1996 SUBARU LEGACY clutch

G2M0545
(2) Disconnect the following cables.
Clutch release spring (MT model)
Clutch cable (MT model)
G2M0309
5) Remove starter.
(1) Disconnect connectors and terminal from starter.
(2) Remove bolt which installs upper side of starter.
(3) Remove nut which installs lower side of starter, and
remove starter from transmission.
G2M0295
6) Remove pitching stopper.
G2M0294
7) Separate torque converter from drive plate. (AT model)
(1) Remove service hole plug.
(2) Remove bolts which hold torque converter to drive
plate.
(3) While rotating the engine, remove other bolts using
ST.
ST 499977000 CRANK PULLEY WRENCH
CAUTION:
Be careful not to drop bolts into torque converter
housing.
B2M0031
8) Remove ATF level gauge. (AT model)
CAUTION:
Plug opening to prevent entry of foreign particles into
transmission fluid.
30
2-11SERVICE PROCEDURE
3. Transmission

G2M0292
20) Remove nuts which hold lower side of transmission to
engine.
G2M0326
21) Place transmission jack under transmission.
CAUTION:
Always support transmission case with a transmis-
sion jack.
On AT model, make sure that the support plates of
transmission jack don’t touch the oil pan.
G2M0831
22) Remove transmission rear crossmember.
MT model
G2M0583
AT model
B2M0035
23) Remove transmission.
CAUTION:
Move transmission jack toward rear until mainshaft
is withdrawn from clutch cover. (MT model)
Move transmission and torque converter as a unit
away from engine. (AT model)
35
2-11SERVICE PROCEDURE
3. Transmission

B2M0035
1) Install transmission onto engine.
(1) Gradually raise transmission with transmission
jack.
(2) Engage them at splines.
CAUTION:
Be careful not to strike mainshaft against clutch cover.
(MT model)
G2M0832
2) Install transmission rear crossmember.
MT model
Tightening torque:
T1: 69±15 N⋅m (7.0±1.5 kg-m, 51±11 ft-lb)
T2: 137±20 N⋅m (14±2 kg-m, 101±14 ft-lb)
G2M0332
AT model
Tightening torque:
T1: 18±5 N⋅m (1.8±0.5 kg-m, 13.0±3.6 ft-lb)
T2: 69±15 N⋅m (7.0±1.5 kg-m, 51±11 ft-lb)
G2M0292
3) Take off transmission jack.
4) Tighten nuts which hold lower side of transmission to
engine.
Tightening torque:
50±4 N⋅m (5.1±0.4 kg-m, 36.9±2.9 ft-lb)
G2M0299
5) Tighten bolt which holds right upper side of transmis-
sion to engine.
Tightening torque:
50±4 N⋅m (5.1±0.4 kg-m, 36.9±2.9 ft-lb)
38
2-11SERVICE PROCEDURE
3. Transmission

G2M0312
16) Install transmission connector holder bracket.
B2M0031
17) Install ATF level gauge. (AT model)
18) Connect connectors and cables.
(1) Connect the following connectors.
Transmission harness connectors
Transmission ground terminal
Front oxygen sensor connector
Vehicle speed sensor 2
Neutral position switch connector (MT model)
Back-up light switch connector (MT model)
(2) Connect the following cables.
Cruise control cable
(With cruise control model)
Clutch cable
G2M0309
19) Install starter.
(1) Install starter onto transmission case, and connect
connectors and terminals.
(2) Tighten bolt and nut which install starter onto trans-
mission.
Tightening torque:
40±4 N⋅m (4.1±0.4 kg-m, 29.7±2.9 ft-lb)
43
2-11SERVICE PROCEDURE
3. Transmission

4. Transmission Case
A: DISASSEMBLY
1. SEPARATION OF TRANSMISSION
B3M0329A
B3M0336A
1) Remove clutch release lever
1and bearing
2. (Refer
to 2-10 clutch.)
G3M0597
2) Remove bearing mounting bolts.
33
3-1SERVICE PROCEDURE
4. Transmission Case

