1999 SUBARU LEGACY Service Repair Manual

(2) Tighten four bolts to secure the roller bear-
ing.
Tightening torque:
41
±3 N´m (4.2±0.3 kg-m, 30.4±2.2 ft-lb)
B3M1091
(3) Install the oil pump housing assembly to the
torque converter clutch case, and secure evenly
by tightening four bolts.
CAUTION:
IThoroughly remove the liquid gasket from
the case mating surface beforehand.
IUse an old gasket or an aluminum washer so
as not to damage the mating surface of the
housing.
Tightening torque:
41
±3 N´m (4.2±0.3 kg-m, 30.4±2.2 ft-lb)
B3M1092
(4) Rotate the drive pinion several times with
ST1 and ST2.
ST1 498937100 HOLDER
ST2 499787100 WRENCH
G3M0384
(5) Tighten the LH retainer until contact is felt
while rotating the shaft. Then loosen the RH
retainer. Keep tightening the LH retainer and
loosening the RH retainer until the pinion shaft
can no longer be turned. This is the ªzeroº state.
G3M0884
(6) After the ªzeroº state is established, back off
the LH retainer 3 notches and secure it with the
lock plate. Then back off the RH retainer and
retighten until it stops. Repeat this procedure
several times. Tighten the RH retainer 1-3/4
notches further. This sets the preload. Finally,
secure the retainer with its lock plate.
G3M0885
NOTE:
Turning the retainer by one tooth changes the
backlash about 0.05 mm (0.0020 in).
H3M1256A
56
3-2[W11C1]SERVICE PROCEDURE
11. Overall Transmission

(7) Turn the drive pinion several rotations with
ST1 and check to see if the backlash is within
the standard value with ST2, ST3, ST4 and
ST5.
NOTE:
After confirming that the backlash is correct, check
the tooth contact.
ST1 499787100 WRENCH
ST2 498247001 MAGNET BASE
ST3 498247100 DIAL GAUGE
ST4 499757800 ADAPTER WRENCH
ST5 498255400 PLATE
Backlash:
0.13 Ð 0.18 mm (0.0051 Ð 0.0071 in)
B3M0570B
(8) Apply red lead evenly to the surfaces of
three or four teeth of the crown gear. Rotate the
drive pinion in the forward and reverse direc-
tions several times. Then remove the oil pump
housing, and check the tooth contact pattern.
If tooth contact is improper, readjust the back-
lash or shim thickness.
57
[W11C1]3-2SERVICE PROCEDURE
11. Overall Transmission

Checking item Contact pattern Corrective action
Tooth contact
Tooth contact pattern is slightly shifted
toward to under no-load rotation.
[When loaded, contact pattern moves
toward heel.]
B3M0317A
Ð
Face contact
Backlash is too large.This may cause noise and chipping at
tooth ends.
B3M0319
Increase thickness of drive pinion height
adjusting shim in order to bring drive pin-
ion close to crown gear.
B3M0323
Flank contact Backlash is too small. This may cause noise and stepped wear
on surfaces.
B3M0320
Reduce thickness of drive pinion height
adjusting shim in order to move drive
pinion away from crown gear.
B3M0324
Toe contact
(Inside end contact)
Contact areas is small.This may cause chipping at toe.
B3M0321
Adjust as for flank contact.
B3M0324
Heel contact (Outside end contact)
Contact area is small.This may cause chipping at heel ends.
B3M0322
Adjust as for face contact.
B3M0323
: Adjusting direction of drive pinion: Adjusting direction of crown gear
58
3-2[W11C1]SERVICE PROCEDURE
11. Overall Transmission

(9) If tooth contact is correct, mark the retainer
position and loosen it. After fitting the O-ring,
screw in the retainer to the marked position.
Then tighten the lock plate to the specified
torque.
Tightening torque:
25
±2 N´m (2.5±0.2 kg-m, 18.1±1.4 ft-lb)
G3M0885
9) Install the seal pipe to the torque converter
clutch case.
CAUTION:
Be sure to use a new seal pipe.
G3M0370
10) Install two oil seals to the oil seal retainer with
ST.
CAUTION:
IAlways discard old oil seals, and install new
ones.
IPay attention to the orientation of the oil
seals.
ST 499247300 INSTALLER
G3M0390
11) Attach the O-ring to the oil seal retainer with
vaseline. Install the seal to the oil pump housing
bore.
CAUTION:
Always discard old O-rings and install new
ones.
B3M1093A
12) Install the oil seal retainer taking care not to
damage the oil seal lips. Then secure with three
bolts.
NOTE:
Make sure the O-ring is fitted correctly in position.
Tightening torque:
7
±1 N´m (0.7±0.1 kg-m, 5.1±0.7 ft-lb)
B3M1094A
59
[W11C1]3-2SERVICE PROCEDURE
11. Overall Transmission

