1996 SUBARU LEGACY brake

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

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

Unit: mm (in)
No. Part Name Part Number Inside diameter Outside diameter Dimension Application
AThrust needle
bearing806530020 30 (1.18) 47 (1.85) 3.3 (0.130)A place of high
clutch
BThrust needle
bearing806537010 38 (1.50) 53 (2.09) 3.2 (0.126)A place of high
clutch hub
CThrust needle
bearing806537010 38 (1.50) 53 (2.09) 3.2 (0.126)A place of front
sun gear
DThrust needle
bearing806558020 58 (2.28) 78 (3.07) 4.0 (0.157)A place of front
planetary carrier
EThrust needle
bearing806535120 35 (1.38) 53 (2.09) 4.8 (0.189)A place of rear
sun gear
FThrust needle
bearing806534010 34 (1.34) 53 (2.09) 3.37 (0.1327)A place of rear
internal gear
GThrust needle
bearing806558020 58 (2.28) 78 (3.07) 4.0 (0.157)A place of
overrunning clutch
hub
HThrust needle
bearing806542010 42 (1.65) 59 (2.32) 3.6 (0.142)A place of low &
reverse brake
IThrust needle
bearing806536020
806535030
36 (1.42) 53 (2.09)3.8, 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
∼
806535070
806535090
7
3-2SPECIFICATIONS AND SERVICE DATA
1. Automatic Transmission and Differential

6. Reverse Clutch and Band Brake
B3M0408A

1Brake band


2Reverse clutch drum


3Lip seal


4Piston


5Lathe cut seal ring


6Spring


7Spring retainer


8Snap ring


9Dish plate


10Driven plate


11Drive plate


12Retaining plate


13Snap ring

14Lock nut


15Brake band adjusting screw


16Strut


17Band servo piston stem


18Spring


19Lathe cut seal ring


20Band servo piston (1-2)


21O-ring


22Retainer


23O-ring


24Spring


25Retainer


26Circlip

27Lathe cut seal ring


28Band servo piston (3-4)


29O-ring


30O.D. servo retainer


31Snap ring


32Lathe cut seal ring


33O-ring


34Washer
Tightening torque: N⋅m (kg-m, ft-lb)
T: 26±2 (2.7±0.2, 19.5±1.4)
16
3-2COMPONENT PARTS
6. Reverse Clutch and Band Brake

8. Forward Clutch and Low & Reverse
Brake
B3M0401A

1Snap ring


2Retaining plate


3Drive plate (5)


4Driven plate (5)


5Dish plate


6Snap ring


7Retaining plate


8Drive plate


9Driven plate


10Dish plate


11Snap ring


12Spring retainer


13Spring


14Lathe cut seal ring


15Overrunning piston

16Lathe cut seal ring


17Forward piston


18Lip seal


19Lathe cut seal ring


20Forward clutch drum


21Needle bearing


22Snap ring


23One-way clutch (1-2)


24Snap ring


25Snap ring


26Retaining plate


27Drive plate (6)


28Driven plate (6)


29Dish plate


30Thrust needle bearing

31Needle bearing


32Seal ring


33Thrust washer


34One-way clutch inner race (1-2)


35Spring retainer


36Socket bolt


37Low & reverse piston


38Lathe cut seal ring


39Lathe cut seal ring
Tightening torque: N⋅m (kg-m, ft-lb)
T: 25±2 (2.5±0.2, 18.1±1.4)
18
3-2COMPONENT PARTS
8. Forward Clutch and Low & Reverse Brake

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

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.
38
3-2SERVICE PROCEDURE
3. Performance Test

Be sure to cool down the engine for at least one minute
after each stall test with the select lever set in the P or
N range and with the idle speed lower than 1,200 rpm.
If the stall speed is higher than the specified range,
attempt to finish the stall test in as short a time as
possible, in order to prevent the automatic transmis-
sion from sustaining damage.
Specifications
Stall speed (at sea level):
2200 cc 2,300 — 2,700 rpm
2500 cc 2,200 — 2,600 rpm
2500 cc OUTBACK 2,400 — 2,800 rpm
3. EVALUATION
Stall speed
(at sea level)Position Cause
Less than specifications2
RThrottle valve not fully open
Erroneous engine operation
Torque converter clutch’s one-way clutch slipping
Greater than specificationsDForward clutch slipping
One-way clutch (1-2) malfunctioning
RLine pressure too low
Reverse clutch slipping
Low & reverse brake slipping
2Line pressure too low
Forward clutch slipping
Brake band slipping
One-way clutch (3-4) malfunctioning
39
3-2SERVICE PROCEDURE
3. Performance Test