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2002 IMPREZA SERVICE MANUAL QUICK

1. Is the resistance less than 1 Q Repair open circuit in harness between ATF tem perature sensor and transmission connector Go to step 13 Go to step 14 Is the resistance more than 1 MQ Repair short circuit in harness between ATF tem perature sensor and transmission connector Is the resistance more than 1 MQ Replace the ATF temperature sen sor lt Ref to 39 Shift Sole noids Duty Sole noids and ATF Temperature Sen sor gt Repair short circuit in harness between ATF tem perature sensor and transmission connector AT 51 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE DTC AUTOMATIC TRANSMISSION DIAGNOSTICS D DTC 31 THROTTLE POSITION SENSOR DIAGNOSIS Input signal circuit of throttle position sensor is open or shorted TROUBLE SYMPTOM Shift point too high or too low excessive shift shock excessive tight corner braking WIRING DIAGRAM NON TURBO MODEL SHIELD AND THROTTLE SENSOR GROUND POSITION SENSOR JOINT CONNECTOR TR0575 AT 52 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE DTC AUTOMATIC TRANSMISSION DIAGNOSTICS TURBO MODEL SHIELD AND THROTTLE SENSOR GROUND POSITION SENSOR JOINT CONNECTOR 1 2
2. unu 26 AT Shift Lock Solenoid and P Position 29 Iritegrated MOOG sce cases acs er Po Dese Ud 31 MT Gear Shift aaron 32 General DIAgoSIG usc ui pos meis dieti tna OR Vea Os 38 GENERAL DESCRIPTION CONTROL SYSTEMS 1 General Description A SPECIFICATIONS Vibration torque of rod against lever N m kgf m ft lb 0 7 0 07 0 5 or less CS 2 GENERAL DESCRIPTION CONTROL SYSTEMS B COMPONENT 1 AT SELECT LEVER 71 2 x 4 a 1 5 A 24 3 Q T i ewe TRO0546 1 Indicator light bulb 13 Cushion 25 Slider 2 Detent arm 14 Guide plate 26 Clip 3 Detent spring 15 Snap 27 P position switch 4 Select lever 16 Outer cable 28 Spring 5 Spring pin 17 Inner cable 29 Button 6 Arm 18 NutB 7 Pin 19 NutA Tightening torque N m kgf m ft lb 8 Plate 20 Clip T1 7 5 0 76 5 5 9 Grommet 21 Lock plate T2 13 1 3 9 4 10 Packing 22 Shift lock solenoid 18 1 8 13 0 11 Grip 23 Clamp 74 33 3 4 25 12 Indicator cover 24 Cover CS 3 CONTROL SYSTEMS 2 MT GEAR SHIFT LEVER 1 Gear shift knob 2 Console boot 3 Plate complete 4 Lever 5 Bush 6 Bush 7 Locking wire 8 Boot 9 Snap ring GENERAL DESC
3. Engine stalls while shifting from one range to another Vehicle moves when the select lever is in N Shock occurs when the select lever is moved from N to D S Low clutch Excessive time lag occurs when the select lever is moved from RP 4e Line pressure duty solenoid N to D Seal ring Front gasket transmission case TCM Harness Control valve ATF deterioration Control valve Low amp reverse clutch Reverse clutch Line pressure duty solenoid Seal ring Front gasket transmission case Parking brake mechanism Planetary gear Shock occurs when the select lever is moved from N to R Excessive time lag occurs when the select lever is moved from N to Vehicle does not start any shift range engine stalls AT 127 SYMPTOM RELATED DIAGNOSTIC AUTOMATIC TRANSMISSION DIAGNOSTICS Symptom Problem parts Vehicle does not start in any shift range engine revving up Vehicle does not start in R range only engine revving up Nehicle does not start in R range only engine stalls Vehicle does not start in D 3 range only engine revving up Vehicle does not start in D 3 or 2 range only engine rev ving up Vehicle does not start in D 3 or 2 range only engine stalls
4. 27 12 Inhibitor iori itn ree eie tien rate ener ne 28 13 Front Vehicle Speed Sensor aiii id 32 14 Rear Vehicle Speed Sensor sse ene 35 15 Torque Converter Turbine Speed 36 16 Control Valve Body ete iara oed vd inea dig qu LES vane 37 17 Shift Solenoids Duty Solenoids and ATF Temperature Sensor 39 18 ATF oeconomus D Sot Uta dete 44 19 Transmission Control Module TOM 45 20 Dropping ResiSIOL 46 21 ATF Cooler Pipe and HO56 dryer ee 47 GENERAL DESCRIPTION AUTOMATIC TRANSMISSION 1 General Description 4 TRANSMISSION GEAR RATIO non turbo 1st 2nd rd 1 TORQUE CONVERTER CLUTCH 39 275 1 619 Foie Nemo Tube X ERE Symmetric 3 element single stage 2 phase torque converter 0 694 2 272 Stall torque 19 24 1 85 2 15 ratio Nominal 5 PLANETARY GEAR AND PLATE 246 mm 9 69 in Stall speed 5100 2 600 rpm 2 600 3 300 rpm at sea level One way Front sun gear number of clutch Sprague type one way clutch teeth Frontpinionnumberofteeth 21 33 21 2 OIL PUMP Front internal gear number 75 of teeth 42 Pracoid
5. Termi nector nal No No 2 B55 B55 B55 18 B55 B54 11 UJ 2 55 20 54 54 54 Check with ignition switch Measuring conditions Brake pedal depressed Brake pedal released ABS switch ON ABS switch OFF Light ON Light OFF Throttle fully closed Throttle fully open Ignition switch ON With engine OFF ATF temperature 20 C 68 F ATF temperature 80 C 176 F Vehicle stopped Vehicle speed at least 20 km h 12 MPH Verise stopped o Vehicle speed at least 20 km h 12 MPH Engine idling after warm up D range Engine idling after warm up N range Vehicle speed at most 10 km h 6 MPH Ignition switch ON with engine OFF Ignition switch ON with engine ON When cruise control is set SET light ON When cruise control is not set SET light OFF More manes More than 4 8 Ignition switch ON with engine ON Ignition switch ON with engine ON Ignition switch ON me 8 Engine idling after warm up 1 5 5 0 Less than 1 Throttle fully closed with engine OFF after warm up Throttle fully open with engine OFF after warm up AT 12 Voltage V More than 10 5 Less than 1 Less than 1 More than 6 5 Less than 1 More than 9 Approx 0 5 Approx 4 3 4 8 5 3 1 6 2 0 More than 1 AC range More than 1 AC range More than
6. Is the P range indicator light bulb OK Replace the P range indicator light bulb Ref to IDI 11 Combina tion Meter Assem bly gt Repair open circuit in harness between TCM con nector and combi nation meter and poor contact in coupling connec tor AT 118 DIAGNOSTIC PROCEDURE FOR NO DIAGNOSTIC TROUBLE CODE DTC AUTOMATIC TRANSMISSION DIAGNOSTICS S T Step CHECK HARNESS CONNECTOR BETWEEN TCM AND INHIBITOR SWITCH 1 Turn the ignition switch to OFF 2 Disconnect the connectors from TCM inhibi tor switch and combination meter 3 Measure the resistance of harness between TCM and chassis ground Connector amp terminal Non turbo model B55 No 23 Chassis ground Turbo model B55 No 1 Chassis ground CHECK HARNESS CONNECTOR BETWEEN TCM AND INHIBITOR SWITCH 1 Turn the ignition switch to OFF 2 Disconnect the connectors from TCM and inhibitor switch 3 Measure the resistance of harness between TCM and inhibitor switch connector Connector amp terminal Non turbo model B55 No 17 T7 No 8 Turbo model B55 No 3 T7 No 8 CHECK INPUT SIGNAL FOR TCM 1 Turn the ignition switch to OFF 2 Connect the connector to TCM and inhibitor switch 3 Turn the ignition switch to ON 4 Measure the voltage between TCM and chassis ground Connector amp terminal Non turbo model B55 No 17 C
7. 0 1575 0 1626 Beco 3 87 3 99 0 1524 0 1571 32294 051 Input shaft holder adjustment Dimension D mm in Number of shim 52 50 53 11 2 0669 2 0909 52 00 52 49 2 0472 2 0665 51 26 51 99 2 0181 2 0468 MANUAL TRANSMISSION AND DIFFERENTIAL 4 DRIVE PINION ASSEMBLY Preload adjustment of thrust bearing Starting torque 0 3 0 8 N m 0 03 0 08 kgf m 0 2 0 6 ft Ib Part No 5 MAIN SHAFT Snap ring Outer 25 to synchronizer hub clear ance 0 060 0 100 mm 0 0024 0 0039 in Snap ring Outer 25 22 2 52 00992 803025053 3 975 0 1565 MT 3 GENERAL DESCRIPTION MANUAL TRANSMISSION AND DIFFERENTIAL 6 REVERSE IDLER GEAR Adjustment of reverse idler gear position Reverse idler gear to transmission case LH wall clearance 6 0 7 5 mm 0 236 0 295 in 8 seraa 0 9 Closer tothe case wall After installing a suitable reverse shifter lever ad just reverse idler gear to transmission case wall clearance to within 0 to 0 5 mm 0 to 0 020 in using washers Washer 20 5 x 26 x t mm in i mm in 0020153 15009 7 SHIFTER FORK AND ROD Select suitable shifter forks so that both coupling sleeve and reverse driven gear are positioned in the center of their synchromesh mechanisms Rod end clearanc
8. 7 G6M0095 2 Remove the lower cover and then disconnect the A Transmission control module connector B Brake pedal bracket 2 Connect the connectors to transmission control module 3 Install in the reverse order of removal 3 Disconnect the connectors from transmission control module 0326 Transmission control module B Brake pedal bracket 4 Remove the transmission control module AT 45 DROPPING RESISTOR AUTOMATIC TRANSMISSION 20 Dropping Resistor B INSTALLATION A REMOVAL i ee the reverse order of removal Tightening torque NOTE 6 4 0 65 kgf m 4 7 ft lb The dropping resister is only equipped to Non turbo models 1 Disconnect the ground terminal from battery B3M2178A Dropping resistor 2 Remove the air intake duct Ref to 6 REMOVAL Air Cleaner Case gt 3 Disconnect the connector from dropping resistor 4 Remove the dropping resistor B3M2178A A Dropping resistor C INSPECTION Yes CHECK RESISTOR Is the resistance between 9 Go to step 2 Replace the drop 1 Turn the ignition switch to OFF and 15 ping resistor Ref 2 Disconnect the connector from dropping to AT 46 Dropping resistor Resistor gt 3 Measure the resistance between dropping resistor terminal Terminals No 1 No 2 CHECK RESISTOR Is the resistance between 9 Dropping resistor the drop
9. POWER 3 Turn the ignition switch to ON OFF SUPPLY AND 4 Start the engine GROUND LINE 5 Drive the vehicle at speeds greater than 20 Diagnostic Proce km h 12 MPH dure for AT OIL 6 Stop the vehicle TEMP Warning 7 Brake pedal depressed and move the select Light lever to 1 range 8 Turn the ignition switch to OFF 9 Turn the ignition switch to ON 10 Move the select lever 2 range 11 Move the select lever 1 range 12 Move the select lever 2 range 13 Move the select lever 3 range 14 Move the select lever D range Does the indicator light blink at AT system is nor Go to step 3 2 Hz intervals NOTE Blinks mal every 0 25 1 4 seconds until ignition switch is turned OFF Is a trouble code outputted Inspect the prob to step 4 lem correspond ing with diagnostic trouble code DTC NOTE Record all diag nostic trouble code DTC CHECK INDICATOR LIGHT Does the indicator light remain Repair the AT OIL Calling up the illuminated TEMP warning diagnostic trouble light circuit Ref code DTC again to AT 31 Diagnos tic Procedure for AT OIL TEMP Warning Light gt or Inspect inhibitor switch wiring TCM etc AT 24 READ DIAGNOSTIC TROUBLE CODE DTC AUTOMATIC TRANSMISSION DIAGNOSTICS The AT OIL TEMP warning light flashes the code corresponding to the faulty part The long segment 1 2 sec on indicates a ten and the short segment 0 2 sec on signifies a
10. 5 Install the radiator under cover Tightening torque 4 9 N m 0 5 kgf m 3 6 ft lb 6 Install the under cover 7 Install the battery and washer tank AT 50 ATF COOLER PIPE AND HOSE AUTOMATIC TRANSMISSION 8 Fill ATF lt Ref to AT 9 Automatic Transmission Fluid gt NOTE Make sure there are no ATF leaks in joints between the transmission radiator pipes and hoses C INSPECTION Repair or replace any defective hoses pipes clamps and washers found from the inspection be low 1 Check for ATF leaks in joints between the trans mission radiator pipes and hoses 2 Check for deformed clamps 3 Lightly bend the hose and check for cracks in the surface and other damage 4 Pinch the hose with your fingers and check for poor elasticity Also check for poor elasticity in the parts where the clamp was installed by pressing with your fingernail 5 Check for peeling cracks and deformation at the tip of the hose AT 51 ATF COOLER PIPE AND HOSE AUTOMATIC TRANSMISSION 52 AUTOMATIC TRANSMISSION DIAGNOSTICS 1 Basic Diagnostic Procedure 2 Check List for Interview nennen nnns 3 General Description a iere e eui neo COD Ma aret tds 4 Electrical Components LocatiOn 5 Transmission Control Module TCM I O 6
11. B54 13 Chassis ground Turbo model B56 No 14 Chassis ground B56 No 5 Chassis ground s the resistance more than 1 AQ Go to step 3 Even if the AT OIL TEMP warning lights up the cir cuit has returned to a normal condi tion at this time A temporary poor contact of the con nector or harness may be the cause Repair harness or connector in the TCM and ECM s the voltage more than 4 8 V Remove dirt and rust s there any dirt or rust at round fine installing point s the tightening torque value to step 7 vithin specification s the tightening torque value vithin specification Go to step 9 s there any trouble Hepair ground ter minal and or ground circuit of AT 67 Repair short circuit harness etween TCM and ICM connector 3o to step 4 30 to step 5 3o to step 6 ighten to speci ied torque ighten to speci ied torque 3o to step 9 Replace the ECM DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE DTC AUTOMATIC TRANSMISSION DIAGNOSTICS H DTC 45 INTAKE MANIFOLD PRESSURE SIGNAL DIAGNOSIS Input signal circuit of TCM from ECM is open or shorted TROUBLE SYMPTOM Excessive shift shock WIRING DIAGRAM Is Te 7 8 16 20 21 TRO580 No Go to step 2 Yes Is there any trouble Repair ground ter
12. 0090 17 Install the gear shift rod and stay 1 Connect the rod to the joint Tightening torque 18 N m 1 8 kgf m 13 0 ft lb B3M1824A 2 Connect the stay to the transmission brack et Tightening torque 18 N m 1 8 kgf m 13 0 ft lb a B3M1823A A Stay B Transmission bracket 18 Install the propeller shaft lt Ref to DS 15 IN STALLATION Propeller Shaft gt 19 Install the heat shield cover If equipped 20 Install the rear exhaust pipe and muffler 21 Install the hanger bracket on the right side of transmission 22 Install the front exhaust pipe and center ex haust pipe Non turbo model Ref to EX SOHC 6 INSTALLATION Front Ex haust Pipe gt 23 Install the center exhaust pipe Turbo model Ref to EX DOHC TURBO 9 INSTALLATION Center Exhaust Pipe gt 24 Install the under cover MT 32 MANUAL TRANSMISSION ASSEMBLY MANUAL TRANSMISSION AND DIFFERENTIAL 25 Install the operating cylinder Tightening torque 37 3 8 kgf m 27 5 ft lb Non turbo model 26 Connect the following connectors 1 Transmission ground terminal Tightening torque 13 N m 1 3 kgf m 9 4 ft lb 2 Vehicle speed sensor connector 3 Neutral position switch connector 4 Back up light switch connector 27 Install the air cleaner case stay Tightening torque 16 1 6 kgf m 11 6 ft lb 28 Install the air cleaner case and intake duct
13. CHECK HARNESS CONNECTOR BETWEEN 2 4 BRAKE TIMING SOLENOID AND TRANSMISSION Measure the resistance of harness between 2 4 brake timing solenoid and transmission con nector Connector amp terminal AT8 No 1 T4 No 4 AT 84 Is the resistance less than 1 Q Go to step 9 Repair open circuit in harness between 2 4 brake timing solenoid and transmission connector DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE DTC AUTOMATIC TRANSMISSION DIAGNOSTICS Step Check Yes No CHECK HARNESS CONNECTOR BETWEEN 5 the resistance more than 1 Even if the ATO 2 4 BRAKE TIMING SOLENOID AND TRANSMISSION Measure the resistance of harness between 2 4 brake timing solenoid connector and trans mission ground Connector amp terminal T4 No 4 Transmission ground MQ AT 85 TEMP warning lights up the cir cuit has returned to a normal condi tion at this time A temporary poor contact of the con nector or harness may be the cause Repair harness or connector in 2 4 brake timing sole noid and transmis sion Repair short circuit harness between 2 4 brake timing solenoid and transmission con nector DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE DTC AUTOMATIC TRANSMISSION DIAGNOSTICS M DTC 75 LINE PRESSURE DUTY SOLENOID DIAGNOSIS Output signal circuit of line pressure duty solenoid is open or shorted TROUBLE SYMPTOM Excessi
14. e _ 01102 04 ps B83 5 6 7 fal TRO576 AT 53 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE DTC AUTOMATIC TRANSMISSION DIAGNOSTICS CHECK ENGINE GROUND TERMINALS Have engine ground terminals Go to step 2 Tighten the engine been tightened ground terminals No 4 2 Non turbo model 1 2 CHECK GROUND CIRCUIT OF Is the resistance less than5 Go to step 3 Repair open circuit 1 Turn the ignition switch to OFF Q in harness 2 Disconnect the connector from ECM between ECM 3 Measure the resistance of harness between connector and ECM and engine ground engine grounding Connector amp terminal terminal Non turbo model B134 No 27 Engine ground B134 No 8 Engine ground B134 No 7 Engine ground B136 No 21 Engine ground B136 No 22 Engine ground B134 No 35 Engine ground B134 No 34 Engine ground Turbo model B134 No 7 Engine ground B134 No 15 Engine ground B134 No 22 Engine ground B136 No 8 Engine ground IE B136 No 17 Engine ground B136 No 18 Engine ground B137 No 8 Engine ground B137 No 9 Engine ground Turbo model B55 No 2 E13 No 3 CHECK THROTTLE POSITION SENSOR Is the resistance between 3 0 Go to step 4 Replace the throt tle position sensor No 1 No 2 Turbo model 1 Disconnect the connector from throttle posi and 4 2 tion sen
15. CHECK ENGINE GROUND TERMINALS AND GROUND CIRCUIT OF ECM minal and or lt Ref to AT 52 DTC 31 THROTTLE POSITION ground circuit of SENSOR Diagnostic Procedure with Diagnos ECM tic Trouble Code DTC gt 2 CHECK HARNESS CONNECTOR BETWEEN 115 the resistance less than 1 TCM AND ECM 1 Turn the ignition switch to OFF 2 Disconnect the connectors from TCM and ECM 3 Measure the resistance of harness between TCM and ECM connector Connector amp terminal B55 No 20 136 No 11 3 CHECK HARNESS CONNECTOR BETWEEN Is the resistance more than 1 TCM AND ECM Measure the resistance of harness between TCM connector and chassis ground Connector amp terminal B55 No 20 Chassis ground 4 PREPARE SUBARU SELECT MONITOR Do you have a Subaru Select Go to step 6 Go to step 5 Monitor AT 68 Go to step 3 Repair open circuit in harness between TCM and ECM connector Go to step 4 Repair short circuit in harness between TCM and ECM connector Step DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE DTC AUTOMATIC TRANSMISSION DIAGNOSTICS Check No CHECK INPUT SIGNAL FOR TCM 1 Connect the connectors to TCM and ECM 2 Start the engine and warm up the transmis sion until the ATF temperature is above 80 C 176 F NOTE If ambient temperature is below 09 32 F drive the vehicle until the ATF reaches its oper ating tempe
16. 1 Remove the air cleaner case and air duct 2 Either jack up the vehicle and place a safety stand under it or lift up the vehicle 3 Draw out the brake fluid from reservoir tank with syringe 4 Refill the reservoir tank with recommended brake fluid Recommended brake fluid FMVSS No 116 fresh DOT3 or 4 brake fluid 5 Drain fluid in the same method as the air bleed ing 6 Refill the brake fluid before reservoir tank be comes empty and drain the contaminated fluid again 7 Repeat the above procedure until the contami nated fluid is completely drained CL 23 CLUTCH FLUID AIR BLEEDING CLUTCH SYSTEM 9 Clutch Fluid Air Bleeding A PROCEDURE NOTE Bleed air from the oil line with the help of a co work er 1 Remove the air cleaner case and air intake duct Non turbo model Ref to IN SOHC 6 REMOV AL Air Cleaner Case and Ref to IN SOHC 7 REMOVAL Air Intake Duct 2 Remove the intercooler Turbo model Ref to IN DOHC TURBO 10 REMOVAL Intercooler gt 3 Fit one end of a vinyl tube into the air bleeder of operating cylinder and put the other end into a brake fluid container Non turbo mode A Clutch hose B Air bleeder C Operating cylinder 4 Slowly depress the clutch pedal and keep it de pressed Then open the air bleeder to discharge air together with the fluid Release the air bleeder for 1 or 2 seconds Next with the bleeder closed slowly release the c
17. 15 CHECK HARNESS CONNECTOR BETWEEN TCM AND TRANSMISSION 1 Disconnect the connector from TCM 2 Measure the resistance of harness between TCM and transmission connector Connector amp terminal Non turbo model B55 No 12 B11 No 14 Turbo model B55 No 8 B11 No 14 CHECK HARNESS CONNECTOR BETWEEN TCM AND TRANSMISSION Measure the resistance of harness between TCM and transmission connector Connector amp terminal Non turbo model B55 No 21 B11 No 15 Turbo model B55 No 9 B11 No 15 CHECK HARNESS CONNECTOR BETWEEN TCM AND TRANSMISSION Measure the resistance of harness between TCM and chassis ground Connector amp terminal Non turbo model B55 No 21 Chassis ground Turbo model B55 No 9 Chassis ground CHECK HARNESS CONNECTOR BETWEEN TCM AND TRANSMISSION Measure the resistance of harness between TCM and chassis ground Connector amp terminal Non turbo model B55 No 12 Chassis ground Turbo model B55 No 8 Chassis ground DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE DTC AUTOMATIC TRANSMISSION DIAGNOSTICS Is the resistance between 450 Go to step 2 Is the resistance less than 1 Q Go to step 3 Is the resistance less than 1 Q Is the resistance more than 1 Go to step 5 MQ Is the resistance more than 1 MQ Go to step 6 Replace the tur bine speed sensor Ref to AT 36 Torque Converter Repair open circuit in
18. 2 Check the bearing for smooth rotation by apply ing pressure in the thrust direction S2M1844A A Bearing case 3 Check wear and damage of bearing case sur face contacting with lever CL 17 OPERATING CYLINDER CLUTCH SYSTEM 5 Operating Cylinder A REMOVAL 1 Remove the air cleaner case and air intake duct Non turbo model Ref to 6 REMOV AL Air Cleaner Case gt and lt Ref to IN SOHC 7 REMOVAL Air Intake Duct gt 2 Remove the intercooler Turbo model lt Ref to IN DOHC TURBO 10 REMOVAL Intercooler gt 3 Remove the clutch hose from operating cylinder CAUTION Cover the hose joint to prevent clutch fluid from flowing out Non turbo model 2 1179 A Clutch hose B Operating cylinder Turbo model aS Ut A Clutch hose B Operating cylinder 4 Remove the operating cylinder from transmis sion Non turbo model CL 18 OPERATING CYLINDER CLUTCH SYSTEM B INSTALLATION 2 After bleeding air from the operating cylinder en 1 Install in the reverse order of removal sure that the clutch operates properly NOTE lt Ref to CL 24 Clutch Fluid Air Bleeding gt Before installing the operating cylinder apply C INSPECTION grease SUNLIGHT 2 P N 003602010 to the con 1 Check the operating cylinder for damage If the tact point of release lever and operating cylinder operating cylinder is damaged replace it Tightening torque 2 Check
19. Go to step 53 Go to step 56 Go to step 19 Go to step 59 Go to step 21 Go to step 62 CHECK 1 RANGE SWITCH When the P range is selected does the 1 range LED light UP AT 117 Go to step 64 Go to step Symp tom Related Diag nostic lt Ref to AT 127 Symptom Related Diagnos tic DIAGNOSTIC PROCEDURE FOR NO DIAGNOSTIC TROUBLE CODE DTC AUTOMATIC TRANSMISSION DIAGNOSTICS ON a 22 CHECK HARNESS CONNECTOR BETWEEN Is the resistance less than 1 Go to step 23 Repair open circuit INHIBITOR SWITCH AND CHASSIS in harness GROUND between inhibitor 1 Turn the ignition switch to OFF switch connector 2 Disconnect the connector from inhibitor and chassis Switch ground and poor 3 Measure the resistance of harness between contact in cou inhibitor switch and chassis ground pling connector Connector amp terminal T7 No 5 Chassis ground CHECK HARNESS CONNECTOR BETWEEN 15 the resistance less than 1 Go to step 24 Repair open circuit TCM AND INHIBITOR SWITCH in harness 1 Turn the ignition switch to OFF between TCM and 2 Disconnect the connectors from TCM and inhibitor switch inhibitor switch connector and 3 Measure the resistance of harness between poor contact in TCM and inhibitor switch connector coupling connec Connector amp terminal tor Non turbo model
20. Inspect Pilot bear ing clutch disc transmission and clutch disc hub spline Clutch and fly ts there any abnormal noise from the transmission gear Go to step 3 Defect in clutch disengaging wheel seizure Inspect clutch disc Inspect clutch disc clutch cover clutch spline of clutch release and clutch disc hub pedal free play CHECK GEAR NOISE 1 Disengage the clutch at idle and shift from neutral to reverse within 0 5 1 0 seconds 2 With the clutch disengaged shift from N to R R to N several times Is there any abnormal noise from the transmission gear CL 32
21. MT 25 TRANSMISSION GEAR OIL MANUAL TRANSMISSION AND DIFFERENTIAL 2 Transmission Gear Oil A INSPECTION 1 Park vehicle on a level surface 2 Turn the ignition switch to OFF and wait until the engine cools 3 Remove the oil level gauge and wipe it clean 4 Reinsert the level gauge all the way Be sure that the level gauge is correctly inserted and in the proper direction 5 Pull out the oil level gauge again and check the oil level on it If it is below the lower level add oil through the oil level gauge hole to bring the level up to the upper level Upper level Lower level B REPLACEMENT 1 Pull out oil level gauge 2 Lift up the vehicle 3 Drain the transmission gear oil completely CAUTION Directly after the engine has been running the transmission gear oil is hot Be careful not to burn yourself NOTE Tighten the transmission gear oil drain plug after draining transmission gear oil Tightening torque 44 4 5 kgf m 32 5 ft lb B els amp 53 0470 Drain plug B Gasket 4 Lower the vehicle 5 Pour the gear oil into the gauge hole Recommended gear oil Use GL 5 or equivalent Gear oil capacity 3 5 0 3 7 US qt 3 1 Imp qt 6 Check the level of the transmission gear oil CAUTION When inserting the level gauge into transmis sion gear align the protrusion on the side of the top part of the level gauge with the notch in the gau
22. Non turbo model Ref to 6 INSTAL LATION Air Cleaner Case and Ref to IN SO HC 7 INSTALLATION Air Intake Duct 29 Install the intercooler Turbo model Ref to IN DOHC TURBO 11 INSTALLATION Intercooler 30 Connect the battery ground terminal 31 Take off the vehicle from lift arms MT 33 TRANSMISSION MOUNTING SYSTEM MANUAL TRANSMISSION AND DIFFERENTIAL 4 Transmission Mounting Sys tem A REMOVAL 1 PITCHING STOPPER 1 Disconnect the battery ground terminal 2 Remove the air intake duct and cleaner case 3 Remove the air intake duct Non turbo model Ref to 7 REMOVAL Air Intake Duct 4 Remove the air cleaner case Non turbo model Ref to IN SOHC 6 REMOVAL Air Cleaner Case 5 Remove the inter cooler Turbo model Ref to IN DOHC TURBO 10 REMOVAL Intercooler gt 6 Remove the pitching stopper 0072 2 CROSSMEMBER AND CUSHION RUB BER 1 Disconnect the battery ground terminal 2 Jack up the vehicle and support it with sturdy racks 3 Remove the front center exhaust pipes Non turbo model lt Ref to EX SOHC 5 REMOVAL Front Exhaust gt CAUTION When removing exhaust pipes be careful each exhaust pipe does not drop out 4 Remove the center exhaust pipe Turbo model lt Ref to EX DOHC TURBO 8 REMOVAL Center Exhaust Pipe gt 5 Remove the rear exhaust pipe and muffler 6 Remove the he
23. Transfer duty solenoid is indicated in 95 Is the value between 80 and 95 Even if the AT OIL TEMP warning lights up the cir cuit has returned to a normal condi tion at this time A temporary poor contact of the con nector or harness may be the cause Repair harness or connector in the transfer duty sole noid and TCM connector Is the value approx 40 AT 102 TRANSMISSION 1 Lift up the vehicle and place safety stand CAUTION On AWD models raise all wheels off ground 2 Drain the automatic transmission fluid CAUTION Do not drain the automatic transmission flu id until it cools down 3 Remove the extension case and disconnect the connector from transfer duty solenoid 4 Measure the resistance between transfer duty solenoid connector and transmission ground Connector amp terminal AT4 No 1 Transmission ground CHECK HARNESS CONNECTOR BETWEEN TRANSFER DUTY SOLENOID AND TRANS MISSION Measure the resistance of harness between transfer duty solenoid and transmission con nector Connector amp terminal T4 6 AT4 1 CHECK HARNESS CONNECTOR BETWEEN TRANSFER DUTY SOLENOID AND TRANS MISSION Measure the resistance of harness between transmission connector and transmission ground Connector amp terminal T4 No 6 Transmission ground DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE DTC AUTOMATIC TRANSMISSION
24. link connector 5 Check the line pressure in accordance with the following chart 3 EVALUATION Range Line pres Throttle posi sure duty osition tion ratio P Standard line pressure Full closed 3 1 Line pressure kPa kg cm psi 1 128 1 304 11 5 13 3 164 189 1 520 1 716 15 5 17 5 220 249 304 412 42 44 60 AT 17 AUTOMATIC TRANSMISSION TRANSFER CLUTCH PRESSURE TEST AUTOMATIC TRANSMISSION 8 Transfer Clutch Pressure Test A INSPECTION 1 TEST METHODS MPT model Check the transfer clutch pressure in accordance with the following chart in the same manner as with line pressure lt Ref to AT 16 Line Pressure Test gt ST 498897700 OIL PRESSURE ADAPTER SET OIL PRESSURE GAUGE ASSY AWD mode D range FWD mode P range engine speed 2 000 rpm CAUTION Before setting in FWD mode install the spare fuse on FWD mode switch ST 498575400 B3M1047C A Test plug VTD model Check the transfer clutch pressure in accordance with the following chart in the same manner as with line pressure ST 498897700 PRESSURE ADAPTER SET ST 498575400 OIL PRESSURE GAUGE ASSY H3M1840B A Test plug 2 EVALUATION MTP model NOTE If the oil pressure is not produced or if it does not change in the AWD mode the transfer duty sole noid or transfer valve assembly may be malfunc tioning If the
25. toria fis 17 18 omia fe fiz fiel 1 2413 1415 he 17 18 5 6 7 8 19120121 9 20 21 22 23 24 TR0577 AT 58 Step CHECK HARNESS CONNECTOR BETWEEN 15 the resistance less than 1 TCM AND TRANSMISSION 1 Turn the ignition switch to OFF 2 Disconnect the connector from TCM and transmission 3 Measure the resistance of harness between TCM and transmission connector Connector amp terminal Non turbo model B55 No 5 B11 No 17 Turbo model B55 No 18 B11 No 17 CHECK HARNESS CONNECTOR BETWEEN TCM AND TRANSMISSION Measure the resistance of harness between TCM and transmission connector Connector amp terminal Non turbo model B55 No 21 B11 No 18 Turbo model B54 No 10 B11 No 18 TCM AND TRANSMISSION Measure the resistance of harness between TCM and transmission connector Connector amp terminal Non turbo model B55 21 Chassis ground Turbo model B54 No 10 Chassis ground TCM AND TRANSMISSION Measure the resistance of harness between TCM and transmission connector Connector amp terminal Non turbo model B55 No 5 Chassis ground Turbo model B55 No 18 Chassis ground connector receptacle s terminals Connector amp terminal T4 No 17 No 18 CHECK HARNESS CONNECTOR BETWEEN CHECK HARNESS CONNECTOR BETWEEN CHECK FRONT VEHICLE SPEED SENSOR Measure
26. 3 Check if there is continuity at equal points when the select lever is turned 1 5 in both directions from the N range If there is continuity in one direction and the conti nuity in the other or if there is continuity at unequal points adjust the inhibitor switch lt Ref to AT 28 ADJUSTMENT Inhibitor Switch gt B3M1586A A Continuity does not exist B Continuity exists C 1 5 4 Repeat the above checks If there are abnormal ities adjust the select cable Ref to CS 27 AD JUSTMENT Select Cable B ADJUSTMENT 1 Shift the select lever to the N range 2 Loosen the three inhibitor switch securing bolts 3 Insert the ST as vertical as possible into the holes in the inhibitor switch lever and switch body ST 499267300 STOPPER PIN 4 Tighten the three inhibitor switch bolts Tightening torque 3 4 N m 0 35 kgf m 2 5 ft Ib 5 Repeat the above checks If the inhibitor switch is determined to be faulty replace it AT 28 INHIBITOR SWITCH AUTOMATIC TRANSMISSION C REMOVAL 1 Set up the vehicle on the lift 2 Move the select lever to neutral position 3 Remove the air cleaner case Non turbo model Ref to IN SOHC 6 REMOVAL Air Cleaner Case 4 Remove the intercooler Turbo model Ref to IN DOHC TURBO 10 REMOVAL Intercooler gt 5 Disconnect the inhibitor switch connector B3M1028B A Inhibitor switch 6 Remove the inhibitor switch connec
27. Measure the resistance between dropping and 15 is normal ping resistor resistor terminal lt Ref to AT 46 Terminals Dropping Resis No 3 4 tor AT 46 ATF COOLER PIPE AND HOSE AUTOMATIC TRANSMISSION 21 ATF Cooler Pipe and Hose 6 Remove the ATF cooler pipe from cylinder head A REMOVAL 1 NON TURBO MODEL 1 Set the vehicle on the lift 2 Lift up the vehicle 3 Remove the under cover 4 Disconnect the ATF cooler hose from radiator NOTE e Do not remove with a screwdriver or other point ed tools 0543 When the hose is difficult to remove wrap a shop 7 Remove the oil cooler inlet and outlet pipes cloth around the hose to protect it Turn it with pli CAUTION ers and then pull directly out with your hand When removing the outlet pipe be careful not to lose the ball and spring used with retaining screw 5 Disconnect the ATF cooler hoses from pipes NOTE e Do not remove with a screwdriver or other point A Inlet pipe ed tools B Outlet pipe When the hose is difficult to remove wrap a shop cloth around the hose to protect it Turn it with pli ers and then pull directly out with your hand AT 47 ATF COOLER PIPE AND HOSE AUTOMATIC TRANSMISSION 2 TURBO MODEL 1 Set the vehicle on the lift Remove the battery and washer tank Lift up the vehicle Remove the under cover 5 Remove the radiator under cover
28. More than 25 minutes Reference Time for temperature rise to 30 C 86 F with atmo spheric temperature of 0 C 32 F Approx 8 min utes By running the vehicle Time for temperature rise to 60 C 140 F with at mospheric temperature of 0 C 32 F More than 10 minutes 5 Method for checking fluid level upon delivery or at periodic inspection Check fluid level after a warm up run of approx 10 minutes During the warm up period the au tomatic transmission functions can also be checked 2 Check the fluid for leaks Check for leaks in the transmission If there are leaks it is necessary to repair or replace gasket oil seals plugs or other parts B REPLACEMENT 1 Lift up the vehicle 2 Drain the ATF completely CAUTION Directly after the engine has been running the ATF is hot Be careful not to burn yourself NOTE Tighten the ATF drain plug after draining the ATF Tightening torque 25 N m 2 5 kgf m 18 1 ft Ib M Rites LZS San B3M1036B A Oil pan B Drain plug C Differential oil drain plug 3 Lower the vehicle AT 9 AUTOMATIC TRANSMISSION FLUID AUTOMATIC TRANSMISSION 4 Pour ATF into the oil charge pipe Recommended fluid Dexron Ill type automatic transmission fluid Capacity Fillthe same amount of fluid drained from the drain plug hole Capacity when transmission is overhauled 9 3 9 6 2 9 8 10 1 US qt 8 2 8 4 Imp qt 5 C
29. STOPPER B3M1362A 9 Place the transmission with case left side facing downward and put ST1 on bearing cup 10 Screw the retainer assembly into left case from the bottom with ST2 Fit ST3 on the transmission main shaft Shift gear into 4th or 5th and turn the shaft several times Screw in the retainer while turning ST3 until a slight resistance is felt on ST2 This is the contact point of hypoid gear and drive pinion shaft Repeat the above sequence several times to ensure the contact point ST1 399780104 WEIGHT ST2 499787000 WRENCH ASSY ST3 499927100 HANDLE B3M1361A MT 55 TRANSMISSION CASE MANUAL TRANSMISSION AND DIFFERENTIAL 11 Remove weight and screw in retainer without O ring on the upper side and stop at the point where slight resistance is felt NOTE At this point the backlash between the hypoid gear and drive pinion shaft is zero ST 499787000 WRENCH ASSY B3M1360A 12 Fit lock plate Loosen the retainer on the lower side by 1 1 2 notches of lock plate and turn in the r tainer on the upper side by the same amount in order to obtain the backlash NOTE The notch on the lock plate moves by 1 2 notch if the plate is turned upside down 13 Turn in the retainer on the upper side addition ally by 1 notch in order to apply preload on taper roller bearing 14 Tighten temporarily both the upper and lower lock plates and mark both holder and lock plate for later readjustment 15 Turn
30. Time lag Less than 1 5 seconds 3 EVALUATION 1 If N 2 D time lag is longer than specified Line pressure too low Low clutch worn One way clutch not operating properly 2 If N 2 time lag is longer than specified Line pressure too low Reverse clutch worn e Low amp reverse brake worn AT 15 LINE PRESSURE TEST AUTOMATIC TRANSMISSION 7 Line Pressure Test A MEASUREMENT 1 GENERAL INFORMATION If the clutch or the brake shows a sign of slippage or shifting sensation is not correct the line pressure should be checked e Excessive shocks during upshifting or shifting takes place at a higher point than under normal cir cumstances may be due to the line pressure being too high e Slippage or inability to operate the vehicle may in most cases be due to loss of oil pressure for the operation of the clutch brake or control valve 1 Line pressure measurement under no load CAUTION Before measuring line pressure jack up all wheels e Maintain temperature of ATF at approximate ly 50 C 122 F during measurement ATF will reach the above temperature after idling the engine for approximately 30 minutes with select lever in N or P 2 Line pressure measurement under heavy load CAUTION Before measuring line pressure apply both foot and parking brakes with all wheels chocked Same as for stall test conditions Measure the line pressure
31. Transfer duty solenoid ATF deterioration e Harness Front vehicle speed sensor e Throttle position sensor e ATF temperature sensor Control valve Transfer clutch e Transfer valve Transfer pipe Transfer duty solenoid e e Transfer clutch Transfer valve e Transfer duty solenoid e Select cable e Select lever Detent spring e Manual plate Detent spring Manual plate Select cable e Select lever Detent spring e Manual plate Symptom Shock occurs when the select lever is moved from 2 to 1 range Shock occurs when the accelerator pedal is released at medium speeds Vibration occurs during straight forward operation Vibration occurs during turns tight corner braking phenome non Front wheel slippage occurs during standing starts Vehicle is not set in FWD mode Select lever is hard to move Select lever is too high to move unreasonable resistance Select lever slips out of operation during acceleration or while driving on rough terrain AT 131 SYMPTOM RELATED DIAGNOSTIC AUTOMATIC TRANSMISSION DIAGNOSTICS AT 132 MANUAL TRANSMISSION AND DIFFERENTIAL T1 General DESCRIPTION 2 Transmission Gear
32. 1 Inspect using the Diagnostic Procedure for No Diagnostic trouble Code lt Ref to AT 108 Diagnostic Procedure for No Diagnostic Trou ble Code DTC gt 2 Inspect using the Symptom Related Diag nostic Ref to AT 127 Symptom Related Diagnostic gt 3 Perform the clear memory mode With SUBARU SELECT MONITOR lt Ref to 27 WITH SUBARU SELECT MONITOR Clear Memory Mode gt Without SUBARU SELECT MONITOR lt Ref to AT 27 WITHOUT SUBARU SELECT MONITOR Clear Memory Mode gt 4 Perform the inspection mode lt Ref to AT 26 Inspection Mode gt Calling up the diagnostic trouble code DTC Without SUBARU SELECT MONITOR Ret to 24 WITHOUT SUBARU SELECT MONITOR Read Diagnostic Trouble Code DTC gt With SUBARU SELECT MONITOR lt Ref to 25 WITH SUBARU SELECT MONITOR OPERATION Read Diagnostic Trouble Code DTC gt PERFORM THE DIAGNOSIS 1 Inspect using the Diagnostics Chart with Diahnostic Trouble Code Ref to AT 44 Diag nostic Procedure with Diagnostic Trouble Code DTC gt NOTE For trouble code table refer to the List of Diag nostic Trouble Code Ref to AT 29 List of Di agnostic Trouble Code DTC gt 2 Repair the trouble cause 3 Perform the clear memory mode With SUBARU SELECT MONITOR Ref to AT 27 WITH SUBARU SELECT MONITOR OPERATION Clear Memory Mode Without SUBARU SELECT MONITOR Ref to AT 27 WITHOUT SUBARU SELECT MONITOR Clear