13) Apply vaseline to the groove on the oil pump
cover, and install two (R) seal rings and two (H)
seal rings.
NOTE:
IFit the seal ring after compressing, and rub
vaseline into the seal ring to avoid expansion.
IThe ªRº seal ring has a large diameter, while ªHº
has small diameter.
B3M1095A
14) Install the rubber seal to the torque converter
clutch case.
CAUTION:
Be careful not to lose the rubber seal.
G3M0394
2. TRANSMISSION CASE SECTION
1) Using a plastic hammer, force-fit the oil seal.
G3M0396
2) Install parking support to transmission case.
Tightening torque:
25
±2 N´m (2.5±0.2 kg-m, 18.1±1.4 ft-lb)
B3M1088A
3) Install inhibitor switch to transmission case.
NOTE:
Temporary tighten inhibitor switch.
B3M1087A
4) Install detention spring to transmission case.
Tightening torque:
6
±1 N´m (0.6±0.1 kg-m, 4.3±0.7 ft-lb)
B3M1086A
60
3-2[W11C2]SERVICE PROCEDURE
11. Overall Transmission

5) Insert range select lever, and tighten bolt.
Tightening torque:
6
±1 N´m (0.6±0.1 kg-m, 4.3±0.7 ft-lb)
B3M1096A
6) Insert manual lever and parking rod.
B3M1085A
7) Insert spring pin to manual lever.
B3M1083A
8) Install the low and reverse piston.
CAUTION:
IBe careful not to tilt the piston when install-
ing.
IBe careful not to damage the lip seal.
B3M1097A
9) Install return spring.
B3M1098A
10) Install spring retainer.
B3M1099A
11) Install the one-way clutch inner race.
61
[W11C2]3-2SERVICE PROCEDURE
11. Overall Transmission

(1) Using a press and ST1, install the needle
bearing to the inner race.
ST1 398497701 INSTALLER
NOTE:
Use the following ST when removing.
ST 398527700 PULLER ASSY
B3M1409A
(2) Install two seal rings to one-way clutch inner
race.
NOTE:
Apply vaseline to the groove of the inner race and
to the seal ring after installation, so that the seal
ring will not expand.
B3M1100A
(3) Tighten eight socket head bolts from the
rear side of the transmission case.
Tightening torque:
25
±2 N´m (2.5±0.2 kg-m, 18.1±1.4 ft-lb)
CAUTION:
Be sure to tighten evenly.
B3M0958
(4) Install thrust needle bearing.NOTE:
Place transmission case with the front facing up.
12) Installation of the low & reverse brake:
(1) Install dish plate, driven plates, drive plates,
and a retaining plate, and secure with a snap
ring.
NOTE:
Pay attention to the orientation of the dish plate.
B3M1081A
(2) Apply compressed air intermittently to
check for operation.
B3M0957
(3) Check the clearance. (Selection of retaining
plate)
NOTE:
Before measuring clearance, place the same thick-
ness of shim on both sides to prevent retaining
plate from tilting.
Standard value:
0.7 Ð 1.2 mm (0.028 Ð 0.047 in)
Allowable limit:
2.2 mm (0.087 in)
B3M0977
62
3-2[W11C2]SERVICE PROCEDURE
11. Overall Transmission

Available retaining plates
Part No. Thickness mm (in)
31667AA320
31667AA330
31667AA340
31667AA350
31667AA360
31667AA370
31667AA3804.2 (0.165)
4.5 (0.177)
4.8 (0.189)
5.1 (0.201)
5.4 (0.213)
5.7 (0.224)
6.0 (0.236)
13) Install leaf spring of low and reverse brake.
CAUTION:
Pay attention to the direction and position of
leaf spring during installation.
B3M0956A
14) Install O-ring to 2-4 brake piston.
CAUTION:
IIf O-ring breaks or damage is noted, replace
with new O-ring.
IApply a coat of vaseline to inner side of
O-ring before installation.
15) Install 2-4 brake piston to 2-4 brake piston
retainer.
B3M1080A
16) Install 2-4 brake piston and retainer to trans-
mission case.
CAUTION:
Align the hole in the 2-4 brake seal of transmis-
sion case with the hole in 2-4 brake piston
retainer during installation.
B3M1079A
17) Install 2-4 brake piston return spring to trans-
mission case.
B3M1078A
18) Position snap ring in transmission. Using ST,
press the snap ring into place.
ST 498677100 COMPRESSOR
B3M1101A
63
[W11C2]3-2SERVICE PROCEDURE
11. Overall Transmission