1997 SUBARU LEGACY Service Repair Manual

climate control alternator belt open hood ad blue lane assist OBD port

Page 705 of 3342

SUBARU LEGACY 1997 Service Repair Manual B3M0100
6) Position drive axle shaft in differential case and hold it
with outer snap ring (28). Using a thickness gauge, mea-
sure clearance between the shaft and case is within speci-
fications.
Cle

Page 706 of 3342

SUBARU LEGACY 1997 Service Repair Manual 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 malfu

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

Page 707 of 3342

SUBARU LEGACY 1997 Service Repair Manual 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 obstructi

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

Page 708 of 3342

SUBARU LEGACY 1997 Service Repair Manual 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 —

Page 709 of 3342

SUBARU LEGACY 1997 Service Repair Manual 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 cha

Page 710 of 3342

SUBARU LEGACY 1997 Service Repair Manual B: ADJUSTING PARTS
G3M0774
4
3-2SPECIFICATIONS AND SERVICE DATA
1. Automatic Transmission and Differential

Page 711 of 3342

SUBARU LEGACY 1997 Service Repair Manual No. Part Name Part Number Dimension mm (in) Application
1 Control piston2500 cc 31235AA000—030
13.5
�0.030
�0.037(0.5315�0.0012
�0.0015), 13.5�0.023
�0.030(0.5315�0.0009
�0.0012),
13.5�0.016
�0.023(

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

Page 712 of 3342

SUBARU LEGACY 1997 Service Repair Manual C: LOCATION AND INSTALLING DIRECTION
OF THRUST NEEDLE BEARING
B3M0400A
6
3-2SPECIFICATIONS AND SERVICE DATA
1. Automatic Transmission and Differential

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