1999 SUBARU LEGACY Service Repair Manual

10) Remove the oil cooler inlet and outlet pipes.
CAUTION:
When removing outlet pipes, be careful not to
lose balls and springs used with retaining
screws.
B3M1053A
2. SEPARATION OF EACH SECTION
1) Separation of torque converter clutch case and
transmission case sections
CAUTION:
IBe careful not to damage the oil seal and
bushing inside the torque converter clutch
case by the oil pump cover.
IBe careful not to lose the rubber seal.
NOTE:
Separate these cases while tapping lightly on the
housing.
B3M1055A
2) Separation of transmission case and extension
sections
(1) Remove vehicle speed sensor 1 (rear).
B3M1056A
(2) Separation of transmission case and exten-
sion case sections
B3M1057A
3. TRANSMISSION CASE SECTION
1) Remove the reduction driven gear.
(1) Straighten the staked portion, and remove
the lock nut.
NOTE:
Set the range selector lever to ªPº.
B3M1058A
(2) Using the ST1 and ST2, extract the reduc-
tion driven gear.
NOTE:
ST1 499737000 PULLER
ST2 899524100 PULLER SET
B3M0954A
48
3-2[W11B2]SERVICE PROCEDURE
11. Overall Transmission

(3) Using the ST, extract the reduction drive
gear.
ST 499737100 PULLER SET
B3M0953A
2) Remove transfer valve body and duty solenoid
C (Transfer).
(1) Disconnect connector from duty solenoid C
(Transfer).
(2) Remove transfer valve body and duty sole-
noid C (Transfer).
B2M2264
(3) Pull out inlet filter
B3M1061A
3) Remove the parking pawl, return spring and
shaft.
B3M1062A
4) Loosen the taper roller bearing mounting bolts.
B3M1063
5) Place two wooden blocks on the workbench,
and stand the transmission case with its rear end
facing down.
CAUTION:
IBe careful not to scratch the rear mating sur-
face of the transmission case.
INote that the parking rod and drive pinion
protrude from the mating surface.
B3M1064A
49
[W11B3]3-2SERVICE PROCEDURE
11. Overall Transmission

6) Remove the oil pan.
NOTE:
Use a scraper to remove oil pan.
B3M1065A
7) Disconnect the harness connectors for the
solenoids, duty solenoids, ATF temperature sensor
and the ground cord.
B2M2263C
(A) Lock-up duty solenoid (Blue)
(B) Low clutch timing solenoid (Gray)
(C) Line pressure duty solenoid (Red)
(D) Shift solenoid 2 (Yellow)
(E) Shift solenoid 1 (Green)
(F) 2-4 brake timing solenoid (Black)
(G) 2-4 brake duty solenoid (Red)
(H) ATF temperature sensor
8) Remove the control valve body.
CAUTION:
When removing control valve body, be careful
not to interfere with transfer duty solenoid C
wiring.
B3M1037A
9) Remove vehicle speed sensor 2 (front) and
torque converter turbine speed sensor.
B3M1066A
10) Remove transmission harness.
B3M1067A
11) Remove the oil pump housing.
CAUTION:
Be careful not to lose the total end play adjust-
ing thrust washer.
B3M1068A
12) Remove 2-4 brake seal.
B3M1069A
50
3-2[W11B3]SERVICE PROCEDURE
11. Overall Transmission

13) Take out the high clutch and reverse clutch
assembly.
CAUTION:
Be careful not to lose thrust needle bearing.
B3M1070A
14) Take out the high clutch hub and the thrust
bearing.
B3M1071A
15) Take out the front sun gear and the thrust
bearing.
B3M1072A
16) Pull out leaf spring.
CAUTION:
Be careful not to bend leaf spring during
removal.
NOTE:
Remove it while pressing down on lower leaf
spring.
B3M1073A
17) Remove snap ring and thrust needle bearing.
B3M1074A
18) Take out retaining plate, drive plate and driven
plate of 2-4 brake.
B3M1075
51
[W11B3]3-2SERVICE PROCEDURE
11. Overall Transmission