33. 2 4 BRAKE TIMING SOLENOID TRO584 AT 82 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE DTC AUTOMATIC TRANSMISSION DIAGNOSTICS R BETWEEN Is the resistance less than 1 Go to step 2 Repair open circuit in harness between TCM and transmission con nector CHECK HARNESS CONNECTO TCM AND TRANSMISSION 1 Turn the ignition switch to OFF 2 Disconnect the connector from TCM and transmission 3 Measure the resistance of harness between TCM and transmission connector Connector amp terminal Non turbo model B54 No 5 B11 No 4 Turbo model B54 No 16 B11 No 4 CHECK HARNESS CONNECTOR BETWEEN the resistance more than 1 Go to step 3 Repair short circuit in harness between TCM and transmission con nector TCM AND TRANSMISSION Measure the resistance of harness between TCM connector and transmission ground Connector amp terminal Non turbo model B54 No 5 Chassis ground Turbo model B54 No 16 Chassis ground CHECK 2 4 BRAKE TIMING SOLENOID Is the resistance between 10 Measure the resistance between transmission and 16 9 connector terminals Connector amp terminal T4 No 4 No 16 SIG Go to step 4 Go to step 7 Is the voltage less than 1V Goto step 5 Go to step 6 1 Connect the connectors to TCM and trans mission
34. 34 4 ft lb 2 Apply a coat of grease to the contacting surfaces of the push rod and piston before installation Grease SILICONE GREASE G40M Part No 004404003 3 To assemble the master cylinder reverse the se quence of disassembly procedure Tightening torque 10 N m 1 0 kgf m 7 ft lb E INSPECTION If any damage deformation wear swelling rust or other faults are found on the cylinder piston push rod fluid reservoir return spring gasket clutch damper and hose replace the faulty part A Master cylinder body B Return spring C Piston D Stop ring E Rod ASSY F Clutch damper Non turbo model CL 21 CLUTCH PIPE AND HOSE Ne a eee CLUTCH SYSTEM 7 Clutch Pipe and Hose A REMOVAL 1 Remove the air cleaner case Non turbo model lt Ref to IN SOHC 6 REMOVAL Air Cleaner Case gt 2 Remove the intercooler Turbo model lt Ref to IN DOHC TURBO 10 REMOVAL Intercooler gt 3 Drain the clutch fluid lt Ref to CL 23 Clutch Flu id gt 4 Remove the clutch pipe from the clutch hose and master cylinder 5 Pull out the clamp then remove the clutch hose from bracket Clamp B Clutch hose 6 Remove the hose from operating cylinder 7 Remove the bracket B INSTALLATION Install in the reverse order of removal NOTE Bleed the clutch fluid lt Ref to CL 24 Clutch Fluid Air Bleeding gt Tightening torque T1 15 1 5 kgf m 10 8 ft
35. DIAGNOSTICS Is there poor contact in transfer duty solenoid circuit ts the resistance between 10 and 17 Q Is the resistance less than 1 Q Is the resistance more than 1 MQ AT 103 Repair poor con tact Go to step 14 Go to step 15 Even if the AT OIL TEMP warning lights up the cir cuit has returned to a normal condi tion at this time A temporary poor contact of the con nector or harness may be the cause Repair harness or contact in the transfer duty sole noid and transmis sion Replace the TCM lt Ref to AT 45 Transmission Con trol Module gt Replace the trans fer duty solenoid Repair open circuit in harness between transfer duty solenoid and transmission con nector Repair short circuit in harness between transfer duty solenoid and transmission con nector DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE DTC AUTOMATIC TRANSMISSION DIAGNOSTICS Q DTC 93 REAR VEHICLE SPEED SENSOR DIAGNOSIS Input signal circuit of TCM is open or shorted TROUBLE SYMPTOM No lock up or excessive tight corner braking WIRING DIAGRAM SHIELD AND SENSOR GROUND JOINT CONNECTOR Goo eee Ni ERE 1 REAR VEHICLE SPEED SENSOR a z e e 5 16 17 18 TRO589 AT 104 CHECK HARNESS CONNECTOR BETWEEN TCM AND TRANSMISSION 1 Turn the ignition switch to
36. If the ambient temperature is below 0 C 32 F drive the vehicle until the ATF reaches its oper ating temperature 6 Read the data of lock up duty solenoid using Subaru Select Monitor Lock up duty solenoid is indicated in 1 Move the select lever to D and slowly increase the vehicle speed to 75 km h 47 MPH Wheels will lock up NOTE The speed difference between front and rear wheels may light the ABS warning light but this indicates no malfunction When the AT control diagnosis is finished perform the ABS memory clearance procedure of on board diagnostics system lt Ref to ABS 22 Clear Memory Mode gt CHECK OUTPUT SIGNAL EMITTED FROM TCM USING SUBARU SELECT MONITOR Return the engine to idling speed and move the select lever to N NOTE i The speed difference between front and rear wheels may light the ABS warning light but this indicates no malfunction When AT control di agnosis is finished perform the ABS memory clearance procedure of on board diagnostics system lt Ref to ABS 22 Clear Memory Mode gt CHECK POOR CONTACT DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE DTC AUTOMATIC TRANSMISSION DIAGNOSTICS Is the value 95 15 the value 5 Is there poor contact in lock up duty solenoid circuit AT 97 No Go to step 9 Even if the AT OIL TEMP warning lights up the cir cuit has returned to a normal condi tion at this time A temporary
37. Remove the transfer drive gear assembly Ref to MT 45 REMOVAL Transfer Drive Gear 2 Remove the shift bracket B3M1381 3 Remove the oil seal from the extension case Ref to MT 36 OIL SEAL gt 19 Install the transfer case with extension case as sembly to the transmission case Tightening torque 25N m 2 5 kgf m 18 1 ft Ib MT 43 TRANSFER CASE AND EXTENSION CASE ASSEMBLY MANUAL TRANSMISSION AND DIFFERENTIAL D ASSEMBLY 1 EXTENSION CASE 1 Using ST install the oil seal to the extension case lt Ref to MT 36 Oil Seal gt CAUTION Use new oil seal 2 Install the shift bracket to the extension case Tightening torque 25 2 5 kgf m 18 1 ft lb B3M1381 3 Install the transfer drive gear to the extension case lt Ref to MT 45 INSTALLATION Transfer Drive Gear gt 2 TRANSFER CASE 1 Install the oil guide to the transfer case Tightening torque 6 4 0 65 kgf m 4 7 ft lb 2 Install the reverse check sleeve assembly to the transfer case lt Ref to MT 50 INSTALLATION Reverse Check Sleeve gt MT 44 TRANSFER DRIVE GEAR 10 Transfer Drive Gear A REMOVAL 1 Remove the manual transmission assembly from vehicle lt Ref to MT 27 REMOVAL Manual Transmission Assembly gt 2 Remove the back up light switch and neutral po sition switch lt Ref to MT 37 REMOVAL Switches and Harness gt 3 Remove the transfer case with extension case assembly
38. Repair harness or connector in the TCM and trans mission DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE DTC AUTOMATIC TRANSMISSION DIAGNOSTICS Go to step 11 Go to step 11 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE DTC CHECK INPUT SIGNAL FOR TCM USING OSCILLOSCOPE 1 Connect the connectors to TCM and trans mission 2 Lift up or raise the vehicle and place safety stands CAUTION Raise all wheels off floor 3 Set the oscilloscope to TCM connector ter minals Turbo model Positive probe B55 No 24 Earth lead B55 No 19 Non turbo model Positive probe B55 No 3 Earth lead B55 No 21 4 Start the engine and set the vehicle in 20 km h 12 MPH condition NOTE The speed difference between front and rear wheels may light the ABS warning light but this indicates no malfunction When the AT control diagnosis is finished perform the ABS memory clearance procedure of on board diagnostics system Ref to ABS 22 Clear Memory Mode 5 Measure the signal voltage indicated on oscilloscope AUTOMATIC TRANSMISSION DIAGNOSTICS is the signal voltage more than AC 1 V Even if the AT OIL Go to step 11 TEMP warning lights up the cir cuit has returned to a normai condi tion at this time A temporary poor contact of the con nector or harness may be the cause Repair harness or connector in the TCM and trans mission Is there poor contact in rear veh
39. Strainer Line pressure duty solenoid Control valve Drive pinion Hypoid gear Axle shaft Differential gear Oil pump Input shaft Output shaft Planetary gear Drive plate ATF level too low Front gasket transmission case Select cable Select lever Control valve Low amp reverse clutch Reverse clutch Low clutch 2 4 brake Planetary gear Parking brake mechanism Low clutch One way clutch Low clutch Reverse clutch Vehicle starts in R range only engine revving up Control valve Acceleration during standing starts is poor high stall rpm Acceleration during standing starts is poor low stall rpm Acceleration is poor when the select lever is in D 3 or 2 range normal stall rpm Acceleration is poor when the select lever is in R normal stall rpm No shift occurs from 1st to 2nd gear No shift occurs from 2nd to 3rd gear Control valve Low clutch Reverse clutch ATF level too low Front gasket transmission case Differential gear oil level too high or too low Oil pump Torque converter one way clutch Engine performance TCM Control valve High clutch e 2 4 brake e Planetary gear Control valve e High clutch e 2 4 brake Planetary gear e TCM Rear vehicle speed sensor Front vehicle speed sensor e Throttie position sensor e Shift solenoid 1 Contro
40. Subaru Select MOHIQOE s uie WS oma HAE RENE d Logd 7 Read Diagnostic Trouble Code DTO 8 Arispection Mode tit eoo tea Pere eh 9 Clear Memory Mode ebrei rera neret eo ERR ene aa EHE EAS e REGE regens 10 AT OIL TEMP Warning Light Display 11 List of Diagnostic Trouble Code DTC sse 12 Diagnostic Procedure for AT OIL TEMP Warning Light 13 Diagnostic Procedure for Select Monitor 14 Diagnostic Procedure with Diagnostic Trouble Code DTO 15 Diagnostic Procedure for No Diagnostic Trouble Code DTC 16 Symptom Related Diaghosli6 natnra et rrr dfe tene t d ni BASIC DIAGNOSTIC PROCEDURE AUTOMATIC TRANSMISSION DIAGNOSTICS 1 Basic Diagnostic Procedure A PROCEDURE CHECK PRE INSPECTION i ight i 1 Repair or replace 1 Ask the customer when and how the trouble the AT problem normal each item occurred using the interview checklist Ref to AT 4 Check List for Interview 2 Before performing diagnosis inspect the fol lowing items which might influence the AT problems General inspection Ref to 5 INSPEC TION General Description leak Stall speed test Ref to AT 13 Stall Test eLine pressure test Ref to AT 16 Line Pres sure Test Transfer clutch pr
41. amp terminal T4 No 2 No 16 AT 75 Go to step 2 Go to step 4 Repair open circuit in harness between TCM and transmission con nector Repair short circuit in harness between TCM and transmission con nector Go to step 6 CHECK OUTPUT SIGNAL EMITTED FROM TCM 1 Connect the connectors to TCM and trans mission 2 Lift up or raise the vehicle and support with safety stand CAUTION On AWD models raise all wheels off ground 3 Start the engine and warm up the transmis sion until the ATF temperature is above 80 C 176 F NOTE If the ambient temperature is below 0 C 32 F drive the vehicle until the ATF reaches its oper ating temperature 4 Move the selector lever to D and slowly increase the vehicle speed to 50 km h 31 MPH NOTE The speed difference between front and rear wheels may light the ABS warning light but this indicates no malfunction When the AT control diagnosis is finished perform the ABS memory clearance procedure of on board diagnostics system lt Ref to ABS 22 Clear Memory Mode gt 5 Measure the voltage between TCM connec tor and chassis ground Connector amp terminal Non turbo model B54 No 6 Chassis ground Turbo model B54 No 5 Chassis ground CHECK POOR CONTACT CHECK SHIFT SOLENOID 2 IN TRANSMIS SION 1 Remove the transmission connector from bracket 2 Drain the automatic tr
42. amp terminal temporary poor Non turbo model contact of the con B54 No 3 Chassis ground nector or harness Turbo model may be the cause B56 No 11 Chassis ground Repair the har ness or connector in TCM 9 CHECK SUBARU SELECT MONITOR Do you have a SUBARU Go to step 10 Go to step 11 SELECT MONITOR CHECK INHIBITOR SWITCH When each range is selected Go to step 11 Check the inhibi 1 Connect the Subaru Select Monitor to data does the LED of Subaru Select tor switch circuit link connector Monitor light up lt Ref to AT 115 2 Turn the ignition switch to ON CHECK INHIBI 3 Subaru Select Monitor to ON TOR SWITCH 4 Read the data of range switch using Subaru Diagnostic Proce Select Monitor dure for No Diag Range switch is indicated in ON lt gt OFF nostic Trouble Code DTC gt CHECK SHORT CIRCUIT OF HARNESS Is the resistance less than 1 Replace the TCM Repair short circuit 1 Disconnect the connector from TCM MQ lt Ref to AT 45 in harness 2 Remove the combination meter Transmission Con between combina 3 Disconnect the connector from combination trol Module tion meter connec meter TCM gt tor and TCM 4 Measure the resistance of harness connec connector tor between TCM and chassis ground Connector amp terminal specified resistance Non turbo model B54 No 3 Chassis ground Turbo model B56 No 11 Chassis ground AT 34 DIAGNOSTIC PROC
43. boot will not come off CAUTION Always use new locking wire B3M0617C A Locking wire B Stay 7 Insert the rod into the boot hole 8 Connect the rod to gear shift lever Tightening torque 11 8 1 2 kgf m 8 7 ft lb B3M1828A A Rod B Shift lever C Stay CS 35 MT GEAR SHIFT LEVER CONTROL SYSTEMS 9 Check the swing torque of the rod in relation to E INSPECTION the gear shift lever 1 Check each part bushing cushion rubber spac If the torque exceeds the specification replace the er boot stay and rod etc for deformation dam bushing or retighten nuts age and wear Repair or replace any defective part Rocking torque Pe defective parts by comparing with new parts 0 7 N m 0 07 kgf m 0 5 ft lb or less B3M1829C A Center of rotation B Swing torque 10 Check that there is no excessive play and that parts move smoothly B3M1765A gt Bushing Cushion rubber Spacer Boot Stay Rod mmoougs E CS 36 MT GEAR SHIFT LEVER CONTROL SYSTEMS 2 Check the swing torque of the rod in relation of the gear shift lever If the torque exceeds the specification replace the bushing or retighten nuts Rocking torque 0 7 0 07 kgf m 0 5 ft lb or less B3M1829C A Center of rotation B Swing torque CS 37 GENERAL DIAGOSTIC CONTROL SYSTEMS 9 General Diagostic A INSPECTION Symptom Problem parts Stop
44. etc to remove if too tight B3MO101H A Main shaft assembly B Drive pinion shaft assembly B INSTALLATION 1 Remove the differential assembly 2 Alignment marks numbers on hypoid gear set The upper number on driven pinion is the match number for combining it with hypoid driven gear The lower number is for shim adjustment If no low er number is shown the value is zero The number on hypoid driven gear indicates a number for com bination with drive pinion 3 Place the drive pinion shaft assembly on right hand transmission main case without shim and tighten the bearing mounting bolts MANUAL TRANSMISSION AND DIFFERENTIAL 4 Inspection and adjustment of ST NOTE e Loosen the two bolts and adjust so that the scale indicates 0 5 correctly when the plate end and the scale end are on the same level Tighten the two bolts DRIVE PINION GAUGE ASSY ST 499917500 B3M0064B A Plate B Scale 5 Position the ST by inserting the knock pin of ST into the knock hole in the transmission case ST 499917500 DRIVE PINION GAUGE ASSY 6 Slide the drive pinion gauge scale with finger tip and read the value at the point where it matches with the end face of drive pinion ST 499917500 DRIVE PINION GAUGE ASSY 0065 A Adjust clearance to zero without shim 7 The thickness of shim shall be determined by adding the value indicated on drive pinion to the value indicated on the S
45. in harness between inte grated module and key lock solenoid Is the resistance more than 1 Q Go to step 7 Repair short circuit in harness between inte grated module and key lock solenoid Is the resistance less than 10 Q Go to step 8 Repair open circuit in harness between key lock solenoid and chas sis ground Is the resistance between 4 Go to step 14 Replace the key and 8 Q lock solenoid Is the resistance less than 1 Q Go to step 10 Repair short circuit in harness between P posi tion switch and integrated module CS 21 AT SHIFT LOCK SYSTEM CONTROL SYSTEMS Step Check Yes CHECK HARNESS BETWEEN AT SHIFT Is the resistance more than 1 Repair open circuit to step 11 LOCK CONTROL MODULE AND P POSI in harness TION SWITCH between inte 1 Disconnect the connector from P position grated module and switch P position switch 2 Measure the resistance of harness between integrated module and P position switch Connector amp terminal B116 No 2 B280 No 6 CHECK HARNESS BETWEEN P POSI Is the resistance more than 1 Go to step 12 Repair open circuit TION SWITCH AND CHASSIS GROUND MQ in harness Measure the resistance of harness P position between P posi switch and chassis ground tion switch
46. lt Ref to MT 41 REMOVAL Transfer Case and Extension Case Assembly gt 4 Remove the extension case assembly 5 Remove the transfer driven gear 6 Remove the transfer drive gear L B3M1986 B INSTALLATION 1 Install the transfer drive gear Tightening torque 26 2 7 kgf m 20 ft lb B3M1986 2 Install the transfer driven gear 3 Install the extension case assembly 4 Install the transfer case and extension case as sembly lt Ref to MT 41 INSTALLATION Transfer Case and Extension Case Assembly gt 5 Install the back up light switch and neutral posi tion switch lt Ref to MT 38 INSTALLATION Switches and Harness gt 6 Install the manual transmission assembly from vehicle lt Ref to MT 30 INSTALLATION Manual Transmission Assembly gt MANUAL TRANSMISSION AND DIFFERENTIAL C DISASSEMBLY 1 Remove the snap ring B3M1988 2 Remove the ball bearing E B3M1989 D ASSEMBLY 1 Set the ST applying to inner race of bearing and instal to drive shaft ST 398177700 CAUTION Do not apply pressure in excess of 10 kN 1 ton 1 1 US ton 1 0 Imp ton INSTALLER TRose3 2 Install the snap ring on transfer drive shaft 3 Inspect the clearance between snap ring and in ner race of ball bearing Ref to MT 46 INSPEC TION Transfer Drive Gear MT 45 TRANSFER DRIVE GEAR MANUAL TRANSMISSION AND DIFFERENTIAL
47. one Normal code l Ul OFF DTC 11 and 23 03 02 0 3 0 8 0 2 0 3 0 2 0 3 0 2 1 2 1 5 1 2 1 2 dl OFF Unit Seconds 2 WITH SUBARU SELECT MONITOR Refer to SUBARU SELECT MONITOR for informa tion about how to obtain and understand trouble codes Ref to AT 22 OPERATION Subaru Se lect Monitor AT 25 INSPECTION MODE AUTOMATIC TRANSMISSION DIAGNOSTICS 8 Inspection Mode A OPERATION Raise the vehicle using a garage jack and place on safety stands or drive the vehicle onto free rollers WARNING Before raising the vehicle ensure parking brakes are applied Do not use a pantograph jack in place of a safety stand e Secure a or wire to the front and rear towing or tie down hooks to prevent the lateral runout of front wheels Do not abruptly depress release clutch pedal or accelerator pedal during works even when the engine is operating at low speeds since this may cause vehicle to jump off free rollers In order to prevent the vehicle from slipping due to vibration do not place any wooden blocks or similar items between the safety stands and the vehicle Since the rear wheels will also rotate do not place anything near them Also make sure that nobody goes in front of the vehicle B2M2969C A Safety stand B Free rollers AT 26 CLEAR MEMORY MODE 9 Clear Memory Mode A OPERATION 1 WITHOUT SUBARU SELECT MONITOR Current tro
48. ring is pressed against the cone Clearance A 0 5 1 0 mm 0 020 0 040 in T 53 0188 68 DRIVE PINION SHAFT ASSEMBLY MANUAL TRANSMISSION AND DIFFERENTIAL When the contact surface of the synchronizer ring insert is scored or abnormally worn down 5 Shifting insert key Replace the insert if deformed excessively worn or defective in any way S3M0189 6 Oil seal Replace the oil seal if the lip is deformed hard ened damaged worn or defective in any way 7 O ring Replace the O ring if the sealing face is deformed hardened damaged worn or defective in any way F ADJUSTMENT 1 THRUST BEARING PRELOAD 1 After completing the preceding steps 1 through 3 select adjusting washer No 1 so that the dimen sion H is zero through visual check Position washer 18 3 x 30 x 4 and lock washer 18 x 30 x 2 and install lock nut 18 x 13 5 B3M0538A 2 Using ST1 ST2 and ST3 tighten the lock nut to the specified torque ST1 899884100 HOLDER ST2 498427100 STOPPER ST3 899988608 SOCKET WRENCH 27 Tightening torque 118 12 kgf m 86 8 ft Ib 3 After removing ST2 measure the starting torque using torque driver ST1 899884100 HOLDER ST3 899988608 SOCKET WRENCH 27 Starting torque 0 3 0 8 0 03 0 08 kgf m 0 2 0 6 ft Ib B3M0085A 4 If starting torque is not within specified limit se lect
49. worn or unlubricated release Replace release bearing bearing Examine whether the noise is generated when the clutch is disengaged engaged Apply grease Replace clutch dis Replace clutch disc e Deteriorated or broken torsion spring Replace clutch disc Replace clutch disc Replace clutch disc c Worn or rusted spline of clutch disc or Take off rust apply grease or replace main shaft clutch disc or main shaft d Deteriorated or broken torsion spring Replace clutch disc e Loose engine mounting Retighten or replace mounting f Deteriorated diaphragm spring Replace 5 Clutch grabs When starting the vehicle with the clutch partially engaged the clutch engages suddenly and the vehicle jumps instead of making a smooth start 2 CLUTCH PEDAL dust pedal pi Adjust pedal res py Replace bushing and or shaft with new one 3 DIAGNOSTIC DIAGRAM OF CLUTCH DRAG Se ex Ne 1 CHECK GEAR NOISE Is there any abnormal noise step 2 Clutch is normal 1 Start the engine from the transmission gear 2 Disengage the clutch and shift quickly from neutral to reverse in idling condition CHECK GEAR NOISE Disengage the clutch at idle and shift from neu tral to reverse within 0 5 1 0 seconds Corrective action Defective trans mission or exces sive clutch drag torque
50. 1 AC range Less than 1 More than 5 0 13 or more More than 4 8 12 18 Resistance to body ohms 450 650 450 650 450 650 TRANSMISSION CONTROL MODULE TCM I O SIGNAL AUTOMATIC TRANSMISSION DIAGNOSTICS Check with ignition switch ON Con Termi to Content nector Measuring conditions Voltage V No nal No body ohms Throttle fully closed with engine OFF after warm up Throttle fully open with engine OFF after warm up When lock up occurs More than 8 5 EQUUM ety dd When lock up is released Less than 0 5 Fuse on FWD switch More than 8 5 aj Fuse removed from FWD Transfer duty solenoid B54 switch with throttle fully open and with select lever in 1st gear Throttle fully closed with engine OFF after warm up Throttle fully open with engine OFF after warm up ie Throttle fully closed with More than 8 5 9 15 Dropping resistor B54 Less than 0 5 Less than 0 5 15 5 0 2 4 brake duty solenoid Less than 1 gi engine OFF after warm up More than 8 5 2 4 brake dropping resistor B54 eng n eee eu Throttle fully open with engine OFF after warm up E 7 B54 5 ist gear Less than 1 10 16 2 3rd gear More than 9 2nd gear Less than 1 4th gear More than 9 0506 Sensor ground line 1 B55 10 0 Less than 1 Sensor ground line
51. 10 and 20 Q Is the shift lock solenoid oper ating properly Is the resistance less than 1 Q Is the resistance more than 1 MQ CS 30 Go to step 2 Go to step 3 Go to step 4 Replace the shift lock solenoid and P position switch assembly Replace the shift lock solenoid and P position switch assembly Replace the P position switch Replace the P position switch INTEGRATED MODULE CONTROL SYSTEMS 7 Integrated Module B INSTALLATION Install in the reverse order of removal A REMOVAL 1 Disconnect the ground terminal from battery i G6M0095 4 5 0082 4 Disconnect the connector from integrated mod ule 5 Remove the integrated module TRO562 CS 31 MT GEAR SHIFT LEVER CONTROL SYSTEMS 8 MT Gear Shift Lever 11 Remove the cushion rubber from body A REMOVAL 1 Set the vehicle on the lift 2 Remove the gear shift knob 3 Disconnect the ground terminal from battery 4 Remove the console box lt Ref to El 41 RE MOVAL Console Box gt 5 Remove the boot plate from body B3M1825A A Stay B Cushion rubber 12 Remove the joint and then extract the spring pin 6 Lift up the vehicle 7 Remove the rear exhaust pipe and muffler 8 Remove the heat shield cover If equipped 9 Remove the stay from transmission bracket B3M1826A A Jo
52. 13 Chassis ground Turbo model B56 14 Chassis ground B56 No 5 Chassis ground CHECK OUTPUT SIGNAL EMITTED FROM TCM 1 Connect the connectors to TCM and ECM 2 Turn the ignition switch to ON engine OFF 3 Measure the voltage between TCM connec tor terminals Connector amp terminal Non turbo model B54 No 21 Chassis ground B54 No 13 Chassis ground Turbo model B56 No 14 Chassis ground B56 No 5 Chassis ground CHECK POOR CONTACT s there poor contact in torque Repair poor con ontrol signal circuit tact CHECK GROUND LINE BETWEEN TRANS MISSION AND BODY Check the installing condition of ground line in transmission and body CHECK GROUND LINE BETWEEN TRANS MISSION AND BODY Check the installing condition of ground line in transmission and body Tightening torque 1313 N m 1 3 0 3 kgf m 9 412 2 ft lb CHECK GROUND LINE INSIDE TRANSMIS SION 1 Drain the AT fluid and remove the oil pan 2 Check the tightening torque value of ground line installing bolt Tightening torque T 8 1 N m 0 810 1 kgf m 5 810 7 ft lb CHECK GROUND CIRCUIT OF ECM Ref to 52 DTC 31 THROTTLE POSITION SENSOR Diagnostic Procedure with Diagnos tic Trouble Code DTC gt RECHECK OUTPUT SIGNAL EMITTED FROM TCM Measure the voltage between TCM connector and chassis ground Connector amp terminal Non turbo model B54 No 21 Chassis ground
53. 2 9 4 1063 6 Disconnect the ATF cooler hose from radiator NOTE Do not remove with a screwdriver or other point ed tools When the hose is difficult to remove wrap a shop cloth around the hose to protect it Turn it with pli ers and then pull directly out with your hand TROS29 7 Disconnect the ATF cooler hoses from pipes NOTE e Do not remove with a screwdriver or other point ed tools When the hose is difficult to remove wrap a shop cloth around the hose to protect it Turn it with pli ers and then pull directly out with your hand TRO330 8 Remove the ATF cooler pipe from frame TRO331 9 Remove the oil cooler inlet and outlet pipes CAUTION When removing the outlet pipe be careful not to lose the ball and spring used with retaining screw A Inlet pipe B Outlet pipe AT 48 ATF COOLER PIPE AND HOSE TOE 3 Connect the ATF cooler hose to pipe transmis B INSTALLATION 1 NON TURBO MODEL 1 Install the oil cooler outlet and inlet pipes CAUTION Be sure to use a new aluminum washer Tightening torque T1 44 N m 4 5 kgf m 32 5 ft lb T2 25 N m 2 5 kgf m 18 1 ft Ib De n Wes NBC VES 7 A DA SS e Ni A Inlet pipe B Outlet pipe 2 Install the ATF cooler pipe to cylinder head Tightening torque 7
54. 2 B55 21 0 Less than 1 9 System ground line 0 Less than 1 Less than 0 5 2 4 brake timing solenoid Low clutch timing solenoid F EWD switch B55 use feimovee More than 9 Fuse installed Less than 1 Fuse ONFWD switch Less than 1 EWD indi D indicator light Fuse removed from FWD More than 9 EE 1 switch Less than 1 AT diagnosis signal than 4 Data link signal Subaru Select Monitor AT 13 TRANSMISSION CONTROL MODULE TCM I O SIGNAL AUTOMATIC TRANSMISSION DIAGNOSTICS 2 TURBO MODEL to B55 1 1 9 6 5 4 3 2 8 7 6 5 8 212019 4 Il 181171165 18 17 16 TRO532 Check with ignition switch ON Con Resistance Content nector Terminal No Measuring conditions Voltage V to body No ohms Back up power supply B56 Ignition switch OFF 10 13 ignition switch ON with Ignition power supply 854 engine OFF 10 13 Select lever in P range Less than 1 range B55 1 Select lever other switch than P range except N More than 8 range Select lever in N range Less than 1 N range Select lever in any other 55 14 switch than range except P More than 8 range Select lever in R ran
55. 3 Manual Transmission Assembly 4 Transmission Mounting System MEISTE 6 Switches Harness a is COR XO RR KE e resi X des 7 M hicle Speed Senso eite debes ced an 8 Preparation for Overhaul sis sess viele bea beet ibo coepti rone ep 9 Transfer Case and Extension Case 41 10 iiec vr De Pee gender Tp eee pier oer RE e inedit 45 it Transfer Driven Gear uii cotto er WEE uror C rd 47 12 Center Differential err pr te reb ERR XV E PAN RR Sn Pera 49 13 Reverse Check 50 14 Transmission cre Ted eq n der deris 54 15 Main Shaft Assembly for Single Range see 57 16 Drive Pinion Shaft Assembly sse 63 17 Front Differential 112 71 18 Speedometer iie rni lodi P HRS 77 19 Reverse Idler 2 nci tee recipe ned de taa 78 20 Shifter Fork and ROG Da EIE CIRC PR PCT VERI NIE 80 21 General DIAGNOSTIC ier er P YER COEPI ti we v E OR 84 GENERAL DESCRIPTION MANUAL TRANSMISSION AND DIFFERENTIAL 1 General Description A SPECIFICATIONS 1 MANUAL TRANSMISSION AND
56. 35 N m 0 75 kgf m 5 42 ft Ib AUTOMATIC TRANSMISSION sion side NOTE Install so that the hose is not folded over exces sively bent or twisted Be careful to insert the hose to the specified po sition 2 RONG x 4 Connect the ATF cooler hose to pipe of radiator side NOTE Install so that the hose is not folded over exces sively bent or twisted Be careful to insert the hose to the specified po sition S2M0895 5 Install the under cover 6 Fill ATF lt Ref to AT 9 Automatic Transmission Fluid gt NOTE Make sure there are no ATF leaks in joints between the transmission radiator pipes and hoses AT 49 ATF COOLER PIPE AND HOSE AUTOMATIC TRANSMISSION 2 TURBO MODEL 3 Connect the ATF cooler hose to pipe transmis 1 Install the oil cooler outlet and inlet pipes sion side CAUTION NOTE e Install so that the hose is not folded over exces sively bent or twisted Tightening torque Be careful to insert the hose to the specified po 1 44 4 5 kgf m 32 5 ft lb sition T2 25 N m 2 5 kgf m 18 1 ft lb Be sure to use a new aluminum washer 4 Connect the ATF cooler hose to pipe of radiator Inlet pipe side B Outlet pipe NOTE e Install so that the hose is not folded over exces 2 Install the ATF cooler pipe to frame sively bent or twisted Be careful to insert the hose to the specified po sition
57. 40 Arm stops closer to reverse gear Part No Remarks 32189AA040 4 9 EXTENSION ASSEMBLY Thrust washer 50 x 61 x t to taper roller bearing table outer race side clearance 0 2 0 3 mm T 0 0008 0 012 in T NOTE T Tight Thrust washer 50 x 61 x t Thrust washer to center differential side clearance 0 15 0 35 mm 0 0059 0 0138 in Thickness mm in TT 0 088 15 0 058 MT 5 GENERAL DESCRIPTION MANUAL TRANSMISSION AND DIFFERENTIAL 10 FRONT DIFFERENTIAL Bevel gear to pinion backlash 0 13 0 18 mm 0 0051 0 0071 in Washer 38 1 x 50 x t Part No Thickness Part No Thickness mm in mm in 0 925 0 950 803038021 0 0364 803038023 0 0374 803038022 EN Pinion shaft to axle drive shaft clearance 0 0 2 mm 0 0 008 in Snap ring Outer 28 Thickness Thickness Part No mm in mm in 1 05 0 0413 805028012 1 20 0 0472 Part No 80502801 1 11 TRANSFER DRIVE GEAR Snap ring Outer 30 to ball bearing clearance 0 01 0 15 mm 0 0004 0 0059 in Snap ring Outer 30 Thickness mm in MT 6 GENERAL DESCRIPTION MANUAL TRANSMISSION AND DIFFERENTIAL COMPONENT 1 TRANSMISSION CASE TRO541 1 Transmission case ASSY 7 Speedometer shaft 13 Oil level gauge Non turbo model 2 Gasket 8 Snap ring Outer 14 Oil level gauge Turbo mod
58. 58 MAIN SHAFT ASSEMBLY FOR SINGLE RANGE D ASSEMBLY 1 Assemble each sleeve and hub assembly NOTE Position open ends of spring 120 apart 3rd 4th hub ASSY B3M1366A 2 Install the 3rd drive gear outer baulk ring syn chro cone inner baulk ring sleeve and hub assem bly for 3rd needle bearing on the transmission main shaft NOTE Align the groove in baulk ring with shifting insert D B3M0837A A 3rd needle bearing B 3rd drive gear C Inner baulk ring D Synchro cone E Outer baulk ring F Sleeve and hub ASSY MANUAL TRANSMISSION AND DIFFERENTIAL 3 Install the 4th needle bearing race onto transmis sion main shaft using ST1 ST2 and a press CAUTION Do not apply pressure in excess of 10 KN 1 ton 1 1 US ton 1 0 Imp ton ST1 899714110 REMOVER ST2 499877000 RACE 4 5 INSTALLER B3M0543D A 4th needle bearing race 4 Install the baulk ring needle bearing 4th drive gear and 4th gear thrust washer to the transmission main shaft NOTE Align the baulk ring and gear amp hub assembly with key groove S3M0045A A Groove B 4th gear side MT 59 MAIN SHAFT ASSEMBLY FOR SINGLE RANGE MANUAL TRANSMISSION AND DIFFERENTIAL 5 Drive the bail bearing onto the rear section of transmission main shaft using ST1 ST2 and a press CAUTION Do not apply pressure in excess of 10 KN 1 ton 1 1 US ton 1 0 Imp ton ST1 899714110 REMOVER ST2 49987
59. A AT OIL TEMP WARNING LIGHT DOES NOT COME ON OR GO OFF DIAGNOSIS The AT OIL TEMP warning light circuit is open or shorted TROUBLE SYMPTOM e When the ignition switch is turned to ON engine OFF AT OIL TEMP warning light does not illuminate e When the on board diagnostics is performed AT OIL TEMP warning light remains illuminated AT 31 DIAGNOSTIC PROCEDURE FOR AT OIL TEMP WARNING LIGHT AUTOMATIC TRANSMISSION DIAGNOSTICS WIRING DIAGRAM IGNITION SBF 1 SBF 4 SWITCH No 13 BATTERY COMBINATION A METER ur o 59 M e A A x e l s B e k t a e je pj xj m ole D NON TURBO MODEL D TURBO MODEL gt CD Ds n l 1 2 3 4 s 6 1 2 3 4 5 15 18 115 1 2 8 4 15 e z le 9 1 2 1 s e 7 8 71819 101112 5161718 10 11 1213 14 15 16 17 18 10 11 1253 14 15 16 17 18 10 11 12113 t4 15 16 17 9 1o 11 12 1912021 22 23 24 19 20 21 22 23 24 19120 21 22 23 Li 1 2 3 4 5 6 a o fio 12 5 6 71 D 8 o 2 4 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 0 0 1 T2 Is 5 e 7 8 9 hof 121 14 15 16 17 18 19 20 21 22 23 24 TRO570 AT 32 DIAGNOSTIC PROCEDURE FOR AT OIL TEMP WARNING LIGHT AUTOMATIC TRANSMISSION DIAGNOSTICS Ye Check Does the AT OIL T
60. B3M0070D Coast side C Heel D Drive side F ADJUSTMENT 1 BEVEL PINION GEAR BACKLASH 1 Disassemble the front differential lt Ref to MT 71 REMOVAL Front Differential Assembly gt 2 Select a different washer from the table and in stall Part No Thickness mm in 0 925 0 950 803038021 0 0364 0 0374 0 975 1 000 803038022 0 0384 0 0394 1 025 1 050 803038023 0 0404 0 0413 3 Adjust until the specified value is obtained Standard backlash 0 13 0 18 mm 0 0051 0 0071 in 2 HYPOID GEAR BACKLASH Adjust the backlash by turning holder in right side case ST 499787000 WRENCH ASSY NOTE Each time holder rotates one tooth backlash changes by 0 05 mm 0 020 in MT 75 FRONT DIFFERENTIAL ASSEMBLY MANUAL TRANSMISSION AND DIFFERENTIAL 3 TOOTH CONTACT OF HYPOID GEAR The drive pinion shim selected before is too thin Adjust until the teeth contact is correct Increase its thickness Backlash is excessive To reduce backlash loosen holder on the upper side case right side and turn in the holder on the lower side case left side by the same amount B3M0074 0071 Backlash is insufficient To increase backlash loosen holder on the lower side case left side and turn in the holder on the upper side case right side by the same amount B3M0072 The drive pinion shim
61. B55 No 23 T7 No 9 Turbo model B55 No 1 T7 No 9 CHECK INPUT SIGNAL FOR TCM 1 Turn the ignition switch to OFF 2 Connect the connector to TCM and inhibitor Switch 3 Turn the ignition switch to ON 4 Measure the voltage between TCM and chassis ground Connector amp terminal Non turbo model B55 No 23 4 Chassis ground Turbo model B55 No 1 Chassis ground CHECK INPUT SIGNAL FOR TCM Measure the voltage between TCM and chas sis ground Connector amp terminal Non turbo model B55 No 23 Chassis ground Turbo model B55 No 1 Chassis ground CHECK P RANGE INDICATOR LIGHT BULB 1 Turn the ignition switch to OFF 2 Remove the combination meter 3 Remove the P range indicator light bulb from combination meter CHECK HARNESS CONNECTOR BETWEEN Is the resistance more than 1 TCM AND COMBINATION METER 1 Disconnect the connectors from TCM and combination meter 2 Measure the resistance of harness between TCM and combination meter Connector amp terminal Non turbo model B55 No 23 i12 No 14 Turbo model B55 No 1 i12 No 14 Is the voltage less than 1 V in P range Go to step 25 Go to step 65 Go to step 27 Go to step 65 Go to step 65 Is the voltage more than 8 V in other ranges Replace the TCM Ref to AT 45 Transmission Con trol Module TCM gt
62. C 4th drive gear 3rd 4th shifter fork Approach to 4th gear by 0 2 mm 0 008 32810AA071 Standard Become distant from 32810AA101 3rd gear Xd 0 2 mm 0 008 in MT 82 SHIFTER FORK AND ROD MANUAL TRANSMISSION AND DIFFERENTIAL 5 Inspect the clearance between 5th drive gear 6 Inspect the rod end clearances and If any and coupling sleeve If any clearance is not within clearance is not within specifications replace the specifications replace shifter fork as required rod or fork as required Clearance a Clearance A 9 3 mm 0 366 in 1st 2nd to 3rd 4th 0 4 1 4 mm 0 016 0 055 in Clearance B 3rd 4th to 5th 0 5 1 3 mm 0 020 0 051 in A a B 53 0191 A 5th drive gear B Coupling sleeve ee 5th shifter fork Non turbo Part No Remarks Approach to 5th gear ida id by 0 2 mm 0 008 in 32812AA211 Standard Become distant from 32812AA221 5th gear by 0 2 mm 0 008 in B3M0530A 5th shifter fork Turbo Part No Mark Approach to 5th gear 32812AA231 by 0 2 mm 0 008 in 32812AA241 Standard Become distant from 32812AA251 5th gear by 0 2 mm 0 008 in MT 83 GENERAL DIAGNOSTIC MANUAL TRANSMISSION AND DIFFERENTIAL 21 General Diagnostic A INSPECTION 1 MANUAL TRANSMISSION Symptom 1 Gears are difficult to intermesh a Worn damaged or burred chamfer of Replace NOTE internal spline of s
63. CAUTION pe When removing the exhaust pipes be careful each exhaust pipe does not drop out 6 Remove the center exhaust pipe Turbo model A Adjusting nuts lt Ref to EX DOHC TURBO 8 REMOVAL Center B Cable bracket Exhaust Pipe gt 7 Remove the heat shield cover If equipped 11 Remove the select cable from plate assembly 8 Remove the snap pin from range select lever Range select lever B Snap pin Select cable Clamp case A Select cable B Plate ASSY C Clamp CS 26 SELECT CABLE CONTROL SYSTEMS B INSTALLATION 1 Install the select cable to plate assembly Tightening torque 32 N m 3 3 kgf m 24 ft lb 2 Install the select cable to range select lever 3 Install the plate assembly to transmission Tightening torque 24 5 2 5 kgf m 18 1 ft lb 7 B3M1030G A Select cable B Plate ASSY 4 Install the snap pin to range select lever B3M1029B A Range select lever B Snap pin C Select cable D Clamp 5 Move the select lever to the N position then ad just the select cable position Ref to CS 27 AD JUSTMENT Select Cable 6 Install the heat shield cover If equipped 7 Install the front and center exhaust pipe Non turbo model Ref to EX SOHC 6 INSTALLA TION Front Exhaust Pipe 8 Install the center exhaust pipe Turbo model Ref to EX DOHC TURBO 9 INST
64. Chassis ground Turbo model B55 No 6 Chassis ground CHECK HARNESS CONNECTOR BETWEEN 15 the resistance less than 1 TCM AND INHIBITOR SWITCH 1 Turn the ignition switch to OFF 2 Disconnect the connectors from TCM and inhibitor switch 3 Measure the resistance of harness between TCM and inhibitor switch connector Connector amp terminal Non turbo model B54 No 1 T7 No 6 Turbo model B55 No 7 T7 No 6 CHECK INPUT SIGNAL FOR TCM 1 Turn the ignition switch to OFF 2 Connect the connector to TCM and inhibitor switch 3 Turn the ignition switch to ON 4 Measure the voltage between TCM and chassis ground Connector amp terminal Non turbo model B54 No 1 Chassis ground Turbo model B55 No 7 Chassis ground CHECK INPUT SIGNAL FOR TCM Is the voltage more than 8 V in Go to step 65 Measure the voltage between TCM and chas other ranges sis ground Connector amp terminal Non turbo model B54 No 1 Chassis ground Turbo model B55 No 7 Chassis ground CHECK 1 RANGE INDICATOR LIGHT BULB 1 Turn the ignition switch to OFF 2 Remove the combination meter 3 Remove the 1 range indicator light bulb from combination meter Go to step 59 Go to step 60 Is the voltage less than 1 V in 1 range Go to step 61 Is the 1 range indicator light bulb OK Go to step 63 AT 125 Repair ground short circuit in 2
