure being too high.
Slippage or inability to operate the vehicle may, in most
cases, be due to loss of oil pressure for the operation of
the clutch, brake band or control valve.
G3M0869
1) Line pressure measurement (under no load)
CAUTION:
Before measuring line pressure, jack-up front
wheels (front-wheel-drive model) or all wheels (4-wheel
drive model).
Maintain temperature of ATF at approximately 50°C
(122°F) during measurement.
(ATF will reach the above temperature after idling the
engine for approximately 30 minutes with select lever
in“N”or“P”.)
G3M0869
2) Line pressure measurement (under heavy load)
CAUTION:
Before measuring line pressure, apply both foot and
parking brakes with all wheels chocked (Same as for
“stall”test conditions).
Measure line pressure when select lever is in“R”,
“2”with engine under stall conditions.
Measure line pressure within 5 seconds after shift-
ing the select lever to each position. (If line pressure
needs to be measured again, allow the engine to idle
and then stop. Wait for at least one minute before mea-
surement.)
Maintain the temperature of ATF at approximately
50°C (122°F) during measurement. (ATF will reach the
above temperature after idling the engine for approxi-
mately 30 minutes with the select lever in“N”or“P”.)
41
3-2SERVICE PROCEDURE
3. Performance Test

G3M0317
2. TEST METHODS
1) Temporarily attach the ST to a suitable place in the
driver’s compartment, remove the blind plug located in
front of the toe board and pass the hose of the ST to the
engine compartment.
ST 498575400 OIL PRESSURE GAUGE ASSY


1Pressure gauge hose


2Hole in toe board (blank cap hole)


3Brake pedal
G3M0869
2) Remove the test plug and install ST1 instead.
3) Connect ST1 with ST2.
ST1 498897200 OIL PRESSURE GAUGE ADAPTER
ST2 498575400 OIL PRESSURE GAUGE ASSY
4) Check for duty ratio changes by opening and closing
throttle valve using select monitor.
5) Check line pressure in accordance with the following
chart.
3. EVALUATION
NOTE:
Under no load:“D”
Under full load:“R”,“2”
(With engine running at stall speed)

Unit: kPa (kg/cm2, psi)
Line pressure
Duty ratio (%)“2”range“R”range“D”range
2200 cc 2500 cc
51,147—1,344
(11.7—13.1, 166—195)1,275—1,569
(13.0—16.0, 185—228)—
22——765—902
(7.8—9.2, 111—131)
100——235—481
(2.4—4.9, 34—70)392—490
(4.0—5.0, 57—71)
42
3-2SERVICE PROCEDURE
3. Performance Test

G3M0870
D: TRANSFER CLUTCH PRESSURE TEST
Check transfer clutch pressure in accordance with the fol-
lowing chart in the same manner as with line pressure.
ST 499897700 OIL PRESSURE ADAPTER SET
ST 498575400 OIL PRESSURE GAUGE ASSY
AWD mode:“D”range
FWD mode:“P”range, engine speed 2000 rpm
CAUTION:
Before setting in FWD mode, install spare fuse on FWD
mode switch.
Unit: kPa (kg/cm2, psi)
Duty ratio
(%)AWD mode FWD mode
5667—804
(6.8—8.2, 97—117)667—804
(6.8—8.2, 97—117)
40137—226
(1.4—2.3, 20—33)—
950
(0, 0)—
If oil pressure is not produced or if it does not change in the
AWD mode, the duty solenoid C or transfer valve assem-
bly may be malfunctioning. If oil pressure is produced in the
FWD mode, the problem is similar to that in the AWD
mode.
E: ROAD TEST
1. GENERAL
Road tests should be conducted to properly diagnose the
condition of the automatic transmission.
CAUTION:
When performing test, do not exceed posted speed
limit.
2. CHECKING FOR SHIFT PATTERNS
Check“kick-down”.
D range: 1st
←
→2nd←
→3rd←
→4th
3 range: 1st←
→2nd←
→3rd←4th
2 range: 2nd←3rd←4th
1 range: 1st←2nd←3rd←4th
3. CHECK FOR ENGINE BRAKE OPERATION
Engine brake operation:
D range→4th gear
3 range→3rd gear
2 range→2nd gear
1 range→1st gear
43
3-2SERVICE PROCEDURE
3. Performance Test