19) Take out the thrust needle bearing, planetary
gear assembly and the low clutch assembly.
B3M1076A
20) Remove snap ring.
B3M1077A
21) Take out 2-4 brake return spring.
B3M1078A
22) Take out 2-4 brake piston and piston retainer.
CAUTION:
When removing the brake piston 2-4 and piston
retainer, be careful not to rub or bump them
against the transmission case.
B3M1079A
23) Separate 2-4 brake piston and piston retainer.
B3M1080A
24) Pull out leaf spring.
CAUTION:
Be careful not to bend leaf spring during
removal.
B3M0956A
25) Remove snap ring.
B3M1081A
26) Take out retaining plate, drive plate, driven
plate and dish plate.
B3M1082
52
3-2[W11B3]SERVICE PROCEDURE
11. Overall Transmission

27) Turning the case upside down, take out the
one-way clutch inner race, retainer and wave
spring.
NOTE:
After loosening all socket bolts, place the side of
the transmission case on the floor.
B3M0958
28) Take out the low & reverse piston by applying
compressed air.
B3M0957
29) Using ST, remove ATF filter.
NOTE:
If any of the clutches or brakes are abnormally
worn, replace ATF filter and oil seal with new ones.
ST 498545400 OIL FILTER WRENCH
B3M1084A
30) Pull off the straight pin of manual lever.
B3M1083A
31) Remove bolts securing select lever, then
remove select lever, manual lever and parking rod.
CAUTION:
Be careful not to damage the lips of the press-
fitted oil seal in the case.
B3M1085A
32) Remove the detention spring.
B3M1086A
33) Remove the inhibitor switch.
B3M1087A
53
[W11B3]3-2SERVICE PROCEDURE
11. Overall Transmission

34) Remove parking support.
B3M1088A
4. TORQUE CONVERTER CLUTCH CASE
SECTION
1) Wrap the axle shaft serration with vinyl tape.
G3M0368
2) Remove the differential side retainer with ST.
CAUTION:
Hold the differential case assembly by hand to
avoid damaging retainer mounting hole of the
torque converter clutch case and speedometer
gears.
ST 499787000 WRENCH ASSY
3) Extract the axle shaft with ST1 and ST2.
CAUTION:
Do not reuse the circlip.
ST1 499095500 REMOVER
ST2 499247300 INSTALLER
G3M0956
4) Remove the differential case assembly.
CAUTION:
IRemove the seal pipe if it is attached. (Reus-
ing is not allowed.)
IBe careful not to damage the retainer mount-
ing hole of the torque converter clutch case
and the speedometer gears.
G3M0370
5. EXTENSION SECTION
1) Take out the transfer clutch by lightly tapping
the end of the rear drive shaft.
CAUTION:
Be careful not to damage the oil seal in the
extension.
B3M1089A
2) Remove the transfer pipe.
CAUTION:
Be careful not to bend the pipe.
B3M1090A
54
3-2[W11B4]SERVICE PROCEDURE
11. Overall Transmission

C: ASSEMBLY OF OVERALL
TRANSMISSION
1. TORQUE CONVERTER CLUTCH CASE
SECTION
1) Check the appearance of each component and
clean.
CAUTION:
Make sure each part is free of harmful cuts,
damage and other faults.
2) Force-fit the oil seal to the torque converter
clutch case with ST.
ST 398437700 DRIFT
G3M0379
3) Install the differential assembly to the case,
paying special attention not to damage the speed-
ometer gears (drive and driven) and the inside of
the case (particularly, the differential side retainer
contact surface).
G3M0380
4) Install the circlip to the axle shaft, insert the
shaft into the differential assembly, and tap it into
position with a plastic hammer.
CAUTION:
IIf no play is felt, check whether the shaft is
fully inserted. If shaft insertion is correct,
replace the axle shaft.
IBe sure to use a new circlip.
Thrust play:
0.3 Ð 0.5 mm (0.012 Ð 0.020 in)
5) Wrap vinyl tape around the splined portion of
the axle shaft.
G3M0368
6) Install the oil seal and outer race (taper roller
bearing) to the differential side retainer. Then
screw in the retainer and the O-ring after coating
the threads with oil.
CAUTION:
IPay attention not to damage the oil seal lips.
IDo not confuse the RH and LH oil seals.
IKeep the O-ring removed from the retainer.
7) Using the ST, screw in the retainer until light
contact is felt.
NOTE:
Screw in the RH side slightly deeper than the LH
side.
ST 499787000 WRENCH ASSY
B3M0352A
8) Hypoid gear backlash adjustment and tooth
contact check
(1) Assemble the drive pinion assembly to the
oil pump housing.
CAUTION:
IBe careful not to bend the shims.
IBe careful not to force the pinion against the
housing bore.
55
[W11C1]3-2SERVICE PROCEDURE
11. Overall Transmission