1996 SUBARU LEGACY clutch

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
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3-2SERVICE PROCEDURE
3. Performance Test

B: TIME LAG TEST
1. GENERAL
If the shift lever is shifted while the engine is idling, there
will be a certain time elapse or lag before the shock can be
felt. This is used for checking the condition of the forward
clutch, reverse clutch, low & reverse brake, forward one-
way clutch and low one-way clutch.
CAUTION:
Perform the test at normal operation fluid tempera-
ture 60 to 80°C (140 to 176°F).
Be sure to allow a one minute interval between tests.
Make three measurements and take the average
value.
2. TEST METHODS
1) Fully apply the parking brake.
2) Start the engine.
Check idling speed (A/C OFF).
“N”range: 800±100 rpm
3) Shift the shift lever from“N”to“D”range.
Using a stop watch, measure the time it takes from shift-
ing the lever until the shock is felt.
Time lag: Less than 1.2 seconds
4) In same manner, measure the time lag for“N”,“R”.
Time lag: Less than 1.5 seconds
3. EVALUATION
1) If“N”,“D”time lag is longer than specified:
Line pressure too low
Forward clutch worn
Low one-way clutch not operating properly
2) If“N”,“R”time lag is longer than specified:
Line pressure too low
Reverse clutch worn
Low & reverse brake worn
Forward one-way clutch not operating properly
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3-2SERVICE PROCEDURE
3. Performance Test

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”.)
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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
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3-2SERVICE PROCEDURE
3. Performance Test

4. CHECK FOR THE AWD FUNCTION
If“tight-corner braking”occurs when the steering wheel is
fully turned at low speed:
1) Determine the applicable trouble code and check the
corresponding duty solenoid C (transfer) for improper
operation.
2) If the solenoid is operating properly, check transfer
clutch pressure.
3) If oil pressure is normal but“tight-corner braking”
occurs:
Check the transfer control valve for sticking, and the trans-
fer clutch facing for wear.

44
3-2SERVICE PROCEDURE
3. Performance Test

G3M0871
A: DISASSEMBLY
1. EXTERNAL PARTS
1) Place the transmission unit on a work bench, with the
oil pan facing down.
CAUTION:
Be careful not to bend or damage external parts.
G3M0325
2) Remove the drain plug, and drain differential oil. Tighten
the plug temporarily after draining.
G3M0326
3) Remove the drain plug, and drain automatic transmis-
sion fluid (ATF). Tighten the plug temporarily after draining.
G3M0327
4) Extract the torque converter clutch assembly.
NOTE:
Extract the torque converter clutch horizontally. Be care-
ful not to scratch the bushing inside the oil pump shaft.
Note that oil pump shaft also comes out.
G3M0328
5) Remove the input shaft.
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3-2SERVICE PROCEDURE
4. Overall Transmission

G3M0874
2. SEPARATION OF EACH SECTION
1) Separation of torque converter clutch case and trans-
mission case sections
CAUTION:
Be careful not to damage the oil seal and bushing
inside the torque converter clutch case by the oil pump
cover.
Be careful not to lose the rubber seal.
NOTE:
Separate these cases while tapping lightly on the housing.
G3M0336
2) Separation of transmission case and extension sections
(AWD)
(1) Remove vehicle speed sensor 1.
G3M0337
(2) While pulling the extension slightly, disconnect the
connector for the duty solenoid C (transfer).
CAUTION:
Be careful not to cut the harness.
3) Separate both sections.
G3M0338
3. TRANSMISSION CASE SECTION
1) Remove the reduction drive gear assembly.
G3M0339
2) Remove the reduction driven gear.
(1) Straighten the staked portion, and remove the lock
nut.
NOTE:
Set the range selector lever to“P”.
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3-2SERVICE PROCEDURE
4. Overall Transmission

G3M0346
11) Remove the three accumulator springs.
G3M0347
12) Loosen the reverse clutch drum lightly by turning the
adjusting screw. Then remove the oil pump housing.
CAUTION:
Be careful not to lose the total end play adjusting
thrust washer.
G3M0348
13) Loosen the brake band adjusting screw with ST, and
take out the strut.
ST 398603610 SOCKET WRENCH
G3M0349
14) Remove the brake band and reverse clutch.
NOTE:
Contract the brake band with a clip.
G3M0350
15) Take out the high clutch.
CAUTION:
Thrust needle bearing and bearing race are removed
together with high clutch. Be careful not to lose them.
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3-2SERVICE PROCEDURE
4. Overall Transmission