1997 SUBARU LEGACY Transfer

G3M0505
7) Coat the seal ring with vaseline, and install it in the seal
ring groove of the shaft.
CAUTION:
Do not expand the seal ring excessively when install-
ing.
ST 899580100 INSTALLER
G3M0913
16. Transfer Valve Body
A: DISASSEMBLY
1) Remove the plate. Then remove the spring and pilot
valve together.
2) Remove the straight pin and pry out the plug with a
screwdriver. Then extract the spring and transfer clutch
valve together.
CAUTION:
Be careful not to damage the valve and valve body.
B: INSPECTION
Check each component for harmful cuts, damage, or other
faults.
C: ASSEMBLY
To assemble, reverse the removal sequence.
NOTE:
Make sure the valve slides smoothly after assembling.
11 2
3-2SERVICE PROCEDURE
15. Transfer Clutch - 16. Transfer Valve Body

10. Transfer and Extension
B3M0375A

1Snap ring


2Pressure plate


3Drive plate


4Driven plate


5Thrust needle bearing


6Snap ring


7Spring retainer


8Lathe cut seal ring


9Transfer clutch piston


10Lathe cut seal ring


11Needle bearing


12Rear drive shaft


13Ball bearing

14Seal ring


15Vehicle speed sensor 1 (AWD only)


16Transfer clutch pipe


17Duty sol. C (Transfer clutch)


18Gasket


19Plate


20Filter


21Gasket


22Roller bearing


23Extension case


24Oil seal


25Dust seal


26Seal transfer piston

27O-ring


28Test plug


29O-ring


30Clip


31Transfer valve body


32Clip


33Stay
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: 13±1 (1.3±0.1, 9.4±0.7)
T4: 25±2 (2.5±0.2, 18.1±1.4)
20
3-2COMPONENT PARTS
10. Transfer and Extension

Standard values
Part name Terminal Resistance (Ω)
Vehicle speed sensor 1 9—16 450—720
ATF temperature sensor 5—12 [2,100—2,900/20°C (68°F) 275—375/80°C (176°F)]
Duty solenoid A
(Line pressure solenoid)7—4, 8 1.5—4.5
Duty solenoid B
(Lock-up solenoid)6—4, 8 9—17
Shift solenoid 1 3—4, 8 20—32
Shift solenoid 2 2—4, 8 20—32
Shift solenoid 3 1—4, 8 20—32
Duty solenoid C (AWD only)
(Transfer clutch solenoid)11—4, 8 9—17
NOTE:
If part is faulty, its resistance value will be different from the
standard value indicated above.
B3M0112A
30
3-2SERVICE PROCEDURE
2. On-Car Service

G3M0304
2. DUTY SOLENOID C AND TRANSFER VALVE BODY
1) Removal
(1) Remove pitching stopper.
G3M0297
(2) Raise vehicle and drain ATF.
G3M0305
(3) Remove front exhaust pipe.
Disconnect oxygen sensor connector, and remove
exhaust pipe.
G3M0782
(4) Remove propeller shaft.
NOTE:
Before removing propeller shaft, scribe matching marks on
propeller shaft and rear differential coupling.
G3M0306
(5) Remove rear crossmember.
Support transmission using a transmission jack and
raise slightly.
Remove bolts and nuts as shown in Figure.
34
3-2SERVICE PROCEDURE
2. On-Car Service

G3M0307
(6) Remove vehicle speed sensor 1.
G3M0308
(7) Remove extension and gasket.
Remove gear select cable nut.
Move gear select cable so that extension bolts can
be removed.
G3M0309
Remove bolts.
Remove extension and disconnect duty solenoid C
connector.
CAUTION:
Do not force extension back before disconnecting
solenoid connector. Otherwise, harness may be dam-
aged.
NOTE:
Use a container to catch oil flowing from extension.
G3M0310
(8) Remove duty solenoid C and transfer valve body
from extension.
Remove transfer clutch drum.
G3M0867
Remove clamp which secures pipe.
Remove bolts.
35
3-2SERVICE PROCEDURE
2. On-Car Service

G3M0867
2) Installation
(1) Install duty solenoid C and transfer valve body.
Install duty solenoid C and transfer valve body.
Install pipe and clamp.
Tightening torque:
8±1 N⋅m (0.8±0.1 kg-m, 5.8±0.7 ft-lb)
Install clutch drum.
G3M0309
(2) Install extension.
Connect connector.
Tighten 11 bolts.
Tightening torque:
25±2 N⋅m (2.5±0.2 kg-m, 18.1±1.4 ft-lb)
G3M0308
Install gear select cable.
Tightening torque:
14±4 N⋅m (1.4±0.4 kg-m, 10.1±2.9 ft-lb)
G3M0307
(3) Install vehicle speed sensor 1.
Tightening torque:
7±1 N⋅m (0.7±0.1 kg-m, 5.1±0.7 ft-lb)
G3M0306
(4) Install rear crossmember.
Tighten bolts.
Tightening torque:
Crossmember to body
69±15 N⋅m (7.0±1.5 kg-m, 51±11 ft-lb)
Crossmember to cushion
18±5 N⋅m (1.8±0.5 kg-m, 13.0±3.6 ft-lb)
Lower and remove transmission jack.
36
3-2SERVICE PROCEDURE
2. On-Car Service

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
43
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