1997 SUBARU LEGACY transmission oil

G3M0564
(1) Place the transmission with case left side facing
downward and put ST1 on bearing cup.
(2) Screw retainer assembly into left case from the bot-
tom with ST2. Fit ST3 on the transmission main shaft.
Shift gear into 4th or 5th and turn the shaft several
times. Screw in the retainer while turning ST3 until a
slight resistance is felt on ST2.
This is the contact point of hypoid gear and drive pin-
ion shaft. Repeat the above sequence several times to
ensure the contact point.
ST1 399780104 WEIGHT
ST2 499787000 WRENCH ASSY
ST3 499927100 HANDLE
B3M0340A
(3) Remove weight and screw in retainer without
O-ring on the upper side and stop at the point where
slight resistance is felt.
NOTE:
At this point, the backlash between the hypoid gear and
drive pinion shaft is zero.
ST 499787000 WRENCH ASSY
B3M0334A
(4) Fit lock plate
11. Loosen the retainer on the lower
side by 1-1/2 notches of lock plate and turn in the
retainer on the upper side by the same amount in order
to obtain the backlash.
NOTE:
The notch on the lock plate moves by 1/2 notch if the plate
is turned upside down.
(5) Turn in the retainer on the upper side additionally
by 1 notch in order to apply preload on taper roller
bearing.
(6) Tighten temporarily both the upper and lower lock
plates and mark both holder and lock plate for later
readjustment.
(7) Turn transmission main shaft several times while
tapping around retainer lightly with plastic hammer.
(8) Set ST1 and ST2. Insert the needle through trans-
mission oil drain plug hole so that the needle comes in
contact with the tooth surface at a right angle and check
the backlash.
46
3-1SERVICE PROCEDURE
4. Transmission Case

B3M0087A
7. Main Shaft Assembly
A: DISASSEMBLY
1) Put vinyl tape around main shaft splines to protect oil
seal from damage. Then pull out oil seal and needle bear-
ing by hand.
2) Remove lock nut from transmission main shaft assem-
bly.
NOTE:
Remove caulking before taking off lock nut.
ST1 498937000 TRANSMISSION HOLDER
ST2 499987003 SOCKET WRENCH (35)
G3M0644
3) Remove insert stopper plate
1, sleeve and hub assem-
bly No. 2, baulk ring

3, 5th drive gear
4, and needle
bearing

5(32 x 36 x 25.7).
G3M0645
4) Using ST1, ST2 and a press, remove:
5th needle bearing inner race

1
5th gear thrust washer
2
Ball bearing
3(25.5 x 65 x 31)
4th gear thrust washer

4
4th drive gear
5
Sleeve and hub assembly
6
Baulk ring
7
4th needle bearing
8
4th needle bearing inner race
9
3rd drive gear
10
ST1 899864100 REMOVER
ST2 899714110 REMOVER
NOTE:
Replace sleeve and hub with new ones. Do not attempt to
disassemble because they must engage at a specified
point. If they should be disassembled, mark engagement
point on splines beforehand.
63
3-1SERVICE PROCEDURE
7. Main Shaft Assembly

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.
72
3-1DIAGNOSTICS
1. Manual Transmission and Differential

Symptom and possible cause Remedy
4. Broken differential (case, gear, bearing, etc.)
Abnormal noise will develop and finally it will become impossible to continue to run due to broken pieces obstructing the gear
revolution.
(a) Insufficient or improper oil Disassemble differential and replace broken components and
at the same time check other components for any trouble,
and replace if necessary.
(b) Use of vehicle under severe conditions such as excessive
load and improper use of clutchReadjust bearing preload and backlash and face contact of
gears.
(c) Improper adjustment of taper roller bearing Adjust.
(d) Improper adjustment of drive pinion and hypoid driven
gearAdjust.
(e) Excessive backlash due to worn differential side gear,
washer or differential pinionAdd recommended oil to specified level. Do not use vehicle
under severe operating conditions.
(f) Loose hypoid driven gear clamping bolts Tighten.
5. Differential and hypoid gear noises
Troubles of the differential and hypoid gear always appear as noise problems. Therefore noise is the first indication of the
trouble. However noises from the engine, muffler, tire, exhaust gas, bearing, body, etc. are easily mistaken for the differential
noise. Pay special attention to the hypoid gear noise because it is easily confused with other gear noises. There are the
following four kinds of noises.
(1) Gear noise when driving: If noise increases as vehicle speed increases it may be due to insufficient gear oil, incorrect
gear engagement, damaged gears, etc.
(2) Gear noise when coasting: Damaged gears due to maladjusted bearings and incorrect shim adjustment
(3) Bearing noise when driving or when coasting: Cracked, broken or damaged bearings
(4) Noise which mainly occurs when turning: Unusual noise from differential side gear, differential pinion, differential pinion
shaft, etc.
(a) Insufficient oil Lubricate.
(b) Improper adjustment of hypoid driven gear and drive
pinionCheck tooth contact.
(c) Worn teeth of hypoid driven gear and drive pinion Replace as a set.
Readjust bearing preload.
(d) Loose roller bearing Readjust hypoid driven gear to drive pinion backlash and
check tooth contact.
(e) Distorted hypoid driven gear or differential case Replace.
(f) Worn washer and differential pinion shaft Replace.
73
3-1DIAGNOSTICS
1. Manual Transmission and Differential