65. Check and press the YES key 7 On the System Selection Menu display screen select the Transmission Control System and press the YES key 8 Press the YES key after displayed the informa tion of transmission type 9 On the Transmission Diagnosis display screen select the Diagnostic Code s Display and press the YES key 10 On the Diagnostic Code s Display display screen select the Latest Diagnostic Code s or Memorized Diagnostic Code s and press the YES key NOTE For detailed operation procedure refer to the SUBARU SELECT MONITOR OPERATION MAN UAL e For detailed concerning diagnostic trouble codes refer to the DIAGNOSTIC TROUBLE CODE LIST DTC lt Ref to AT 29 List of Diagnostic Trouble Code DTC gt 2 READ CURRENT DATA 1 On the Main Menu display screen select the Each System Check and press the YES key 2 On the System Selection Menu display screen select the Transmission Control System and press the YES key 3 Press the YES key after displayed the informa tion of transmission type 4 On the Transmission Diagnosis display screen select the Current Data Display amp Save and press the YES key AT 22 SUBARU SELECT MONITOR AUTOMATIC TRANSMISSION DIAGNOSTICS 5 On the Data Display Menu display screen se A list of the support data is shown in the following lect the Data Display and press the YES key table 6 Usin
66. Connector amp terminal T4 No 9 AT7 1 CHECK HARNESS CONNECTOR BETWEEN TRANSMISSION AND 2 4 BRAKE DUTY SO LENOID Measure the resistance of harness between transmission connector and transmission ground Connector amp terminal T4 No 9 Transmission ground DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE DTC AUTOMATIC TRANSMISSION DIAGNOSTICS Is the value less than 2596 Is there poor contact in 2 4 brake duty solenoid circuit Is the resistance between 2 0 and 4 5 0 Is the resistance less than 1 Q Is the resistance more than 1 MQ AT 93 Even if the AT OIL TEMP warning lights up the cir cuit has returned to a normal condi tion at this time A temporary poor contact of the con nector or harness may be the cause Repair harness or connector in TCM and transmission Repair poor con tact Go to step 17 Go to step 15 Replace the TCM Ref to AT 45 Transmission Con tro Module TCM gt Replace the 2 4 brake duty sole noid lt Ref to AT 39 Shift Sole noids Duty Sole Go to step 18 Even if the AT OIL TEMP warning lights up the cir cuit has returned to a normal condi tion at this time A temporary poor contact of the con nector or harness may be the cause Repair harness or connector in line pressure duty solenoid and transmission noids and ATF Temperature Sen SOr Repair open circuit in harness between
67. E INSPECTION 1 Bearings Replace bearings in the following cases Broken or rusty bearings Worn or damaged Bearings that fail to turn smoothly or make ab normal noise when turned after gear oil lubrication 2 Drive gear Replace drive gear in the following cases If their tooth surfaces and shaft are excessively broken or damaged 3 Measure the clearance between snap ring and inner race of ball bearing with a thickness gauge Clearance 0 01 0 15 mm 0 0004 0 0059 in B3M1991 If the measurement is not within the specification select suitable snap ring Snap ring Outer 30 MT 46 TRANSFER DRIVEN GEAR 11 Transfer Driven Gear A REMOVAL 1 Remove the manual transmission assembly from vehicle lt Ref to MT 27 REMOVAL Manual Transmission Assembly gt 2 Remove the back up light switch and neutral po sition switch lt Ref to MT 37 REMOVAL Switches and Harness gt 3 Remove the transfer case with extension case assembly lt Ref to MT 41 REMOVAL Transfer Case and Extension Case Assembly gt 4 Remove the extension case assembly 5 Remove the transfer driven gear 6 Remove the bearing cup from extension case and transfer case B3M1993A A Bearing cup transfer case B Bearing cup extension case MANUAL TRANSMISSION AND DIFFERENTIAL B INSTALLATION 1 Install the bearing cup to extension case and transfer case TR
68. Exhaust Pipe gt and lt to EX SOHC 11 INSTALLATION Muffler gt 6 Install the center rear exhaust pipes and muffler Turbo model lt Ref to EX DOHC TURBO 14 IN STALLATION Muffler gt lt Ref to EX DOHC TUR BO 13 INSTALLATION Rear Exhaust Pipe gt lt Ref to EX DOHC TURBO 9 INSTALLATION Center Exhaust Pipe gt AT 26 EXTENSION CASE OIL SEAL AUTOMATIC TRANSMISSION 11 Extension Case Oil Seal A INSPECTION Make sure that the ATF does not leak from the joint of the transmission and propeller shaft If so re place the oil seal lt Ref to AT 27 REPLACE MENT Extension Case Oil Seal gt REPLACEMENT 1 Set the vehicle on the lift 2 Disconnect the ground terminal from battery 3 Lift up the vehicle 4 Clean the transmission exterior 5 Drain the ATF completely NOTE Tighten the ATF drain plug after draining the ATF Tightening torque 25 N m 2 5 kgf m 18 1 ft lb A pan B Drain plug C Differential oil drain plug 6 Remove the rear exhaust pipe and muffler Non turbo model lt Ref to EX SOHC 9 REMOVAL Rear Exhaust Pipe gt and lt Ref to EX SOHC 11 REMOVAL Muffler gt Turbo model lt Ref to EX DOHC TURBO 13 REMOVAL Rear Exhaust Pipe gt lt Ref to EX DOHC TURBO 14 REMOVAL Muffler gt 7 Remove the heat shield cover If equipped 8 Remove the propeller shaft lt Ref to DS 14 RE MOVAL Propeller Shaft gt 9 Using the ST
69. FILTER AUTOMATIC TRANSMISSION 18 ATF Filter C INSPECTION Replace the part if any defect is found from the in A REMOVAL 4 2 Check for rust hole ATF leaks and other damage The ATF filter is maintenance free 1 Lift up the vehicle 2 Using the ST remove the ATF filter ST 498545400 OIL FILTER WRENCH ATF filter 3 Get a new ATF filter and apply a thin coat of ATF to the oil seal B INSTALLATION 1 Install the ATF filter Turn it by hand being care ful not to damage oil seal 2 Using the ST tighten the ATF filter to transmis sion case Calculate the ATF filter torque specifications using the following formula T2 L1 L1 L2 x T1 T1 14 N m 1 4 kgf m 10 1 ft lb Required torque setting T2 Tightening torque L1 ST length 0 078 m 3 07 in L2 Torque wrench length Example Torque wrench length mm in kgf m ft lb 2 9 0 CAUTION Align the ST with torque wrench while tighten ing the ATF filter ST 498545400 FILTER WRENCH 3 Add ATF 4 Inspect the level of ATF lt Ref to AT 9 Automat ic Transmission Fluid gt AT 44 TRANSMISSION CONTROL MODULE TCM AUTOMATIC TRANSMISSION 19 Transmission Control Mod B INSTALLATION ule TCM 1 Install the transmission control module Tightening torque A REMOVAL 7 5 N m 0 76 kgf m 5 5 ft Ib 1 Disconnect the ground terminal from battery TRO326
70. MODULE Measure the resistance of harness between stop light switch and chassis ground Connector amp terminal Without cruise control model B64 No 1 Chassis ground Without cruise control model B65 No 3 Chassis ground Q in harness between inte grated module and stop light switch Go to step 4 CHECK HARNESS BETWEENINTEGRATED MODULE AND SHIFT LOCK SOLENOID 1 Disconnect the shift lock solenoid connector 2 Measure the resistance of harness between integrated module and shift lock solenoid Connector amp terminal B116 No 4 B281 No 9 Is the resistance more than 1 MO Repair open circuit in harness between inte grated module and shift lock solenoid Go to step 5 CHECK HARNESS BETWEEN INTEGRATED MODULE AND SHIFT LOCK SOLENOID Measure the resistance of harness between shift lock solenoid and chassis ground Connector amp terminal B116 No 4 Chassis ground Is the resistance less than 1 Q Repair short circuit in harness between inte grated module and shift lock solenoid Go to step 6 CHECK HARNESS BETWEEN SHIFT LOCK Is the resistance more than 1 SOLENOID AND CHASSIS GROUND Measure the resistance of harness between shift lock solenoid and chassis ground Connector amp terminal B116 No 5 Chassis ground MQ 4 Repair open circuit in harness between shift lock solenoid and body ground Go to st
71. Repair short circuit harness between shift solenoid 1 and transmission connector DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE DTC AUTOMATIC TRANSMISSION DIAGNOSTICS AT 73 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE DTC AUTOMATIC TRANSMISSION DIAGNOSTICS J DTC 72 SHIFT SOLENOID 2 DIAGNOSIS Output signal circuit of shift solenoid 2 is open or shorted TROUBLE SYMPTOM Does not shift WIRING DIAGRAM NON TURBO MODEL 18 TURBO MODEL SHIFT SOLENOID 2 TRANSMISSION Ts sls bal ea AT 74 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE DTC AUTOMATIC TRANSMISSION DIAGNOSTICS CHECK HARNESS CONNECTOR BETWEEN 15 the resistance less than 1 TCM AND TRANSMISSION 1 Turn the ignition switch to OFF 2 Disconnect the connector from TCM and transmission 3 Measure the resistance of harness between TCM and shift solenoid 2 connector Connector amp terminal Non turbo model B54 No 6 B11 No 2 Turbo model B54 No 5 B11 No 2 CHECK HARNESS CONNECTOR BETWEEN Is the resistance more than 1 TCM AND TRANSMISSION Measure the resistance of harness between TCM connector and chassis ground Connector amp terminal Non turbo model B54 No 6 Chassis ground Turbo model B54 No 5 Chassis ground CHECK SHIFT SOLENOID 2 Is the resistance between 10 Measure the resistance between transmission and 16 Q connector terminals Connector
72. Shifter arm turns lightly toward the 1st 2nd gear side but heavily toward the reverse gear side be cause of the function of the return spring until arm contacts the stopper 3 Make adjustment so that the heavy stroke re verse side is a little more than the light stroke 1st 2nd side 4 To adjust remove bolts holding reverse check sleeve assembly to the case move sleeve assem bly outward and place adjustment shim 0 to 1 ea between sleeve assembly and case to adjust the clearance CAUTION Be careful not to break O ring when placing shim s NOTE When the shim is removed the neutral position will move closer to reverse when the shim is add ed the neutral position will move closer to 1st gear f the shims alone cannot adjust the clearance replace the reverse accent shaft and re adjust Thickness mm in 0059 0118 32190AA000 0 15 0 0059 32190AA010 0 30 0 0118 Reverse accent shaft PartNo Mark 33188 AA090 position is closer to 1st SeTeBARTOO Standard 1 Neutral position is closer to reverse gear 32188AA110 MT 52 REVERSE CHECK SLEEVE MANUAL TRANSMISSION AND DIFFERENTIAL 2 REVERSE CHECK PLATE ADJUST MENT 1 Shift the shifter arm to 5th and then to reverse to see if reverse check mechanism operates prop erly 2 Also check to see if the arm returns to neutral when released from the reverse position If the arm does not return proper
73. TURBO 8 REMOVAL Center Exhaust Pipe AT 39 SHIFT SOLENOIDS DUTY SOLENOIDS AND ATF TEMPERATURE SENSOR AUTOMATIC TRANSMISSION 9 Raise the vehicle and drain the ATF A pan Drain plug C Defferential oil drain plug 10 Remove the heat shield cover If equipped 11 Remove the propeller shaft lt Ref to DS 14 REMOVAL Propeller Shaft gt 12 Remove the rear crossmember 1 Support the transmission using a transmis sion jack and raise slightly 2 Remove the bolts and nuts as shown in the figure 14 Remove the select cable nut G3M0308 15 Move the gear select cable so that extension bolts can be removed 16 Remove the bolts 17 Remove the extension case NOTE Use a container to catch oil flowing from extension 18 Disconnect the transfer duty solenoid connec tor 19 Remove the transfer duty solenoid and transfer valve body B3M1045F Transfer valve body B Transfer duty solenoid connector C Transfer duty solenoid AT 40 SHIFT SOLENOIDS DUTY SOLENOIDS AND ATF TEMPERATURE SENSOR AUTOMATIC TRANSMISSION B INSTALLATION 1 Install the solenoids and ATF temperature sen sor Tightening torque T 8 N m 0 8 kgf m 5 8 ft Ib 6 D gt Lock up duty solenoid Blue Low clutch timing solenoid Gray Line pressure duty solenoid Red Shift s
74. Turbo model Ref to IN DOHC TURBO 10 REMOVAL Intercooler gt 7 Remove the nut which secures clutch master cylinder 8 Remove the bolts and nuts which secure brake and clutch pedals and remove pedal assembly B INSTALLATION 1 Install in the reverse order of removal CAUTION f the cable clamp is damaged replace it with a new one e Never fail to cover outer cable end with boot e Be careful not to kink the accelerator cable Always use a new clevis pins 2 Adjust the clutch pedal after installation Ref to CL 27 ADJUSTMENT Clutch Pedal C DISASSEMBLY 1 Remove the clutch switches 2 Remove the clips assist spring rod and bush ing B2M4115A gt Clip B Assist spring C Assist rod D Bushing E Clevis pin ee one 3 Remove the spring pin and lever B2M4116A Pin B Lever CL 26 CLUTCH PEDAL CLUTCH SYSTEM 4 Remove the clutch pedal and bushings B2M4117A A Clutch pedal B Bushing 5 Remove the stopper clip O ring rod S and then remove the spring and bushing S B2M4118A A Clip B O ring C Bushing S D Spring S E RodS F Stopper 6 Remove the stoppers from clutch pedal 7 Remove the clutch pedal pad Non turbo model D ASSEMBLY 1 Attach the clutch switch etc to pedal bracket temporarily 2 Clean the inside of bores of clutch pedal and brake pedal apply grease and set bushings into bores 3
75. and Connector amp terminal chassis ground B116 No 6 Chassis ground CHECK P POSITION SWITCH Is the resistance less than 1 Go to step 13 Replace the P 1 Move the select lever to P position Q position switch 2 Measure resistance between P position switch connector terminals Terminal No 2 No 6 CHECK P POSITION SWITCH Is the resistance more than 1 Go to step 14 Replace the P 1 Move the select lever to other than P posi MQ position switch tion 2 Measure resistance between P position switch connector terminals Terminal No 2 No 6 d CHECK OUTPUT SIGNAL FOR INTEGRAT 15 the voltage 7 5 and 16 V Go to step 15 Replace the inte ED MODULE grated module 1 Connect all connectors 2 Turn the ignition switch to ON engine OFF 3 Move the select lever to P position 4 Press the brake pedal 5 Measure the voltage between integrated module connector and chassis ground Connector amp terminal B281 No 3 Chassis ground CHECK POOR CONTACT Is there poor contact in AT shift Repair poor con Replace the inte lock circuit grated module CS 22 SELECT LEVER CONTROL SYSTEMS 4 Select Lever A REMOVAL 1 Set the vehicle on the lift 2 Disconnect the ground terminal from battery 3 Move the select lever to the N position 4 Lift up the vehicle 5 Remove the rear exhaust pipe and muffler 6 Rem
76. and installing automatic trans mission assembly to engine B3M2043 AT 6 GENERAL DESCRIPTION AUTOMATIC TRANSMISSION amp amp ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 020 41099AA020 ENGINE SUPPORT Used for supporting engine B3M1976 41099AA010 ENGINE SUPPORT Used for supporting engine BRACKET B3M1975 Turbo model CRANK PULLEY Used for removing and installing bolts which hold 499977300 WRENCH torque converter clutch and drive plate Non turbo model 499977100 B2M4157 24082AA150 CARTRIDGE Troubleshooting for electrical systems Newly adopted tool B2M3876 AT 7 GENERAL DESCRIPTION AUTOMATIC TRANSMISSION ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 22771AA030 SELECT MONITOR Troubleshooting for electrical systems KIT English 22771 AA030 Without printer German 22771AA070 Without printer French 22771AA080 Without printer Spanish 22771AA090 Without printer B2M3877 499267300 STOPPER PIN Used for installing and adjusting inhibitor switch B3M2008 2 GENERAL PURPOSE TOOLS TOOL NAME REMARKS Circuit Tester Used for measuring resistance voltage and ampere AT 8 AUTOMATIC TRANSMISSION FLUID 2 Automatic Transmission Fluid A INSPECTION 1 Check the level of the ATF 1 Raise the ATF temperature to 60 to 80 C 140
77. be careful not to lose the balls and springs used with retain ing screws 18 Remove the front and rear vehicle speed sen sor and torque converter turbine speed sensor Front vehicle speed sensor and torque converter turbine speed sensor A Front vehicle speed sensor B Torque converter turbine speed sensor Rear vehicle speed sensor B3M1056B A Rear vehicle speed sensor B Front vehicle speed sensor 19 Remove the oil pan AUTOMATIC TRANSMISSION 20 Disconnect the duty solenoids and ATF tem perature sensor connectors Remove the connec tors from clip and disconnect the connectors 2 22631 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 1 Transfer duty solenoid Brown J Transmission ground 21 Remove the harness assembly B INSTALLATION 1 Pass the harness assembly through the hole in the transmission case 7 0 B3M1067 AT 33 FRONT VEHICLE SPEED SENSOR AUTOMATIC TRANSMISSION 2 Connect the harness connectors Connect the connectors of same color and secure the connectors to valve body sing clips Tightening torque Transmission ground termi nal 8 0 8 kgf m 5 8
78. between between inte shift lock solenoid and chassis ground grated module and Connector amp terminal shift lock solenoid B281 No 9 Chassis ground CHECK HARNESS BETWEEN SHIFT LOCK 15 the resistance less than 1 to step 12 Repair open circuit SOLENOID AND CHASSIS GROUND Q in harness Measure the resistance of harness between between shift lock shift lock solenoid and chassis ground solenoid and chas Connector amp terminal sis ground B116 No 5 Chassis ground CHECK SHIFT LOCK SOLENOID Is the resistance between 10 Go to step 13 Replace the shift Measure the resistance of shift lock solenoid 20 0 lock solenoid connector terminals Terminal No 4 No 5 CHECK SHIFT LOCK SOLENOID Is shift lock solenoid operating Go to step 14 Replace the shift Connect the battery with shift lock solenoid properly lock solenoid connector terminal and operate solenoid Terminal No 4 No 5 CHECK OUTPUT SIGNAL FOR AT SHIFT Is the voltage more than 8 5 V Go to step 15 Replace the inte LOCK CONTROL MODULE grated module 1 Turn the ignition switch to ON engine OFF 2 Measure the voltage between integrated module and chassis ground Connector amp terminal B281 9 Chassis ground CHECK POOR CONTACT Is there poor contact in key Repair poor con Replace the inte lock circuit tact grated module CS 18 AT SHIFT LOC
79. con nector or harness may be the cause Repair harness or connector in lock up duty solenoid and transmission DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE DTC AUTOMATIC TRANSMISSION DIAGNOSTICS Replace the lock up duty solenoid Ref to AT 39 Shift Solenoids Duty Solenoids and ATF Tempera ture Sensor Repair open circuit in harness between TCM and transmission con nector Repair short circuit in harness between lock up duty solenoid and transmission con nector DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE DTC AUTOMATIC TRANSMISSION DIAGNOSTICS AT 99 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE DTC AUTOMATIC TRANSMISSION DIAGNOSTICS P DTC 79 TRANSFER DUTY SOLENOID DIAGNOSIS Output signal circuit of transfer duty solenoid is open or shorted TROUBLE SYMPTOM Excessive braking in tight corners WIRING DIAGRAM NA NON TURBO MODEL TURBO MODEL TRANSFER DUTY SOLENOID TRANSMISSION zz n I 1 2 314 IDE s e z s 9 sDqe 7Dx s 1011 12 13 14 15 16 17 18 9 T11 12 19 20 21 22 23 24 16 1718 19 20 TRO588 AT 100 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE DTC AUTOMATIC TRANSMISSION DIAGNOSTICS Ste
80. connec tor and chassis ground Connector amp terminal Non turbo model B54 No 15 Chassis ground Turbo model B54 No 6 Chassis ground 6 CHECK OUTPUT SIGNAL EMITTED FROM the voltage between 5 and 7 Even if the AT OIL to step 12 TCM V in D range TEMP warning Measure the voltage between TCM connector lights up the cir and chassis ground cuit has returned Connector amp terminal to a normal condi Non turbo model tion at this time A B54 No 15 Chassis ground temporary poor Turbo model contact of the con B54 No 6 Chassis ground nector or harness may be the cause Repair harness or connector in the TCM and trans mission Is the target non turbo model to step 8 CHECK VEHICLE Go to step 10 AT 101 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE DTC AUTOMATIC TRANSMISSION DIAGNOSTICS Yes Go to step 9 Go to step 12 CHECK OUTPUT SIGNAL EMITTED FROM TCM USING SUBARU SELECT MONITOR 1 Connect the connectors to TCM and trans mission 2 Connect the Subaru Select Monitor to data link connector 3 Turn the ignition switch to ON engine OFF and turn the Subaru Select Monitor switch to ON 4 Move the select lever to D with throttle fully open vehicle speed 0 km h or 0 MPH 5 Read the data of transfer duty solenoid using Subaru Select Monitor Transfer dut
81. ft lb 2 22631 Lock up duty solenoid Blue B Low clutch timing solenoid Gray zu 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 1 Transfer duty solenoid Brown Transmission ground 3 Apply proper amount of liquid gasket to the en tire oil pan mating surface Fluid packing Three Bond 1217B 4 Install the oil pan Tightening torque 25 N m 2 5 kgf m 18 1 ft lb 5 Install the front and rear vehicle speed sensor and also the torque converter turbine speed sen sor and then fasten the harness Tightening torque 7 N m 0 7 kgf m 5 1 ft lb 6 Install the oil cooler outlet pipe CAUTION Be sure to use a new aluminum washer Tightening torque 25 2 5 kgf m 18 1 ft lb 7 Install the transmission rear crossmember bolts Tightening torque 75 7 6 kgf m 55 ft lb 8 Install the propeller shaft lt Ref to DS 15 IN STALLATION Propeller Shaft gt 9 Install the shield cover If equipped 10 Install the front center rear exhaust pipes and muffler Non turbo model lt Ref to EX SOHC 6 INSTALLATION Front Ex haust Pipe gt and lt Ref to EX SOHC 9 INSTAL LATION Rear Exhaust Pipe gt and lt Ref to EX SOHC 11 INSTALLATION Muffler gt 11 Install the center rear exhaust pipes and muf fler Turbo m
82. including bolts and nuts to the specified torque e Place shop jacks or safety stands at the specified points Apply gear onto sliding or revolution surfaces before installation e Replace deformed or otherwise damaged snap rings with new ones Before installing O rings or oil seals apply suffi cient amount of ATF fluid to avoid damage and de formation Be careful not to incorrectly install or fail to install O rings snap rings and other such parts Before securing a part on a vice place cushion ing material such as wood blocks aluminum plate or shop cloth between the part and the vice Avoid damaging the mating surface of the case Before applying sealant completely remove the old seal TOOL NUMBER DESCRIPTION REMARKS PULLER ASSY Used for removing and installing extension case roller bearing 498057300 B3M1972 INSTALLER 0598 for installing extension oil seal AT 5 GENERAL DESCRIPTION AUTOMATIC TRANSMISSION ILLUSTRATION TOOL NUMBER 498575400 B3M2040 B3M2041 DESCRIPTION OIL PRESSURE GAUGE ASSY REMARKS Used for measuring oil pressure 498897200 ADAPTER Used for oil pump housing when measuring reverse clutch pressure and line pressure 498545400 FILTER WRENCH Used for removing and installing ATF filter B3M2042 498277200 STOPPER SET Used for removing
83. light switch Shift lock solenoid Integrated module Stop light switch Shift lock solenoid Integrated module Inhibitor switch Key warning switch P position switch Key lock solenoid Integrated module Key warning switch P position switch Key lock solenoid Integrated module Inhibitor switch Select cable Starter circuit Inhibitor switch Select cable Back up light circuit Shift lock does not function Shift lock cannot be released Key interlock does not function Key interlock cannot be released Starter does not run Back up light does not light up CS 38 AUTOMATIC TRANSMISSION Page 1 General DeseripliOri aec rue ortae rre Ende e ated ass died xb Mas Aa iua 2 2 Automatic Transmission Fluid uiuis ermita etn dee Re SE 9 3 Differential cric aiu pe titties aaa 11 4 Hoad Test cce ced visitors er aere 12 By Stall Testseite ox tede 13 MEE IU EDXNI c 15 7 Line Pressure ib o aS Ee keen do MR 16 8 Transfer Clutch Pressure Test o dr e ciet ke rua creda 18 9 Automatic Transmission Assembly 222 1111 19 10 Transmission Mounting ebbe trio Gara ta dee Ete Stange 25 11 Extension Case Oil
84. manufacturers D PREPARATION TOOL 1 SPECIAL TOOLS ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 398791700 REMOVER B3M1938 399411700 ACCENT BALL INSTALLER B3M1939 Be sure to tighten fasteners including bolts and nuts to the specified torque e Place shop jacks or safety stands at the specified points Apply gear oil onto sliding or revolution surfaces before installation Replace deformed or otherwise damaged snap rings with new ones e Before installing O rings or oil seals apply suffi cient amount of gear oil to avoid damage and defor mation Becareful not to incorrectly install or fail to install O rings snap rings and other such parts e Before securing a part on a vice place cushion ing material such as wood blocks aluminum plate or shop cloth between the part and the vice Avoid damaging the mating surface of the case Before applying sealant completely remove the old seal Used for removing and installing spring pin 6 mm Used for installing reverse shifter rail arm MT 14 GENERAL DESCRIPTION MANUAL TRANSMISSION AND DIFFERENTIAL ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 399527700 PULLER SET Used for removing and installing roller bearing Differential 1 BOLT 899521412 2 PULLER 399527702 3 HOLDER 399527703 6 4 ADAPTER 398497701 Sf 5 BOLT 899520107 6 NUT 021008000 B3M1940A 399780104 WEIGHT Used for measuring preload on rol
85. may be the cause Repair harness or connector in the TCM and ECM Even if the AT OIL TEMP warning lights up the cir cuit has returned to a normal condi tion at this time A temporary poor contact of the con nector or harness may be the cause Repair harness or connector in the TCM and ECM TEven if the to step 6 Go to step 6 CHECK POOR CONTACT CONFIRM DTC 11 Is there poor contact in engine speed signal circuit Replace the ECM with a new one Does the trouble code appear again after the mem ory has been cleared AT 45 tact Replace the TCM Ref to AT 45 Transmission Con trol Module TCM gt E MM s Repair poor con to step 7 Replace the ECM DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE DTC AUTOMATIC TRANSMISSION DIAGNOSTICS B DTC 23 MASS AIR FROW SIGNAL DIAGNOSIS Input signal circuit of TCM from ECM is open or shorted TROUBLE SYMPTOM Excessive shift shock WIRING DIAGRAM cg 05 3 Repair ground ter Go to step 2 GROUND CIRCUIT OF ECM minal and or Ref to AT 52 DTC 31 THROTTLE POSITION ground circuit of SENSOR Diagnostic Procedure with Diagnos ECM tic Trouble Code DTC gt CHECK HARNESS CONNECTOR BETWEEN s the resistance less than 1 Go to step 3 Repair open circuit TCM AND ECM 92 in harness 1 Turn the ignition switch to OFF between TCM and 2 Disconnect the connectors from TCM and
86. more than 1 LOW CLUTCH TIMING SOLENOID AND TRANSMISSION Measure the resistance of harness between low clutch timing solenoid connector and trans mission ground Connector amp terminal T4 No 3 Transmission ground Is the resistance between 10 and 16 Q AT 80 Go to step 8 Go to step 9 Even if the AT OIL TEMP warning lights up the cir cuit has returned to a normal condi tion at this time A temporary poor contact of the con nector or harness may be the cause Repair harness or connector in low clutch timing sole noid and transmis sion DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE DTC AUTOMATIC TRANSMISSION DIAGNOSTICS Replace the low clutch timing sole noid lt Ref to AT 39 Shift Sole noids Duty Sole noids and ATF Temperature Sen sor gt Repair open circuit in harness between low clutch timing solenoid and transmission connector Repair short circuit harness between low clutch timing solenoid and transmission con nector DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE DTC AUTOMATIC TRANSMISSION DIAGNOSTICS AT 81 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE DTC AUTOMATIC TRANSMISSION DIAGNOSTICS L DTC 74 2 4 BRAKE TIMING SOLENOID DIAGNOSIS Output signal circuit of 2 4 brake timing solenoid is open or shorted TROUBLE SYMPTOM Excessive shift shock WIRING DIAGRAM NA NON TURBO MODEL TURBO MODEL
87. nector or harness may be the cause Repair harness or connector in trans mission Is the value less than 25 Go to step 15 CHECK POOR CONTACT 15 there poor contact in line pressure duty solenoid circuit Repair poor con tact CHECK LINE PRESSURE DUTY SOLENOID IN TRANSMISSION 1 Remove the transmission connector from bracket 2 Drain the automatic transmission fluid CAUTION Do not drain the automatic transmission flu id until it cools down 3 Remove the oil pan and disconnect the con nector from line pressure duty solenoid 4 Measure the resistance between line pres sure duty solenoid connector and transmission ground Terminal No 1 Transmission ground CHECK HARNESS CONNECTOR BETWEEN TRANSMISSION AND LINE PRESSURE DUTY SOLENOID Measure the resistance of harness between line pressure duty solenoid and transmission connector Connector amp terminal T4 No 5 AT2 No 1 CHECK HARNESS CONNECTOR BETWEEN TRANSMISSION AND LINE PRESSURE DUTY SOLENOID Measure the resistance of harness between transmission connector and transmission ground Connector amp terminal T4 No 5 Transmission ground Replace the TCM Ref to AT 45 Transmission Con trol Module TCM gt Is the resistance between 2 0 Go to step 17 Is the resistance less than 1 Q Go to step 18 Even if the AT OIL TEMP warning lights up the cir cuit has returned to a no
88. oil pressure is produced in the FWD mode the problem is similar to that in the AWD mode Standard transfer clutch pressure kPa kg cm psi Duty ratio Throttle AWD mode FWD 96 position mode zs 932 1 089 5 9 5 11 1 2 3 throt 216 294 tle 2 2 3 0 31 43 135 158 39 00 0 VTD model andard transfer clutch pressure Duty ratio Throttle St 96 position kPa kg cm psi closed 9 5 11 1 135 158 2 3 throt 216 294 e 4 4 2 2 3 0 31 43 AT 18 AUTOMATIC TRANSMISSION ASSEMBLY AUTOMATIC TRANSMISSION 9 Automatic Transmission As sembly A REMOVAL 1 Set the vehicle on the lift 2 Open the front hood fully and support it with stay 3 Disconnect the ground terminal from battery 4 Remove the air intake duct Non turbo model lt Ref to IN SOHC 7 REMOVAL Air Intake Duct gt 5 Remove the air cleaner case Non turbo model lt Ref to IN SOHC 6 REMOVAL Air Cleaner Case gt 6 Remove the air cleaner case stay Non turbo model 7 Remove the intercooler Turbo model lt Ref to IN DOHC TURBO 10 REMOVAL Intercooler gt 8 Remove the front center rear exhaust pipe and muffler Non turbo model lt Ref to EX SOHC 5 REMOVAL Front Exhaust Pipe gt lt Ref to EX SOHC 9 REMOVAL Rear Exhaust Pipe gt and lt Ref to EX SOHC 11 RE MOVAL Muffler gt 9 Remove the center re
89. 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 1 Transfer duty solenoid Brown 4 Attach the magnet at the specified position 5 Apply proper amount of liquid gasket to the en tire oil pan mating surface Fluid packing Tree Bond 1217B 6 Install the oil pan Tightening torque 4 9 0 5 kgf m 3 6 ft lb 7 Pour ATF into the oil charge pipe lt Ref to AT 9 Automatic Transmission Fluid gt 8 Check the level of the ATF lt Ref to AT 9 Automatic Transmission Fluid gt C DISASSEMBLY Refer to AUTOMATIC TRANSMISSION lt Pub No G0853ZE a separate publication D ASSEMBLY Refer to AUTOMATIC TRANSMISSION lt Pub No G0853ZE gt a separate publication E INSPECTION Refer to AUTOMATIC TRANSMISSION lt Pub 508537 gt a separate publication AT 38 SHIFT SOLENOIDS DUTY SOLENOIDS AND ATF TEMPERATURE SENSOR AUTOMATIC TRANSMISSION 17 Shift Solenoids Duty Sole noids and ATF Temperature Sensor A REMOVAL 1 Set the vehicle on the lift 2 Disconnect the ground terminal from battery 3 Lift up the vehicle 4 Clean the transmission exterior 5 Drain the ATF completely NOTE Tighten the ATF drain plug after draining the ATF Tightening torque 25 2 5 kgf m 18 1 ft lb A Oil pan B Drain pl
90. remove the oil seal ST 398527700 PULLER ASSY 10 Using the ST install the oil seal ST 498057300 INSTALLER 11 Install the propeller shaft lt Ref to DS 15 IN STALLATION Propeller Shaft gt 12 Install the heat shield cover If equipped 13 Install the rear exhaust pipe and muffler Non turbo model lt Ref to EX SOHC 9 INSTALLATION Rear Ex haust Pipe gt and lt Ref to EX SOHC 11 INSTAL LATION Muffler gt Turbo model lt Ref to EX DOHC TURBO 14 INSTALLATION Muffler gt lt Ref to EX DOHC TURBO 13 IN STALLATION Rear Exhaust Pipe gt 14 Pour ATF and check the ATF level lt Ref to AT 9 Automatic Transmission Fluid gt AT 27 INHIBITOR SWITCH AUTOMATIC TRANSMISSION 12 Inhibitor Switch A INSPECTION When the driving condition or starter motor opera tion is erroneous first check the shift linkage for im proper operation If the shift linkage is functioning properly check the inhibitor switch 1 Disconnect the inhibitor switch connector 2 Check continuity in inhibitor switch circuits with the select lever moved to each position CAUTION Also check that continuity in ignition circuit does not exist when the select lever is in R D 3 2 and 1 ranges NOTE If the inhibitor switch is inoperative check for poor contact of connector on transmission side Signal sent to TCM Starter circuit Back up light circuit 4 3 2 1 dmm 0016
91. rti ition Q No up shift Symptoms shi 1 Noise or vibration Shift shock or slip 3 Select lever does not move AT 4 GENERAL DESCRIPTION 3 General Description A CAUTION Supplemental Restraint System Airbag The airbag system wiring harness is routed near the transmission contro module TCM CAUTION All airbag system wiring harness and con nectors are colored yellow Do not use electri cal test equipment on these circuit Be careful not to damage the airbag system wiring harness when performing diagnostics and servicing the TCM Measurement When measuring the voltage and resistance of the ECM TOM or each sensor use a tapered pin with a diameter of less than 0 64 mm 0 025 in in order to avoid poor contact Do not insert the pin more than 6 5 mm 0 256 in B INSPECTION 1 BATTERY Measure the battery voltage and specific gravity of electrolyte Standard voltage 12V or more Specific gravity Above 1 260 2 TRANSMISSION GROUND Make sure that the ground terminal bolt is tightened securely Chassis side Tightening torque 13 1 3 kgf m 9 4 TRO373 AUTOMATIC TRANSMISSION DIAGNOSTICS 3 ATF LEVEL Make sure the ATF level is in the specification 5 a HOT B3M0173B A Upper level B Lower level 4 FRONT DIFFERENTIAL OIL LEVEL Make sure the front differential oil leve
92. sent from ECM DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE DTC AUTOMATIC TRANSMISSION DIAGNOSTICS Is the voltage between 0 4 and 1 8V is the value between 0 4 1 8V Is there poor contact in intake manifold pressure signal cir cuit AT 47 Even if the AT OIL TEMP warning lights up the cir cuit has returned to a normal condi tion at this time A temporary poor contact of the con nector or harness may be the cause Repair harness or connector in the TCM and ECM Even if the AT OIL TEMP warning lights up the cir cuit has returned to a normal condi tion at this time A temporary poor contact of the con nector or harness may be the cause Repair harness or connector in the TCM and ECM Repair the poor contact Go to step 7 Go to step 7 Replace the TCM Ref to AT 45 Transmission Con trol Module TCM gt DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE DTC AUTOMATIC TRANSMISSION DIAGNOSTICS C DTC 27 ATF TEMPERATURE SENSOR DIAGNOSIS Input signal circuit of TCM to ATF temperature sensor is open or shorted TROUBLE SYMPTOM Excessive shift shock WIRING DIAGRAM TURBO MODEL NA NON TURBO MODEL ATF TEMPERATURE SENSOR TRANSMISSION 0574 48 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE DTC Step AUTOMATIC TRANSMISSION DIAGNOSTICS CHECK HARNESS CONNECTOR BETWEEN 15 the resis
93. terminal F67 No 29 Chassis ground CHECK HARNESS CONNECTOR BETWEEN TCM AND FWD SWITCH Measure the resistance of harness connector between TCM and body to make sure that cir cuit does not short Connector amp terminal B55 No 14 Chassis ground CHECK INPUT SIGNAL FOR TCM 1 Turn the ignition switch to OFF 2 Connect the connector to TCM and FWD Switch 3 Turn the ignition switch to ON 4 Measure the signal voltage for TCM while installing the fuse to FWD switch connector Connector amp terminal B55 No 14 Chassis ground CHECK INPUT SIGNAL FOR TCM Measure the signal voltage for TCM while removing the fuse from FWD switch connector Connector amp terminal B55 No 14 Chassis ground CHECK HARNESS CONNECTOR BETWEEN TCM AND COMBINATION METER 1 Turn the ignition switch to OFF 2 Disconnect the connector from TCM and combination meter 3 Measure the resistance of harness between TCM and diagnosis connector Connector amp terminal B54 No 12 i11 No 4 DIAGNOSTIC PROCEDURE FOR NO DIAGNOSTIC TROUBLE CODE DTC AUTOMATIC TRANSMISSION DIAGNOSTICS When the fuse is inserted to FWD switch does the LED light up Is the FWD indicator light bulb OK Is the resistance less than 1 Q Is the resistance less than 1 Q Is the resistance more than 1 MQ Is the voltage less than 1 V in FWD switch while installing Is the voltage more than 6 V in FWD switch while removi
94. the on board diagnostics operation Problems which occurred previously can also be identified through the mem ory function If the AT OIL TEMP warning does not show a problem although a problem is occurring the problem can be determined by checking the performance characteristics of each sensor using the select monitor Indicator signal is as shown in the figure 5 5 ON OFF Hm Normal ON 2 secs RT OFF Abnormal Trouble occurs ON OFF T Normal power switch ON ON 2 secs OFF Blink Power indicator light ON S3M0062A AT 28 LIST OF DIAGNOSTIC TROUBLE CODE DTC AUTOMATIC TRANSMISSION DIAGNOSTICS 11 List of Diagnostic Trouble Code DTC A LIST Gontent of diagnosis Engine speed signal Mass air flow signal ATF temperature sensor Throttle position sensor Front vehicle speed sensor Torque converter tur bine speed sensor Torque control signal Intake manifold pres sure signal Non turbo model Shift solenoid 1 Shift solenoid 2 Low clutch timing sole noid 2 4 brake timing sole noid Line pressure duty sole noid 2 4 brake duty solenoid Lock up duty solenoid Transfer duty solenoid Rear vehicle speed sensor Detects open or shorted input signal circuit Detects open or shorted input signal circuit Detects o
95. the right and Be careful not to damage retainer oil seal left axle drive shafts to prevent damage to oil seal A Vinyl tape MT 54 TRANSMISSION CASE B INSTALLATION 1 Wipe off grease oil and dust on the mating sur faces of transmission cases with white gasoline 2 Install the front differential assembly 3 Install the main shaft assembly Install the needle bearing knock pin hole into trans mission case knock pin 4 Install the drive pinion shaft assembly Install the roller bearing knock pin hole into trans mission case knock pin 5 Apply the liquid gasket and then put the case right side and left side together Liquid gasket THREE BOND 1215 or equivalent 6 Tighten seventeen bolts with bracket clip etc as shown in the figure NOTE Insert the bolts from the bottom and tighten nuts at the top Put the cases together so that the drive pinion shim and input shaft holder shim are not caught up in between Confirm that speedometer gear is meshed Tightening torque 8mm bolt 25 2 5 kgf m 18 1 ft lb 10 mm bolt 39 N m 4 0 kgf m 28 9 ft lb 16 ii it 7 Tighten the ball bearing attachment bolts Tightening torque 29 3 0 kgf m 21 7 ft lb MANUAL TRANSMISSION AND DIFFERENTIAL 8 Backlash adjustment of hypoid gear and preload adjustment of roller bearing NOTE Support the drive pinion assembly with ST AWD model ST 498427100
