1999 SUBARU LEGACY diff

1. EVALUATION
NOTE:
If part is faulty, its resistance value will be different
from the standard value indicated above.
Part name Terminal Resistance (W)
Vehicle speed sensor 1 17 Ð 18 450 Ð 650
Vehicle speed sensor 2 19 Ð 20 450 Ð 650
ATF temperature sensor 11 Ð 122,100 Ð 2,900/
20ÉC (68ÉF)
275 Ð 375/
80ÉC (176ÉF)
Torque converter turbine
speed sensor14 Ð 15 450 Ð 650
Shift solenoid 1 1 Ð 16 10 Ð 17
Shift solenoid 2 2 Ð 16 10 Ð 17
Duty solenoid A
(Line pressure solenoid)5Ð16 2.0Ð4.5
Duty solenoid B
(Lock-up solenoid)13Ð16 10Ð17
Duty solenoid D
(2-4 brake solenoid)9Ð16 2.0Ð4.5
Low clutch timing solenoid 3 Ð 16 10 Ð 16
2-4 brake timing solenoid 4 Ð 16 10 Ð 16
Duty solenoid C
(Transfer clutch solenoid)6Ð16 10Ð17
4. Shift Solenoid, Duty
Solenoid and Valve
A: REMOVAL
1) Clean transmission exterior.
2) Drain ATF completely.
NOTE:
Tighten ATF drain plug after draining ATF.
Tightening torque:
25
±2 N´m (2.5±0.2 kg-m, 18.1±1.4 ft-lb)
B3M1036A
3) Remove oil pan.
NOTE:
Drain oil into a container.
4) Disconnect solenoid and sensor connectors.
Remove connectors from clip and disconnect con-
nectors at 8 places.
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
34
3-2[W3A1]SERVICE PROCEDURE
4. Shift Solenoid, Duty Solenoid and Valve

5. Duty Solenoid C and
Transfer Valve Body
A: REMOVAL
1) Remove air intake duct and chamber. (Except
2200 cc California spec. vehicles)

S6M0007
2) Remove air intake duct and cleaner case.
(2200 cc California spec. vehicles)
and
B2M2320
3) Remove pitching stopper.
B3M1042
4) Raise vehicle and drain ATF.
B3M1036A
5) Remove front exhaust pipe and center exhaust
pipe.
Disconnect oxygen sensor connector, and remove
exhaust pipe.
and
G3M0305
6) Remove propeller shaft.

NOTE:
Before removing propeller shaft, scribe matching
marks on propeller shaft and rear differential cou-
pling.
G3M0782
37
[W5A0]3-2SERVICE PROCEDURE
5. Duty Solenoid C and Transfer Valve Body

2) Install extension case to transmission case.
(1) Tighten 11 bolts.
Tightening torque:
25
±2 N´m (2.5±0.2 kg-m, 18.1±1.4 ft-lb)
(2) Install select cable.
Tightening torque:
14
±4 N´m (1.4±0.4 kg-m, 10.1±2.9 ft-lb)
G3M0308
3) Install vehicle speed sensor 1 (rear).
Tightening torque:
T: 7
±1 N´m (0.7±0.1 kg-m, 5.1±0.7 ft-lb)
B3M1043A
4) Install rear crossmember.
(1) Tighten bolts.
Tightening torque:
T1: 37
±10 N´m (3.8±1.0 kg-m, 27±7 ft-lb)
T2: 69
±15 N´m (7.0±1.5 kg-m, 51±11 ft-lb)
S2M0221B
(2) Lower and remove transmission jack.5) Install propeller shaft.

NOTE:
Align matching marks on propeller shaft and rear
differential coupling.
G3M0782
6) Install front exhaust pipe and center exhaust
pipe.
and
G3M0305
7) Lower and remove jack.
8) Connect the following parts:
(1) Oxygen sensor connector
(2) Transmission harness connector
S2M0212A
39
[W5B0]3-2SERVICE PROCEDURE
5. Duty Solenoid C and Transfer Valve Body

G3M0322
3. ENGINE BRAKE OPERATION
Engine brake operation:
D range
®4th gear
3 range
®3rd gear
2 range
®2nd gear
1 range
®1st gear
4. AWD FUNCTION
If ªtight-corner brakingº 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 ªtight-corner brak-
ingº occurs:
Check the transfer control valve for sticking, and
the transfer clutch facing for wear. [W20B0].> and
7. Stall Test
A: MEASUREMENT
1. GENERAL INFORMATION
The stall test is of extreme importance in diagnos-
ing the condition of the automatic transmission and
the engine. It should be conducted to measure the
engine stall speeds in R and 2 ranges.
Purposes of the stall test:
1) To check the operation of the automatic trans-
mission clutch.
2) To check the operation of the torque converter
clutch.
3) To check engine performance.
2. TEST METHODS
1) Preparations before test:
(1) Check that throttle valve opens fully.
(2) Check that engine oil level is correct.
(3) Check that coolant level is correct.
(4) Check that ATF level is correct.
(5) Check that differential gear oil level is cor-
rect.
(6) Increase ATF temperature to 50 to 80ÉC
(122 to 176ÉF) by idling the engine for approxi-
mately 30 minutes (with select lever set to ªNº
or ªPº).
2) Install an engine tachometer at a location vis-
ible from the driver's compartment and mark the
41
[W7A2]3-2SERVICE PROCEDURE
7. Stall Test

G3M0322
3. ENGINE BRAKE OPERATION
Engine brake operation:
D range
®4th gear
3 range
®3rd gear
2 range
®2nd gear
1 range
®1st gear
4. AWD FUNCTION
If ªtight-corner brakingº 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 ªtight-corner brak-
ingº occurs:
Check the transfer control valve for sticking, and
the transfer clutch facing for wear. [W20B0].> and
7. Stall Test
A: MEASUREMENT
1. GENERAL INFORMATION
The stall test is of extreme importance in diagnos-
ing the condition of the automatic transmission and
the engine. It should be conducted to measure the
engine stall speeds in R and 2 ranges.
Purposes of the stall test:
1) To check the operation of the automatic trans-
mission clutch.
2) To check the operation of the torque converter
clutch.
3) To check engine performance.
2. TEST METHODS
1) Preparations before test:
(1) Check that throttle valve opens fully.
(2) Check that engine oil level is correct.
(3) Check that coolant level is correct.
(4) Check that ATF level is correct.
(5) Check that differential gear oil level is cor-
rect.
(6) Increase ATF temperature to 50 to 80ÉC
(122 to 176ÉF) by idling the engine for approxi-
mately 30 minutes (with select lever set to ªNº
or ªPº).
2) Install an engine tachometer at a location vis-
ible from the driver's compartment and mark the
41
[W7A2]3-2SERVICE PROCEDURE
7. Stall Test

11. Overall Transmission
A: SECTIONS THAT CAN BE DETACHED/ASSEMBLED
H3M1250A
B: DISASSEMBLY
1. EXTERNAL PARTS
1) Place the transmission unit on a work bench,
with the oil pan facing down.
CAUTION:
Be careful not to bend or damage external
parts.
B3M1048A
2) Remove the drain plug, and drain differential oil.
Tighten the plug temporarily after draining.
3) Remove the drain plug, and drain automatic
transmission fluid (ATF). Tighten the plug tempo-
rarily after draining.
B3M1036A
46
3-2[W11A0]SERVICE 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