1996 SUBARU LEGACY Rear differential ratio

1. Manual Transmission and
Differential
A: SPECIFICATIONS
ItemModel
FWD AWD
2200 cc 2200 cc*2200 cc
OUTBACK
Type 5-forward speeds with synchromesh and 1-reverse
Transmission gear ratio1st 3.545
2nd 2.111
3rd 1.448
4th 1.088
5th 0.825 0.780 0.871
Reverse 3.416
Front
reduction
gearFinalType of gear Hypoid
Gear ratio 3.454 3.900 4.111
Rear
reduction
gearTransferType of gear — Helical
Gear ratio — 1.000
FinalType of gear — Hypoid
Gear ratio — 3.900 4.111
Front
differentialType and number of gear Straight bevel gear (Bevel pinion: 2, Bevel gear: 2)
Center
differentialType and number of gear —Straight bevel gear
(Bevel pinion: 2, Bevel gear: 2 and viscous coupling)
Transmission gear oil GL-5
Transmission oil capacity3.3
(3.5 US qt, 2.9 Imp
qt)3.5
(3.7 US qt, 3.1 Imp qt)
*: Step roof model only
2
3-1SPECIFICATIONS AND SERVICE DATA
1. Manual Transmission and Differential

1. General
A: APPLICATION
Large titleModel
AWD FWD
1 General


2Transfer Case and Extension
(AWD Model)

3 Rear Case (FWD Model)

4 Transmission Case


5 Drive Pinion Assembly (AWD Model)

6 Drive Pinion Assembly (FWD Model)

7 Main Shaft Assembly


8 Center Differential (AWD Model)

9 Front Differential


The table above shows the titles of the main sections in
Service Procedures and the applicable vehicle models.
Carry out service operations by referring to the sections
applicable to the vehicle to be serviced.
15
3-1SERVICE PROCEDURE
1. General

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

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

1. AWD System
A: SPECIFICATIONS
1. REAR FINAL REDUCTION GEAR RATIO
Type of gearHypoid
MT AT
2200 cc*2200 cc
OUTBACK2200 cc 2500 cc
Gear ratio
(Number of
gear teeth)3.900
(39/10)4 . 111
(37/9)4 . 111
(37/9)4.444
(40/9)
Oil capacity 0.8
(0.8 US qt, 0.7 Imp qt)
Rear
differential
gear oilGL-5
*: Step roof model only
2. PROPELLER SHAFT
Front propeller shaft
Joint-to-joint length:
L mm (in)AT 539 (21.22)
MT 598 (23.54)
Outside dia. of tube
mm (in)D
163.5 (2.500)
D
257.0 (2.244)
G3M0014
2
3-4SPECIFICATIONS AND SERVICE DATA
1. AWD System

G3M1049
B: IDENTIFICATION
When replacing a rear differential assembly, select the cor-
rect one according to the following table.
CAUTION:
Using the different rear differential assembly causes
the drive line and tires to “drag” or emit abnormal
noise when AWD is selected.
Gear ratio Part number Label stuck on rear differential
2200 cc
MT3.900 38369AA450
B3M0124
2200 cc
AT
4.111 38369AA460
B3M0127
*2200 cc
OUTBACK
MT
2500 cc
AT4.444 38369AA510
B3M0421
*: Step roof model only
3
3-4SPECIFICATIONS AND SERVICE DATA
1. AWD System

Symptom and possible cause Remedy
5. Noises when cornering


1Damaged differential gear. Replace.


2Excessive wear or damage of thrust washer. Replace.


3Broken pinion mate shaft. Replace.


4Seized or damaged side bearing. Replace.
6. Gear noises
Since noises from engine, muffler, transmission, propeller shaft, wheel bearings, tires, and body are sometimes mistaken for noises
from differential assembly, be careful in checking them. Inspection methods to locate noises include coasting, accelerating, cruising,
and jacking-up all four wheels. Perform these inspections according to condition of trouble. When listening to noises, shift gears into
four wheel drive and fourth speed position, trying to pick up only differential noise.


1Improper tooth contact of hypoid gear. Readjust or replace hypoid gear set.


2Improper backlash for hypoid gear. Readjust.


3Scored or chipped teeth of hypoid gear. Replace hypoid gear set.


4Seized hypoid gear. Replace hypoid gear set.


5Improper preload for front or rear bearings. Readjust.


6Seized, scored, or chipped front or rear bearing. Replace.


7Seized, scored, or chipped side bearing. Replace.


8Vibrating differential carrier. Replace.
2. Propeller Shaft
Symptom and possible cause Remedy
1. Vibration of propeller shaft
Vibration is caused by propeller shaft during operation and is transferred to vehicle body. Generally vibration increase in proportion to
vehicle speed.


1Worn or damaged universal joint. Replace.


2Unbalanced propeller shaft due to bend or dent. Replace.


3Loose installation of propeller shaft. Retighten.


4Worn or damaged center bearing and damaged center mount-
ing rubber.Replace.
2. Tapping when starting and noise while cruising, caused by propeller shaft.


1Worn or damaged universal joint. Replace.


2Worn spline of sleeve yoke. Replace.


3Loose installation of propeller shaft. Retighten.


4Loose installation of joint. Replace.


5Worn or damaged center bearing and damaged center mount-
ing rubber.Replace.
NOTE:
Vibration while cruising may be caused by an unbalanced
tire, improper tire inflation pressure, improper wheel
alignment, etc.
41
3-4DIAGNOSTICS
1. Rear Differential - 2. Propeller Shaft

Symptom and possible cause Remedy
5. Noises when cornering


1Damaged differential gear. Replace.


2Excessive wear or damage of thrust washer. Replace.


3Broken pinion mate shaft. Replace.


4Seized or damaged side bearing. Replace.
6. Gear noises
Since noises from engine, muffler, transmission, propeller shaft, wheel bearings, tires, and body are sometimes mistaken for noises
from differential assembly, be careful in checking them. Inspection methods to locate noises include coasting, accelerating, cruising,
and jacking-up all four wheels. Perform these inspections according to condition of trouble. When listening to noises, shift gears into
four wheel drive and fourth speed position, trying to pick up only differential noise.


1Improper tooth contact of hypoid gear. Readjust or replace hypoid gear set.


2Improper backlash for hypoid gear. Readjust.


3Scored or chipped teeth of hypoid gear. Replace hypoid gear set.


4Seized hypoid gear. Replace hypoid gear set.


5Improper preload for front or rear bearings. Readjust.


6Seized, scored, or chipped front or rear bearing. Replace.


7Seized, scored, or chipped side bearing. Replace.


8Vibrating differential carrier. Replace.
2. Propeller Shaft
Symptom and possible cause Remedy
1. Vibration of propeller shaft
Vibration is caused by propeller shaft during operation and is transferred to vehicle body. Generally vibration increase in proportion to
vehicle speed.


1Worn or damaged universal joint. Replace.


2Unbalanced propeller shaft due to bend or dent. Replace.


3Loose installation of propeller shaft. Retighten.


4Worn or damaged center bearing and damaged center mount-
ing rubber.Replace.
2. Tapping when starting and noise while cruising, caused by propeller shaft.


1Worn or damaged universal joint. Replace.


2Worn spline of sleeve yoke. Replace.


3Loose installation of propeller shaft. Retighten.


4Loose installation of joint. Replace.


5Worn or damaged center bearing and damaged center mount-
ing rubber.Replace.
NOTE:
Vibration while cruising may be caused by an unbalanced
tire, improper tire inflation pressure, improper wheel
alignment, etc.
41
3-4DIAGNOSTICS
1. Rear Differential - 2. Propeller Shaft