96. the transmission main shaft several times while tapping around retainer lightly with plastic hammer 16 Inspect and adjust backlash and tooth contact of hypoid gear lt Ref to MT 74 INSPECTION Front Differential Assembly gt 17 After checking the tooth contact of hypoid gears remove the lock plate Then loosen the re tainer until the O ring groove appears Fit O ring into the groove and tighten the retainer into the po sition where retainer has been tightened in Tighten the lock plate NOTE Carry out this job on both upper and lower retain ers Tightening torque 25 N m 2 5 kgf m 18 1 ft lb S3M0014C 18 Selecting of main shaft rear plate Ref to MT 62 ADJUSTMENT Main Shaft Assembly for Sin gle Range 19 Install the clutch release lever and bearing Ref to CL 15 INSTALLATION Release Bearing and Lever 20 Install the transfer case with extension case as sembly Ref to MT 41 INSTALLATION Transfer Case and Extension Case Assembly 21 Install the manual transmission assembly into the vehicle Ref to MT 30 INSTALLATION Man ual Transmission Assembly C INSPECTION Check the transmission case for cracks damage and oil leaks MT 56 MAIN SHAFT ASSEMBLY FOR SINGLE RANGE 15 Main Shaft Assembly for Sin gle Range A REMOVAL 1 Remove the manual transmission assembly from vehicle lt Ref to MT 27 REMOVAL Manual Transmission Assembly gt 2 Remove the tra
97. to 176 F from 40 to 60 C 104 to 140 F when cold by driving a distance of 5 to 10 km 3 to 6 miles NOTE The level of ATF varies with fluid temperature Pay attention to the fluid temperature when checking oil level a B m oF HOT B ot C 4 OLD Lo Fo Coon B3M1020B A ATF level gauge B Upper level C Lower level 2 Make sure the vehicle is level After select ing all positions P R N D 3 2 1 set the se lect leveler in P range Measure fluid level with the engine idling NOTE After running idle the engine for one or two min utes before measurement 3 If the fluid level is below the center between upper and lower marks add the recommended ATF until the fluid level is found within the spec ified range above the center between upper and lower marks When the transmission is hot the level should be above the center of upper and lower marks and when it is cold the level should be found below the center of these two marks CAUTION e Use care not to exceed the upper limit level ATF level varies with temperature Remem ber that the addition of fluid to the upper limit mark when the transmission is cold will result in overfilling of fluid AUTOMATIC TRANSMISSION 4 Fluid temperature rising speed By idling the engine Time for temperature rise to 60 C 140 F with at mospheric temperature of 0 C 32 F
98. to the end of driven shaft to prevent damage Do not apply pressure in excess of 10 kN 1 ton 1 1 US ton 1 0 Imp ton NOTE When press fitting align the oil holes of shaft and bush ST1 499277200 ST2 499587000 INSTALLER INSTALLER B3M0078F 5 Install the 2nd driven gear inner baulk ring syn chro cone outer baulk ring and insert onto driven shaft D A S3M0445A gt 2nd driven gear Inner baulk ring Synchro cone Outer baulk ring B C D 6 After installing key on driven shaft install the 3rd 4th driven gear using ST and press CAUTION Do not apply pressure in excess of 10 kN 1 ton 1 1 US ton 1 0 Imp ton NOTE Align the groove in baulk ring with insert ST 499277200 INSTALLER MT 66 DRIVE PINION SHAFT ASSEMBLY 7 Install a set of roller bearings onto the driven shaft using ST and press CAUTION Do not apply pressure in excess of 10 KN 1 ton 1 1 US ton 1 0 Imp ton INSTALLER ST 499277200 8 Position the woodruff key in groove on the rear of driven shaft Install 5th driven gear onto drive shaft using ST and press CAUTION Do not apply pressure in excess of 10 KN 1 ton 1 1 US ton 1 0 Imp ton ST 499277200 INSTALLER 9 Install the lock washer Install lock nut and tight en to the specified torque using ST ST 4999
99. to transmission Tightening torque 24 5 2 50 kgf m 18 1 ft lb 10301 A Select cable B Plate ASSY 7 Install the snap pin to range select lever Snap ring B Select cable C Range select lever 8 Install the front exhaust pipe with center exhaust pipe Non turbo model Ref to EX SOHC 6 INSTALLATION Front haust Pipe gt 9 Install the center exhaust pipe Turbo model lt Ref to EX DOHC TURBO 9 INSTALLATION Center Exhaust Pipe gt 10 Lower the vehicle 11 Install the inhibitor switch connector from stay AT 30 INHIBITOR SWITCH 12 Connect the inhibitor switch connector B3M1028B A Inhibitor switch 13 Install the air cleaner case Non turbo model lt Ref to IN SOHC 6 INSTALLATION Air Cleaner Case gt 14 Install the intercooler Turbo model lt Ref to IN DOHC TURBO 11 INSTALLATION Intercooler gt 715 Inspect the inhibitor switch Ref to AT 28 IN SPECTION Inhibitor Switch AT 31 AUTOMATIC TRANSMISSION FRONT VEHICLE SPEED SENSOR AUTOMATIC TRANSMISSION 13 Front Vehicle Speed Sensor A REMOVAL 1 Set up the vehicle on the lift 2 Disconnect the ground terminal from battery 3 Remove the air cleaner case Non turbo model lt Ref to IN SOHC 6 REMOVAL Air Cleaner Case gt 4 Remove the intercooler Turbo model lt Ref to IN DOHC TURBO 10 REMOVAL Intercooler gt 5 Disconnect the t
100. voltage more than 9 V CS 13 AT SHIFT LOCK SYSTEM CONTROL SYSTEMS 2 SELECT LEVER CANNOT BE SHIFT LOCKED WIRING DIAGRAM SBF 1 BATTERY STOP LIGHT SWITCH B B281 INTEGRATED MODULE SHIFT LOCK SOLENOID WITHOUT CRUISE CONTROL MODEL WITH CRUISE CONTROL MODEL n 3 n i 112 1 2 DIETE BEIDE 713 T4 s e 7 8 314 11 12 13 14 15 16 17 18 19 20 911011 12113 14 15 16 TRO552 CS 14 AT SHIFT LOCK SYSTEM Step CONTROL SYSTEMS Yes No CHECK STOP LIGHT SWITCH Depress the brake pedal CHECK HARNESS BETWEEN STOP LIGHT SWITCH AND INTEGRATED MODULE 1 Turn the ignition switch to OFF 2 Disconnect the integrated and stoplight switch connector 3 Measure the resistance of harness between stop light switch and integrated module Connector amp terminal Without cruise control model B64 No 1 B280 9 Without cruise control model B65 No 3 B280 No 9 _ Does the stop light turn ON Go to step 2 Inspect the stop light system 15 the resistance more than 1 MQ in harness between inte grated module and stop light switch Repair open circuit Go to step 3 CHECK HARNESS BETWEEN STOP LIGHT liste resistance less than 1 Repair short circuit SWITCH AND INTEGRATED
101. warning lights up the cir cuit has returned to a normal condi tion at this time A temporary poor contactor or har ness may be the case Repair har ness or connector in the front vehicle speed sensor cir cuit Even if the AT OIL TEMP warning lights up the cir cuit has returned to a normal condi tion at this time A temporary poor contactor or har ness may be the case Repair har ness or connector in the front vehicle speed sensor cuit Go to step 11 Go to step 11 Step DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE DTC AUTOMATIC TRANSMISSION DIAGNOSTICS Check CHECK INPUT SIGNAL FOR TCM USING SUBARU SELECT MONITOR 1 Connect all connectors 2 Connect the Subaru Select Monitor to data link connector 3 Lift up or raise the vehicle and place safety stands CAUTION On AWD models raise all wheels off floor 4 Turn the ignition switch to ON and turn the Subaru Select Monitor switch to ON 5 Start the engine 6 Read the data of vehicle speed using Subaru Select Monitor Compare the speedometer with Subaru Select Monitor indications Vehicle speed is indicated in km h or MPH 1 Slowly increase the vehicle speed to 60 km h or 37 MPH NOTE The speed difference between front and rear wheels may light the ABS warning light but this indicates no malfunction When the AT control diagnosis is finished perform the ABS memory clearance procedure of on
102. when the select le ver is in 2 with engine under stall condi tions e Measure the line pressure within 5 the sec onds after shifting the select lever to each posi tion If the line pressure needs to be measured again allow the engine to idle and then stop Wait for at least one minute before measure ment e Maintain the temperature of ATF at approxi mately 50 C 122 F during measurement ATF will reach the above temperature after idling the engine for approximately 30 minutes with the select lever or P 2 TEST METHODS 1 Temporarily attach the ST to a suitable place in the driver s compartment remove the blind plug lo cated in front of the toe board and pass the hose of the ST to the engine compartment OIL PRESSURE GAUGE ASSY ST 498575400 A Pressure gauge hose B Hole in toe board blind plug hole C Brake pedal 2 Remove the test plug and install the ST instead ST 498897200 PRESSURE GAUGE ADAPTER B3M1046C A Test plug 3 Connect ST1 with ST2 ST1 498897200 OIL PRESSURE GAUGE ADAPTER ST2 498575400 PRESSURE GAUGE ASSY AT 16 LINE PRESSURE TEST 4 Check for duty ratio changes by opening and closing the throttie valve using the Subaru Select Monitor 1 Insert the cartridge to the Subaru Select Monitor lt Ref to AT 5 PREPARATION TOOL General Description gt 2 Connect the Subaru Select Monitor to data
103. 0 008 to 0 012 B3M1983 MT 41 TRANSFER CASE AND EXTENSION CASE ASSEMBLY MANUAL TRANSMISSION AND DIFFERENTIAL 7 Select the nearest washer in the following table Standard clearance between thrust washer and taper roller bearing 0 2 0 3 mm T 0 008 0 012 in T NOTE Tight 8 Fit the thrust washers on transfer drive shaft 9 Measure the depth 5 between transfer case and center differential ST 398643600 GAUGE B3M1407A 10 Measure the depth T between extension case and transfer drive gear ST 398643600 GAUGE B3M1395A 11 Calculate the space U using the following equation U 2 S T 12 Select the suitable washer in the following ta ble Standard clearance 0 15 0 35 mm 0 0059 0 0138 in Thrust washer 13 Fit the thrust washer on center differential 14 Install the bearing cone into extention case 15 Apply proper amount of liquid gasket to the transfer case mating surace Liquid gasket THREE BOND 1215B 0522 42 TRANSFER CASE AND EXTENSION CASE ASSEMBLY MANUAL TRANSMISSION AND DIFFERENTIAL 16 Install the extension assembly into the transfer DISASSEMBLY ase j 1 TRANSFER CASE Tightening torque 40N m 4 1 kgf m 29 7 ft lb 1 Remove the reverse check assembly Ref to MT 50 REMOVAL Reverse Check Sleeve 2 Remove the oil guide 2 EXTENSION CASE 1
104. 0 STRAIGHT PINREMOVER 5 Install the interlock plunger onto 3 4 fork rod CAUTION Apply a coat of grease to plunger to prevent it from falling 6 Install the 3 4 fork rod into 3 4 shifter fork via the hole on the rear of transmission case 7 Align the holes in rod and fork and drive straight pin into these holes CAUTION Replace straight pin with a new one NOTE e Set the reverse fork rod to neutral Make sure the interlock plunger installing be fore is on the reverse fork rod side ST 398791700 STRAIGHT PIN REMOVER 8 Install the 5th shifter fork onto the rear of reverse fork rod Align the holes in the two parts and drive straight pin into place CAUTION Replace straight pin with a new one ST 398791700 STRAIGHT PIN REMOVER B3M0333J A 5th shifter fork B Reverse fork rod C Straight pin MANUAL TRANSMISSION AND DIFFERENTIAL 9 Position the balls checking ball springs and gas kets into 3 4 and 1 2 rod holes and install plugs CAUTION Replace gasket with a new one A 5th shifter fork B Reverse fork rod C Straight pin 10 Install the differential assembly lt Ref to MT 71 INSTALLATION Front Differential Assembly gt 11 Install the main shaft assembly Single range model lt Ref to MT 57 INSTALLATION Main Shaft As sembly for Single Range gt 12 Install the drive pinion shaft assembly lt Ref to MT 63 INSTALLATION Drive Pinion Shaft As se
105. 1 and 2 of clutch switch terminal Terminals Specified resistance When clutch pedal depressed 1 2 Less than 10 Terminals Specified resistance When clutch pedal not depressed 1 2 than 1MQ Clutch switch Starter interlock 3 If not as specified replace the clutch switch CL 30 GENERAL DIAGNOSTIC TABLE CLUTCH SYSTEM 12 General Diagnostic Table A INSPECTION 1 CLUTCH T Clutch slippage tis hard to perceive clutch slippage in is Seriy aus Engine speeds up when shifting High speeds driving is impossible e Defective release bearing holder Correct or replace especially rapid acceleration impossible and vehicle speed does not increase in proportion to an increase in engine speed Power falls particularly when ascend ing a slope and there is a smell of burn ing of the clutch facing Method of testing Put the vehicle in a stationary condition with parking brake fully applied Disengage the clutch and shift the transmission gear into the first Gradually allow the clutch to engage while gradually increasing the engine Speed The clutch function is satisfactory if the engine stalls However the clutch is slipping if the vehicle does not start off and the engine does not stall 2 Clutch drags As a symptom of this trouble a harsh scratching noise develops and control becomes quite difficult when shifting gears The symptom becomes more apparent when shi
106. 10 Lever 74 37 3 8 27 5 CL 5 GENERAL DESCRIPTION CLUTCH SYSTEM 4 CLUTCH PIPE AND HOSE FOR TURBO MODEL TRO536 1 Operating cylinder 6 Pipe Tightening torque kgf m ft lb 2 Washer 7 Master cylinder ASSY T1 8 0 8 5 8 3 Clutch hose 8 Clevis pin 2 15 1 5 11 4 9 Snap T3 18 1 8 13 0 5 10 Lever 74 37 3 8 27 5 CL 6 GENERAL DESCRIPTION CLUTCH SYSTEM 5 MASTER CYLINDER NON TURBO MODEL TRO431 1 Reservoir cap 7 Diaphragm spring Tightening torque N m kgf m ft Ib 2 Reservoir tank 8 Gasket T1 10 1 0 7 3 Oil seal 9 Return spring T2 46 6 4 75 34 4 4 Straight pin 10 Piston 5 Master cylinder 11 Push rod 6 Seat 12 Piston stop ring CL 7 CLUTCH SYSTEM GENERAL DESCRIPTION e TURBO MODEL TRO545 1 2 3 4 5 Reservoir cap Reservoir tank Oil seal Straight pin Master cylinder 6 7 8 9 10 Seat Tightening torque N m kgf m ft lb Return spring 10 1 0 7 Piston Push rod Piston stop ring CL 8 GENERAL DESCRIPTION CLUTCH SYSTEM 6 CLUTCH PEDAL us pe A 4 0537 1 Stopper 12 Clutch clevis pin 23 Clutch switch With cruise control 2 Bushing 13 Assist rod A 24 Stop light switch 3 Spring pin 14 Clip 25 Pedal bracket 4 Snap pin 15 Assist spring 26 Clutch master cylind
107. 136 No 15 Turbo model B54 No 2 B135 9 PREPARE SUBARU SELECT MONITOR Do you have a Subaru Select to step 14 Go to step 12 i Monitor CHECK INPUT SIGNAL FOR TCM Is the voltage between approx Go to step 13 Go to step 18 1 Connect the connectors to TCM throttle 0 5 V in throttle fully closed position sensor and ECM 2 Turn the ignition switch to ON engine OFF 3 Close the throttle completely 4 Measure the voltage between TCM connec tor and chassis ground Connector amp terminal Non turbo model B55 No 2 Chassis ground Turbo model B54 No 3 Chassis ground CHECK INPUT SIGNAL FOR TCM Is the voltage between approx Go to step 16 Go to step 18 1 Open the throttle completely 4 3 V with throttle fully open 2 Measure the voltage between TCM connec tor and chassis ground Connector amp terminal Non turbo model B55 No 2 Chassis ground Turbo model B54 No 3 Chassis ground AT 55 Step Check Yes DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE DTC AUTOMATIC TRANSMISSION DIAGNOSTICS No CHECK INPUT SIGNAL FOR TCM USING SUBARU SELECT MONITOR 1 Connect the connectors to TCM throttle position sensor and ECM 2 Connect the Subaru Select Monitor to data link connector 3 Turn the ignition switch to ON engine OFF 4 Turn the Subaru Select Monitor switch to ON 5 Throttle fully closed 6 Read the d
108. 2 4 brake duty solenoid and transmission con nector Repair short circuit in harness between 2 4 brake duty solenoid and transmission con nector DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE DTC AUTOMATIC TRANSMISSION DIAGNOSTICS O DTC 77 LOCK UP DUTY SOLENOID DIAGNOSIS Output signal circuit of lock up duty solenoid is open or shorted TROUBLE SYMPTOM No lock up after engine warm up WIRING DIAGRAM NA NON TURBO MODEL TURBO MODEL TRANSMISSION I Li il 1 2 s 4 se 7 8 9 10 t1 12 13 14 15 16 17 19 20 21 22 23 24 LN 17 18 94 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE DTC AUTOMATIC TRANSMISSION DIAGNOSTICS 1 CHECK DTC Do multiple trouble codes Go to another trou Go to step 2 appear in the on board diag ble code nostics test mode CHECK HARNESS CONNECTOR BETWEEN Is the resistance less than 1 Go to step 3 Repair open circuit TCM AND TRANSMISSION Q in harness 1 Turn the ignition switch to OFF between TCM and 2 Disconnect the connector from TCM and transmission con transmission nector 3 Measure the resistance of harness between TCM and transmission connector Connector amp terminal Non turbo model B54 No 16 B11 No 13 Turbo model B54 No 7 B11 13 CHECK HARNESS CONNECTOR BETWEEN 15 the resistance more than 1 Go to step 4 Repair short circuit TCM AND TRAN
109. 2 600 rpm Turbo model 2 600 3 300 rpm AT 13 STALL TEST AUTOMATIC TRANSMISSION 3 EVALUATION Throttle valve not fully open Less than specifications Erroneous engine operation Torque converter clutch s one way clutch slipping Line pressure too low Low clutch slipping One way clutch malfunctioning Line pressure too low Greater than specifications Reverse clutch slipping Low amp reverse brake slipping Line pressure too low Low clutch slipping 2 4 brake slipping AT 14 TIME LAG TEST AUTOMATIC TRANSMISSION 6 Time Lag Test A INSPECTION 1 GENERAL INFORMATION If the select lever is shifted while the engine is idling there will be a certain time elapse or lag be fore the shock can be felt This is used for checking the condition of the low clutch reverse clutch low amp reverse brake and one way clutch CAUTION e Perform the test at normal operation fluid temperature 60 to 80 C 140 to 176 F e Be sure to allow a one minute interval be tween tests Make three measurements and take the aver age value 2 TEST METHODS 1 Fully apply the parking brake 2 Start the engine 3 Check the idling speed A C OFF 4 Shift the select lever from N to D range Using a stop watch measure the time it takes from shifting the lever until the shock is felt Time lag Less than 1 2 seconds 5 In the same manner measure the time lag for gt R
110. 2 Lift up or raise the vehicle and support with safety stands CAUTION On AWD models raise all wheels off ground 3 Start the engine and warm up the transmis sion until the ATF temperature is above 80 C 176 F NOTE If the ambient temperature is below 0 C 32 F drive the vehicle until the ATF reaches its oper ating temperature 4 Move the select lever to 1 and slowly increase vehicle speed to 10 km h 6 MPH NOTE The speed difference between front and rear wheels may light the ABS warning light but this indicates no malfunction When the AT control diagnosis is finished perform the ABS memory clearance procedure of on board diagnostics system Ref to ABS 22 Clear Memory Mode 5 Measure the voltage between TCM connec tor and chassis ground Connector amp terminal Non turbo model B54 No 5 Chassis ground Turbo model B54 No 16 Chassis ground AT 83 Step Check Yes DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE DTC AUTOMATIC TRANSMISSION DIAGNOSTICS CHECK OUTPUT SIGNAL EMITTED FROM TCM 1 Move the select lever to D and slowly increase vehicle speed to 65 km h 40 MPH NOTE The speed difference between front and rear wheels may light the ABS warning light but this indicates no malfunction When the AT control diagnosis is finished perform the ABS memory clearance procedure of on board diagnostics System Ref to ABS 22 Clear Memory M
111. 2002 IMPREZA SERVICE MANUAL QUICK REFERENCE INDEX TRANSMISSION SECTION CONTROL SYSTEMS AUTOMATIC TRANSMISSION AUTOMATIC TRANSMISSION DIAGNOSTICS MANUAL TRANSMISSION AND DIFFERENTIAL This service manual has been prepared to provide SUBARU service personnel with the necessary information and data for the correct maintenance and repair of SUBARU vehicles This manual includes the procedures for maintenance disassembling reas sembling inspection and adjustment of components and diagnostics for guid ance of experienced mechanics Please peruse and utilize this manual fully to ensure complete repair work for satisfying our customers by keeping their vehicle in optimum condition When replacement of parts during repair work is needed be sure to use SUBARU genuine parts CLUTCH SYSTEM CL All information illustration and specifi cations contained in this manual are based on the latest product information available at the time of publication approval FUJI HEAVY INDUSTRIES LTD G1830BE4 e CONTROL SYSTEMS General 5 55 2 Electrical Component ep paye innu euis aua ca oai 6 Lock C ooo Reto Hone netos dried erit acest ean 8 ete t De tede tr ce orit o od ausos rv Venen ei 23
112. 3 No 4 AT 90 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE DTC AUTOMATIC TRANSMISSION DIAGNOSTICS Go to step 5 CHECK HARNESS CONNECTOR BETWEEN 15 the resistance less than 1 TCM AND DROPPING RESISTOR 1 Disconnect the connector from TCM 2 Measure the resistance of harness between TCM connector and dropping resistor connec tor Connector amp terminal B54 No 17 B4 No 3 CHECK HARNESS CONNECTOR BETWEEN TCM AND DROPPING RESISTOR Measure the resistance of harness between dropping resistor connector and chassis ground Connector amp terminal B4 No 3 Chassis ground CHECK HARNESS CONNECTOR BETWEEN TRANSMISSION AND DROPPING RESIS TOR 1 Disconnect the connector from transmission 2 Measure the resistance of harness between transmission and dropping resistor connector Repair open circuit in harness between TCM and dropping resistor connector Is the resistance more than 1 MQ Repair short circuit in harness between TCM and dropping resistor connector Is the resistance less than 1 Q Repair open circuit in harness between dropping resistor and trans mission connector Connector amp terminal B4 No 4 B11 No 9 TRANSMISSION AND DROPPING RESIS TOR Measure the resistance of harness between dropping resistor connector and chassis ground Connector amp termi
113. 498277200 3 Install the transmission onto engine 1 Gradually raise the transmission with trans mission jack 2 Engage them at splines 4 Install the transmission rear crossmember Tightening torque T1 35 N m 3 6 kgf m 26 ft Ib 2 70 7 1 kgf m 51 4 ft lb 5 Take off the transmission jack 6 Tighten the nuts and bolts which hold lower side of transmission to engine Tightening torque 50 N m 5 1 kgf m 36 9 ft Ib 7 Lower the vehicle 8 Connect the engine and transmission 1 Remove the ST from torque converter clutch case NOTE Be careful not to drop the ST into the torque con verter clutch case when removing the ST ST 498277200 STOPPER SET 2 Install the starter Ref to SC 7 INSTALLATION Starter 3 Tighten the bolt which holds right upper side of transmission to engine Tightening torque 50 N m 5 1 kgf m 36 9 ft Ib AT 22 AUTOMATIC TRANSMISSION ASSEMBLY AUTOMATIC TRANSMISSION 9 Install the torque converter clutch to drive plate 12 Lift up the vehicle 1 Tighten the bolts which hold torque convert Install the front drive shafts into transmission er clutch to drive plate 1 Lift up the vehicle 2 Tighten the other bolts while rotating the en 2 Install the front drive shaft into transmission gine by using ST 3 Drive the spring pin into chamfered hole of CAUTION drive shaft Be careful not to drop bolts into the torque con CAUTION v
114. 6 INSTALLA TION Air Cleaner Case and Ref to IN SOHC 7 INSTALLATION Air Intake Duct 4 Install the intercooler Turbo model Ref to IN DOHC TURBO 11 INSTALLATION Intercooler gt 5 Connect the battery ground terminal C INSPECTION 1 BACK UP LIGHT SWITCH Inspect the back up light switch lt Ref to LI 6 IN SPECTION Back up Light System gt 2 NEUTRAL POSITION SWITCH 1 Turn the ignition switch to OFF 2 Disconnect the connector neutral position switch 3 Measure the resistance between neutral position switch terminal Non turbo model Gear shift position Specified resistance Less than 1Q Neutral position More than 1MQ Other positions Turbo model Gear shift position Specified resistance 1 and 2 More than 1MQ than 1MQ Neutral position Less than 1Q Other positions Other positions Non turbo model r TRO100 Turbo model TRO101 4 Replace defective parts MT 38 VEHICLE SPEED SENSOR 7 Vehicle Speed Sensor A REMOVAL 1 Disconnect the ground terminal from battery 2 Lift up the vehicle 3 Remove the front and center exhaust pipes 4 Disconnect the connector from vehicle speed sensor 5 Turn and remove the vehicle speed sensor INSTALLATION NOTE Discard the vehicle speed sensor and after re moval replace with a new one Ensure the sensor mounting hole is clean and free of foreign mat
115. 7000 RACE 4 5 INSTALLER SO V7 MH QA B3M0553F 6 Using ST1 and ST2 install the 5th gear thrust washer and 5th needle bearing race onto the rear section of transmission main shaft CAUTION Do not apply pressure in excess of 10 KN 1 ton 1 1 US ton 1 0 Imp ton NOTE Face the thrust washer in the correct direction ST1 899714110 REMOVER ST2 499877000 RACE 4 5 INSTALLER 00910 Face this surface to 5th gear side 7 Install the bearing onto synchro cone 8 Install the baulk ring and synchro cone onto 5th Rev sleeve and hub assembly using ST and a press CAUTION Do not apply pressure in excess of 10 KN 1 ton 1 1 US ton 1 0 Imp ton NOTE Use new ball bearing e After press fitting make sure synchro cone ro tates freely ST 499757002 INSTALLER B3M1370A A Baulk ring B Synchro cone C Ball bearing 9 Install the synchro cone stopper and snap ring to 5th Rev sleeve and hub assembly B3M0435B Synchro cone stopper B Snap ring MT 60 MAIN SHAFT ASSEMBLY FOR SINGLE RANGE 10 Install the rest parts to the rear section of trans mission main shaft NOTE Align the groove in baulk ring with shifting insert B3M1371A A B Needle bearing 5th drive gear Baulk ring GOB 5th Rev sleeve and hub ASSY Lock washer Lock nuts E 11 Tighten the lock nuts to the spe
116. 714110 REMOVER 2 amp suoeno 8 Remove the key 9 Remove the 2nd driven gear inner baulk ring synchro cone and outer baulk ring 3M0445A A 2nd driven gear B Inner baulk ring C Synchro cone D Outer baulk ring 10 Remove the 1st driven gear 2nd gear bushing gear and hub using ST1 and ST2 NOTE Replace the gear and hub if necessary Do not at tempt to disassemble if at all possible because they must engage at a specified point If they have to be disassembled mark the engaging point before hand ST1 499757002 INSTALLER ST2 899714110 REMOVER G3M0611 MT 65 DRIVE PINION SHAFT ASSEMBLY MANUAL TRANSMISSION AND DIFFERENTIAL 11 Remove the sub gear for 1st driven gear D ASSEMBLY 1 Install the sleeve and assembly by matching alignment marks NOTE Use the new gear and hub assembly if the gear or hub have been replaced B3M0077E 1st gear side x B 2nd gear side C Flush surface D Stepped surface 2 Install the washer snap ring and sub gear to 1st driven gear 3 Install the 1st driven gear 1st baulk ring gear and hub assembly onto driven shaft NOTE Take care to install gear and hub assembly in proper direction Align the baulk ring and gear amp hub assembly with key groove 4 Install the 2nd driven gear bushing onto driven shaft using ST1 ST2 and press CAUTION e Attach a cloth
117. 87300 SOCKET WRENCH 50 Tightening torque 265 27 kgf m 195 ft lb MANUAL TRANSMISSION AND DIFFERENTIAL NOTE Stake the lock nut at two points e Using spring balancer check that starting torque of roller bearing is 0 1 to 1 5 N 0 01 to 0 15 kgf 0 02 to 0 33ft 10 Install the roller bearing onto drive pinion NOTE When installing roller bearing note its directions front and rear because the knock pin hole in outer race is offset B3M1661A A Roller bearing B Knock pin hole 11 Install the washer using ST1 ST2 and press CAUTION e Discard old lock nuts replace with new ones e Secure lock nut in four places ST1 499277100 BUSH 1 2 INSTALLER ST2 499277200 INSTALLER B3M0080E A Washer MT 67 DRIVE PINION SHAFT ASSEMBLY MANUAL TRANSMISSION AND DIFFERENTIAL 12 Install the thrust bearing and needle bearing Install the driven shaft assembly B3M0082 13 Install the drive pinion collar needle bearing adjusting washer No 2 thrust bearing adjusting washer No 1 and differential bevel gear sleeve in that order NOTE Be careful because the spacer must be installed in proper direction St B3M0083D Driven shaft Drive shaft Drive pinion collar D Needle bearing 25 x 30 x 20 Washer No 2 25 x 36 x 4 Thrust bearing 25 x 37 5 x 3 G Washer No 1 25 x 36 xt H Differential bevel gea
118. ALLATION Center Exhaust Pipe C INSPECTION Check the removed cable and replace if damaged rusty or malfunctioning 1 Check for smooth operation of the cable 2 Check the inner cable for damage and rust 3 Check the outer cable for damage bends and cracks 4 Check the boot for damage cracks and deterio ration 5 Move the select lever from P position to 1 po sition You should be able to feel the detentes in each position If the detentes cannot be felt or the position pointer is improperly aligned adjust the ca ble D ADJUSTMENT 1 Set the vehicle on the lift 2 Disconnect the ground terminal from battery 3 Set the lever to N position 4 Lift up the vehicle 5 Remove the rear exhaust pipe and muffler 6 Remove the heat shield cover If equipped 7 Loosen the adjusting nut on each side SS a B A B3M1792A A Adjusting nut A B Adjusting nut B CS 27 SELECT CABLE CONTROL SYSTEMS 8 Turn the adjusting nut B until it ligntly touches the connector B3M1793A A Front side Select lever Connector Adjusting nut B B D E F Contact point Adjusting nut A 9 While preventing the adjusting nut B from mov ing with a wrench tighten adjusting nut A Tightening torque 7 5 N m 0 76 kgf m 5 5 ft Ib A Adjusting nut A B Adjusting nut B 10 After completion of fitting make sure that the select lever operates smoothl
119. Align the bores of pedal bracket clutch pedal and brake pedal attach brake pedal return spring assist rods and spring and bushing NOTE Clean up inside of bushings and apply grease be fore installing the spacer E INSPECTION Move the clutch pedal pads in the lateral direction with a force of approximately 10 N 1 kgf 2 Ib to ensure the pedal deflection is in specified range CAUTION If excessive deflection is noted replace the bushings with new ones Deflection of clutch pedal Service limit 5 0 mm 0 197 in or less B2M4119A A Clutch pedal B Brake pedal F ADJUSTMENT 1 Turn the lock nuts until clutch pedal full stroke length is within specifications CAUTION Do not attempt to turn the clutch switch to ad just clutch pedal full stroke length NOTE If the lock nuts cannot adjust the clutch pedal full stroke length to specifications turn the master cyl inder push rod to adjust it Specified clutch pedal full stroke A 130 135 mm 5 12 5 31 in Tightening torque Clutch switch lock nut 8 N m 0 8 kgf m 5 8 ft Ib B4M1190C CL 27 CLUTCH PEDAL CLUTCH SYSTEM 2 Turn the master cylinder push rod so that the cle vis pin moves to the left and then to the right Clevis pin must move without resistance while it is rattling Tightening torque Push rod lock nut 10 1 0 kgf m 7 ft lb B4M1189G Clevis Snap pin C Push rod Loc
120. BING CONTROL FUNCTION Check that the gear remains in 3rd when going up a grade Check that the gear remains in 3rd when apply ing the brakes while going down a grade 10 0IL LEAKS After the driving test inspect for oil leaks AT 12 STALL TEST AUTOMATIC TRANSMISSION 5 Stall Test A INSPECTION 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 the throttle valve opens fully 2 Check that the engine oil level is correct 8 Check that the coolant level is correct 4 Check that the ATF level is correct 5 Check that the differential gear oil level is correct 6 Increase ATF temperature to 50 to 80 C 122 to 176 F by idling the engine for approxi mately 30 minutes with select lever set to or P5 2 Install an engine tachometer at a location visible from the driver s compartment and mark the stall speed range on the tachometer scale 3 Place the wheel chocks at the front and rear of all wheels and engage the parking brake 4 Move the manual linkage to ensure it operat
121. CK INPUT SIGNAL FOR TCM USING SUBARU SELECT MONITOR 1 Connect the connectors to TCM and trans mission 2 Connect the Subaru Select Monitor to data link connector 3 Lift up or raise the vehicle and place safety stands CAUTION Raise all wheels off floor 4 Turn the ignition switch to ON and turn the Subaru Select Monitor switch to ON 5 Start the engine 6 Read the data of vehicle speed using Subaru Select Monitor Compare the speedometer with Subaru Select Monitor indications Vehicle speed is indicated in km h or MPH 1 Slowly increase the vehicle speed to 60 km h or 37 MPH NOTE The speed difference between front and rear wheels may light the ABS warning light but this indicates no malfunction When the AT control diagnosis is finished perform the ABS memory clearance procedure of on board diagnostics system lt Ref to ABS 22 Clear Memory Mode Is the voltage more than AC 1 v Does the speedometer indica tion increase as the Subaru Select Monitor data increases AT 106 Even if the AT OIL TEMP warning lights up the cir cuit has returned to a normal condi tion at this time A temporary poor contact of the con nector or harness may be the cause Repair harness or connector in the TCM and trans mission Even if the AT OIL TEMP warning lights up the cir cuit has returned to a normal condi tion at this time A temporary poor contact of the con nector or harness may be the cause
122. CTION Repair or replace parts if the results of the inspec tion below are not satisfactory 1 PITCHING STOPPER Make sure that the pitching stopper is not bent or damaged Make sure that the rubber is not stiff cracked or otherwise damaged 2 CROSSMEMBER AND CUSHION RUB BER Make sure that the crossmember is not bent or damaged Make sure that the cushion rubber is not stiff cracked or otherwise damaged MT 35 OIL SEAL MANUAL TRANSMISSION AND DIFFERENTIAL 5 Oil Seal A INSPECTION Inspect for oil leakage from the oil seal Replace the oil seal if the lips is deformed hardened dam aged worn or defective if any B REPLACEMENT 1 Clean the transmission exterior 2 Drain the gear oil completely NOTE Tighten the drain plug after draining gear oil Tightening torque 44 N m 4 5 kgf m 32 5 ft lb B3M0037 3 Remove the rear exhaust pipe and muffler 4 Remove the heat shield cover If equipped 5 Remove the propeller shaft lt Ref to DS 14 RE MOVAL Propeller Shaft gt 6 Using ST remove the oil seal ST 398527700 PULLER ASSY B3M2135A A Oil seal 7 Using ST install the oil seal INSTALLER ST 498057300 8 Install the propeller shaft Ref to DS 15 IN STALLATION Propeller Shaft 9 Install the heat shield cover If equipped 10 Install the rear exhaust pipe and muffler 11 Pour the gear oil and check the oil level Ref to MT 26 Transmission G
123. Connect the transfer duty solenoid connec tor EIN RU OR ee 1 25242 Les B3M1045G Transfer valve body B Transfer duty solenoid connector C Transfer duty solenoid 2 Install the extension case to transmission case 1 Tighten eleven bolts Tightening torque 25 2 5 kgf m 18 1 ft lb 2 Adjust the select cable lt Ref to CS 27 AD JUSTMENT Select Cable gt 3 Install the rear vehicle speed sensor Tightening torque T 7 N m 0 7 kgf m 5 1 ft lb NS 043A 4 Install the rear crossmember 1 Tighten the bolts Tightening torque T1 35 3 6 kgf m 26 ft Ib T2 70 N m 7 1 kgf m 51 4 ft Ib 52 0221 2 Lower and remove the transmission jack 5 Install the propeller shaft lt Ref to DS 15 IN STALLATION Propeller Shaft gt 6 Install the front exhaust pipe and center exhaust pipe 7 Lower and remove the jack 8 Connect the transmission harness connector 9 Install the pitching stopper Tightening torque T1 50 5 1 kgf m 37 ft Ib T2 58 N m 5 9 kgf m 43 ft Ib 10 Install the air cleaner case and duct AT 42 SHIFT SOLENOIDS DUTY SOLENOIDS AND ATF TEMPERATURE SENSOR AUTOMATIC TRANSMISSION 11 Fill ATF up to the middle of the COLD side on level gauge by using the gauge hole lt Ref to AT 9 Automatic Transmission Fluid gt 12 Check the ATF level lt Ref to AT 9 Automatic Transmission Fluid gt AT 43 ATF
124. DIFFERENTIAL Sedan 5 forward speeds with synchromesh and 1 reverse 1st 3 454 3 454 2 062 1947 1 448 1 366 Transmission gear ratio e x 4th 1 088 0 972 0 780 0 738 Reverse 3 333 Type of gear Hypoid Bossi 211 3900 Type of gear Helical Transfer WPeofgear 1 000 100 R ducti Rear reduction gear me 0 gear Hypoid 4 111 3 900 3 545 Front differential Type and number of gear Straight bevel gear Bevel pinion 2 Bevel gear 2 Straight bevel gear Center differential Type and number of gear Bevel pinion 2 Bevel gear 2 and viscous coupling Transmission gear oil capacity 3 5 0 3 7 US qt 3 1 Imp qt 2 TRANSMISSION GEAR OIL Recommended oil ITEM Transmission gear oil API Classification GL 5 SAE Viscosity No and Applicable Temperature C 30 26 5 0 25 30 1 TF ele 1 15 1 T CF 22 15 5 23 32 59 77 86 B1H0024 MT 2 GENERAL DESCRIPTION 3 TRANSMISSION CASE ASSEMBLY Drive pinion shim adjustment Hypoid gear backlash 0 13 0 18 mm 0 0051 0 0071 in Part No Thickness Part No Thickness mm in mm in 0 150 0 250 32295AA031 0 0059 32295AA071 0 0098 0 175 0 275 32295 041 0 0069 32295 081 0 0108 0 200 0 300 32295 051 0 0079 32295AA091 0 0118 0 225 0 500 32295AA061 0 0089 32295AA101 0 0197 Selection of main shaft rear plate Main shaft rear plate Dimension A mmn PartNo
125. Does the combination meter N range indicator illuminate CHECK N RANGE SWITCH When the D range is selected does the N range LED light up CHECK D RANGE SWITCH CHECK INDICATOR LIGHT When the D range is selected does the LED light up Does the combination meter D range indicator illuminate When the 3 range is selected does the D range LED light up When the 3 range is selected does the LED light up Does the combination meter 3 range indicator illuminate Go to step 9 Go to step 40 Go to step 11 Go to step 46 Go to step 14 Go to step 15 CHECK 3 RANGE SWITCH When the 2 range is selected does the 3 range LED light up CHECK 2 RANGE SWITCH When the 2 range is selected does the LED light up CHECK INDICATOR LIGHT CHECK 2 RANGE SWITCH CHECK 1 RANGE SWITCH Does the combination meter 2 range indicator illuminate When the 1 range is selected does the 2 range LED light up When the 1 range is selected does the LED light up CHECK INDICATOR LIGHT Does the combination meter 1 range indicator illuminate Go to step 52 Go to step 38 Go to step 10 Go to step 41 Go to step 12 Go to step 44 Go to step 13 Go to step 47 Go to step 50 Go to step 16 Go to step 17 Go to step 18 Go to step 58 Go to step 20
126. E CODE DTC AUTOMATIC TRANSMISSION DIAGNOSTICS WIRING DIAGRAM IGNITION SWITCH SBF 1 SBF 4 _ No 13 I COMBINATION METER C BATTERY eoe INHIBITOR SWITCH of HEEE 5 e 7 e s B 314 ao VIE 3 5 6 pais bal m 19 20 21 22 23 24 TRO591 AT 116 Step CHECK P RANGE SWITCH DIAGNOSTIC PROCEDURE FOR NO DIAGNOSTIC TROUBLE CODE DTC AUTOMATIC TRANSMISSION DIAGNOSTICS Yes When P range is selected does the LED light up CHECK INDICATOR LIGHT CHECK P RANGE SWITCH CHECK R RANGE SWITCH Does the combination meter P range indicator illuminate When the range is selected does the P range LED light up When the range is selected does the LED light up CHECK INDICATOR LIGHT Does the combination meter R range indicator illuminate Go to step 2 Go to step 3 Go to step 28 Go to step 5 Go to step 22 Go to step 26 Go to step 4 Go to step 29 CHECK R RANGE SWITCH When the N range is selected does the R range LED light up CHECK N RANGE SWITCH When the N range is selected does the LED light up Go to step 6 Go to step 32 Go to step 34 Go to step 7 Go to step 8 Go to step 35 CHECK INDICATOR LIGHT