G3M0557
3) Install differential assembly
3on left hand transmission
case.
CAUTION:
Be careful not to fold the sealing lip of oil seal.
NOTE:
Wrap the left and right splined sections of axle shaft with
vinyl tape to prevent scratches.
G3M0558
4) Install needle bearing and oil seal onto the front of
transmission main shaft assembly

4, and position in left
side transmission case.
CAUTION:
Wrap clutch splined section with vinyl tape to pre-
vent damage to oil seal.
Apply grease (Unilube #2 or equivalent) to the seal-
ing lip of oil seal.
NOTE:
Align the end face of seal with surface A of left side
transmission main case when installing oil seal.
Be careful not to drop oil seal when installing right side
transmission main case.
Make sure straight pin is positioned in hole in needle
bearing’s outer race.
G3M0575
5) Install drive pinion shaft assembly
5with shims
selected before into transmission case.
NOTE:
Ensure that the knock pin of the case is fitted into the hole
in the bearing outer race.
43
3-1SERVICE PROCEDURE
4. Transmission Case

G3M0573
12) Selecting of main shaft rear plate
Using ST, measure the amount A of ball bearing protrusion
from transmission main case surface and select the proper
plate in the following table:
ST 498147000 DEPTH GAUGE
Dimension“A”
mm (in)Part No. Mark
4.00—4.13
(0.1575—0.1626)32294AA040 1
3.87—3.99
(0.1524—0.1571)32294AA050 2
NOTE:
Before measuring, tap the end of main shaft with a plastic
hammer lightly in order to make the clearance zero
between the main case surface and the moving flange of
bearing.
B3M0336A
13) Install clutch release lever
1and bearing
2.
49
3-1SERVICE PROCEDURE
4. Transmission Case

1. Manual Transmission and
Differential
Symptom and possible cause Remedy
1. Gears are difficult to intermesh.
The cause for difficulty in shifting gears can be classified into two kinds: one is malfunction of the gear shift system and the
other is malfunction of the transmission. However, if the operation is heavy and engagement of the gears is difficult, defective
clutch disengagement may also be responsible. Check whether the clutch is correctly functioning, before checking the gear
shift system and transmission.
(a) Worn, damaged or burred chamfer of internal spline of
sleeve and reverse driven gearReplace.
(b) Worn, damaged or burred chamfer of spline of gears Replace.
(c) Worn or scratched bushings Replace.
(d) Incorrect contact between synchronizer ring and gear
cone or wearCorrect or replace.
2. Gear slips out.
(1) Gear slips out when coasting on rough road.
(2) Gear slips out during acceleration.
(a) Defective pitching stopper adjustment Adjust.
(b) Loose engine mounting bolts Tighten or replace.
(c) Worn fork shifter, broken shifter fork rail spring Replace.
(d) Worn or damaged ball bearing Replace.
(e) Excessive clearance between splines of synchronizer hub
and synchronizer sleeveReplace.
(f) Worn tooth step of synchronizer hub (responsible for slip-
out of 3rd gear)Replace.
(g) Worn 1st driven gear, needle bearing and race Replace.
(h) Worn 2nd driven gear, needle bearing and race Replace.
(i) Worn 3rd drive gear and bushing Replace.
(j) Worn 4th drive gear and bushing Replace.
(k) Worn reverse idler gear and bushing Replace.
3. Unusual noise comes from transmission.
If an unusual noise is heard when the vehicle is parked with its engine idling and if the noise ceases when the clutch is
disengaged, it may be considered that the noise comes from the transmission.
(a) Insufficient or improper lubrication Lubricate or replace with specified oil.
(b) Worn or damaged gears and bearings Replace.
NOTE: If the trouble is only wear of the tooth surfaces, merely
a high roaring noise will occur at high speeds, but if any part
is broken, rhythmical knocking sound will be heard even at
low speeds.
69
3-1DIAGNOSTICS
1. Manual Transmission and Differential