Automatic
transmissionOil pumpType Variable-capacity type vane pump
Driving method Driven by engine
Number of vanes 9 pieces
Hydraulic
controlTy p eElectronic/hydraulic control
[Four forward speed changes by electrical signals of car speed
and accelerator (throttle) opening]
Fluid Dexron II or Dexron III type Automatic transmission fluid
Fluid
capacity2200 cc 7.9(8.4 US qt, 7.0 Imp qt)
2500 cc 9.5(10.0 US qt, 8.4 Imp qt)
LubricationLubrication system Forced feed lubrication with oil pump
Oil Automatic transmission fluid (above mentioned.)
Cooling Cooling system Liquid-cooled cooler incorporated in radiator
HarnessInhibitor switch 12 poles
Transmission harnessFWD ... 11 poles
AWD ... 13 poles
TransferTransfer clutch Hydraulic multi-plate clutch
Clutch number of transfer clutch Drive plate & driven plate 5
Control method Electronic, hydraulic type
LubricantThe same Automatic Transmission Fluid used in automatic
transmission.
1st reduction gear ratio 1.000 (53/53)
Final
reductionFinal gear
ratioFront driveFWD 3.900 (39/10)
AWD2200 cc 4.111 (37/9)
2500 cc 4.444 (40/9)
Speedometer gear ratio2200 cc & LSi 0.83 (19/23)
GT 0.80 (20/25)
OUTBACK 0.76 (19/25)
Lubrication oilAPI, GL-5
Oil capacity Front drive 1.2(1.3 US qt, 1.1 Imp qt)
ATF cooling
systemRadiation capacity 1.651 kW (1,420 kcal/h, 5,635 BTU/h)
3
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

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

1Plug


2Snap ring


3Oil seal


4Manual shaft


5Range select lever (Plastic body type)


6Inhibitor switch ASSY (Plastic body type)


7Nipple


8Plate ASSY


9Air breather hose


10Oil level gauge


11O-ring


12Oil charger pipe


13Gasket


14Relief valve


15Pipe


16Gasket


17Transmission cover (FWD model)


18Shim


19Roller bearing


20Parking support


21Ball bearing


22Parking rod


23Return spring


24Shaft


25Parking pawl


26Gasket


27Inlet pipe


28Test plug


29O-ring


30Spring


31O-ring


32Accumulator piston (N-D)


33O-ring


34O-ring


35Accumulator piston (2-3)


36O-ring


37Spring


38O-ring


39Accumulator piston (1-2)


40O-ring

41Spring


42O-ring


43Accumulator piston (3-4)


44O-ring


45Spring


46Magnet


47Oil pan


48Gasket


49Drain plug


50Detention spring


51Pipe (AWD model)


52Plug (FWD model)


53Gasket (FWD model)


54Gasket


55Outlet pipe


56Spring


57Ball


58Stopper


59Manual lever


60Manual plate


61Spring pin


62Stud bolt


63Range select lever (Aluminum body type)


64Inhibitor switch (Aluminum body type)


65Clip (Aluminum body type)
Tightening torque: N⋅m (kg-m, ft-lb)
T1: 3.4±0.5 (0.35±0.05, 2.5±0.4)
T2: 4.9±0.5 (0.50±0.05, 3.6±0.4)
T3: 5.9±1.0 (0.60±0.10, 4.3±0.7)
T4: 6.4±0.5 (0.65±0.05, 4.7±0.4)
T5: 7.8±1.0 (0.80±0.10, 5.8±0.7)
T6: 12.7±1.0 (1.30±0.10, 9.4±0.7)
T7: 17.7±2.9 (1.80±0.30, 13.0±2.2)
T8: 24.5±2.0 (2.50±0.20, 18.1±1.4)
T9: 30.9±3.4 (3.15±0.35, 22.8±2.5)
T10: 34.3±2.9 (3.50±0.30, 25.3±2.2)
T11: 47.1±2.0 (4.80±0.20, 34.7±1.4)
T12: 47.1±4.9 (4.80±0.50, 34.7±3.6)
15
3-2COMPONENT PARTS
5. Transmission Case, Transmission Cover and Control Device