127. ECM connector ECM 3 Measure the resistance of harness between TCM and ECM connector Connector amp terminal B54 No 1 B135 28 CHECK HARNESS CONNECTOR BETWEEN s the resistance more than 1 Go to step 4 Repair short circuit TCM AND ECM in harness Measure the resistance of harness between between TCM and TCM connector and chassis ground ECM connector Connector amp terminal B54 No 1 Chassis ground 4 PREPARE SUBARU SELECT MONITOR 20 you have a Subaru Select Go to step 6 Go to step 5 Monitor AT 46 CHECK INPUT SIGNAL FOR TCM 1 Connect the connectors to TCM and ECM 2 Start the engine and warm up the transmis sion until ATF temperature is above 80 C 176 F NOTE If ambient temperature is below 0 C 32 F drive the vehicle until the ATF reaches its oper ating temperature 3 Engine idling 4 Measure the voltage between TCM connec tor and chassis ground Connector amp terminal B54 No 1 Chassis ground CHECK INPUT SIGNAL FOR TCM USING SUBARU SELECT MONITOR 1 Connect the connectors to TCM and ECM 2 Connect the Subaru Select Monitor to data link connector 3 Start the engine and turn the Subaru Select monitor switch to ON 4 Warm up the engine until the engine coolant temperature is above 80 C 176 F 5 Engine idling 6 Read the data of intake manifold pressure signal using Subaru Select Monitor Display shows the intake manifold pressure signal value
128. EDURE FOR AT OIL TEMP WARNING LIGHT AUTOMATIC TRANSMISSION DIAGNOSTICS AT 35 DIAGNOSTIC PROCEDURE FOR AT OIL TEMP WARNING LIGHT AUTOMATIC TRANSMISSION DIAGNOSTICS B CHECK POWER SUPPLY AND GROUND LINE WIRING DIAGRAM BATTERY CTS C Q uL a E Q 2 O GENERATOR Q 7 5 2 QD ses ED Ge L IGNITION Pa SWITCH Q z C ef Jo EE 1 BIB TRANSMISSION NON TURBO MODEL TURBO MODEL B40 112 415 8 9 112131 s Te 7 8 EE 17 t8 ho iBa 41506 1920121 23 24 5 2 2 3 7 s o to 1213141 20121 02 23 24 1516 7 8 TRO571 AT 36 DIAGNOSTIC PROCEDURE FOR AT OIL TEMP WARNING LIGHT AUTOMATIC TRANSMISSION DIAGNOSTICS Step Check Yes No CHECK IGNITION SWITCH Is the ignition switch ON Go to step 2 Turn the ignition switch ON CHECK GENERATOR 1 Start the engine 2 ldle the engine 3 Measure the voltage between generator and chassis ground Terminal Generator B terminal 4 Chassis ground Is the voltage between 10 and Go to step 3 15 V Repair the genera tor Ref to SC 13 Generator CHECK BATTERY TERMINAL Turn the ignition switch to OFF Is there poor contact at battery Repair the battery Go to step 4 terminal
129. EMP warn ing light illuminate Is the AT OIL TEMP warning light bulb OK Step CHECK AT OIL TEMP WARNING LIGHT Turn the ignition switch to ON engine OFF CHECK AT OIL TEMP WARNING LIGHT 1 Turn the ignition switch to OFF 2 Remove the combination meter 3 Remove the ATF temp warning light bulb from combination meter CHECK AT OIL TEMP WARNING LIGHT Perform Read Diagnostic Trouble Code Ret to AT 24 WITHOUT SUBARU SELECT MONITOR OPERATION Read Diagnostic Trouble Code DTC Go to step 3 Go to step 2 Go to step 4 Replace the AT OIL TEMP warn ing light bulb A temporary poor Go to step 10 contact of the con nector or harness may be the cause Repair the har ness or connector in TCM inhibitor switch and combi nation meter Replace the fuse No 13 If the replaced fuse No 13 is blown out easily repair short circuit in harness between fuse No 13 and combina tion meter Go to step 6 Does the AT OIL TEMP warn ing light blink CHECK FUSE No 13 Remove the fuse No 13 Is the fuse No 13 blown out Go to step 5 CHECK HARNESS CONNECTOR BETWEEN COMBINATION METER AND IGNITION SWITCH 1 Turn the ignition switch to ON engine OFF 2 Measure the voltage between combination meter connector and chassis ground Connector amp terminal i10 No 7 Chassis ground CHECK COMBINATION ME
130. ER CONTROL SYSTEMS 10 Remove the select lever lower then take away the select lever upper from plate B3M1848A A Select lever lower B Select lever upper C Plate 11 Remove the spring and remove the detent arm A Detent arm B Spring 12 Remove the cushion D ASSEMBLY 1 Clean all parts before assembly 2 Apply grease NIGTIGHT LYW No 2 or equiva lent to each parts lt Ref to CS 3 AT Select Le ver gt 3 Assembly is in the reverse order of disassembly 4 After completion of fitting transfer the select le ver to range P 1 then check whether the in dicator and select lever agree whether the pointer and position mark agree and what the operating force is E INSPECTION 1 Inspect the removed parts by comparing with new ones for deformation damage and wear Cor rect or replace if defective 2 Confirm the following parts for operating condi tion before assembly Moving condition of the se lector lever upper it should move smoothly CS 25 SELECT CABLE CONTROL SYSTEMS 5 Select Cable 10 Disconnect the cable from select lever and then remove the cable bracket A REMOVAL 1 Set the vehicle on the lift 2 Disconnect the ground terminal from battery 3 Prior to removal set the lever to position 4 Lift up the vehicle 5 Remove the front and center exhaust pipe Non turbo model Ref to EX SOHC 5 REMOVAL Front Exhaust Pipe
131. ER DESCRIPTION REMARKS 499987003 SOCKET WRENCH Used for removing and installing driven pinion lock nut and main shaft lock nut B3M1960 499987300 SOCKET WRENCH Used for removing and installing driven gear assembly lock nut B3M1961 899714110 REMOVER Used for fixing transmission main shaft drive pinion rear drive shaft B3M1962 899864100 REMOVER Used for removing parts on transmission main shaft and drive pinion B3M1963 MT 20 ILLUSTRATION GENERAL DESCRIPTION TOOL NUMBER 5 B3M1964 P B3M1965 B3M1966 S B3M1967 899884100 899904100 899988608 398497701 MANUAL TRANSMISSION AND DIFFERENTIAL DESCRIPTION REMARKS HOLDER Used for tightening lock nut on sleeve REMOVER Used for removing and installing straight pin SOCKET WRENCH Used for removing and installing drive pinion lock ADAPTER Used for installing roller bearing onto differen tial case Used with INSTALLER 499277100 MT 21 GENERAL DESCRIPTION MANUAL TRANSMISSION AND DIFFERENTIAL ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 499587000 INSTALLER Used for installing driven gears to driven shaft B3M1968 899824100 PRESS Used for installing speedometer shaft oil seal B3M1969 499987100 SOCKET WRENCH Used for removing and installing drive pinion lock B3M1970 899984103 SOCKET WRENCH Us
132. K SYSTEM CONTROL SYSTEMS CS 19 AT SHIFT LOCK SYSTEM CONTROL SYSTEMS 4 KEY INTERLOCK DOES NOT LOCK OR RELEASE WIRING DIAGRAM SBF 2 SBF 1 NO BATTERY KEY WARNING SWITCH 6281 INTEGRATED MODULE P POSITION SWITCH KEY LOCK SOLENOID 112 31 41 5 6 7 8 9 10 11 12113 1415 16 17 18 19 20 21122123124 0554 CS 20 AT SHIFT LOCK SYSTEM CONTROL SYSTEMS oa e Is the voltage between 9 and to step 2 Repair open or 16 V short circuit in har ness between bat tery and key warning switch Step CHECK HARNESS BETWEEN BATTERY AND KEY WARNING SWITCH 1 Disconnect the connector key warning switch 2 Measure the voltage of harness between key warning switch and chassis ground Connector amp terminal B74 No 2 Chassis ground CHECK KEY WARNING SWITCH Measure the resistance of stop light switch connector terminals Terminal No 1 No 2 CHECK KEY WARNING SWITCH 1 Remove the key 2 Measure the resistance of stop light switch connector terminals Terminal No 1 No 2 CHECK HARNESS BETWEEN AT SHIFT LOCK CONTROL MODULE AND KEY WARNING SWITCH 1 Disconnect the integrated module connector 2 Measure the voltage of harness integrated module and chassis ground Connector amp terminal B280 No 20 Chassis ground CHECK HARNESS BETWEEN INTEGRATED MODULE AND KEY LOCK SOLENOID 1 D
133. L DESCRIPTION MANUAL TRANSMISSION AND DIFFERENTIAL 5 TRANSFER CASE AND EXTENSION 10 11 12 13 14 15 guide Gasket Transfer case Ball Reverse accent spring Gasket Plug Oil seal Snap ring Inner Reverse check plate Reverse check spring Reverse return spring Reverse check cam Reverse accent shaft Return spring cap 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 Return spring O ring Adjusting select shim Reverse check sleeve Gasket Neutra switch Gasket Back up light switch Roller bearing Transfer driven gear Roller bearing Adjusting washer Ball bearing Center differential Adjusting washer MT 11 31 32 33 34 35 36 37 TROO09 Transfer drive gear Ball bearing Extension Oil seal Dust cover Shift bracket Snap ring Tightening torque N m kgf m ft Ib T1 T2 T3 T4 T5 6 4 0 65 4 7 10 1 0 7 2 25 2 5 18 1 26 2 7 20 40 4 1 29 7 GENERAL DESCRIPTION MANUAL TRANSMISSION AND DIFFERENTIAL 6 FRONT DIFFERENTIAL 5 H3M1967A 1 Drive pinion shaft 8 Snap ring Outer 15 Retainer lock plate 2 MHypoid driven gear 9 Roller bearing 3 Pinion shaft 10 Differential case Tightening torque N m kgf m ft Ib 4 Straight pin 11 Oil seal T1 25 2 5 18 1 5 Washer 12 Differential side retainer T2 62 6 3 45 6 6 Differential bevel gea
134. LLOSCOPE 1 Connect the connectors to TCM and trans mission 2 Set the oscilloscope to TCM connector ter minals Turbo model Positive probe B55 No 8 Earth lead B55 No 9 Non turbo model Positive probe B55 No 12 Earth lead B55 No 21 3 Start the engine and move the select lever to P or N range Is the revolution value same as the tachometer reading shown on the combination meter Is the signal voltage more than AC 1 V CHECK POOR CONTACT 15 there poor contact in torque converter turbine speed sensor circuit AT 64 Yes DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE DTC AUTOMATIC TRANSMISSION DIAGNOSTICS No Even if the AT OIL TEMP warning lights up the cir cuit has returned to a normal condi tion at this time A temporary poor contact of the con nector or harness may be the cause Repair harness or connector in the TCM and trans mission Even if the AT OIL TEMP warning lights up the cir cuit has returned to a normal condi tion at this time A temporary poor contact of the con nector or harness may be the cause Repair harness or connector in the TCM and trans mission Even if the AT OIL TEMP warning lights up the cir cuit has returned to a normal condi tion at this time A temporary poor contact of the con nector or harness may be the cause Repair harness or connector in the TCM and trans mission Repair poor c
135. Memory Mode 4 Perform the inspection mode Ref to AT 26 Inspection Mode 5 Calling up the diagnostic trouble code DTC Without SUBARU SELECT MONITOR Ref to 24 WITHOUT SUBARU SELECT MONITOR OPERATION Read Diagnostic Trouble Code DTC gt With SUBARU SELECT MONITOH Ref to AT 25 WITH SUBARU SELECT MONITOR OPERATION Read Diagnostic Trouble Code DTC gt AUTOMATIC TRANSMISSION DIAGNOSTICS Is the diagnostic trouble code Go to step 6 DTC displayed Complete the diagnosis is the diagnostic trouble code DTC displayed Inspect using the Complete the Diagnostics Chart diagnosis with Diagnostic Connector Ref to AT 44 Diagnos tic Procedure with Diagnostic Trou ble Code DTC AT 3 CHECK LIST FOR INTERVIEW AUTOMATIC TRANSMISSION DIAGNOSTICS 2 Check List for Interview NOTE Use copies of this page for interviewing customers A CHECK Check the following items when problem has oc curred ee a 7 E I Continuous UiIntermittent times a day wee 2 2 Suburbs Inner city Uphill Rough road Q Various Others High Q Others km h MPH Malfunction indicator lamp MIL Driving condition Not affected At starting Q While idling At racing A While accelerating While cruising While decelerating A While turning RH O LH iti
136. N 1 PITCHING STOPPER 1 Install the pitching stopper Tightening torque T1 50 N m 5 1 kgf m 37 ft lb T2 58 N m 5 9 kgf m 43 ft lb e 8 y 17 ANEN TROO86 2 Install the air intake duct and cleaner case Non turbo model Ref to IN SOHC 7 REMOVAL Air Intake Duct Ref to IN SOHC 6 REMOVAL Air Cleaner Case 3 Install the intercooler Turbo model Ref to IN DOHC TURBO 10 REMOVAL Intercooler gt AT 25 TRANSMISSION MOUNTING SYSTEM AUTOMATIC TRANSMISSION 2 CROSSMEMBER AND CUSHION RUB C INSPECTION BER Repair or replace parts if the results of the inspec 1 Install the rear cushion rubber tion below are not satisfactory Tightening torque 1 PITCHING STOPPER 39 N m 4 0 kgf m 29 ft lb Make sure that the pitching stopper is not bent or 2 Install the crossmember damaged Make sure that the rubber is not stiff Tightening torque cracked or otherwise damaged T1 35 N m 3 6 kgf m 26 ft lb 2 CROSSMEMBER AND CUSHION RUB 2 70 N m 7 1 kgf m 51 4 ft lb BER Make sure that the crossmember is not bent or damaged Make sure that the cushion rubber is not stiff cracked or otherwise damaged 3 Remove the transmission jack 4 Install the heat shield cover If equipped 5 Install the front center rear exhaust pipes and the muffler Non turbo model lt Ref to EX SOHC 6 INSTALLATION Front Ex haust Pipe gt lt Ref to EX SOHC 9 INSTALLA TION Rear
137. O125 A Bearing cup B Bearing cup C Transfer case D Extension case 2 install the transfer driven gear 3 Install the transfer case and extension case as sembly lt Ref to MT 41 INSTALLATION Transfer Case and Extension Case Assembly gt 4 Install the back up light switch and neutral posi tion switch lt Ref to MT 38 INSTALLATION Switches and Harness gt 5 Install the manual transmission assembly to ve hicle lt Ref to MT 30 INSTALLATION Manual Transmission Assembly gt MT 47 TRANSFER DRIVEN GEAR MANUAL TRANSMISSION AND DIFFERENTIAL C DISASSEMBLY 1 Using ST remove the roller bearing extension case side ST 498077000 REMOVER B3M2136A A Roller bearing 2 Using ST1 and ST2 remove the roller bearing transfer case side ST1 498077000 REMOVER 512 899864100 REMOVER B3M2137A A Roller bearing D ASSEMBLY 1 Using ST install the roller bearing extension case side ST1 398177700 INSTALLER ST2 899864100 REMOVER CAUTION Do not apply pressure in excess of 10 KN 1 ton 1 1 US ton 1 0 Imp ton Roller bearing B3M2138A 2 Using ST install the roller bearing transfer case side ST 499757002 CAUTION Do not apply pressure in excess of 10 KN 1 ton 1 1 US ton 1 0 Imp ton INSTALLER B3M2139A A Roller bearing E INSPECTION 1 Bearings Replace the bearings in the following cas
138. OFF 2 Disconnect the connector from TCM and transmission 3 Measure the resistance of harness between TCM and transmission connector Connector amp terminal Non turbo model B55 No 3 B11 No 19 Turbo model B55 No 24 B11 No 19 CHECK HARNESS CONNECTOR BETWEEN TCM AND TRANSMISSION Measure the resistance of harness between TCM and transmission connector Connector amp terminal Non turbo model B55 No 21 B11 No 20 Turbo model B54 No 19 B11 No 20 CHECK HARNESS CONNECTOR BETWEEN TCM AND TRANSMISSION Measure the resistance of harness between TCM and chassis ground Connector amp terminal Non turbo model B55 No 3 Chassis ground Turbo model B55 No 24 Chassis ground CHECK HARNESS CONNECTOR BETWEEN TCM AND TRANSMISSION Measure the resistance of harness between TCM and chassis ground Connector amp terminal Non turbo model B55 No 21 Chassis ground Turbo model B54 No 19 Chassis ground CHECK REAR VEHICLE SPEED SENSOR Measure the resistance between transmission connector receptacle s terminals Connector amp terminal T4 No 19 No 20 PREPARE OSCILLOSCOPE PREPARE SUBARU SELECT MONITOR DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE DTC AUTOMATIC TRANSMISSION DIAGNOSTICS s the resistance less than 1 22 s the resistance less than 1 2 s the resistance more than 1 MO s the resistance more than 1 MO S the resistance bet
139. OSTIC TROUBLE CODE DTC AUTOMATIC TRANSMISSION DIAGNOSTICS CHECK HARNESS CONNECTOR BETWEEN Is the resistance more than 1 to step 8 Repair short circuit AND THROTTLE POSITION SENSOR MQ in harness Measure the resistance of harness between between TCM and TCM connector and chassis ground throttle position Connector amp terminal sensor connector Non turbo model B55 No 2 Chassis ground Turbo model B54 No 3 Chassis ground CHECK HARNESS CONNECTOR BETWEEN IIs the resistance more than 1 Repair short circuit AND THROTTLE POSITION SENSOR MQ in harness Measure the resistance of harness between between TCM and TCM connector and chassis ground throttle position Connector amp terminal sensor connector Non turbo model B55 No 1 Chassis ground Turbo model B54 No 2 Chassis ground CHECK HARNESS CONNECTOR BETWEEN Is the resistance less than 1 Go to step 10 Repair open circuit TCM AND ECM Q in harness Measure the resistance of harness between between TCM and TCM and ECM connector ECM connector Connector amp terminal Non turbo model B55 No 2 B136 No 17 Turbo model B54 No 3 B135 No 7 CHECK HARNESS CONNECTOR BETWEEN Is the resistance less than 1 Go to step 11 Repair open circuit TCM AND ECM in harness Measure the resistance of harness between between TCM and TCM and ECM connector ECM connector Connector amp terminal Non turbo model B55 No 1 B
140. Oil seal Replace the oil seal if the lip is deformed hard ened damaged worn or defective in any way 7 O ring Replace the O ring if the sealing face is deformed hardened damaged worn or defective in any way MT 61 MAIN SHAFT ASSEMBLY FOR SINGLE RANGE MANUAL TRANSMISSION AND DIFFERENTIAL 8 Gearshift mechanism Repair or replace the gearshift mechanism if ex cessively worn bent or defective in any way F ADJUSTMENT Selection of main shaft rear plate Using ST measure the amount A of ball bearing protrusion from transmission main case surface and select the proper plate in the following table NOTE Before measuring tap the end of main shaft with a plastic hammer lightly in order to make the clear ance zero between the main case surface and the moving flange of bearing ST 498147000 DEPTH GAUGE mm in 4 00 4 13 0 1575 32294AA041 0 1626 3 87 3 99 0 1524 32294AA051 0 1571 B3M0531A MT 62 DRIVE PINION SHAFT ASSEMBLY 16 Drive Pinion Shaft Assembly A REMOVAL 1 Remove the manual transmission assembly from vehicle lt Ref to MT 27 REMOVAL Manual Transmission Assembly gt 2 Remove the transfer case with extension case assembly lt Ref to MT 41 REMOVAL Transfer Case and Extension Case Assembly gt 3 Remove transmission case lt Ref to MT 54 RE MOVAL Transmission Case gt 4 Remove the drive pinion shaft assembly NOTE Use a hammer handle
141. RIPTION 10 11 12 13 14 15 16 17 18 9 9 O ring A O ring B Bush A Cushion rubber Bush B Joint Rod Bracket Washer CS 4 19 Stay 20 Spacer Tightening torque N m kgf m ft Ib T1 7 5 0 76 5 5 2 12 1 2 8 7 T3 18 1 8 13 0 GENERAL DESCRIPTION CONTROL SYSTEMS C CAUTION e Wear working clothing including cap protec tive goggles and protective shoes during opera tion Remove contamination including dirt and corro sion before removal installation or disassembly Keep the disassembled parts in order and pro tect them from dust or dirt Before removal installation or disassembly be sure to clarify the failure Avoid unnecessary re moval installation disassembly and replacement Use SUBARU genuine grease etc or the equiv alent Do not mix grease etc with that of another grade or from other manufacturers Be sure to tighten fasteners including bolts and nuts to the specified torque Place shop jacks or safety stands at the specified points Apply grease onto sliding or revolution surfaces before installation Before installing O rings or snap rings apply suf ficient amount of grease to avoid damage and de formation Before securing a part on a vice place cushion ing material such as wood blocks aluminum plate or shop cloth between the part and the vice Before disconnecting electrical connectors be su
142. Replace GENERAL DIAGNOSTIC MANUAL TRANSMISSION AND DIFFERENTIAL MT 86 CLUTCH SYSTEM General Description 2 Disc and s eta S TR TENOR SUN A EH NERA NOE 11 EIVWIIBOL 14 Release Bearing and n DENEN 15 COberalirig GVIIBOBE uisa iced ere pesa detecto Sea d 18 Master eur 20 Clutch Pipe and HOoS8 e dide eati nee ret et Pa lorcet nese 22 Cl teh a a aa a aar a 23 Clutch Fluid Air Bleeding 24 Pedal iones aseo vase Pak bx Xe EPI SER ata 26 luteo SWIIGIES coni cota ER Dpto E Qiu Hi 30 General Diagnostic 31 GENERAL DESCRIPTION CLUTCH SYSTEM 1 General Description A SPECIFICATIONS NOHUREO TURBO Type Push type Pull type Diaphragm set load kg Ib 580 1 279 830 1 830 Clutch disk Facing material Woven Non asbestos O D x I D x thickness 225 x150x 3 5 230x150x3 5 8 86 x 5 91 x 0 138 9 06 x 5 91 x 0 138 Spline O D i 25 2 0 992 No of teeth 24 Clutch release lever ratio Release bearing Grease packed self aligni
143. SMISSION MQ in harness Measure the resistance of harness connector between TCM and between TCM and chassis ground transmission con Connector amp terminal nector Non turbo model B54 No 16 Chassis ground Turbo model B54 No 7 Chassis ground CHECK LOCK UP DUTY SOLENOID Is the resistance between 10 Measure the resistance between transmission and 17 connector receptacle s terminals Connector amp terminal T4 No 13 No 16 5 PREPARE SUBARU SELECT MONITOR Do you have a Subaru Select Monitor Go to step 5 Go to step 11 AT 95 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE DTC AUTOMATIC TRANSMISSION DIAGNOSTICS CHECK OUTPUT SIGNAL EMITTED FROM TCM 1 Connect the connectors to TCM and trans mission 2 Lift up the vehicle and place safety stand CAUTION On AWD models raise all wheels off ground 3 Start the engine and warm up the transmis sion until the ATF temperature is above 80 C 176 F NOTE If the ambient temperature is below 0 C 32 F drive the vehicle until the ATF reaches its oper ating temperature 4 Move the select lever to D and slowly increase the vehicle speed to 75 km h 47 MPH Wheels will lock up NOTE The speed difference between front and rear wheels may light the ABS warning light but this indicates no malfunction When the AT control diagnosis is finished perform the ABS
144. T Add if the number on drive pinion is prefixed by and subtract if the num ber is prefixed by ST 499917500 DRIVE PINION GAUGE ASSY MT 63 DRIVE PINION SHAFT ASSEMBLY MANUAL TRANSMISSION AND DIFFERENTIAL 8 Select one to three shims from the next table for the value determined as described above and take a shim thickness which is closest to the said value Drive pinion shim 0 275 0 0708 0 500 6 0197 9 Install the differential assembly Ref to MT 71 INSTALLATION Front Differential Assembly 10 Set the transmission main shaft assembly and drive pinion assembly in position So there is no clearance between the two when moved all the way to the front Inspect the suitable 1st 2nd 3rd 4th and 5th shifter fork so that the coupling sleeve and reverse driven gear are positioned in the cen ter of their cynchronizing mechanisms Ref to MT 68 INSPECTION Drive Pinion Shaft Assem bly 11 Install the transmission case Ref to MT 55 INSTALLATION Transmission Case 12 Install the transfer case with extension case as sembly Ref to MT 41 INSTALLATION Transfer Case and Extension Case Assembly 13 Install the manual transmission assembly to ve hicle Ref to MT 27 Manual Transmission As sembly gt C DISASSEMBLY CAUTION Attach a cloth to the end of driven shaft on the frictional side of thrust needle bearing during disassembly or reassembly to prev
145. T STOPPER 2 Tighten the flywheel attaching bolts to the spec ified torque NOTE Tighten the flywheel installing bolts gradually Each bolt should be tightened to the specified torque in a crisscross method Tightening torque 72 7 3 kgf m 52 8 ft lb B2M0331B 3 Install the clutch disc and cover lt Ref to CL 11 INSTALLATION INSTALLATION Clutch Disc and Cover gt 4 Install the transmission assembly lt Ref to MT 30 INSTALLATION Manual Transmission Assem bly gt C INSPECTION CAUTION Since this bearing is grease sealed and is of a non lubrication type do not wash with gaso line or any solvent 1 Damage of facing and ring gear If defective replace the flywheel 0448 A Flywheel B Ring gear 2 Smoothness of rotation Rotate the ball bearing applying pressure in thrust direction 3 If noise or excessive play is noted replace the flywheel CL 14 RELEASE BEARING AND LEVER CLUTCH SYSTEM 4 Release Bearing and Lever A REMOVAL 1 NON TURBO MODEL 1 Remove the transmission assembly from vehicle body lt Ref to MT 27 REMOVAL Manual Transmission Assembly gt 2 Remove the two clips from clutch release lever and remove the release bearing CAUTION Be careful not to deform the clips 3 Remove the release lever seal B2M4222A A Clutch release lever B Release lever seal 4 Remove the release lever retainer spri
146. TER Measure the voltage between combination meter connector and chassis ground Connector amp terminal i11 No 5 Chassis ground CHECK OPEN CIRCUIT OF HARNESS 1 Turn the ignition switch to OFF 2 Disconnect the connector from combination meter connector 3 Measure the resistance of harness between combination meter Connector amp terminal Non turbo model B54 No 3 i11 No 5 Turbo model B56 No 11 i11 No 5 Is the voltage more than 9 V Repair open or short circuit in har ness between combination meter and battery Is the voltage less than 1 V Go to step 7 Repair the combi nation meter Ref to IDI 11 Combination Meter Assembly Is the resistance less than 1 Go to step 8 Repair open circuit Q in harness between TCM and combination meter and poor contact in cou pling connector AT 33 DIAGNOSTIC PROCEDURE FOR AT OIL TEMP WARNING LIGHT AUTOMATIC TRANSMISSION DIAGNOSTICS CHECK INPUT SIGNAL FOR TCM Is the voltage less than 1 V Even if the AT OIL Replace the TCM 1 Connect the connector to TCM and combina TEMP warning Ref to AT 45 tion meter lights up the cir Transmission Con 2 Turn the ignition switch to ON engine OFF cuit has returned trol Module 3 Measure the voltage between TCM connec i to a normal condi TCM gt tor and chassis ground tion at this time A Connector
147. TOMATIC TRANSMISSION DIAGNOSTICS B SCHEMATIC 1 NON TURBO MODEL 1 28 29 30 31 34 32 33 35 27 18 TRO0566 TRANSMISSION CONTROL MODULE TCM I O SIGNAL AUTOMATIC TRANSMISSION DIAGNOSTICS 1 10 11 12 13 14 15 16 17 Transmission control module Data link connector Cruise set switch ABS contro module Ignition switch Brake switch Brake light Battery Combination meter AT OIL TEMP warning light FWD indicator light FWD switch P range indicator light range indicator light range indicator light D range indicator light 3 range indicator light 18 19 20 21 22 23 24 25 26 27 28 29 30 81 32 33 34 2 range indicator light 1 range indicator light P range switch R range switch N range switch D range switch 3 range switch 2 range switch 1 range switch Throttle position sensor Engine speed signal Torque control cut signal Torque control signal 2 Torque control signal 1 AT load signal AT diagnostics signal Engine control module AT 19 35 36 37 38 39 40 41 42 43 44 45 46 47 48 ATF temperature sensor Torque converter turbine speed sensor Front vehicle speed sensor Rear vehicle speed sensor Shift solenoid 1 Shift soleno
148. VAL Shifter Fork and Rod 9 Pull out the straight pin and remove the idler gear shaft reverse idler gear and washer O B3M0524C Straight pin B Idler gear shaft C Idler gear D Washer 10 Remove the reverse shifter lever B INSTALLATION 1 Install the reverse shifter lever reverse idler gear and reverse idler gear shaft and secure with straight pin NOTE Be sure to install the reverse idler shaft from the rear side Q B3M0526C A Reverse shifter lever B Reverse idler gear C Reverse idler gear shaft D Straight pin 2 Inspect and adjust the clearance between re verse idler gear and transmission case wall lt Ref to MT 78 INSTALLATION Reverse Idler Gear gt and lt Ref to MT 79 ADJUSTMENT Reverse Idler Gear gt 3 Install the shifter forks and rods lt Ref to MT 80 INSTALLATION Shifter Fork and Rod gt 4 Install the differential assembly lt Ref to MT 71 INSTALLATION Front Differential Assembly gt 5 Install the main shaft assembly lt Ref to MT 57 INSTALLATION Main Shaft As sembly for Single Range gt 6 Install the drive pinion shaft assembly lt Ref to MT 63 INSTALLATION Drive Pinion Shaft As sembly gt 7 Install the transmission case lt Ref to MT 55 IN STALLATION Transmission Case gt 8 Install the transfer case with extension case as sembly lt Ref to MT 41 INSTALLATION Transfer Case and Extension Case Assembly gt 9 Insta
149. WITH DIAGNOSTIC TROUBLE CODE DTC AUTOMATIC TRANSMISSION DIAGNOSTICS I DTC 71 SHIFT SOLENOID 1 DIAGNOSIS Output signal circuit of shift solenoid 1 is open or shorted TROUBLE SYMPTOM Does not shift WIRING DIAGRAM NON TURBO MODEL TURBO MODEL TRANSMISSION 23 0 11 12 1920121 TRO581 AT 70 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE DTC CHECK HARNESS CONNECTOR BETWEEN TCM AND TRANSMISSION 1 Turn the ignition switch to OFF 2 Disconnect the connector from TCM and transmission 3 Measure the resistance of harness between TCM and shift solenoid 1 connector Connector amp terminal Non turbo model B54 No 7 B11 1 Turbo model B54 No 22 B11 1 CHECK HARNESS CONNECTOR BETWEEN TCM AND TRANSMISSION Measure the resistance of harness between TCM connector and chassis ground Connector amp terminal Non turbo model B54 No 7 Chassis ground Turbo model B54 No 22 Chassis ground CHECK SHIFT SOLENOID 1 Measure the resistance between transmission connector terminals Connector amp terminal T4 No 1 No 16 CHECK OUTPUT SIGNAL EMITTED FROM TCM 1 Connect the connectors to TCM and trans mission 2 Turn the ignition switch to ON engine OFF 3 Move the select lever to D range 4 Measure the voltage between TCM connec tor and chassis ground Connector amp terminal Non turbo model B54 No 7 Cha
150. air harness and connector between battery and data link con nector and poor contact in cou pling connector Repair open circuit in harness between data link connector and ground terminal and poor contact in coupling con nector Go to step 4 CHECK COMMUNICATION OF SELECT MONITOR 1 Turn the ignition switch to OFF 2 Disconnect the TCM connector 3 Check whether communication to other sys tems such as ABS etc can be executed nor mally system displayed on the select monitor CHECK COMMUNICATION OF SELECT MONITOR 1 Turn the ignition switch to OFF 2 Connect the TCM connector 3 Disconnect the ECM connector 4 Check whether communication to other sys tems such as ABS etc can be executed nor mally Are the name and year of the system displayed on the select monitor CHECK COMMUNICATION OF SELECT MONITOR 1 Turn the ignition switch to OFF 2 Connect the ECM connector 3 Disconnect the ABSCM amp H U connector 4 Check whether communication to other sys tems such as engine etc can be executed normally Are the name and year of the system displayed on the select monitor CHECK COMMUNICATION OF SELECT MONITOR 1 Turn the ignition switch to OFF 2 Connect the ABSCM amp H U module connec tor 3 Disconnect the cruise control module con nector 4 Check whether communication to other sys tems such as engine etc can be executed normally NOTE If the vehicle is
151. ans Fluid hie mission fluid f 9 3 9 6 0 9 8 10 1 US qt Fluid capacity 74 7 7 Imp at Lubrication system Forced feed lubrication with oil pump DEM Automatic transmission fluid above mentioned 10 FINAL REDUCTION Electronic hydraulic control Four forward speed changes by electri 8 COOLING AND HARNESS Liquid cooled cooler incorpo Cooling system rated in radiator Inhibitor switch 12 poles 20 poles 9 TRANSFER C ma Nome Multi plate Variable torque Transfer type transfer distribution VTD Drive amp driven plate number of transfer 5 3 clutch Control method Electronic hydraulic type The same Automatic transmission Lubricant fluid used in automatic transmis 1st reduction gear ratio 1 000 53 53 sion Model Sedan non turbo Except sedan non turbo Front final gear ratio 4 444 40 9 4 111 37 9 Lubrication oil ITEM Front differential gear oil Classification L 5 SAE Viscosity No and Applicable Temperature 6 30 26 26 50 15 2530 T T F 22 15 5 23 32 59 7786 H3M1235A Front differential oil capacity 1 2 0 1 3 US qt 1 1 Imp qt AT 3 GENERAL DESCRIPTION AUTOMATIC TRANSMISSION B COMPONENT NOTE For information about other transmission mounting components refer to AUTOMATIC TRANSMISSION Pub No G0853ZE gt a se
152. ansmission fluid CAUTION Do not drain the automatic transmission flu id until it cools down 3 Remove the oil pan and disconnect the con nector from shift solenoid 2 4 Measure the resistance between shift sole noid 2 connector and transmission ground Connector amp terminal No 1 Transmission ground Is the voltage less than 1 V Even if the AT OIL TEMP warning lights up the cir cuit has returned to a normal condi tion at this time A temporary poor contact of the con nector or harness may be the cause Repair harness or connector in the TCM and trans mission Is there poor contact in shift solenoid 2 circuit Is the resistance between 10 and 16 Q CHECK HARNESS CONNECTOR BETWEEN Is the resistance less than 1 SHIFT SOLENOID 2 AND TRANSMISSION Measure the resistance of harness between shift solenoid 2 and transmission connector Connector amp terminal AT6 No 1 T4 No 2 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE DTC AUTOMATIC TRANSMISSION DIAGNOSTICS Go to step 5 Repair poor con tact Go to step 7 Replace the TCM Ref to AT 45 Transmission Con trol Module TCM gt Replace the shift solenoid 2 assem bly lt Ref to AT 39 Shift Solenoids Duty Solenoids and ATF Tempera ture Sensor gt Q AT 76 Go to step 8 Repair open circuit in harness between shift sole noid 2 and trans mission conn
153. ar exhaust pipe and muffer Turbo model lt Ref to EX DOHC TUR BO 8 REMOVAL Center Exhaust Pipe gt lt Ref to EX DOHC TURBO 13 REMOVAL Rear Ex haust Pipe gt and lt Ref to EX DOHC TURBO 14 REMOVAL Muffler gt 10 Disconnect the following connectors 1 Transmission harness connector 2 Transmission ground terminal 11 Remove the starter lt Ref to SC 6 REMOVAL Starter gt 12 Install the ST to torque converter clutch case ST 498277200 STOPPER SET H2M1961A 13 Remove the pitching stopper E AZ l TR0072 14 Separate the torque converter clutch from drive plate 1 Remove the service hole plug 2 Remove the bolts which hold torque con verter clutch to drive plate 3 While rotating the engine remove the other bolts using ST CAUTION Be careful not to drop bolts into the torque con verter clutch housing AT 19 AUTOMATIC TRANSMISSION ASSEMBLY AUTOMATIC TRANSMISSION Turbo model 17 Remove the bolt which holds right upper side of ST 499977300 CRANK PULLEY WRENCH transmission to engine Non turbo model ST 499977100 CRANK PULLEY WRENCH B3M2044 18 Lift up the vehicle 19 Remove the under cover 15 Remove the ATF level gauge 20 Remove the heat shield cover If equipped CAUTION 21 Drain the ATF to remove the ATF drain plug Plug the opening to prevent entry of foreign particles into transmission fluid A Oil pan B Dra
154. ard the inside of the case so that it does not hit against the case B3M0523C Straight pin B 3 4 fork rod C Shifter fork 11 Drive out the straight pin and pull out the 1 2 fork rod and shifter fork 12 Remove the outer snap ring and pull out re verse shifter rod arm from reverse fork rod Then take out the ball spring and interlock plunger from rod And then remove the rod NOTE When pulling out reverse shifter rod arm be careful not to let ball pop out of arm 13 Remove the reverse shifter lever B INSTALLATION 1 Install the reverse arm fork spring ball and inter lock plunger to reverse fork rod arm Insert the re verse fork rod into hole in reverse fork rod arm and hold it with outer snap ring using ST CAUTION Apply grease to plunger to prevent it from fall ing ST 399411700 ACCENT BALL INSTALLER 2 Position the ball spring and gasket in reverse shifter rod hole on left side transmission case and tighten the checking ball plug CAUTION Replace gasket with a new one 3 Install the 1 2 fork rod into 1 2 shifter fork via the hole on the rear of the transmission case MT 80 SHIFTER FORK AND ROD 4 Align the holes in rod and fork and drive straight pin into these holes using ST CAUTION Replace straight pin with a new one NOTE Set other rods to neutral Make sure interlock plunger is on the 3 4 fork rod side ST 39879170
155. askets lock washers and lock nut must be re placed with new ones 7 Liquid gasket should be used where specified to prevent leakage MT 40 TRANSFER CASE AND EXTENSION CASE ASSEMBLY MANUAL TRANSMISSION AND DIFFERENTIAL 9 Transfer Case and Extension 2 Remove the bearing cone from the extension case assembly and install to taper roller bearing of Case Assembly the transfer driven gear A REMOVAL 1 Remove the manual transmission assembly from vehicle lt Ref to MT 27 REMOVAL Manual Transmission Assembly gt 2 Remove the back up light switch and neutral po sition switch lt Ref to MT 37 REMOVAL Switches and Harness gt 3 Remove the transfer case with extension case CU 2 Sz AW A Bearing cone Extension case B Extension case B3M2172A 3 While pressing the bearing cone horizontally turn the driven shaft ten rotations 4 Measure the height W between transfer case and taper roller bearing on the transfer driven gear B3M1373 4 Remove the shifter arm 5 Remove the extension case assembly B3M1984A 5 Measure the depth NOTE Measure with bearing cone and thrust washer re moved B INSTALLATION 1 Install the center differential and transfer driven gear into transfer case B3M1406A 6 Calculate space t using the following equation t X W 0 2 to 0 3 mm
156. at shield cover If equipped 7 Set the transmission jack under the transmission body CAUTION Always support transmission case with a trans mission jack 8 Remove the rear crossmember G2M0831 9 Remove the rear cushion rubber B INSTALLATION 1 PITCHING STOPPER 1 Install the pitching stopper Tightening torque T1 50 N m 5 1 kgf m 37 ft lb T2 58 5 9 kgf m 43 ft Ib 2 Install the air intake duct and cleaner case Non turbo model Ref to IN SOHC 6 INSTALLATION Air Cleaner Case and Ref to IN SOHC 7 INSTALLATION Air Intake Duct 3 Install the intercooler Turbo model Ref to IN DOHC TURBO 11 INSTALLATION Intercooler gt 4 Connect the battery ground terminal MT 34 TRANSMISSION MOUNTING SYSTEM 2 CROSSMEMBER AND CUSHION RUB BER 1 Install for rear cushion rubber Tightening torque 35 N m 3 6 kgf m 26 ft lb 2 Install the crossmember Tightening torque T1 70 N m 7 1 kgf m 51 ft lb T2 140 N m 14 3 kgf m 103 ft lb 3 Remove the transmission jack 4 Install the heat shield cover If equipped 5 Install the front and center exhaust pipes Non turbo model lt Ref to EX SOHC 6 INSTALLATION Front Ex haust Pipe gt 6 Install the center exhaust pipe Turbo model lt Ref to EX DOHC TURBO 9 INSTALLATION Center Exhaust Pipe gt 7 Install the rear exhaust pipe and muffler MANUAL TRANSMISSION AND DIFFERENTIAL C INSPE
157. ata of throttle position sensor using Subaru Select Monitor Throttle position sensor input signal is indi cated Is the value voltage between approx 0 5 V CHECK INPUT SIGNAL FOR TCM USING SUBARU SELECT MONITOR Throttle fully open NOTE Must be changed correspondingly with acceler ator pedal operation from released to de pressed position Is the value voltage between approx 4 3 V Go to step 17 CHECK INPUT SIGNAL FOR TCM THROT TLE POSITION SENSOR POWER SUPPLY Measure the voltage between TCM connector and chassis ground Connector amp terminal Non turbo model B55 No 1 Chassis ground Turbo model B54 No 2 Chassis ground Is the voltage between 4 8 and Even if the AT OIL 5 3 V TEMP warning lights up the cir cuit has returned to a normal condi tion at this time A temporary poor contact of the con nector or harness may be the cause Repair harness or connector in throt tle position sensor CHECK INPUT SIGNAL FOR TCM USING Is the value voltage between SUBARU SELECT MONITOR THROTTLE POSITION SENSOR POWER SUPPLY Read the data of throttle position sensor power supply using Subaru Select Monitor Throttle position sensor power supply voltage is indicated 4 8 and 5 3 V circuit Even if the AT OIL TEMP warning lights up the cir cuit has returned to a normal condi tion at this time A temporary poor contact of
158. board diagnostics system Ref to ABS 22 Clear Memory Does the speedometer indica tion increase as the Subaru Select Monitor data increases Is there poor contact in front vehicle speed sensor circuit AT 61 Even if the AT OIL TEMP warning lights up the cir cuit has returned to a normal condi tion at this time A temporary poor connector or har ness may be the case Repair har ness or connector in the front vehicle speed sensor cir cuit Repair poor con tact Go to step 11 Replace the TCM Ref to AT 45 Transmission Con trol Module TCM gt DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE DTC AUTOMATIC TRANSMISSION DIAGNOSTICS F DTC 36 TORQUE CONVERTER TURBINE SPEED SENSOR DIAGNOSIS Input signal circuit of TCM is open or shorted TROUBLE SYMPTOM Excessive shift shock WIRING DIAGRAM NON TURBO MODEL TURBO MODEL SHIELD AND SENSOR GROUND JOINT CONNECTOR m monem mc M nim m m TORQUE CONVERTER TURBINE SPEED SENSOR HT TSTSTIS ST ETTST S Te TsTeTsTe Te Te poga z ro i19 20 21 22 23 24 0578 62 CHECK TORQUE CONVERTER TURBINE SPEED SENSOR 1 Turn the ignition switch to OFF 2 Disconnect the connector from transmission 3 Measure the resistance between transmis sion connector receptacle s terminals Connector amp terminal 74 No 14
159. ch position position 9 16 V when key is inserted Key warning switch signal B280 20 0 V when key is removed B281 3 4 5281 el a 7 5 16 V when turning ignition switch to ON select lever is in P position and brake switch is ON 0 V at other conditions than above Key lock solenoid signal CS 8 AT SHIFT LOCK SYSTEM CONTROL SYSTEMS B SCHEMATIC 5 pom 2 6 _ OSS 000 7 3 8 2 9 lL Ue TRO550 1 Ignition switch 4 Integrated module 7 Shift lock solenoid 2 Stop light switch 5 Inhibitor switch 8 position switch 3 Key warning switch 6 Key lock solenoid 9 Battery CS 9 AT SHIFT LOCK SYSTEM CONTROL SYSTEMS C INSPECTION CHECK SHIFT LOCK 1 Turn the ignition switch ON 2 Move the select lever to P position While brake pedal is depressed can select lever move from P range to other positions While brake pedal is not depressed can select lever move from P range to other positions Inspect SELECT LEVER CANNOT BE SHIFT LOCKED lt Ref to CS 14 SELECT LEVER CANNOT BE SHIFT LOCKED INSPECTION AT Shift Lock Sys tem gt inspect SELECT LEVER SHIFT LOCK CANNOT BE RELEASED lt Ref to CS 16 SELECT LEVER SHIFT LOCK CANNOT BE RELEASED INSPECTION AT Shift Lock Sys t
160. cified torque us ing ST1 and ST2 NOTE Secure the lock nuts in two places after tightening ST1 499987003 SOCKET WRENCH ST2 498937000 TRANSMISSION HOLDER Tightening torque 118 N m 12 0 kgf m 86 8 ft lb MANUAL TRANSMISSION AND DIFFERENTIAL E INSPECTION Disassembled parts should be washed clean first and then inspected carefully 1 Bearings Replace the bearings in the following cases e Bearings whose balls outer races and inner rac es are broken or rusty Worn bearings Bearings that fail to turn smoothly or make ab normal noise when turned after gear oil lubrication Bearings having other defects 2 Bushing each gear Replace the bushing in the following cases When the sliding surface is damaged or abnor mally worn e When the inner wall is abnormally worn 3 Gears e Replace the gears with new ones if their tooth surfaces are broken damaged or excessively worn e Correct or replace if the cone that contacts the baulk ring is rough or damaged Correct or replace if the inner surface or end face is damaged 4 Baulk ring Replace the ring in the following cases e When the inner surface and end face are dam aged When the ring inner surface is abnormally or par tially worn down When the contact surface of the synchronizer ring insert is scored or abnormally worn down 5 Shifting insert key Replace the insert if deformed excessively worn or defective in any way 6
161. clutch pipe to master cylinder CAUTION Check that the pipe is routed properly Tightening torque T1 15 1 5 kgf m 10 8 ft lb T2 18 1 8 kgf m 13 0 ft lb 2 Connect the push rod of master cylinder to clutch pedal and install the clevis pin and snap pin NOTE Apply grease to the clevis pin 4 1189 Clevis pin B Snap pin C Push rod 3 After bleeding air from the system ensure that the clutch operates properly lt Ref to CL 24 Clutch Fluid Air Bleeding gt 4 Install the air cleaner case and air intake duct Non turbo model lt Ref to 6 INSTAL LATION Air Cleaner Case gt and lt Ref to IN SO HC 7 INSTALLATION Air Intake Duct gt 5 Install the intercooler Turbo model lt Ref to IN DOHC TURBO 11 INSTALLATION Intercool er CL 20 MASTER CYLINDER CLUTCH SYSTEM DISASSEMBLY 1 Remove the straight pin and reservoir tank 0471 Reservoir tank B Straight pin 2 Remove the oil seal A Oil seal B Master cylinder 3 Move the cylinder boot backward A Cylinder boot B Master cylinder 4 Remove the stop ring CAUTION Be careful when removing the snap ring to pre vent the rod washer piston and return spring from flying out 5 Remove the clutch damper Non turbo model D ASSEMBLY 1 Install the clutch damper Non turbo model Tightening torque 46 6 N m 4 75 kgf m
162. connector 3 Start the engine and turn the Subaru Select Monitor switch to ON 4 Warm up the transmission until the ATF tem perature is above 80 C 176 F NOTE If the ambient temperature is below 0 C 32 F drive the vehicle until the ATF reaches its oper ating temperature 5 Stop the engine and turn the ignition switch to ON engine OFF 6 Move the select lever to N 7 Read the data of line pressure duty solenoid using Subaru Select Monitor Line pressure duty solenoid is indicated in 9o 1 Throttle is fully closed Is the voltage between 1 5 and Go to step 12 5 0 V with throttle fully closed Go to step 15 Even if the AT OIL TEMP warning lights up the cir cuit has returned to a normal condi tion at this time A temporary poor contact of the con nector or harness Is the voltage less than 1 V with throttle fully open Go to step 15 may be the cause Repair harness or connector in trans mission Go to step 14 Is the value 10096 Go to step 15 AT 88 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE DTC AUTOMATIC TRANSMISSION DIAGNOSTICS Step Yes CHECK OUTPUT SIGNAL EMITTED FROM TCM USING SUBARU SELECT MONITOR 1 Turn the ignition switch to ON Engine OFF 2 Throttle is fully open Even if the AT OIL TEMP warning lights up the cir cuit has returned to a normal condi tion at this time A temporary poor contact of the con
163. connector between TCM and data link connec tor Insert the TCM connector into TCM Replace the TCM lt Ref to AT 45 Transmission Con trol Module TCM gt DIAGNOSTIC PROCEDURE FOR SELECT MONITOR COMMUNICATION AUTOMATIC TRANSMISSION DIAGNOSTICS AT 43 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE DTC AUTOMATIC TRANSMISSION DIAGNOSTICS 14 Diagnostic Procedure with Diagnostic Trouble Code DTC A DTC 11 ENGINE SPEED SIGNAL DIAGNOSIS Engine speed input signal circuit is open or shorted TROUBLE SYMPTOM s No lock up after engine warm up AT OIL TEMP warning light remains on when the vehicle speed is 0 WIRING DIAGRAM NON TURBO MODEL TB TURBO MODEL q n D 1 2 s 4 s e a e 1112 13 415 hel nz 16 20 21 22 23 24 TRO572 AT 44 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE DTC AUTOMATIC TRANSMISSION DIAGNOSTICS Step No CHECK HARNESS CONNECTOR BETWEEN TCM AND ECM 1 Turn the ignition switch to OFF 2 Disconnect the connectors from TCM and ECM 3 Measure the resistance of harness between TCM and ECM connector Connector amp terminal Non turbo model B55 No 4 B134 No 30 Turbo model B55 No 17 B136 No 9 Is the resistance less than 1 Go to step 2 Repair open circuit in harness between TCM and ECM connector CHECK HARNESS CONNECTOR BETWEEN 15 the resistance more
164. constant displacement pump Rear sun gear number of 37 Driving method Driven by engine teeth mero _ 89 _ Rear pinion number of teeth Number of teeth Non turbo ids Tooth number of rear inter nal gear 3 TRANSMISSION CONTROL ELEMENT Drive amp driven plate number of high clutch Drive amp driven plate number of low clutch Drive amp driven plate number of reverse clutch Drive amp driven plate number of 2 4 brake Drive amp driven plate number of low amp reverse brake 4 forward 1 reverse double row plane tary gears Multi plate clutch Multi plate brake One way clutch sprague type 1 sets AT 2 GENERAL DESCRIPTION AUTOMATIC TRANSMISSION 6 SELECTOR POSITION Transmission in neutral output member immov able and engine start possible P Park R Reverse Transmission in reverse for backing Transmission in neutral and engine start possi ble Automatic gear change 1st _ 2nd 3rd _ 4th Automatic gear change 1st _ 2nd 3rd lt 3 3rd 4th 2 2nd gear locked Deceleration possible 2nd 3rd lt 4th 1s 1st gear locked Deceleration possible 1st 2nd lt 3rd lt 4th Edad Hydraulic remote control 7 HYDRAULIC CONTROL AND LUBRICA TION cal signals of vehicle speed and Type accelerator throttle opening Dexron II type Automatic tr
165. ctor from TCM and transmission 3 Measure the resistance of harness between TCM and transmission connector Connector amp terminal Non turbo model B54 No 14 B11 No 3 Turbo model B54 No 15 B11 No 3 CHECK HARNESS CONNECTOR BETWEEN IIs the resistance more than 1 TCM AND TRANSMISSION Measure the resistance of harness between TCM connector and transmission ground Connector amp terminal Non turbo model B54 No 14 Chassis ground Turbo model B54 No 15 Chassis ground CHECK LOW CLUTCH TIMING SOLENOID Measure the resistance between transmission connector terminals Connector amp terminal T4 No 3 No 16 CHECK OUTPUT SIGNAL EMITTED FROM TCM 1 Connect the connectors to TCM and trans mission 2 Turn the ignition switch to ON engine OFF 3 Move the select lever to D range 4 Measure the voltage between TCM connec tor and chassis ground Connector amp terminal Non turbo model B54 No 14 Chassis ground Turbo model B54 No 15 Chassis ground CHECK OUTPUT SIGNAL EMITTED FROM TCM 1 Move the select lever to 2 range 2 Measure the voltage between TCM connec tor and chassis ground Connector amp terminal Non turbo model B54 No 14 Chassis ground Turbo model B54 No 15 Chassis ground Is the resistance between 10 and 16 Q Is the voltage more than 9V Is the voltage less than 1V Is there poor contact in low clutch ti
166. djust the inhibi tor switch and select cable Ref to AT 28 ADJUST MENT Inhibitor Select Cable SYMPTOM RELATED DIAGNOSTIC AUTOMATIC TRANSMISSION DIAGNOSTICS 16 Symptom Related Diagnostic A INSPECTION Problem part nhibitor switch Starter does not rotate when the select lever is in or N Select cable starter rotates when the select lever is in R D 3 or 2 Select lever Starter motor and harness Strainer Transfer duty solenoid Oil pump Drive plate e ATF level too high or too low Hissing noise occurs during standing start ds d 9 9 9 i ATF level too high or too low Noise occurs while driving in D1 Final gear Planetary gear Noise occurs while driving in D2 Reduction gear Noise occurs while driving in Abnormal noise when the select lever is in P or N Differential gear oil level too high or too low Final gear Low amp reverse brake Reduction gear Differential gear oil level too high or too low Final gear Low amp reverse brake Planetary gear Reduction gear Differential gear oil level too high or too low Control valve Lock up damper Engine performance Input shaft Low clutch e Harness Control valve e ATF deterioration Control valve Noise occurs while driving in D4
167. drive gear Inner baulk ring Synchro cone 3rd Outer baulk ring Coupling sleeve 3rd 4th Synchronizer hub 3rd 4th Shifting insert key 3rd 4th 4th baulk ring 4th drive gear 4th needle bearing race 15 16 17 18 19 20 21 22 23 24 25 26 27 28 Needle bearing 4th gear thrust washer Ball bearing 5th gear thrust washer 5th needle bearing race Needle bearing Main shaft rear plate 5th drive gear 5th baulk ring Shifting insert key 5th Rev Synchronizer hub 5th Rev Coupling sleeve 5th Rev Rev baulk ring Synchro cone Rev MT 9 N 59 Ball bearing Synchro cone stopper Snap ring Lock washer Lock nut Reverse idler gear shaft Straight pin Reverse idler gear Washer Rc oat AN gt IL 22 o 51 Tightening torque N m kgf m ft lb 118 12 0 86 8 GENERAL DESCRIPTION MANUAL TRANSMISSION AND DIFFERENTIAL 4 SHIFTER FORK AND SHIFTER ROD Shifter arm 5th shifter fork Straight pin Reverse fork rod Checking ball plug Gasket Checking bail spring Ball 9 10 11 12 13 14 15 16 3rd 4th fork rod Interlock plunger 1st 2nd fork rod 3rd 4th shifter fork 1st 2nd shifter fork Ball Spring Snap ring Outer MT 10 17 18 Reverse fork rod arm Reverse shifter lever T 19 6 2 0 14 5 H3M1966A Tightening torque N m kgf m ft lb GENERA
168. duty solenoid Control valve 2 4 brake duty solenoid 2 4 brake ATF deterioration 2 4 brake timing solenoid TCM Throttle position sensor ATF temperature sensor Line pressure duty solenoid Control valve ATF deterioration 2 4 brake duty solenoid 2 4 brake timing solenoid Low clutch timing solenoid Shock occurs from 2nd to 3rd gear Slippage occurs from 2nd to 3rd gear Shock occurs from 3rd to 4th gear Slippage occurs from 3rd to 4th gear Shock occurs when the select lever is moved from 3 to 2 range Shock occurs when the select lever is moved from D to 1 range AT 130 SYMPTOM RELATED DIAGNOSTIC AUTOMATIC TRANSMISSION DIAGNOSTICS TCM Throttle position sensor ATF temperature sensor Line pressure duty solenoid Control valve Low amp reverse clutch ATF deterioration 2 4 brake duty solenoid 2 4 brake timing solenoid Low clutch timing solenoid TCM Throttle position sensor ATF temperature sensor Line pressure duty solenoid Control valve Lock up damper Engine performance 2 4 brake duty solenoid 2 4 brake timing solenoid Low clutch timing solenoid TCM Lock up duty solenoid Lock up facing Lock up damper e Front vehicle speed sensor Rear vehicle speed sensor Throttle position sensor ATF temperature sensor Transfer clutch Transfer valve
169. e A 1st 2nd 3rd 4th 0 4 1 4 mm 0 016 0 055 in B 3rd 4th 5th 0 5 1 3 mm 0 020 0 051 in 1st 2nd shifter fork Remarks Approach to 1st gear by 0 2 mm 0 008 in Part No 32804AA060 Approach to 2nd gear 32804AA080 by 0 2 mm 0 008 in Remarks Approach to 4th gear by 0 2 mm 0 008 in Standard Approach to 3rd gear by 0 2 mm 0 008 in 5th shifter fork Non turbo Approach to 5th gear 32812AA201 by 0 2 mm 0 008 in 32812AA211 Standard Become distant from 32812AA221 5th gear by 0 2 mm 0 008 in 5th shifter fork Turbo Part No Mark Remarks 32812AA231 7 Approach to 5th gear 32812AA241 No mark Standard Become distant from 9 5th gear by 0 2 mm 0 008 in Part No 32810AA061 32810AA071 32810AA101 by 0 2 mm 0 008 in 32812AA251 MT 4 GENERAL DESCRIPTION MANUAL TRANSMISSION AND DIFFERENTIAL 8 TRANSFER CASE Neutral position adjustment Thickness mm in Reverse accent shaft Part No Neutral position is closer to 1st 32188AA100 0 Standard 35188AA110 Neutral position is closer to reverse gear Reverse check plate adjustment 32188AA090 Reverse check plate Angle 0 32189AA000 28 Arm stops closer to 5th gear 32189AA010 1 31 Arm stops closer to 5th gear 33189AA020 stops in 32189 3 Arm stops closer to reverse gear
170. e Body 5 Disconnect the duty solenoids and ATF temper ature sensor connectors Remove the connectors A REMOVAL from clip and disconnect the connectors 1 Lift up the vehicle 2 Clean the transmission exterior 3 Drain the ATF completely NOTE Tighten the ATF drain plug after draining the ATF Tightening torque 25 2 5 kgf m 18 1 ft lb B2M2263J 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 1 Transfer duty solenoid Brown B Drain plug C Differential oil drain plug 6 Remove the control valve When removing the TEM control valve body be careful not to interfere with 4 Remove the oil pan transfer duty solenoid wiring NOTE e Remove and clean the magnet Remove the old gasket on the oil pan and trans mission case completely AT 37 CONTROL VALVE BODY AUTOMATIC TRANSMISSION B INSTALLATION 1 Set the range select lever in position 2 Install the control valve and ground earth con nectors Tightening torque 8 0 8 kgf m 5 8 ft lb A Short bolts B Long bolts 3 Connect all connector B2M2263J A Lock up duty solenoid Blue B Low clutch timing solenoid Gray C Line
171. e bolts by hand Each bolt should be tightened to the specified torque in a crisscross method Tightening torque 15 7 1 6 kgf m 11 6 ft lb A Clutch cover 3 Remove the clutch cover and clutch disc CAUTION e Take care not to allow oil on the clutch disc facing e Do not disassemble either the clutch cover or clutch disc INSTALLATION 1 Insert the ST into the clutch disc and install them on the flywheel by inserting the ST end into the pi lot bearing ST 499747100 CLUTCH DISC GUIDE B2M1011B A 0 marks 3 Remove the ST ST 499747100 CLUTCH DISC GUIDE 4 Install the transmission assembly lt Ref to MT 30 INSTALLATION Manual Transmission Assem bly gt CL 11 CLUTCH DISC AND COVER CLUTCH SYSTEM C INSPECTION 1 CLUTCH DISC 1 Facing wear Measure the depth of rivet head from the surface of facing Replace if the facings are worn locally or worn down to less than the specified value Depth of rivet head Limit of sinking 0 3 mm 0 012 in CAUTION Do not wash the clutch disc with any cleaning fluid 2 Hardened facing Correct by using emery paper or replace 3 Oil soakage on facing Replace the clutch disc and inspect transmission front oil seal transmission case mating surface engine rear oil seal and other points for oil leakage A Facing 4 Deflection on facing If deflection exceeds the specified value a
172. e the resistance of harness between TCM and chassis ground Connector amp terminal Non turbo model B55 No 22 Chassis ground Turbo model B55 No 14 Chassis ground CHECK HARNESS CONNECTOR BETWEEN 15 the resistance less than 1 TCM AND INHIBITOR SWITCH 1 Turn the ignition switch to OFF 2 Disconnect the connectors from TCM and inhibitor switch 3 Measure the resistance of harness between TCM and inhibitor switch connector Connector amp terminal Non turbo model B55 No 8 T7 No 3 Turbo model B55 No 4 T7 No 3 CHECK INPUT SIGNAL FOR TCM 1 Turn the ignition switch to OFF 2 Connect the connector to TCM and inhibitor switch 3 Turn the ignition switch to ON 4 Measure the voltage between TCM and chassis ground Connector amp terminal Non turbo model B55 No 8 Chassis ground Turbo model B55 No 4 Chassis ground Is the N range indicator light bulb OK Is the voltage less than 1 V in D range AT 121 No Go to step 39 Go to step 65 Go to step 41 Go to step 43 Replace the N range indicator light bulb lt Ref to IDI 11 Combina tion Meter Assem bly gt Repair open circuit in harness between TCM con nector and combi nation meter and poor contact in TCM connector Repair ground short circuit in N range circuit Repair open circuit in harness between TCM and inhibitor switch connect
173. ear Oil MT 36 SWITCHES AND HARNESS MANUAL TRANSMISSION AND DIFFERENTIAL me 6 Switches and Harness 6 Remove the back up light switch and neutral po sition switch with harness A REMOVAL 1 BACK UP LIGHT AND NEUTRAL POSI 552 TION SWITCH 1 Disconnect the connector battery ground termi R nal b Ce 2 Remove the air intake duct and cleaner case gt Non turbo model Ref to IN SOHC 6 REMOV Sr Y O AL Air Cleaner Case gt and lt Ref to IN SOHC 7 REMOVAL Air Intake Duct gt 3 Remove the intercooler Turbo model lt Ref to B3M1372C IN DOHC TURBO 10 REMOVAL Intercooler gt 4 Disconnect the connector back up light switch Neutral switch Brown connector and neutral position switch B Back up light switch Gray connector Non turbo model A Neutral switch Brown B Back up light switch Gray Turbo model 5 Lift up the vehicle MT 37 SWITCHES AND HARNESS MANUAL TRANSMISSION AND DIFFERENTIAL B INSTALLATION 1 BACK UP LIGHT SWITCH AND NEU TRAL POSITION SWITCH 1 Install the back up light switch and neutral posi tion switch with harness Tightening torque 24 5 N m 2 5 kgf m 18 1 ft Ib 7 Neutral switch B Back up light switch 2 Connect the connector of back up light switch and neutral position switch 3 Install the air intake duct and cleaner case Non turbo model Ref to IN SOHC
174. ear side using ST NOTE Lock the straight pin after installing ST 899904100 REMOVER B3M0609C A Pinion shaft B Differential case C Straight pin 4 Install the roller bearing to differential case CAUTION Do not apply pressure in excess of 10 KN 1 ton 1 1 US ton 1 0 Imp ton NOTE Be careful because roller bearing outer races are used as a set ST1 499277100 BUSH 1 2 INSTALLER ST2 398497701 ADAPTER G3M0671 5 Install the hypoid driven gear to differential case using twelve bolts Tightening torque T 62 N m 6 3 kgf m 45 6 ft Ib B 0554 Hypoid driven gear B Differential case MT 73 FRONT DIFFERENTIAL ASSEMBLY MANUAL TRANSMISSION AND DIFFERENTIAL E INSPECTION Repair or replace the differential gear in the follow ing cases The hypoid drive gear and drive pinion shaft tooth surface are damaged excessively worn or seized The roller bearing on the drive pinion shaft has worn or damaged roller path There is damage wear or seizure of the differ ential bevel pinion differential bevel gear washer pinion shaft and straight pin The differential case has worn or damaged slid ing surfaces B3M0558C A Drive pinion shaft B Hypoid driven gear C Pinion shaft D Straight pin E Washer F Differential bevel gear G Differential bevel pinion H Snap ring I Roller bearing J Differe
175. ector DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE DTC AUTOMATIC TRANSMISSION DIAGNOSTICS Check Yes SHIFT SOLENOID 2 AND TRANSMISSION Measure the resistance of harness between shift solenoid 2 connector and transmission ground Connector amp terminal T4 No 2 Transmission ground MO AT 77 Step CHECK HARNESS CONNECTOR BETWEEN the resistance more than 1 Even if the AT OIL TEMP warning lights up the cir cuit has returned to a normal condi tion at this time A temporary poor contact of the con nector or harness may be the cause Repair harness or connector in shift solenoid 2 and transmission Repair short circuit harness between shift solenoid 2 and transmission connector DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE DTC AUTOMATIC TRANSMISSION DIAGNOSTICS K DTC 73 LOW CLUTCH TIMING SOLENOID DIAGNOSIS Output signal circuit of low clutch timing solenoid is open or shorted TROUBLE SYMPTOM Excessive shift shock WIRING DIAGRAM E NA NON TURBO MODEL TURBO MODEL LOW CLUTCH TIMING SOLENOID TRANSMISSION a 2 3 a 1112113 192021 0583 78 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE DTC AUTOMATIC TRANSMISSION DIAGNOSTICS CHECK HARNESS CONNECTOR BETWEEN 15 the resistance less than 1 TCM AND TRANSMISSION 1 Turn the ignition switch to OFF 2 Disconnect the conne
176. ed for removing and installing drive pinion lock B3M1971 MT 22 GENERAL DESCRIPTION MANUAL TRANSMISSION AND DIFFERENTIAL ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 498057300 i NSTALLER Jsed for installing extension seal B3M1972 498255400 Used for measuring backlash B3M1973 498077400 REMOVER Used for removing synchronizer cone of main shaft Used for removing 5th driven gear of drive pin ion shaft B3M1974 41099AA010 ENGINE SUPPORT BRACKET Used for supporting engine lt a P B3M1975 MT 23 GENERAL DESCRIPTION MANUAL TRANSMISSION AND DIFFERENTIAL ILLUSTRATION TOOL NUMBER 41099AA020 B3M1976 398527700 DESCRIPTION ENGINE SUPPORT PULLER ASSY REMARKS Used for supporting engine Used for removing and installing extension case B3M1977 B3M1978 B3M1905 398643600 38177700 roller bearing Used for measuring total end play extension end play and drive pinion height INSTALLER Used for installing bearing cone of transfer driven gear transfer case side Used for installing ball bearing of transfer drive gear MT 24 GENERAL DESCRIPTION MANUAL TRANSMISSION AND DIFFERENTIAL 2 GENERAL PURPOSE TOOLS TOOL NAME REMARKS Circuit Tester Used for measuring resistance voltage and ampere
177. een 9 and Go to step 7 ED MODULE 16 V 1 Connect all connectors 2 Turn the ignition switch to ON 3 Measure the voltage between integrated module and chassis ground Connector amp terminal B280 No 5 Chassis ground CHECK STOP LIGHT SWITCH Does the stop light turn on Go to step 8 Inspect stop light Depress the brake pedal system CHECK HARNESS BETWEEN STOP LIGHT Is the voltage more than 9 V Go to step 9 Repair open or SWITCH AND AT SHIFT LOCK CONTROL short circuit in har MODULE ness between inte 1 Depress the brake pedal grated module and 2 Measure the voltage between integrated stop light switch module and chassis ground Connector amp terminal B280 No 9 Chassis ground CHECK HARNESS BETWEEN INTEGRATED 15 the resistance more than Repair open circuit Go to step 10 MODULE AND SHIFT LOCK SOLENOID in harness 1 Turn the ignition switch to OFF between inte 2 Disconnect the connector from shift lock grated module and solenoid and integrated module shift lock solenoid 3 Measure the resistance of harness between integrated module and shift lock solenoid Connector amp terminal B281 No 9 B116 No 4 CS 17 AT SHIFT LOCK SYSTEM CONTROL SYSTEMS Step Yes No CHECK HARNESS BETWEEN INTEGRATED Is the resistance less than 10 Go to step 11 Repair short circuit MODULE AND SHIFT LOCK SOLENOID in harness Measure the resistance of harness
178. el 3 Drain plug 9 seal 4 Snap ring Outer 10 Clamp Tightening torque N m kgf m ft Ib 5 Speedometer driven gear 11 Pitching stopper bracket T 44 4 5 32 5 6 Washer 12 Clip B mm bai 25 25 181 1 lt 4 gt 10 mm bolt lt 16 gt lt 17 gt 39 4 0 28 9 All models Tightening torque N m kgf m ft lb P MT 7 GENERAL DESCRIPTION MANUAL TRANSMISSION AND DIFFERENTIAL 2 DRIVE PINION ASSEMBLY Drive pinion shaft 2 Roller bearing Washer 4 Thrust bearing 5 Needle bearing 6 Driven shaft 7 Key 8 Woodruff key 9 Drive pinion collar 10 Needle bearing 11 Snap ring Outer Washer 13 Sub gear 1st driven gear Baulk ring 1st 2nd synchronizer hub Insert key Reverse driven gear Outer baulk ring Synchro cone Inner baulk ring 2nd driven gear 2nd driven gear bush 3rd 4th driven gear Driven pinion shim Roller bearing 5th driven gear Lock washer MT 8 S3M0423B 29 Lock nut 30 Washer 31 Thrust bearing 32 Differential bevel gear sleeve 33 Washer 34 Lock washer 35 Lock nut Tightening torque N m kgf m ft Ib 1 29 3 0 21 7 2 118 12 0 86 8 T3 265 27 195 3 MAIN SHAFT ASSEMBLY GENERAL DESCRIPTION MANUAL TRANSMISSION AND DIFFERENTIAL B3M1 357A 1 10 11 12 13 14 Oil seal Needle bearing Transmission main shaft Needle bearing 3rd
179. em gt Go to step 3 When select lever is in other Inspect KEY than P position does ignition Switch turn to LOCK position Or when select lever is in P position does ignition switch turn to LOCK position CS 10 INTERLOCK DOES NOT BE LOCKED OR RELEASED Ref to CS 20 KEY INTERLOCK DOES NOT LOCK OR RELEASE INSPECTION AT Shift Lock Sys tem AT shift lock sys tem is normal AT SHIFT LOCK SYSTEM CONTROL SYSTEMS CS 11 AT SHIFT LOCK SYSTEM CONTROL SYSTEMS _ ____ INTEGRATED MODULE POWER SUPPLY AND GROUND LINE WINING DIAGRAM IGNITION B B281 INTEGRATED MODULE 123141518 71819110 1 2 3 415 6 7 8 11112113114 15 16 17 18 19 20 9 10 11 12 13 14115116 TRO551 CS 12 AT SHIFT LOCK SYSTEM CONTROL SYSTEMS CHECK FUSE No 3 4 and 11 1 Remove the fuse No 3 4 and 11 Is the fuse No 3 4 or 11 blown out Replace the fuse Go to step 2 No 3 4 or 11 If the replaced fuse No 3 4 or 11 has blown out eas ily repair short cir cuit in harness between fuse and integrated module Go to step 3 Go to step 4 Go to step 5 Go to step 6 CHECK HARNESS CONNECTOR BETWEEN Is the resistance less than 1 INTEGRATED MODULE AND BODY GROUND 1 Turn the ignition switch to OFF 2 Measure the resistance of harness between
180. en in harness 30 to step 5 transmission and dropping resistor connector between TCM and Connector amp terminal Is the resistance more than 1 Repair short circuit in harness between TCM and dropping resistor connector Is the resistance less than 1 0 Repair open circuit in harness between dropping resistor and trans mission connector dropping resistor connector 30 to step 6 B4 No 2 B11 No 5 Nu CHECK HARNESS CONNECTOR BETWEEN Is the resistance more than 1 to step 7 TRANSMISSION AND DROPPING RESIS MQ TOR Measure the resistance of harness between dropping resistor connector and chassis ground Connector amp terminal B4 No 2 Chassis ground CHECK HARNESS CONNECTOR BETWEEN 15 the resistance less than 1 30 to step 8 TCM AND TRANSMISSION Q 3o to step 9 Repair short circuit in harness between TCM and transmission con Connector amp terminal nector B54 No 9 Chassis ground 1 Turn the ignition switch to OFF CHECK LINE PRESSURE DUTY SOLENOID 15 the resistance between 2 0 30 to step 10 Go to step 16 Measure the resistance between transmission and 4 5 Q connector receptacle s terminals Terminal T4 No 5 No 16 2 Disconnect the connector from transmission PREPARE SUBARU SELECT MONITOR Do you have a Subaru Select 3o to step 13 Go to step 11 Monitor Repair s
181. ening torque 6 4 N m 0 65 kgf m 4 7 ft lb 2 Install the ball spring washer and plug to trans fer case Tightening torque 10 N m 1 0 kgf m 7 2 ft lb 3 Install the shifter arm to transfer case assembly 4 Install the transfer case with extension case as sembly lt Ref to MT 41 INSTALLATION Transfer Case and Extension Case Assembly gt 5 Install the manual transmission assembly to ve hicle lt Ref to MT 30 INSTALLATION Manual Transmission Assembly gt MT 50 REVERSE CHECK SLEEVE C DISASSEMBLY 1 Cover the reverse check sleeve with a rag and remove snap ring using a screwdriver NOTE Replace the snap ring with a new one if deformed or weakened B3M1383C Snap ring 2 Remove the reverse check plate reverse check spring reverse check cam return spring 5th Rev reverse accent shaft return spring cap and return spring 1st 2nd F B3M1384A A Reverse check plate B Reverse check spring C Return spring 5th Rev D Reverse check cam E Reverse accent shaft F Return spring cap G Return spring 1st 2nd 3 Remove O ring NOTE e Reverse check sleeve assembly uses an O ring which should not be scratched Be careful not to break adjustment shim placed between reverse check sleeve assembly and case MANUAL TRANSMISSION AND DIFFERENTIAL D ASSEMBLY 1 Install the return spring 1st 2nd return spring cap reverse accent shaft check cam
182. ent damage 1 Straighten the lock nut at staked portion Re move the lock nut using ST1 ST2 and ST3 ST1 899884100 HOLDER ST2 498427100 STOPPER ST3 899988608 SOCKET WRENCH 27 G3M0595 2 Withdraw the drive pinion from driven shaft Remove the differential bevel gear sleeve adjust ing washer No 1 adjusting washer No 2 thrust bearing needle bearing drive pinion collar needle bearing and thrust bearing Differential bevel gear sleeve Washer No 1 25 x 37 5 xt Thrust bearing 25 x 37 5 x 3 Washer No 2 25 x 37 5 x 4 Needle bearing 25 x 30 x 20 Drive pinion collar Needle bearing 30 x 37 x 23 Thrust bearing 33 x 50 x 3 Og Ou 2 ol MT 64 DRIVE PINION SHAFT ASSEMBLY MANUAL TRANSMISSION AND DIFFERENTIAL 3 Remove the roller bearing and washer using ST and press CAUTION Do not reuse roller bearing ST 498077000 REMOVER tet F NUI ST loj db G3M0607 4 Straighten the lock nut at staked portion Re move the lock nut using ST1 and ST2 ST1 499987300 SOCKET WRENCH 50 _ST2 899884100 HOLDER 5 Remove the 5th driven gear using ST 5TH DRIVEN GEAR REMOV ER ST 499857000 6 Remove the woodruff key 7 Remove the roller bearing 3rd 4th driven gear using ST1 and ST2 ST1 499757002 INSTALLER ST2 899
183. ep 7 CHECK SHIFT LOCK SOLENOID Measure the resistance of shift lock solenoid connector terminals Terminal No 4 5 li the resistance between 10 and 20 9 to step 8 Replace the shift lock solenoid CHECK SHIFT LOCK SOLENOID Connect the battery with shift lock solenoid connector terminal and operate solenoid Terminal No 4 No 5 Does the shift lock solenoid operate properly to step 9 Replace the shift lock solenoid CHECK POOR CONTACT lock circuit CS 15 Is there poor contact in key Repair poor con Replace the inte tact grated module AT SHIFT LOCK SYSTEM CONTROL SYSTEMS 3 SELECT LEVER SHIFT LOCK CANNOT BE RELEASED WIRING DIAGRAM INHIBITOR STOP LIGHT SWITCH SWITCH L B INTEGRATED MODULE SHIFT LOCK SOLENOID L5 a WITHOUT CRUISE CONTROL MODEL E E We WITH CRUISE CONTROL MODEL 8200 8261 1T T m 12 1121 am me un Eti T2 3 4 5 6 7 8 96 HT2TST4 5 8 78 11112 1314 15 16 17 18 19 20 9 10 11 12 1311415 16 TRO553 AT SHIFT LOCK SYSTEM CONTROL SYSTEMS Yes CHECK INHIBITOR SWITCH Combination meter indicator Go to step 2 Adjust inhibitor 1 Turn the ignition switch to ON engine OFF lamp and select lever P R switch and select 2 Move the select lever from P to 1 2 2 and 1 are c
184. er bracket 5 Brake pedal pad 16 Assist bushing 27 Lever 6 Brake pedal 17 Assist rod B 28 Clutch switch Starter interlock 7 18 Spring S 8 Brake pedal spring 19 Rods Tightening torque N m kgf m ft Ib 9 Clutch pedal pad 20 Bushing S T1 8 0 8 5 8 10 Clutch pedal 21 O ring T2 18 1 8 13 0 11 Bushing C 22 Clip T3 30 3 1 22 4 CL 9 GENERAL DESCRIPTION CLUTCH SYSTEM C CAUTION Wear working clothing including a cap protec tive goggles and protective shoes during opera tion e Remove contamination including dirt and corro sion before removal installation or disassembly Keep the disassembled parts in order and pro tect them from dust or dirt Before removal installation or disassembly be sure to clarify the failure Avoid unnecessary re moval installation disassembly and replacement e careful not to burn your hands because each part on the vehicle is hot after running e Use SUBARU genuine fluid grease etc or the equivalent Do not mix fluid grease etc with that of another grade or from other manufacturers D PREPARATION TOOL 1 SPECIAL TOOLS ILLUSTRATION TOOL NUMBER DESCRIPTION CRANKSHAFT STOPPER 498497100 B2M3853 Be sure to tighten fasteners including bolts and nuts to the specified torque Place shop jacks or safety stands at the specified points Apply grease onto sliding or revolution surfaces before i
185. erter clutch housing Always use a new spring pin Turbo model ST 499977300 CRANK PULLEY WRENCH Non turbo model ST 499977100 CRANK PULLEY WRENCH Tightening torque 25 N m 2 5 kgf m 18 1 ft lb 13 Install the ball joint into housing 14 Connect the stabilizer link to transverse link and temporarily tighten the bolts CAUTION Discard the loosened self locking nut and re place with a new one Tightening torque T1 30 N m 3 1 kgf m 22 4 ft lb T2 50 5 1 kgf m 37 ft lb TRO291 11 Install the pitching stopper 15 Install the shift select cable onto select lever Ref to CS 27 INSTALLATION Select Cable 16 Install the ATF level gauge guide and connect the ATF cooler hoses to pipe Tightening torque T1 50 N m 5 1 kgf m 37 ft Ib T2 58 N m 5 9 kgf m 43 ft Ib gi Cai Az ES AGG AT 23 AUTOMATIC TRANSMISSION ASSEMBLY AUTOMATIC TRANSMISSION 17 Install the propeller shaft lt Ref to DS 15 INSTALLATION Propeller Shaft gt 18 Install the heat shield cover If equipped 19 Install the front center rear exhaust pipes and muffler Non turbo model lt Ref to EX SOHC 6 INSTALLATION Front Ex haust Pipe Ref to EX SOHC 9 INSTALLA TION Rear Exhaust Pipe and lt Ref to EX SOHO 11 INSTALLATION Muffler gt 20 Install the center rear exhaust pipes and muf fler Turbo model Ref to EX DOHC TURBO 9 INSTALLATION Cen
186. es Broken or rusty bearings Worn or damaged Bearings that fail to turn smoothly or make ab normal noise when turned after gear oil lubrication 2 Driven gear Replace drive gear in the following cases f their tooth surfaces and shaft are excessively broken or damaged MT 48 CENTER DIFFERENTIAL MANUAL TRANSMISSION AND DIFFERENTIAL 12 Center Differential A REMOVAL 1 Remove the manual transmission assembly from vehicle lt Ref to MT 27 REMOVAL Manual Transmission Assembly gt 2 Remove the transfer case with extension case assembly lt Ref to MT 41 REMOVAL Transfer Case and Extension Case Assembly gt 3 Remove the extension case assembly lt Ref to MT 41 REMOVAL Transfer Case and Extension Case Assembly gt 4 Remove the transfer driven gear lt Ref to MT 47 REMOVAL Transfer Driven Gear gt 5 Remove the center differential B INSTALLATION 1 Install the center differential into transfer case 2 Install the transfer driven gear lt Ref to MT 47 INSTALLATION Transfer Driven Gear 3 Install the extension case assembly lt Ref to 41 INSTALLATION Transfer Case and Exten sion Case Assembly 4 Install the transfer case with extension case as sembly Ref to MT 41 REMOVAL Transfer Case and Extension Case Assembly 5 Install the back up light switch and neutral posi tion switch Ref to MT 37 REMOVAL Switches and Harness 6 Install
187. es properly and shift the select lever to the 2 range 5 While forcibly depressing the foot brake pedal gradually depress the accelerator pedal until the engine operates at full throttle B3M1589B A Brake pedal B Accelerator pedal 6 When the engine speed is stabilized read that speed quickly and release the accelerator pedal 7 Shift the select lever to Neutral and cool down the engine by idling it for more than one minute 8 Record the stall speed 9 If the stall speed in 2 range is higher than spec ifications low clutch slipping and 2 4 brake slip ping may occur To identify it conduct the same test as above in D range 10 Perform the stall tests with the select lever in the R range NOTE Do not continue the stall test for MORE THAN FIVE SECONDS at a time from closed throttle ful ly open throttle to stall speed reading Failure to follow this instruction causes the engine oil and ATF to deteriorate and the clutch and brake to be adversely affected Be sure to cool down the engine for at least one minute after each stall test with the select lever set in the P or N range and with the idle speed lower than 1 200 rpm If the stall speed is higher than the specified range attempt to finish the stall test in as short a time as possible in order to prevent the automatic transmission from sustaining damage Stall speed at sea level Non turbo model 2 100
188. essure test Ref to AT 18 Transfer Clutch Pressure Test Time lag test Ref to AT 15 Time Lag Test Road test Ref to AT 12 Road Test Inhibitor switch Ref to AT 28 Inhibitor Switch CHECK AT OIL TEMP WARNING LIGHT Does not the AT OIL TEMP Go to step 3 Go to step 4 Turn the ignition switch to ON warning light light up CHECK AT OIL TEMP WARNING LIGHT Is the AT OIL TEMP warning to step 4 Go to step 5 1 Turn the ignition switch to OFF light flashing 2 Repair the AT OIL TEMP warning light circuit or power supply and ground line circuit Ref to AT 31 Diagnostic Procedure for AT OIL TEMP Warning Light 3 Turn the ignition switch to ON CHECK INDICATION OF DTC Is the diagnostic trouble code Go to step 6 Go to step 5 Calling up the diagnostic trouble code DTC DTC displayed NOTE Without SUBARU SELECT MONITOR Record all diag Ref to AT 24 WITHOUT SUBARU SELECT nostic trouble code MONITOR Read Diagnostic Trouble Code DTC DTC gt With SUBARU SELECT MONITOR lt Ref to AT 25 WITH SUBARU SELECT MONITOR Read Diagnostic Trouble Code DTC gt NOTE If the communication function of the select monitor cannot be executed normally check the communication circuit lt Ref to AT 39 COMMUNICATION FOR INITIALIZING IM POSSIBLE Diagnostic Procedure for Select Monitor Communication gt AT 2 BASIC DIAGNOSTIC PROCEDURE PERFORM THE GENERAL DIAGNOSTICS
189. fting into the first gear However because much trouble of this sort is due to defective synchronization mechanism carry out the test as described after Method of testing Ref to CL 32 DIAGNOSTIC DIAGRAM OF CLUTCH DRAG INSPECTION General Diagnos tic Table It may be judged as insufficient disen gagement of clutch if any noise occurs during this test 3 Clutch chatters Clutch chattering is an unpleasant vibra tion to the whole body when the vehicle is just started with clutch partially engaged a Worn or rusty clutch disc hub spline Replace clutch disc b Excessive deflection of clutch disc Correct or replace facing isc faci n d Cracked clutch disc facing e e Sticked clutch disc smeared by oil or water c Seized crankshaft pilot needle bear Replace ing a Adhesion of oil on the facing Replace clutch disc b Weak or broken torsion spring Replace clutch disc c Defective facing contact or excessive Replace clutch disc defection disc d Warped pressure plate or flywheel Correct or replace Loose disc rivets Replace clutch disc f Loose engine mounting Retighten or replace mounting g Improper adjustment of pitching stop Adjustment per CL 31 GENERAL DIAGNOSTIC TABLE CLUTCH SYSTEM Symptom 4 Noisy clutch a Broken
190. g the scroll key move the display screen up or down until the desired data is shown Display Battery voltage Battery Voltage Rear vehicle speed sensor signal Rear Wheel Speed km h or MPH Front vehicle speed sensor signal Front Wheel Speed km h or MPH Engine speed signal Engine Speed rpm Automatic transmission fluid temperature signal ATF Temp C or F Throttle position signal Throttle Sensor Voltage V Gear position Gear Position Line pressure control duty ratio Line Pressure Duty Ratio 96 Lock up clutch control duty ratio Lock Up Duty Ratio Transfer clutch control duty ratio Transfer Duty Ratio 96 Power supply for throttle position sensor Throttle Sensor Power Torque converter turbine speed signal Turbine Revolution Speed rpm 2 4 brake timing pressure control duty ratio Brake Clutch Duty Ratio Mass air flow sensor signal Turbo model Air Flow Sensor Voltage V J Intake manifold pressure sensor voltage Non turbo model 2 wheel drive switch signal Non turbo model FWD Switch Stop lamp switch signal Stop Light Switch Anti lock brake system signal ABS Signal Cruise control system signal Cruise Control Signal Neutral Parking range signal N P Range Signal Reverse range signal R Range Signal Drive range signal D Range Signal 3rd range signal 3rd Range Signal 2nd range signal 2nd Range Signal 1st range signal 1st Range Signal Shift control solenoid A Shift Solenoid 1 Shift contral solenoid Torque control output signal 1 ON or OFF Tor
191. gap between the reverse idler gear and transmission case wall is within specification Clearance 0 0 5 mm 0 0 020 in Washer MT 79 SHIFTER FORK AND ROD MANUAL TRANSMISSION AND DIFFERENTIAL 20 Shifter Fork and Rod A REMOVAL 1 Remove the manual transmission assembly from vehicle lt Ref to MT 27 REMOVAL Manual Transmission Assembly gt 2 Remove the back up light switch and neutral po sition switch lt Ref to MT 37 REMOVAL Switches and Harness gt 3 Remove the transfer case with extension case assembly lt Ref to MT 41 REMOVAL Transfer Case and Extension Case Assembly gt 4 Remove the transmission case lt Ref to MT 54 REMOVAL Transmission Case gt 5 Removes the drive pinion shaft assembly Ref to 63 REMOVAL Drive Pinion Shaft Assem bly gt 6 Remove the main shaft assembly lt Ref to MT 57 REMOVAL Main Shaft Assembly for Single Range gt 7 Remove the differential assembly lt Ref to MT 74 REMOVAL Front Differential Assembly 8 Drive out the straight pin with ST and 5th shifter fork ST 398791700 STRAIGHT PINREMOVER 3 0333 Straight 5th shifter fork 9 Remove the plugs springs and checking balls 10 Drive out the straight pin and pull out 3 4 fork rod and shifter fork NOTE When removing rod keep other rods in neutral Al so when pulling out straight pin remove it tow
192. ge Less than 1 R range B55 3 Select lever in any other witch swi than R range More than 8 Inhibitor Select lever in D range switch D range B55 4 Select th switch elec ever in any other More than 8 than D range 3 range Select lever in 3 range Less than 1 B i switch 55 5 Select lever in any other More than 8 than 3 range 2 range Select lever in 2 range Less than 1 B switch 55 Select lever in any other More than 8 than 2 range Select lever in 1 range Less than 1 1 range B55 7 Select lever in any other switch uan y More than 8 than 1 range Brake pedal depressed More than 10 5 Brake switch B55 12 Brake pedal depressed mesh 0 Brake pedal released Less than 1 M Light ON Less than 1 OIL TEMP warning light 856 8 Light OFF More than 9 AT 14 TRANSMISSION CONTROL MODULE TCM I O SIGNAL AUTOMATIC TRANSMISSION DIAGNOSTICS Con Content nector Throttle position sensor Throttle position sensor power supply ATF temperature sensor Rear vehicle speed sensor Front vehicle speed sensor Torque converter turbine speed sensor B56 55 56 56 54 Vehicle speed output signal Engine speed signal Cruise set signal Torque control signal 1 Torque control signal 2 B Torque control cut signal B54 B Mass air flow signal Shift solenoid 1 Shift solenoid 2 Line pressure duty sole
193. ge hole NOTE The level should be within the specified range marked on the gauge MT 26 MANUAL TRANSMISSION ASSEMBLY MANUAL TRANSMISSION AND DIFFERENTIAL 3 Manual Transmission As 3 Vehicle speed sensor sembly A REMOVAL 1 Open the front hood fully and support with stay 2 Disconnect the battery ground terminal 3 Remove the air intake duct and cleaner case Non turbo model Ref to IN SOHC 7 REMOV AL Air Intake Duct gt and lt Ref to IN SOHC 6 REMOVAL Air Cleaner Case gt 4 Remove the air cleaner case stay Non turbo model 52 0907 7 Remove the starter lt Ref to SC 6 REMOVAL Starter gt 8 Remove the operating cylinder from the trans mission e Non turbo model 5 Remove the intercooler Turbo model Ref to IN DOHC TURBO 10 REMOVAL Intercooler 6 Disconnect the following connectors 1 Neutral position switch connector 2 Back up light switch connector Non turbo model A Neutral switch Brown B Back up light switch Gray Turbo model MT 27 MANUAL TRANSMISSION ASSEMBLY MANUAL TRANSMISSION AND DIFFERENTIAL 10 Separate the clutch release fork from the re lease bearing Turbo model 1 Remove the clutch operating cylinder from the transmission 2 Remove the plug using 10 mm hexagon wrench 52 1935 3 Screw the 6 mm dia bolt into the release fork shaft and remove it 52 1936 S
194. haft Bolt 4 Raise the release fork and unfasten the re lease bearing tabs to free release fork CAUTION Step 4 is required to prevent interference with engine when removing engine from transmis sion 11 Set ST NOTE Also is availabie Part No 927670000 ST 41099AA020 ENGINE SUPPORT ASSY 12 Remove the bolt which holds right upper side of transmission to the engine B2M2791 13 Remove the front and center exhaust pipes Non turbo model with OBD Ref to EX SOHC 5 REMOVAL Front Exhaust Pipe gt 14 Remove the center exhaust pipe Turbo mod el lt Ref to EX DOHC TURBO 8 REMOVAL Center Exhaust Pipe gt 15 Remove the rear exhaust pipe and muffler CAUTION When removing exhaust pipes be careful each exhaust pipe does not drop out 16 Remove the heat shield cover If equipped 17 Remove the hanger bracket from right side of transmission 18 Remove the propeller shaft Ref to DS 14 REMOVAL Propeller Shaft MT 28 MANUAL TRANSMISSION ASSEMBLY MANUAL TRANSMISSION AND DIFFERENTIAL 19 Remove the gear shift rod and stay from trans 22 Remove the spring pins and separate front mission drive shafts from each side of the transmission 1 Disconnect the stay from the transmission CAUTION 2 Disconnect the rod from the transmission Discard removing spring pin Replace with a new one B3M1824A Stay B Rod 23 Remove the nuts which hold lower
195. harness between TCM and transmission con nector Repair open circuit in harness between TCM and transmission con nector and poor contact in cou pling connector Repair short circuit in harness between TCM and transmission con nector Repair short circuit in harness between TCM and transmission con nector and poor contact in cou pling connector 6 PREPARE OSCILLOSCOPE Do you have an oscilloscope Go to step 10 Go to step 7 Do you have a Subaru Select Go to step 9 Go to step 8 Monitor 7 PREPARE SUBARU SELECT MONITOR AT 63 Step Check CHECK INPUT SIGNAL FOR TCM 1 Connect the connectors to TCM and trans mission 2 Start the engine and move select lever to P or N range 3 Measure the voltage between TCM connec tor terminals Connector amp terminal Non turbo model B55 No 12 No 21 Turbo model B55 No 8 9 Is the voltage more than AC 1 v CHECK INPUT SIGNAL FOR TCM USING SUBARU SELECT MONITOR 1 Connect the connectors to TCM and trans mission 2 Connect the Subaru Select Monitor to data link connector 3 Turn the ignition switch to ON and turn the Subaru Select Monitor switch to ON 4 Start the engine 5 Move the select lever to P or N range 6 Read the data of turbine speed using Subaru Select Monitor Compare the tachometer with Subaru Select Monitor indications CHECK INPUT SIGNAL FOR TCM USING OSCI
196. hassis ground Turbo model B55 No 3 Chassis ground CHECK INPUT SIGNAL FOR TCM Measure the voltage between TCM and chas sis ground Connector amp terminal Non turbo model B55 No 17 Chassis ground Turbo model B55 No 3 Chassis ground CHECK R RANGE INDICATOR LIGHT BULB 1 Turn the ignition switch to OFF 2 Remove the combination meter 3 Remove the R range indicator light bulb from combination meter s the resistance less than 1 AQ 3o to step 29 s the resistance less than 1 2 3o to step 30 s the voltage less than 1 V in R range 30 to step 31 s the voltage more than 8 V in 3o to step 65 ther ranges s the R range indicator light ulb OK 3o to step 33 AT 119 ground hort circuit in P ange circuit iepair open circui harness vetween TCM anc hibitor switch onnector and oor contact in oupling connec or 30 to step 65 teplace the TCM Ref AT 45 Tansmission Con rol Module TCM gt leplace the ange indicator ght bulb Ref tc DI 11 Combina ion Meter Assem My DIAGNOSTIC PROCEDURE FOR NO DIAGNOSTIC TROUBLE CODE DTC AUTOMATIC TRANSMISSION DIAGNOSTICS CHECK HARNESS CONNECTOR BETWEEN TCM AND COMBINATION METER 1 Disconnect the connectors from TCM and combination meter 2 Measure the resistance of harness between TCM and combination meter Connector amp ter
197. he connector to TCM and combina tion meter 3 Turn the ignition switch to ON 4 Measure the signal voltage for TCM while installing and removing the fuse to FWD switch connector Connector amp terminal B54 No 12 Chassis ground Is the voltage less than 1 V in FWD switch while installing Go to step 11 Go to step 12 CHECK OUTPUT SIGNAL EMITTED FROM TCM Measure the signal voltage for TCM while removing the fuse from FWD switch connector Connector amp terminal Is the voltage more than 9 V in FWD switch while removing Go to step 12 Replace the TCM lt Ref to AT 45 Transmission Con trol Module TCM gt B54 No 12 Chassis ground CHECK POOR CONTACT CHECK BRAKE SWITCH Step Is there poor contact in FWD switch circuit Repair poor con tact Replace the TCM lt Ref to AT 45 Transmission Con tro Module TCM gt No CHECK BRAKE SWITCH When the brake pedal is depressed does the LED light up AT 112 Go to step CHECK Check the brake ABS SWITCH switch circuit lt Ref to AT 113 CHECK ABS SWITCH Diag nostic Procedure for No Diagnostic Trouble Code DTC gt DIAGNOSTIC PROCEDURE FOR NO DIAGNOSTIC TROUBLE CODE DTC AUTOMATIC TRANSMISSION DIAGNOSTICS CHECK ABS SWITCH Step Check CHECK ABS SWITCH CHECK CRUISE CONTROL 22 SWITCH Step Does the LED of ABS switch light u
198. heck the level and leaks of the ATF Ref to AT 9 INSPECTION Automatic Transmis sion Fluid AT 10 DIFFERENTIAL GEAR OIL 3 Differential Gear Oil A INSPECTION 1 Park the vehicle on a level surface 2 Remove the oil level gauge and wipe it clean 3 Reinsert the level gauge all the way Be sure that the level gauge is correctly inserted and in the proper orientation 4 Remove it again and note the reading If the dif ferential gear oil level is below the L line add oil to bring the level up to the F line 5 To prevent overfilling the differential gear oil do not add oil above the F line S3M0478A A Upper level B Lower level AUTOMATIC TRANSMISSION B REPLACEMENT 1 Lift up the vehicle 2 Drain the differential gear oil completely CAUTION Directly after the engine has been running the differential gear oil is hot Be careful not to burn yourself NOTE Tighten the differential gear oil drain plug after draining the differential gear oil Tightening torque 44 N m 4 5 kgf m 32 5 ft lb A Oil pan B Drain plug C Differential oil drain plug 3 Lower the vehicle 4 Pour gear oil into the gauge hole Recommended fluid Use GL 5 or equivalent Gear oil capacity 1 2 2 1 3 US qt 1 1 Imp qt 5 Check the level of the differential gear oil lt Ref to AT 11 INSPECTION Differential Gear Oil gt AT 11 ROAD TEST AUTOMATIC TRANSMISSION 4 Road Te
199. hen pull out the oil seal and needle bearing by hand 2 Remove the lock nut from transmission main shaft assembly NOTE Remove the caulking before off lock nut ST1 499987000 TRANSMISSION HOLDER ST2 498937003 SOCKET WRENCH 35 3 Remove the 5th Rev sleeve and hub assembly baulk ring 5th drive gear and needle bearing B3M0437B A 5th Rev sleeve and hub ASSY B Baulk ring C 5th drive gear 4 Remove the snap ring and synchro cone stopper from 5th Rev sleeve and hub assembly 0435 A Synchro cone stopper B Snap ring MT 57 MAIN SHAFT ASSEMBLY FOR SINGLE RANGE MANUAL TRANSMISSION AND DIFFERENTIAL 5 Using ST1 ST2 and a press remove the ball bearing synchro cone and baulk ring Rev NOTE Replace the sleeve and hub with new ones Do not attempt to disassemble because they must en gage at a specified point If they should be disas sembled mark engagement point on the splines beforehand Do not reuse the ball bearing ST1 499757002 INSTALLER ST2 498077400 SYNCHRO CONE REMOV B3M1365A A Ball bearing B Synchro cone C Baulk ring 6 Using ST1 and ST2 remove the rest of parts NOTE Replace sleeve and hub with new ones Do not at tempt to disassemble because they must engage at a specified point If they should be disassem bled marking engagement point on splines before hand ST1 899864100 REMOVER ST2 899714110 REMOVER B3M0835A MT
200. hort circuit in harness between dropping resistor and trans mission connector Repair open circuit in harness between TCM and transmission con nector and TCM 3 Measure the resistance of harness between TCM and transmission connector Connector amp terminal B54 No 9 B11 No 5 CHECK HARNESS CONNECTOR BETWEEN TCM AND CHASSIS GROUND Measure the resistance of harness between TCM and chassis ground Is the resistance more than 1 MQ AT 87 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE DTC AUTOMATIC TRANSMISSION DIAGNOSTICS CHECK OUTPUT SIGNAL EMITTED FROM TCM 1 Connect all connectors 2 Start the engine and warm up the transmis sion until the ATF temperature is above 80 C 176 F NOTE If the ambient temperature is below 0 C 32 F drive the vehicle until the ATF reaches its oper ating temperature 3 Turn the ignition switch to ON engine OFF 4 Move the select lever to N 5 Measure the voltage between TCM connec tor and chassis ground Connector amp terminal B54 No 9 Chassis ground CHECK OUTPUT SIGNAL EMITTED FROM TCM Measure the voltage between TCM connector and chassis ground Connector amp terminal B54 No 9 Chassis ground CHECK OUTPUT SIGNAL EMITTED FROM TCM USING SUBARU SELECT MONITOR 1 Connect the connectors to TCM and trans mission 2 Connect the Subaru Select Monitor to data link
201. ication failure AT 39 DIAGNOSTIC PROCEDURE FOR SELECT MONITOR COMMUNICATION AUTOMATIC TRANSMISSION DIAGNOSTICS WIRING DIAGRAM BATTERY IGNITION DATA LINK SWITCH CONNECTOR TRANSMISSION NON TURBO MODEL TURBO MODEL 1 1 H L 12131 516 7 8 1 2 s 4 s e v e 9 2 4 s es 1415 zl 18 10111213 E 16 23 0 11 12 13 14 1516 19 20 21 22 24 19 20 21 22 23 24 0571 40 Step DIAGNOSTIC PROCEDURE FOR SELECT MONITOR COMMUNICATION AUTOMATIC TRANSMISSION DIAGNOSTICS Check Yes No CHECK SUBARU SELECT MONITOR POW ER SUPPLY CIRCUIT Measure the voltage between data link con nector and chassis ground Connector amp terminal B40 No 1 Chassis ground Is the voltage more than 10V Go to step 2 CHECK SUBARU SELECT MONITOR Is the resistance less than 1 GROUND CIRCUIT Measure the resistance of harness between data link connector and chassis ground Connector amp terminal B40 No 12 Chassis ground B40 No 13 Chassis ground Go to step 3 CHECK COMMUNICATION OF SELECT Are the name and year of the MONITOR 1 Turn the ignition switch to ON 2 Using the select monitor check whether communication to other systems such as engine ABS etc can be executed normally system displayed on the select monitor Go to step 8 Rep
202. icle speed sensor circuit Repair poor con tact Replace the TCM Ref to AT 45 Transmission Con tro Module TCM gt AT 107 DIAGNOSTIC PROCEDURE FOR NO DIAGNOSTIC TROUBLE CODE DTC AUTOMATIC TRANSMISSION DIAGNOSTICS 15 Diagnostic Procedure for No Diagnostic Trouble Code DTC A CHECK GEAR POSITION CHECK GEAR POSITION 1 Lift up the vehicle and place safety stand CAUTION On AWD models raise all wheels off ground 2 Start the engine 3 Move the select lever to D and drive the vehicle 4 Read the data of gear position using Subaru Select Monitor Gear position is indicated NOTE The speed difference between front and rear wheels may light the ABS warning light but this indicates no malfunction When the AT control diagnosis is finished perform the ABS memory clearance procedure of on board diagnostics system lt Ref to ABS 22 Clear Memory Does the transmission gear correspond to the gear which is shown on display Is the target non turbo model AT 108 Go to step 2 Go to step CHECK FWD SWITCH lt Ref to AT 110 CHECK FWD SWITCH Diagnostic Proce dure for No Diag nostic Trouble Code DTC gt Check shift sole noid 1 and shift solenoid 2 signal circuit lt Ref to AT 70 DTC 71 SHIFT SOLENOID 1 Diagnostic Proce dure with Diagnos tic Trouble Code DTC gt and lt Ref to AT 74 DTC 72 SHIFT SOLE NOID 2 Diagnos tic Procedure w
203. id 2 2 4 brake timing solenoid Line pressure duty solenoid Line pressure dropping resistor 2 4 brake duty solenoid 2 4 brake dropping resistor Lock up duty solenoid Low clutch timing solenoid Transfer duty solenoid TRANSMISSION CONTROL MODULE TCM I O SIGNAL AUTOMATIC TRANSMISSION DIAGNOSTICS 2 TURBO MODEL 26 a 27 mO 28 5 29 32 Lo o 30 E 6 ii F 7 31 77 33 B 3 x 3 9 Pw P es 97 9 38 AP 39 LES 8 40 UD ws 429 43 64 nd TRO567 AT 20 TRANSMISSION CONTROL MODULE TCM I O SIGNAL Transmission control module Cruise control module ABS control module Ignition switch Brake switch Brake light Battery Combination meter Speedome ter circuit AT OIL TEMP light P range indicator light P range switch range indicator light range switch range indicator light range switch 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 D range indicator light D range switch 3 range indicator light 3 range switch 2 range indicator light 2 range switch 4 range indicator light 1 range switch Data link connector Throttle position sensor Engine speed signal Torque control cut signal Torque c
204. ightening torque 50 N m 5 1 kgf m 36 9 ft Ib 7 Connect the engine and transmission 1 Install the starter Ref to SC 7 INSTALLATION Starter 2 Tighten the bolt which holds right upper side of transmission to the engine Tightening torque 50 N m 5 1 kgf m 36 9 ft Ib B2M2791 MT 30 MANUAL TRANSMISSION ASSEMBLY MANUAL TRANSMISSION AND DIFFERENTIAL 14 Drive the spring pin into the chamfered hole of drive shaft CAUTION Always use a new spring pin 9 Push the clutch release lever to fit bearing into clutch cover 10 Install the plug Tightening torque 44 N m 4 5 kgf m 32 5 ft lb 15 install the ball joints of lower arm into knuckle arm of housing and tighten the installing bolts Tightening torque 49 N m 5 0 kgf m 36 ft lb 4 LES A Plug B Transmission ASSY S 02 11 Install the pitching stopper Tightening torque A Transverse link B Ball joint T1 50 N m 5 1 kgf m 37 ft Ib 2 58 N m 5 9 kgf m 43 ft Ib 12 Lift up the vehicle 13 Install the front drive shaft into the transmis sion MT 31 MANUAL TRANSMISSION ASSEMBLY MANUAL TRANSMISSION AND DIFFERENTIAL 16 Install the stabilizer link from the transverse link Except sedan turbo model Tightening torque 30 N m 3 1 kgf m 22 1 ft lb TROO89 Sedan turbo model Tightening torque 45 4 6 kgf m 33 2 ft lb
205. il the back up light switch and neutral posi tion switch lt Ref to MT 38 INSTALLATION Switches and Harness gt 10 Install the manual transmission assembly to ve hicle lt Ref to MT 30 INSTALLATION Manual Transmission Assembly gt MT 78 REVERSE IDLER GEAR MANUAL TRANSMISSION AND DIFFERENTIAL C INSPECTION 1 Move the reverse shifter rod toward the reverse side Inspect the clearance between reverse idler gear and transmission case wall If out of specification select the appropriate re verse shifter lever and adjust Clearance A 6 0 7 5 mm 0 236 0 295 in 2 After installing a suitable reverse shifter lever shift into neutral Inspect the clearance between re verse idler gear and transmission case wall If out of specification select the appropriate washer and adjust Clearance 0 0 5 mm 0 0 020 3 Check the reverse idler gear and shaft for dam age Replace if damaged D ADJUSTMENT 1 Select the appropriate reverse shifter lever from the table below and adjust until the gap between the reverse idler gear and transmission case wall is within specification Clearance A 6 0 7 5 mm 0 236 0 295 in i mi gt Q e x a Reverse shifter lever Mark 28208 080 8 Sanaa S2 amp 20AAQ80 9 Closer io case wal 2 Select the appropriate washer from the table be low and adjust until the
206. in plug 16 Set the ST NOTE 22 Disconnect the ATF cooler hoses from pipes of transmission side and remove the ATF level gauge Also is available Part No 41099AA010 guide ST 41099AA020 ENGINE SUPPORT ASSY 23 Remove the propeller shaft Ref to 05 14 REMOVAL Propeller Shaft 24 Remove the shift select cable Ref to CS 26 REMOVAL Select Cable 25 Disconnect the stabilizer link from transverse link AT 20 AUTOMATIC TRANSMISSION ASSEMBLY 26 Remove the bolt securing ball joint of trans verse link to housing 27 Remove the spring pins and separate front drive shafts from each side of the transmission 28 Remove the nuts which hold lower side of transmission to engine 29 Place the transmission jack under transmis sion CAUTION Make sure that the support plates of trans mission jack don t touch the oil pan AUTOMATIC TRANSMISSION 30 Remove the transmission rear crossmember from vehicle S2M0221 31 Remove the transmission CAUTION Move the transmission and torque converter as a unit away from engine 32 Separate transmission assembly and rear cushion rubber AT 21 AUTOMATIC TRANSMISSION ASSEMBLY AUTOMATIC TRANSMISSION B INSTALLATION 1 Install the rear cushion rubber to transmission assembly Tightening torque 39 N m 4 0 kgf m 29 ft lb 2 Install the ST to torque converter clutch case STOPPER SET ST
207. int B Spring pin 13 Lower the vehicle 14 Remove the gear shift lever _ B3M1823A A Stay B Transmission bracket 10 Remove the rod from joint B3M1824A CS 32 MT GEAR SHIFT LEVER CONTROL SYSTEMS B INSTALLATION 7 Connect the rod to the joint 1 Install the joint to the transmission and secure Tightening torque with the straight pin 18 N m 1 8 kgf m 13 0 ft Ib 2 Insert the gear shift lever from room side NOTE After inserting the rod and stay temporarily put them onto transmission mount B3M1824A Stay B Rod 8 Connect the stay to transmission bracket 3 Lift up the vehicle 4 _4 Install the joint to shifter arm a ly EIRA 13 0 ft lb 5 Insert the spring pin CE B3M1826A A Stay B Transmission bracket A Joint B Spring pin 9 Install the heat shield cover If equipped 10 Install the rear exhaust pipe and muffler Tightening torque 11 Lower the vehicle 18 N m 1 8 kgf m 13 0 ft Ib 12 Install the boot plate to body Tightening torque 7 5 N m 0 76 kgf m 5 5 ft lb 6 Mount the cushion rubber on the body LATION Console Box B3M1825A A Stay B Cushion rubber CS 33 13 Install the consol box Ref to El 41 INSTAL CONTROL SYSTEMS MT GEAR SHIFT LEVER C DISASSEMBLY 1 Disassemble the locking wire B3M0617C Locking wire B Stay 2 Remove the rod fro
208. integrated module and chassis ground Connector amp terminal B281 No 4 Chassis ground B281 No 13 Chassis ground CHECK BATTERY POWER SUPPLY 1 Turn the ignition switch to ON engine OFF 2 Measure the voltages between integrated module and chassis ground Connector amp terminal B281 No 1 Chassis ground Repair open circuit in harness between inte grated module and body ground Is the voltage more than 9 V Repair open circuit harness between and poor contact in coupling con nector Repair open circuit harness between battery and inte grated module and poor contact in coupling con nector Repair open circuit harness between battery and inte grated module and poor contact CHECK IGNITION POWER SUPPLY CIR CUIT 1 Turn the ignition switch to ACC 2 Measure the voitage between integrated module and chassis ground Connector amp terminal 8280 10 Chassis ground CHECK IGNITION POWER SUPPLY CUIT 1 Turn the ignition switch to ON engine OFF 2 Measure the voltage between integrated module and chassis ground Connector amp terminal in coupling con B281 No 19 Chassis ground nector 6 CHECK POOR CONTACT Is there poor contact in power Repair poor con Replace the inte supply and ground line circuit tact grated module Is the voltage more than 9 V Is the
209. isconnect the connector key lock solenoid 2 Measure the resistance of harness between integrated module and key lock solenoid Connector amp terminal B73 No 2 B281 No 3 CHECK HARNESS BETWEEN INTEGRATED MODULE AND KEY LOCK SOLENOID Measure the resistance of harness between integrated module and chassis ground Connector amp terminal B281 No 3 Chassis ground CHECK HARNESS BETWEEN KEY LOCK SOLENOID AND CHASSIS GROUND Measure the resistance of harness between key lock solenoid and chassis ground Connector amp terminal B73 No 1 Chassis ground 8 CHECK KEY LOCK SOLENOID Measure the resistance of key lock solenoid connector terminals Connector amp terminal B73 No 1 No 2 CHECK HARNESS BETWEEN P POSI TION SWITCH AND CHASSIS GROUND Measure the resistance of harness between P position switch and chassis ground Connector amp terminal B116 No 2 Chassis ground Is the resistance more than 1 MQ Replace key warn ing switch Go to step 4 Is the resistance more than 1 MQ Go to step 4 Replace key warn ing switch Is the resistance more than9 Go to step 5 v Repair open circuit in harness between inte grated module and key warning Switch Is the resistance more than 1 MQ Repair open circuit Go to step 6
210. ise all wheels off floor 3 Start the engine and set the vehicle in 20 km h 12 MPH condition NOTE The speed difference between front and rear wheels may light the ABS warning light but this indicates no malfunction When the AT control diagnosis is finished perform the ABS memory clearance procedure of on board diagnostics system lt Ref to ABS 22 Clear Memory Mode gt 4 Measure the voltage between TCM connec tor terminals Connector amp terminal Non turbo model B55 No 5 B54 No 21 Turbo model B55 No 18 B54 No 10 CHECK FRONT VEHICLE SPEED SENSOR USING OSCILLOSCOPE 1 Connect all connectors 2 Lift up the vehicle and place safety stands CAUTION On AWD models raise all wheels off ground 3 Set the oscilloscope to TCM connector ter minals Non turbo model Positive probe B55 No 18 Earth lead B54 No 10 Turbo model Positive probe B55 No 5 Earth lead B54 No 21 4 Start the engine and drive the wheels slowly NOTE The speed difference between front and rear wheels may light the ABS warning light but this indicates no malfunctions When the AT control diagnosis is finished perform the ABS memory clearance procedure of self diagnosis system lt Ref to ABS 22 Clear Memory Mode gt 5 Measure the signal voltage indicated on oscilloscope Is the voltage more than AC 1 v Is the voltage more than AC 4 V AT 60 Even if the AT OIL TEMP
211. ission until the ATF tem lights up the cir perature is about 80 C 176 F cuit has returned NOTE to a normal condi If ambient temperature is below 0 C 32 F tion at this time drive the vehicle until the ATF reaches its oper Temporary poor ating temperature contact of the con 3 Measure the voltage between TCM connec nector or harness tor terminal may be the case Connector amp terminal Repair harness or Non turbo model contact in the ATF B55 No 11 No 10 temperature sen Turbo model sor and transmis B54 No 11 20 sion connector CHECK INPUT SIGNAL FOR TCM USING Does the ATF temperature Even if the AT OIL Go to step 10 SUBARU SELECT MONITOR gradually decrease TEMP warning 1 Connect the connector to transmission lights up the cir 2 Turn the ignition switch to ON engine OFF cuit has returned to a normal condi tion at this time Temporary poor contact of the con nector or harness may be the case Repair harness or contact in the ATF temperature sen sor and transmis sion connector Is there poor contact in ATF Repair poor con Replace the TCM temperature sensor circuit tact lt Ref to AT 45 Transmission Con trol Module TCM gt AT 50 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE DTC AUTOMATIC TRANSMISSION DIAGNOSTICS ON 11 CHECK HARNESS CONNECTOR BETWEEN 15 the resistance less than 1 Go to step 12 Repair o
212. ith Diagnostic Trou ble Code DTC gt Go to step CHECK BRAKE SWITCH lt Ref to 112 CHECK BRAKE SWITCH Diag nostic Procedure for No Diagnostic Trouble Code DTC gt DIAGNOSTIC PROCEDURE FOR NO DIAGNOSTIC TROUBLE CODE DTC AUTOMATIC TRANSMISSION DIAGNOSTICS AT 109 DIAGNOSTIC PROCEDURE FOR NO DIAGNOSTIC TROUBLE CODE DTC AUTOMATIC TRANSMISSION DIAGNOSTICS B CHECK FWD SWITCH DIAGNOSIS LED does not come on even if FWD switch is ON FWD switch circuit is open or short WIRING DIAGRAM IGNITION SWITCH BATTERY SBF 4 SBF 1 FWD SWITCH 1 L 2 1 Is e 7 e Te polita pajis pe 17 18 9 20 21 22 25 24 1 2 3 4 5 6 7 a o 5161 9 0814 17 21221 25 10 o 3 8 12 16 9120 24 27 28 190 ANNE TRO590 AT 110 CHECK FWD INDICATOR LIGHT 1 Turn the ignition switch to OFF 2 Remove the combination meter 3 Remove the FWD indicator light bulb from combination meter CHECK HARNESS CONNECTOR BETWEEN TCM AND FWD SWITCH 1 Turn the ignition switch to OFF 2 Disconnect the connector from TCM and FWD switch 3 Measure the resistance of harness between TCM and FWD switch connector Connector amp terminal B55 No 14 F67 No 30 CHECK HARNESS CONNECTOR BETWEEN FWD SWITCH AND CHASSIS GROUND Measure the resistance of harness between FWD switch and chassis ground Connector amp
213. k nut P 3 Depress and release the clutch pedal 2 to 3 times to ensure that the clutch pedal and release fork operates smoothly If the clutch pedal and re lease fork do not operate smoothly bleed air from the clutch hydraulic system Ref to CL 24 Clutch Fluid Air Bleeding 4 Measure the clutch pedal full stroke length again to ensure that it is within specifications If it is not repeat adjustment procedures again from the be ginning Specified clutch pedal full stroke 130 135 5 12 5 31 in 5 Move the clevis pin to the left and then to the right It should move without resistance while it is rattling If resistance is felt repeat adjustment pro cedures again from the beginning 6 Push the release lever until operating cylinder push rod retracts Ensure that the clutch fluid level in reservoir tank increases If the clutch fluid level increases hydraulic clutch is properly adjusted if fluid level does not increase or push rod does not retract replace the master cylinder with a new one lt Ref to CL 20 Master Cylinder gt B4M1191B 1 Push rod 2 Release lever 3 Operating cylinder 7 Push the release lever until operating cylinder push rod retracts Check that the clutch fluid level in reservoir tank increases B4M1191B 1 Push rod 2 Release lever 3 Operating cylinder 8 If the clutch fluid level increases hydraulic clutch play is correct 9 If the clutch fluid le
214. l gear oil too high Seal pipe Double oil seal High clutch 2 4 brake Low amp reverse clutch Reverse clutch Lock up facing ATF deterioration TCM Throttle position sensor 2 4 brake duty solenoid ATF temperature sensor Line pressure duty solenoid Control valve 2 4 brake ATF deterioration Engine performance 2 4 brake timing solenoid TCM Throttle position sensor 2 4 brake duty solenoid ATF temperature sensor Line pressure duty solenoid Control valve 2 4 brake 2 4 brake timing solenoid High clutch AT 129 SYMPTOM RELATED DIAGNOSTIC AUTOMATIC TRANSMISSION DIAGNOSTICS TCM Throttle position sensor 2 4 brake duty solenoid ATF temperature sensor Line pressure duty solenoid Control valve High clutch 2 4 brake ATF deterioration Engine performance 2 4 brake timing solenoid TCM Throttle position sensor 2 4 brake duty solenoid ATF temperature sensor Line pressure duty solenoid Contro valve High clutch 2 4 brake 2 4 brake timing solenoid TCM Throttle position sensor 2 4 brake duty solenoid ATF temperature sensor Line pressure duty solenoid Control valve 2 4 brake timing solenoid 2 4 brake ATF deterioration Engine performance Low clutch timing solenoid Low clutch TCM Throttle position sensor 2 4 brake duty solenoid ATF temperature sensor Line pressure duty solenoid Control valve 2 4 brake 2 4 brake timing solenoid TCM Throttle position sensor ATF temperature sensor Line pressure
215. l is in the specification B3M0174B A Upper level B Lower level 5 OPERATION OF SHIFT SELECT LEVER Make sure there is no abnormal noise dragging or contact pattern in each select lever range WARNING Stop the engine while checking operation of the selector lever B3M1747 AT 5 GENERAL DESCRIPTION AUTOMATIC TRANSMISSION DIAGNOSTICS C PREPARATION TOOL 1 SPECIAL TOOLS ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 24082AA150 CARTRIDGE Troubleshooting for electrical systems Newly adopted tool B2M3876 22771 AA030 SELECT MONITOR KIT Troubleshooting for electrical systems English 22771 AA030 Without printer German 22771AA070 Without printer French 22771AA080 Without printer Spanish 22771AA090 Without printer B2M3877 2 GENERAL PURPOSE TOOLS Used for measuring resistance voltage and ampere Used for measuring sensor Oscilloscope AT 6 ELECTRICAL COMPONENTS LOCATION AUTOMATIC TRANSMISSION DIAGNOSTICS 4 Electrical Components Loca tion A LOCATION 1 CONTROL MODULE 1 Engine contro module ECM 3 Transmission control module TCM 2 ATF temperature warning light AT diagnostic indicator 4 Data link connector light 0564 TRO563 TRO382 7 ELECTRICAL COMPONENTS LOCATION AUTOMATIC TRANSMISSION DIAGNOSTICS 2 SENSOR 1 T TRO565 1 Throttle positi
216. l valve 2 4 brake TCM Control valve e High clutch e Shift solenoid 2 AT 128 SYMPTOM RELATED DIAGNOSTIC Symptom AUTOMATIC TRANSMISSION DIAGNOSTICS Problem parts No shift occurs from 3rd to 4th gear Shift solenoid 1 ATF temperature sensor Control valve 2 4 brake Engine brake is not effected when the select lever is in 3 range Inhibitor switch Throttle position sensor Control valve Engine brake is not effected when the select lever is in 3 or 2 range Control valve Engine brake is not effected when the select lever is in 1 Control valve range Low amp reverse brake Shift characteristics are erroneous nhibitor switch Front vehicle speed sensor Rear vehicle speed sensor Throttle position sensor Control valve Ground earth No lock up occurs Parking brake is not effected Shift lever cannot be moved or is hard to move from P range ATF spurts out Differential oil spurts out Differential oil level changes excessively Odor is produced from ATF supply pipe Shock occurs from 1st to 2nd gear Slippage occurs from 1st to 2nd gear TCM Throttle position sensor ATF temperature sensor Control valve Lock up facing Engine speed signal Select cable Select lever Parking mechanism ATF level too high Differentia
217. lb 2 18 N m 1 8 kgf m 13 0 ft lb T3 25 N m 2 5 kgf m 18 1 ft Ib TR0538 A Clutch pipe B Clip C Clutch hose C INSPECTION Check pipes and hoses for cracks breakage or damage Check joints for fluid leakage If any cracks breakage damage or leakage is found re pair or replace the applicable pipe or hose CL 22 CLUTCH FLUID CLUTCH SYSTEM 8 Clutch Fluid A INSPECTION 1 Park the vehicle on a level surface 2 Inspect the fluid level using the scale on the out side of the reservoir tank If the level is below MIN add fluid to bring it up to MAX and also inspect for leakage A Max level B Min level C Reservoir tank B REPLACEMENT CAUTION The FMVSS No 116 fresh DOT3 or 4 brake fluid must be used Cover the bleeder with waste cloth when loosening it to prevent brake fluid from being splashed over surrounding parts Avoid mixing different brands of brake fluid to prevent degrading the quality of the fluid Be careful not to allow dirt or dust to get into the reservoir tank NOTE During bleeding operation keep the clutch reser voir tank filled with brake fluid to eliminate entry of air Clutch pedal operating must be very slow e For convenience and safety it is advisable to have two men working The amount of brake fluid required is approxi mately 70 m 0 2 4 US fl oz 2 5 Imp fl oz for total clutch system
218. leeve and reverse The cause for difficulty in shifting gears driven gear can be classified into two kinds one is b Worn damaged or burred chamfer of Replace spline of gears malfunction of the gear shift system and c Worn or scratched bushings the other is malfunction of the transmis sion However if the operation is heavy d incorrect contact between synchro Correct or replace nizer ring and gear cone or wear 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 2 Gear slips out Gear slips out when coasting on rough road Gear slips out during acceleration a Defective pitching stopper adjustment Adjust b Loose engine mounting bolts Tighten or replace Worn fork shifter broken shifter fork Replace ail spring r 9 Worn or damaged ball bearing e Excessive clearance between splines Replace of synchronizer hub and synchronizer sleeve f Worn tooth step of synchronizer hub Replace responsible for slip out of 3rd gear g Worn 1st driven gear needle bearing Replace E h Worn 2nd driven gear needle bearing Replace j Worn 4th drive gear and bushing k Worn reverse idler gear and bushing 3 Unusual noise comes from transmis a I
219. ler bearing REMOVER Used for removing roller bearing of drive pinion shaft CENTER DIFFER Used for removing the center differential cover ENTIAL BEARING ball bearing REMOVER B3M1941 498077000 B3M1942 498077300 B3M1943 MT 15 GENERAL DESCRIPTION MANUAL TRANSMISSION AND DIFFERENTIAL ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 498147000 DEPTH GAUGE Used for adjusting main shaft axial end play B3M1944 498247001 MAGNET BASE e Used for measuring backlash between side gear and pinion and hypoid gear Used with DIAL GAUGE 498247100 B3M1945 498247100 DIAL GAUGE Used for measuring backlash between side gear and pinion and hypoid gear Used with MAGNET BASE 498247001 B3M1946 498427100 STOPPER Used for securing the drive pinion shaft assem bly and driven gear assembly when removing the drive pinion shaft assembly lock nut B3M1947 MT 16 ILLUSTRATION GENERAL DESCRIPTION MANUAL TRANSMISSION AND DIFFERENTIAL TOOL NUMBER DESCRIPTION REMARKS B3M1948 B3M1949 B3M1950 B3M1951 498787100 498937000 499277100 499277200 MAIN SHAFT STOPPER Used for removing and installing transmission main shaft lock nut TRANSMISSION Used for removing and installing transmission HOLDER BUSH 1 2 INSTALLER INSTALLER MT 17 main shaft lock nut Used for installing 1st driven gear thrust plate and 1st 2nd d
220. ls off ground 3 Drain the automatic transmission fluid CAUTION Do not drain the automatic transmission flu id until it cools down 4 Remove the oil pan and disconnect the con nector from shift solenoid 1 5 Measure the resistance between shift sole noid 1 connector and transmission ground Terminal No 1 Transmission ground CHECK HARNESS CONNECTOR BETWEEN 15 the resistance less than 1 SHIFT SOLENOID 1 AND TRANSMISSION Measure the resistance of harness between shift solenoid 1 and transmission connector Connector amp terminal AT5 No 1 T4 No 1 CHECK HARNESS CONNECTOR BETWEEN Is the resistance more than 1 SHIFT SOLENOID 1 AND TRANSMISSION Measure the resistance of harness between shift solenoid 1 connector and transmission ground Connector amp terminal 4 No 1 Transmission ground AT 72 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE DTC AUTOMATIC TRANSMISSION DIAGNOSTICS Go to step 8 Replace the shift solenoid 1 lt Ref Solenoids Duty Solenoids and ATF Temperature Sen sor gt Go to step 9 Even if the AT OIL TEMP warning lights up the cir cuit has returned to a normal condi tion at this time A temporary poor contact of the con nector or harness may be the cause Repair harness or connector in shift solenoid 1 and transmission Repair open circuit in harness between shift sole noid 1 and trans mission connector
221. lutch pedal Non turbo mode A Operating cylinder B Vinyl tube 5 Repeat these steps until there are no more air bubbles in the vinyl tube CAUTION Cover the bleeder with waste cloth when loos ening it to prevent brake fluid from being splashed over surrounding parts CL 24 CLUTCH FLUID AIR BLEEDING CLUTCH SYSTEM 6 Tighten the air bleeder Tightening torque T 8 N m 0 8 kgf m 5 8 ft lb Non turbo model 7 Repeat steps 2 through 4 using the air bleeder on operating cylinder 8 Tighten the air bleeder Tightening torque 8 N m 0 8 kgf m 5 8 ft lb 9 After depressing the clutch pedal make sure that there are no leaks evident in the entire system 10 After bleeding air from the system ensure that the clutch operates properly CL 25 CLUTCH PEDAL CLUTCH SYSTEM 10 Clutch Pedal A REMOVAL 1 Remove the steering column lt Ref to PS 23 REMOVAL Tilt Steering Column gt 2 Disconnect the connectors from stop light and clutch switches 3 Remove the snap pins which secure lever to push rod and operating rod 4 Remove the clevis pins which secure lever to push rod and operating rod TI B4M1743A A Operating rod B Push rod C Snap pin D Clevis pin 5 Remove the air cleaner case and intake duct Non turbo model Ref to 6 REMOV AL Air Cleaner Case and Ref to IN SOHC 7 REMOVAL Air Intake Duct 6 Remove intercooler
222. ly replace reverse check plate Reverse check plate Angle Remarks Part No Arm stops closer to R 5th gear 32189AA010 1 19 Arm stops closer to 5th gear Arm stops in the cen 32189AA020 2 34 ter 32189AA030 3 Arm stops closer to reverse gear 42189AA040 Arm stops closer to reverse gear 32189AA000 B3M0054D MT 53 TRANSMISSION CASE MANUAL TRANSMISSION AND DIFFERENTIAL 14 Transmission Case 7 Separate the transmission case into the right and left cases by loosening coupling bolts and nuts A REMOVAL 1 Remove the manual transmission assembly from vehicle lt Ref to MT 27 REMOVAL Manual Transmission Assembly gt 2 Remove the clutch release lever lt Ref to CL 15 REMOVAL Release Bearing and Lever gt 3 Remove the transfer case with extension case assembly lt Ref to MT 41 REMOVAL Transfer Case and Extension Case Assembly gt 4 Remove the bearing mounting bolts 8 Remove the drive pinion shaft assembly from left side transmission case NOTE Use a hammer handle etc to remove if too tight VCO B3M0101H A Main shaft assembly B Drive pinion shaft assembly 9 Remove the main shaft assembly 10 Remove the differential assembly 53 0100 CAUTION Be careful not to confuse right and left roller A Main shaft rear plate bearing outer races 6 Put the vinyl tape around splines of
223. m gear shift lever B3M1828A A Rod B Gear shift lever C Stay 3 Remove the snap ring from bush B then discon nect the stay B3M0619B Snap ring B Bushing B C Boot 4 Remove the boot from gear shift lever CS 34 5 Remove the bush and cushion rubber from stay B3M0830D A Bushing B Stay C Cushion rubber 6 Remove the O ring then disconnect the bush D B3M0620C A O ring B B O ringA C Bushing B 7 Draw out the spring pin then remove the bush C from gear shift lever B3M0621B A Spring pin B Bushing A MT GEAR SHIFT LEVER CONTROL SYSTEMS D ASSEMBLY 1 Clean all parts before assembly 2 Mount the bushing B and cushion rubber on the stay B3M0830C A Bushing B Cushion rubber 3 Mount each part boot O ring bush spacer bush A bush B and straight pin on the gear shift le Ver CAUTION Always use new O rings Apply grease DNIGTIGHT LYW No 2 or equivalent to the inner and side surfaces of the bushing when installing the spacer D p Pie ces LOA 7 B3M0623C A Boot B O ring B C Bushing D Spacer E Bushing A F Bushing B G Spring pin H O ring A 4 Insert the gear shift lever into the boot hole 5 Install the snap ring and stay to the bushing B B3M0619C A Snap ring B Bushing B 6 Tighten with locking wire to the extent that the
224. mbly gt 13 Install the transmission case Ref to MT 55 INSTALLATION Transmission Case 14 Install the transfer case with extension case as sembly Ref to MT 41 INSTALLATION Transfer Case and Extension Case Assembly 15 Install the back up light switch and neutral po sition switch Ref to MT 38 INSTALLATION Switches and Harness 16 Install the manual transmission assembly to ve hicle Ref to MT 30 INSTALLATION Manual Transmission Assembly MT 81 SHIFTER FORK AND ROD MANUAL TRANSMISSION AND DIFFERENTIAL C INSPECTION 1 Check the shift shaft and shift rod for damage Replace if damaged 2 Gearshift mechanism Repair or replace the gearshift mechanism if ex cessively worn bent or defective in any way 3 Inspect the clearance between 1st 2nd driven gear and reverse driven gear If any clearance is not within specifications replace the shifter fork as required Clearance a and b 9 5 mm 0 374 in A 1st driven gear B Reverse driven gear C 2nd driven gear 1st 2nd shifter fork Approach to 1st gear 3280444070 Standard Become distant from 32804AA080 3 2nd gear by 0 2 mm 0 008 in 4 Inspect the clearance between 3rd 4th drive gear and coupling sleeve If any clearance is not within specifications replace shifter fork as re quired Clearance a and b 9 3 mm 0 366 in B3M1411A A 3rd drive gear B Coupling sleeve
225. memory clearance procedure of on board diagnostics system Mode 5 Measure the voltage between TCM connec tor and chassis ground Connector amp terminal Non turbo model B54 No 16 Chassis ground Turbo model B54 No 7 Chassis ground CHECK OUTPUT SIGNAL EMITTED FROM TCM 1 Return the engine to idling speed and move the select lever to N 2 Measure the voltag between TCM connec tor and chassis ground Connector amp terminal Non turbo model B54 No 16 Chassis ground Turbo model B54 No 7 Chassis ground Ref to ABS 22 Clear Memory Is the voltage more than 8 5 V Go to step 7 Go to step 10 Even if the AT OIL TEMP warning lights up the cir cuit has returned to a normal condi tion at this time A temporary poor contact of the con nector or harness may be the cause Repair harness or connector in TCM and transmission Is the voltage less than 0 5 V Go to step 10 AT 96 CHECK OUTPUT SIGNAL EMITTED FROM TCM USING SUBARU SELECT MONITOR 1 Connect the connectors to TCM and trans mission 2 Lift up the vehicle and place safety stand CAUTION On AWD models raise all wheels off ground 3 Connect the Subaru Select Monitor to data link connector 4 Start the engine and turn the Subaru Select Monitor switch to ON 5 Start the engine and warm up the transmis sion until the ATF temperature is above 80 C 176 F NOTE
226. minal Non turbo model B55 No 17 112 13 Turbo model B55 No 3 112 No 13 CHECK HARNESS CONNECTOR BETWEEN TCM AND INHIBITOR SWITCH 1 Turn the ignition switch to OFF 2 Disconnect the connectors from TCM inhibi tor switch and combination meter 3 Measure the resistance of harness between TCM and chassis ground Connector amp terminal Non turbo model B55 No 17 Chassis ground Turbo model B55 No 3 Chassis ground CHECK HARNESS CONNECTOR BETWEEN TCM AND INHIBITOR SWITCH 1 Turn the ignition switch to OFF 2 Disconnect the connectors from TCM and inhibitor switch 3 Measure the resistance of harness between TCM and inhibitor switch connector Connector amp terminal Non turbo model B55 No 22 T7 No 10 Turbo model B55 No 14 T7 No 10 CHECK INPUT SIGNAL FOR TCM 1 Turn the ignition switch to OFF 2 Connect the connector to TCM and inhibitor switch 3 Turn the ignition switch to ON 4 Measure the voltage between TCM and chassis ground Connector amp terminal Non turbo model B55 No 22 Chassis ground Turbo model B55 No 14 Chassis ground 15 the resistance less than 1 Go to step 65 Is the resistance more than 1 Go to step 35 MQ Is the resistance less than 1 Q Is the voltage less than 1 V in N range Go to step 36 Go to step 37 Repair open circuit in harness between TCM con nector and combi natio
227. ming solenoid circuit AT 79 Even if the AT OIL TEMP warning lights up the cir cuit has returned to a normal condi tion at this time A temporary poor contact of the con nector or harness may be the cause Repair harness or contact in the TCM and transmission Repair poor con tact Repair open circuit in harness between TCM and transmission con nector Repair short circuit in harness between TCM and transmission con nector Go to step 7 Go to step 6 Replace the TCM Ref to AT 45 Transmission Con trol Module TCM gt CHECK LOW CLUTCH TIMING SOLENOID IN TRANSMISSION 1 Remove the transmission connector from bracket 2 Lift up or raise the vehicle and support with safety stands CAUTION On AWD models raise all wheels off ground 3 Drain the automatic transmission fluid CAUTION Do not drain the automatic transmission flu id until it cools down 4 Remove the oil pan and disconnect the con nector from low clutch timing solenoid 5 Measure the resistance between low clutch timing solenoid connector and transmission ground Terminal No 1 Transmission ground CHECK HARNESS CONNECTOR BETWEEN 115 the resistance less than 1 LOW CLUTCH TIMING SOLENOID AND TRANSMISSION Measure the resistance of harness between low clutch timing solenoid and transmission connector Connector amp terminal AT9 No 1 74 No 3 CHECK HARNESS CONNECTOR BETWEEN 15 the resistance
228. n and TCM 3 Turn the ignition switch to ON and start engine 4 Warm up the transmission until the ATF tem perature reaches to 80 C 176 F NOTE If ambient temperature is below 0 C 32 F drive the vehicle until the ATF reaches its oper ating temperature 5 Disconnect the connector from transmission 6 Measure the resistance between transmis sion connector terminals Connector amp terminal T4 No 11 No 12 MQ Is the resistance more than 1 MQ Is the resistance between 275 and 375 Q AT 49 15 the resistance more than s to step 4 Repair short circuit in harness between TCM and transmission con nector Go to step 5 Repair short circuit in harness between TCM and transmission con nector Go to step 6 Go to step 11 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE DTC AUTOMATIC TRANSMISSION DIAGNOSTICS CHECK ATF TEMPERATURE SENSOR Does the resistance value Go to step 7 Go to step 11 1 Turn the ignition switch to ON engine OFF increase while the ATF temper 2 Measure the resistance between transmis lature decreases sion connector terminals Connector amp term nal T4 No 11 No 12 7 PREPARE SUBARU SELECT MONITOR Do you have a Subaru Select Go to step 9 Go to step 8 Monitor CHECK INPUT SIGNAL FOR TCM Is the voltage between 0 4 and Even if the AT OIL to step 10 1 Connect the connector to transmission 0 9 V TEMP warning 2 Warm up the transm
229. n meter and poor contact in TCM connector Repair ground short circuit in R range circuit Repair open circuit in harness between TCM and inhibitor switch connector and poor contact in coupling connec tor Go to step 65 CHECK INPUT SIGNAL FOR TCM Measure the voltage between TCM and chas sis ground Connector amp terminal Non turbo model B55 No 22 Chassis ground Turbo model B55 14 Chassis ground Is the voltage more than 8 V in Go to step 65 other ranges AT 120 Replace the TCM lt Ref to AT 45 Transmission Con trol Module TCM gt DIAGNOSTIC PROCEDURE FOR NO DIAGNOSTIC TROUBLE CODE DTC AUTOMATIC TRANSMISSION DIAGNOSTICS CHECK N RANGE INDICATOR LIGHT BULB 1 Turn the ignition switch to OFF 2 Remove the combination meter 3 Remove the range indicator light bulb from combination meter CHECK HARNESS CONNECTOR BETWEEN 15 the resistance less than 1 TCM AND COMBINATION METER 1 Disconnect the connectors from TCM and combination meter 2 Measure the resistance of harness between TCM and combination meter Connector amp terminal Non turbo model B55 No 22 i12 No 12 Turbo model B55 No 14 112 No 12 CHECK HARNESS CONNECTOR BETWEEN 15 the resistance more than 1 TCM AND INHIBITOR SWITCH 1 Turn the ignition switch to OFF 2 Disconnect the connectors from TCM inhibi tor switch and combination meter 3 Measur
230. n switch to OFF 2 Disconnect the connector from TCM and transmission 3 Measure the resistance of harness between TCM and transmission connector Connector amp terminal Non turbo model B55 No 9 B11 No 16 B55 No 19 B11 No 16 Turbo model B56 No 19 B11 No 16 B54 No 21 B11 No 16 Is the resistance less than 1 Go to step 9 AT 37 Repair open circuit in harness between TCM transmission har ness connector and poor contact in coupling con nector DIAGNOSTIC PROCEDURE FOR AT OIL TEMP WARNING LIGHT AUTOMATIC TRANSMISSION DIAGNOSTICS CHECK HARNESS CONNECTOR BETWEEN 15 the resistance less than 1 Go to step 10 Repair open circuit TRANSMISSION AND TRANSMISSION 7 in harness GROUND between transmis Measure the resistance of harness between sion and transmis transmission and transmission ground sion ground Connector amp terminal T4 No 16 Transmission ground CHECK POOR CONTACT IN CONNECTORS Is there poor contact in control Repair the con Replace the TCM module power supply ground Ref to AT 45 line and data link connector Transmission Con trol Module TCM AT 38 DIAGNOSTIC PROCEDURE FOR SELECT MONITOR COMMUNICATION AUTOMATIC TRANSMISSION DIAGNOSTICS 13 Diagnostic Procedure for Select Monitor Communication A COMMUNICATION FOR INITIALIZING IMPOSSIBLE DIAGNOSIS Faulty harness connector TROUBLE SYMPTOM e Select the monitor commun
231. nal B4 No 4 Chassis ground TCM AND TRANSMISSION 1 Turn the ignition switch to OFF and TCM TCM and transmission connector Connector amp terminal Non turbo model B54 No 8 B11 No 9 Turbo model B54 No 18 B11 No 9 TCM AND CHASSIS GROUND Measure the resistance of harness between TCM and chassis ground Connector amp terminal Non turbo model B54 No 8 Chassis ground Turbo model B54 No 18 Chassis ground CHECK 2 4 BRAKE DUTY SOLENOID connector receptacle s terminals Terminal T4 No 16 No 9 CHECK HARNESS CONNECTOR BETWEEN CHECK HARNESS CONNECTOR BETWEEN 2 Disconnect the connector from transmission 3 Measure the resistance of harness between CHECK HARNESS CONNECTOR BETWEEN Measure the resistance between transmission PREPARE SUBARU SELECT MONITOR Do you have a Subaru Select to step 13 Go to step 11 Monitor Go to step 6 Go to step 7 Go to step 8 Go to step 10 Is the resistance more than 1 MQ Repair short circuit in harness between dropping resistor and trans mission connector Is the resistance less than 1 Q Repair open circuit in harness between TCM and transmission con nector Is the resistance more than 1 MQ Repair short circuit in harness between TCM and transmission con nector Is the resistance between 2 0 a
232. nd 4 5 Q Go to step 16 AT 91 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE DTC AUTOMATIC TRANSMISSION DIAGNOSTICS CHECK OUTPUT SIGNAL EMITTED FROM TCM 1 Connect all connectors 2 Start the engine and warm up the transmis sion until the ATF temperature is above 80 C 176 F NOTE If the ambient temperature is below 0 C 32 F drive the vehicle until the ATF reaches its oper ating temperature 3 Turn the ignition switch to ON engine OFF 4 Move the select lever to N 5 Measure the voltage between TCM connec tor and chassis ground Connector amp terminal Non turbo model B54 No 8 Chassis ground Turbo model B54 No 18 Chassis ground CHECK OUTPUT SIGNAL EMITTED FROM TCM Measure the voltage between TCM connector and chassis ground Connector amp terminal Non turbo model B54 No 8 Chassis ground Non turbo model B54 No 18 Chassis ground CHECK OUTPUT SIGNAL EMITTED FROM TCM USING SUBARU SELECT MONITOR 1 Connect all connectors 2 Connect the Subaru Select Monitor to data link connector 3 Start the engine and turn the Subaru Select Monitor switch to ON 4 Warm up the transmission until the ATF tem perature is above 80 C 176 F NOTE If the ambient temperature is below 0 C 32 F drive the vehicle until the ATF reaches its oper ating temperature 5 Stop the engine and turn the ignition switch to ON engine OFF 6 Mo
233. new adjusting washer No 1 and recheck start ing torque A Adjusting washer No 1 B Adjusting washer No 2 MT 69 DRIVE PINION SHAFT ASSEMBLY MANUAL TRANSMISSION AND DIFFERENTIAL 5 If specified starting torque range cannot be ob tained when a No 1 adjusting washer is used then select a suitable No 2 adjusting washer from those listed in the following table Repeat steps 1 through 4 to adjust starting torque B3M0536l A Adjusting washer No 1 B Adjusting washer No 2 Starting torque Washer No 2 Select thicker one Select thinner one Adjusting washer No 2 Thickness mm 803025059 3 850 0 1516 803025054 4 000 0 1575 803025058 4 150 0 1634 6 Recheck that the starting torque is within speci fied range then clinch the lock nut at four positions MT 70 FRONT DIFFERENTIAL ASSEMBLY 17 Front Differential Assembly A REMOVAL 1 Remove the manual transmission assembly from vehicle lt Ref to MT 27 REMOVAL Manual Transmission Assembly gt 2 Remove the transfer case with extension case assembly lt Ref to MT 41 REMOVAL Transfer Case and Extension Case Assembly gt 3 Remove the transmission case lt Ref to MT 54 REMOVAL Transmission Case gt 4 Removes the drive pinion shaft assembly lt Ref to MT 63 REMOVAL Drive Pinion Shaft Assem bly gt 5 Remove the main shaft assembly lt Ref to MT 57 REMOVAL Main Shaft Assembly f
234. ng Clutch pedal Full stroke mm in 180 135 5 12 5 31 Clutch disk Stroke mm in 12 13 6 0 473 0 535 13 3 14 7 0 524 0 579 Clutch disk Depth of rivet head mm in Standard 1 3 1 9 0 051 0 075 Limit of 0 3 0 012 sinking Limit for deflection 1 0 0 039 at R 107 4 21 0 8 0 031 at R 110 4 33 KD Inner diameter O D Outer diameter CL 2 GENERAL DESCRIPTION CLUTCH SYSTEM B COMPONENT 1 CLUTCH ASSEMBLY FOR NON TURBO MODEL TRO533 1 Clutch release lever sealing 6 Release bearing Tightening torque N m kgf m ft lb 2 Retainer spring 7 Clutch cover T1 15 7 1 6 11 6 3 Pivot 8 Clutch disc 2 72 7 3 52 8 4 Release lever 9 Flywheel 5 Clip CL 3 GENERAL DESCRIPTION CLUTCH SYSTEM 2 CLUTCH ASSEMBLY FOR TURBO MODEL 8 TRO534 1 Clutch release lever sealing 6 Clutch cover Tightening torque N m kgf m ft lb 2 Release lever shaft 7 Clutch disc T1 15 7 1 6 11 6 3 Plug 8 Flywheel T2 44 4 5 32 5 4 Release lever 9 Spring 5 Release bearing 10 Bracket CL 4 GENERAL DESCRIPTION CLUTCH SYSTEM 3 CLUTCH PIPE AND HOSE FOR NON TURBO MODEL 1 Operating cylinder 6 Pipe Tightening torque N m kgf m ft lb 2 Washer 7 Master cylinder ASSY T1 8 0 8 5 8 3 Clutch hose 8 Clevis pin T2 15 1 5 11 4 Bracket 9 Snap pin 18 1 8 13 0 5 Clip
235. ng Is the resistance less than 1 Q AT 111 Go to step CHECK BRAKE SWITCH lt Ref to 112 CHECK BRAKE SWITCH Diagnostic Proce dure for No Diag nostic Trouble Code DTC gt Go to step 3 Go to step 4 Go to step 5 Go to step 6 Go to step 7 Go to step 8 Go to step 9 Go to step 2 Replace the FWD indicator light bulb lt Ref to 101 11 Combination Meter Assembly gt Repair open circuit in harness between TCM and FWD switch con nector Repair open circuit in harness between FWD switch connector and chassis ground Repair short circuit in harness between TCM and FWD switch con nector Replace the TCM lt Ref to 45 Transmission Con trol Module TCM gt Repair open circuit in harness between TCM and combination meter and poor contact in coupling con nector Step Yes DIAGNOSTIC PROCEDURE FOR NO DIAGNOSTIC TROUBLE CODE DTC AUTOMATIC TRANSMISSION DIAGNOSTICS No CHECK HARNESS CONNECTOR BETWEEN TCM AND COMBINATION METER Measure the resistance of harness connector between TCM and chassis ground to make sure that circuit does not short Connector amp terminal B54 No 12 Chassis ground Is the resistance more than 1 Go to step 10 Repair short circuit in harness between TCM and combination meter connector CHECK OUTPUT SIGNAL EMITTED FROM TCM 1 Turn the ignition switch to OFF 2 Connect t
236. ng from release lever pivot with a screwdriver by accessing it through the clutch housing release lever hole Then remove the release lever B2M4223A A Clutch release lever B Screwdriver 2 TURBO MODEL 1 Remove the transmission assembly from vehicle body lt Ref to MT 27 REMOVAL Manual Trans mission Assembly gt 2 Remove the clutch release lever from transmis sion 3 Put the clutch release bearing in engine side 4 Remove the clutch release bearing from clutch cover using a flat type screwdriver S2M1843A A Clutch release bearing B INSTALLATION 1 NON TURBO MODEL CAUTION Before or during assembling lubricate the fol lowing points with a light coat of grease Contact surface of lever and pivot Contact surface of lever and bearing Transmission main shaft spline Use grease containing molybdenum disulphide Contact surface of lever and operating cylin der 1 While pushing the release lever to pivot and twisting it to both sides fit the retainer spring onto the constricted portion of pivot NOTE Apply grease SUNLIGHT 2 P N 003602010 to the contact point of release lever and operating cyl inder Confirm that the retainer spring is securely fitted by observing it through the main case hole B2M4224A Release lever 2 Install the release bearing and fasten it with two clips CL 15 RELEASE BEARING AND LEVER CLUTCH SYSTEM 3 Install the
237. ng when select le ver is in position P but not in other positions 2 The back up light is lit when the select lever is in position R but not in other positions 3 Select lever and indicator positions are matched 11 Check the shift lock system 1 Ensure the ignition switch rotates from ACC to LOCK when the select lever is set at P Also check that ignition key can be removed only from the LOCK position 2 Ensure the select lever moves from P to any other position when the brake pedal is de pressed with ignition key set at ON or START 12 Install heat shield cover If equipped 13 Install rear exhaust pipe and muffler CS 23 SELECT LEVER CONTROL SYSTEMS C DISASSEMBLY 6 Remove the lock plate 1 Remove the grip 2 Remove the indicator light and then remove the indicator cover NOTE Be careful not to break the indicator light during re moval B3M1511A A Grip B Indicator cover C Indicator light 3 Remove the slider 4 Remove the clips and then remove the guide plate TR0557 8 Remove the clip and remove the P position Switch B3M2177A A Clips A Clip B Guide plate B P position switch 5 Remove the clamp and shift lock solenoid 9 Remove the cap and then extract straight pin TRO0555 B3M1797A A Clamp B Shift lock solenoid A Straight pin B Select lever lower CS 24 SELECT LEV
238. noid B54 Lock up duty solenoid Transfer duty solenoid Check with ignition switch ON Terminal No Measuring conditions Throttle fully closed Throttle fully open Ignition switch ON With engine OFF ATF temperature 20 C 68 F ATF temperature 80 C 176 F Voltage V Approx 0 5 Approx 4 3 Approx 5 0 1 6 2 0 0 Vehicle stopped Vehicle speed at least 20 km h 12 MPH Vehicle speed at least 20 km h 12 MPH up N range Vehicle speed at most 10 km h 6 MPH Ignition switch ON with engine OFF Ignition switch ON with engine ON When cruise control is set SET lamp ON When cruise control is not set SET lamp OFF Ignition switch ON with engine ON Ignition switch ON with engine ON More than 1 AC range Engine idling after warm 0 up D range Engine idling after warm More than 1 AC range Less than 1 More than 5 0 13 or more Less than 1 More than 6 5 More than 4 More than 4 More than 1 AC range Vehicle stopped 0 Resistance to body ohms 2 1k 2 9k 275 375 450 650 450 650 450 650 10 Ignition switch ON 8 Engine 427 warm 05 12 m 1st or 4th gear 1 22 2nd or 3rd gear Ignition switch ON with engine OFF Throttle fully closed after warm up Ignition switch ON with engine OFF Throttle fully open after warm up When lock up occurs When lock up is released Throttle f
239. not equipped with cruise control Go to step 8 the name and year of the system displayed on the select monitor AT 41 Are the name and year of the Go to step 10 Inspect the ECM Inspect the ABSCM amp H U Inspect the cruise control module Go to step 5 Go to step 6 Go to step 7 Go to step 8 DIAGNOSTIC PROCEDURE FOR SELECT MONITOR COMMUNICATION AUTOMATIC TRANSMISSION DIAGNOSTICS B40 No 4 Chassis ground Is the voltage more than 1 V CHECK HARNESS CONNECTOR BETWEEN IIs the resistance less than 0 5 TCM AND DATA LINK CONNECTOR Measure the resistance between TCM connec tor and data link connector Connector amp terminal Non turbo model B55 No 7 B40 5 B55 No 16 B40 No 4 Turbo model B56 No 6 B40 No 5 B56 No 15 B40 No 4 Is TCM connector inserted into TCM Turn the ignition switch to OFF CHECK POOR CONTACT IN CONNECTORS Is there poor contact in control module and data link connec tor AT 42 3o to step 9 Repair harness ind connector Repair harness and connector between each trol module and data link connec tor A temporary poor contact or har yetween each con ness may be the rol module and Jata link connec or 30 to step 11 30 to step 12 Repair the poor sontact case Repair har ness or connector in the select moni tor communication circuit Repair harness and
240. nsfer case with extension case assembly lt Ref to MT 41 REMOVAL Transfer Case and Extension Case Assembly gt 3 Remove the transmission case lt Ref to MT 41 REMOVAL Transfer Case and Extension Case Assembly gt 4 Remove the drive pinion shaft assembly Ref to MT 63 REMOVAL Drive Pinion Shaft Assem bly 5 Remove the main shaft assembly B INSTALLATION 1 Install the needle bearing and oil seal onto the front of transmission main shaft assembly CAUTION Wrap clutch splined section with vinyl tape to prevent damage to oil seal Apply grease Unilube 2 or equivalent to the sealing lip of oil seal Use a new one 2 install the needle bearing outer race knock pin hole into transmission case knock pin NOTE Align the end face of seal with surface A when in stalling oil seal B3M0528A 3 Install the drive pinion assembly lt Ref to MT 63 INSTALLATION Drive Pinion Shaft Assembly gt 4 Install the transmission case lt Ref to MT 55 IN STALLATION Transmission Case gt 5 Install the transfer case with extension case as sembly lt Ref to MT 41 INSTALLATION Transfer Case and Extension Case Assembly gt 6 Install the manual transmission assembly to ve hicle lt Ref to MT 30 INSTALLATION Manual Transmission Assembly gt MANUAL TRANSMISSION AND DIFFERENTIAL C DISASSEMBLY 1 Put the vinyl tape around main shaft splines to protet oil seal from damage T
241. nstallation Before installing O rings or snap rings apply suf ficient amount of fluid to avoid damage and defor mation Before securing a part on a vice place cushion ing material such as wood blocks aluminum plate or shop cloth between the part and the vice Keep fluid away from the vehicle body If any flu id contacts the vehicle body immediately flush the area with water REMARKS Used for stopping rotation of flywheel when loos ening tightening bolt etc 499747100 B2M4112 2 GENERAL PURPOSE TOOLS CLUTCH DISC GUIDE Used when installing clutch disc to flywheel TOOL NAME REMARKS Circuit Tester Used for measuring resistance voltage and ampere Dial Gauge Used for measuring clutch disk run out CL 10 CLUTCH DISC AND COVER CLUTCH SYSTEM 2 Clutch Disc and Cover 2 Install the clutch cover on flywheel and tighten bolts to the specified torque A REMOVAL NOTE 1 Remove the transmission assembly from vehicle When installing the clutch cover on the flywheel body lt Ref to MT 27 REMOVAL Manual Trans position the clutch cover so that there is a gap of mission Assembly gt 120 or more between 0 marks on the flywheel 2 Install the ST on flywheel and clutch cover 0 marks indicate the directions ST 499747100 CLUTCH DISC GUIDE of residual unbalance e Note the front and rear of the clutch disc when in stalling e Temporarily tighten th
242. nsufficient or improper lubrication Sacer NOTE NOTE If an unusual noise is heard when the ve If the trouble is only wear of the tooth sur hicle is parked with its engine idling and if faces merely a high roaring noise will oc the noise ceases when the clutch is disen cur at high speeds but if any part is gaged it may be considered that the broken rhythmical knocking sound will be noise comes from the transmission heard even at low speeds MT 84 GENERAL DIAGNOSTIC MANUAL TRANSMISSION AND DIFFERENTIAL 2 DIFFERENTIAL 1 Broken differential case gear bear ing etc NOTE Abnormal noise will develop and finally it will become impossible to continue to run due to broken pieces obstructing the gear revolution Possible cause a Insufficient or improper oil Remedy Disassemble differential and replace bro ken components and at the same time check other components for any trouble and replace if necessary b Use of vehicle under severe condi tions such as excessive load and improper use of clutch c Improper adjustment of taper roller bearing d Improper adjustment of drive pinion and hypoid driven gear e Excessive backlash due to worn dif ferential side gear washer or differential pinion vehicle under severe operating 2 Differential and hypoid gear noises F Troubles of the differential and hypoid gea
243. ntial case 1 BEVEL PINION GEAR BACKLASH Measure the backlash between bevel gear and pin ion If itis not within specifications install a suitable washer to adjust it NOTE Be sure the pinion gear tooth contacts adjacent gear teeth during measurement ST1 498247001 MAGNET BASE ST2 498247100 DIAL GAUGE Standard backlash 0 13 0 18 mm 0 0051 0 0071 in 45 7 ar 2 HYPOID GEAR BACKLASH Set the ST1 ST2 and ST3 Insert the needle through transmission oil drain plug hole so that the needle comes in contact with the tooth surface at a right angle and check the backlash ST1 498247001 MAGNET BASE ST2 498247100 DIAL GAUGE ST3 498255400 PLATE Backlash 0 13 0 18 mm 0 0051 0 0071 in Vv 9 ye o B3M1363A NOTE If the backlash is outside specified range adjust it by turning holder in right side case MT 74 FRONT DIFFERENTIAL ASSEMBLY MANUAL TRANSMISSION AND DIFFERENTIAL 3 TOOTH CONTACT OF HYPOID GEAR Check tooth contact of hypoid gear as follows Ap ply a uniform thin coat of red lead on both tooth sur faces of 3 or 4 teeth of the hypoid gear Move the hypoid gear back and forth by turning the transmis sion main shaft until a definite contact pattern is de veloped on hypoid gear and judge whether face contact is correct If it is inaccurate make adjust ment lt Ref to MT 75 ADJUSTMENT Front Differ ential Assembly gt Tooth contact is correct
244. o 10 Chassis ground Turbo model B55 No 6 Chassis ground 1 Turn the ignition switch to OFF 2 Remove the combination meter 3 Remove the 2 range indicator light bulb from combination meter CHECK HARNESS CONNECTOR BETWEEN 15 the resistance less than 1 TCM AND COMBINATION METER 1 Disconnect the connectors from TCM and combination meter 2 Measure the resistance of harness between TCM and combination meter Connector amp terminal Non turbo model B54 No 10 i12 No 4 Turbo model B55 No 6 i12 No 4 Is the voltage more than 8 V in Go to step 65 other ranges Is the 2 range indicator light bulb OK AT 124 Go to step 57 Go to step 65 Replace the TCM lt Ref to AT 45 Transmission Con trol Module gt Replace the 2 range indicator light bulb lt Ref to IDI 11 Combina tion Meter Assem bly gt Repair open circuit in harness between TCM and combination meter and poor contact in TCM connector DIAGNOSTIC PROCEDURE FOR NO DIAGNOSTIC TROUBLE CODE DTC AUTOMATIC TRANSMISSION DIAGNOSTICS CHECK HARNESS CONNECTOR BETWEEN 15 the resistance more than 1 TCM AND INHIBITOR SWITCH 1 Turn the ignition switch to OFF 2 Disconnect the connectors from TCM inhibi tor switch and combination meter 3 Measure the resistance of harness between TCM and chassis ground Connector amp terminal Non turbo model B54 No 10
245. ode 2 Measure the voltage between TCM connec tor and chassis ground Connector amp terminal Non turbo model B54 No 5 4 Chassis ground Turbo model B54 No 16 Chassis ground Is the voltage more than 9 V Even if the AT OIL TEMP warning lights up the cir cuit has returned to a normal condi tion at this time A temporary poor contact of the con nector or harness may be the cause Repair harness or contact in the transmission Go to step 6 CHECK POOR CONTACT Is there poor contact in 2 4 brake timing solenoid circuit Repair poor con tact Replace the TCM Ref to AT 45 Transmission Con trol Module TCM gt CHECK 2 4 BRAKE TIMING SOLENOID IN 15 the resistance betwee TRANSMISSION 1 Remove the transmission connector from bracket 2 Lift up or raise the vehicle and support with safety stands CAUTION On AWD models raise all wheels off ground 3 Drain the automatic transmission fluid CAUTION Do not drain the automatic transmission flu id until it cools down 4 Remove the oil pan and disconnect the con nector from 2 4 brake timing solenoid 5 Measure the resistance between 2 4 brake timing solenoid connector and transmission ground Terminal No 1 Transmission ground and 16 Q 10 Go to step 8 Replace the 2 4 brake timing sole noid lt Ref to AT 39 Shift Sole noids Duty Sole noids and ATF Temperature Sen Sor
246. odel lt Ref to EX DOHC TURBO 14 INSTALLATION Muffler gt Ref to EX DOHC TURBO 13 INSTALLATION Rear Exhaust Pipe Ref to EX DOHC TURBO 9 INSTALLA TION Center Exhaust Pipe 12 Lower the vehicle 13 Install the transmission connector to the stay 14 Install the air cleaner case Non turbo model Ref to IN SOHC 6 INSTALLATION Air Cleaner Case 15 Install the intercooler Turbo model Ref to IN DOHC TURBO 11 INSTALLATION Intercool er AT 34 REAR VEHICLE SPEED SENSOR AUTOMATIC TRANSMISSION 14 Rear Vehicle Speed Sensor A REMOVAL When removing the rear vehicle speed sensor re fer to Front Vehicle Speed Sensor lt Ref to AT 32 REMOVAL Front Vehicle Speed Sensor gt B INSTALLATION When installing the rear vehicle speed sensor refer to Front Vehicle Speed Sensor lt Ref to AT 33 INSTALLATION Front Vehicle Speed Sensor gt AT 35 TORQUE CONVERTER TURBINE SPEED SENSOR AUTOMATIC TRANSMISSION 15 Torque Converter Turbine Speed Sensor A REMOVAL When removing the torque converter turbine speed sensor refer to Front Vehicle Speed Sensor lt Ref to AT 32 REMOVAL Front Vehicle Speed Sensor gt B INSTALLATION When installing the torque converter turbine speed sensor refer to Front Vehicle Speed Sensor lt Ref to AT 33 INSTALLATION Front Vehicle Speed Sensor gt AT 36 CONTROL VALVE BODY AUTOMATIC TRANSMISSION 16 Control Valv
247. olenoid 2 Yellow Shift solenoid 1 Green 2 4 brake timing solenoid Black 2 4 brake duty solenoid Red ATF temperature sensor goSg 2 2 ye 29 2 Connect the harness connectors Connect the connectors of same color and secure the connectors to valve body using clips B C D E B2M2263J Lock up duty solenoid Blue Low clutch timing solenoid Gray Line pressure duty solenoid Red Shift solenoid 2 Yellow E Shift solenoid 1 Green 2 4 brake timing solenoid Black 2 4 brake duty solenoid Red ATF temperature sensor Transfer duty solenoid Brown 3 Apply proper amount of liquid gasket to the en tire oil pan mating surface Fluid packing Tree Bond 1217B 4 Install the oil pan Tightening torque 4 9 N m 0 50 kgf m 3 6 ft Ib A Oil pan B Drain plug 5 Fill ATF up to the middle of the COLD side on level gauge by using the gauge hole Ref to AT 9 Automatic Transmission Fluid 6 Check the ATF level Ref to AT 9 Automatic Transmission Fluid AT 41 SHIFT SOLENOIDS DUTY SOLENOIDS AND ATF TEMPERATURE SENSOR AUTOMATIC TRANSMISSION 1 TRANSFER DUTY SOLENOID AND TRANSFER VALVE BODY 1 Install the transfer duty solenoid and transfer valve body 1 Install the transfer duty solenoid and trans fer valve body Tightening torque T 8 0 8 kgf m 5 8 ft Ib 2
248. on tact Go to step 11 Go to step 11 Go to step 11 Replace the TCM lt Ref to AT 45 Transmission Con trol Module TCM gt DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE DTC AUTOMATIC TRANSMISSION DIAGNOSTICS AT 65 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE DTC AUTOMATIC TRANSMISSION DIAGNOSTICS G DTC 38 TORQUE CONTROL SIGNAL DIAGNOSIS The signal circuit is open or shorted TROUBLE SYMPTOM Excessive shift shock WIRING DIAGRAM 2 1 fe le o wo tttajra 1415 fre 7 fiel keleof21 122 23 24 TCM AND ECM 1 Turn the ignition switch to OFF 2 Disconnect the connectors from TCM and ECM 3 Measure the resistance of harness between TCM and ECM connector Connector amp terminal Non turbo model B54 No 21 B134 No 17 B54 No 13 B134 16 Turbo model B56 No 14 B135 No 18 B56 No 5 B135 No 19 AT 66 NON TURBO MODEL TURBO MODEL 1 2 3 e z lej o 22 23 24 TRO579 Go to step 2 Repair open circuit in harness between TCM and ECM connector DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE DTC AUTOMATIC TRANSMISSION DIAGNOSTICS CHECK HARNESS CONNECTOR BETWEEN TCM AND ECM Measure the resistance of harness between TCM connector and chassis ground Connector amp terminal Non turbo model B56 No 21 Chassis ground B54
249. on sensor 4 Rear vehicle speed sensor 6 ATF temperature sensor 2 Front vehicle speed sensor 5 Torque converter turbine speed 7 Dropping resistor Non turbo 8 Inhibitor switch sensor model AT 8 ELECTRICAL COMPONENTS LOCATION AUTOMATIC TRANSMISSION DIAGNOSTICS Non turbo model TRO387 Turbo model TRO592 TRO388 o 0390 0389 SUBARU TR0593 AT 9 ELECTRICAL COMPONENTS LOCATION AUTOMATIC TRANSMISSION DIAGNOSTICS 3 SOLENOID 11 i I AT d 1 186 1 Solenoid 1 4 Low clutch timing solenoid 7 2 4 brake timing solenoid 2 Solenoid 2 b Lock up duty solenoid 8 Transfer duty solenoid 3 Line pressure duty solenoid 6 2 4 brake duty solenoid 5 4 B2M2263D B2M2264E AT 10 TRANSMISSION CONTROL MODULE TCM I O SIGNAL AUTOMATIC TRANSMISSION DIAGNOSTICS 5 Transmission Control Mod ule TCM I O Signal A ELECTRICAL SPECIFICATION 1 NON TURBO MODEL 8 117 16 24 23 22 2 2269 Check with ignition switch ON Con Measuring conditions Voltage V Resistance to No nal No body ohms Back up power supply B55 6 Ignition switch OFF 10 13 O Ignition power supply Ignition Switch 10 13 54 engine OFF P range Select lever in P range Less than 1 B55 23 i
250. ontrol signal 2 Torque control signal 1 Mass air flow signal AT diagnostics signal AT 21 35 36 37 38 39 40 41 42 43 44 AUTOMATIC TRANSMISSION DIAGNOSTICS Engine control module ATF temperature sensor Torque converter turbine speed sensor Rear vehicle speed sensor Front vehicle speed sensor Shift solenoid 1 Shift solenoid 2 2 4 brake timing solenoid Line pressure duty solenoid 2 4 brake duty solenoid Lock up duty solenoid Low clutch timing solenoid Transfer duty solenoid SUBARU SELECT MONITOR AUTOMATIC TRANSMISSION DIAGNOSTICS 6 Subaru Select Monitor A OPERATION 1 READ DIAGNOSTIC TROUBLE CODE DTC 1 Prepare the Subaru Select Monitor kit 52 0285 2 Connect the diagnosis cable to Subaru Select Monitor 3 Insert the cartridge into Subaru Select Monitor lt Ref to AT 6 PREPARATION TOOL General De scription gt S2M0286 4 Connect the Subaru Select Monitor to data link connector 1 Data link connector located in the lower por tion of the instrument panel on the driver s side A Data link connector 2 Connect the diagnosis cable to data link connector CAUTION Do not connect scan tools except for Subaru Select Monitor and OBD II general scan tool 5 Turn the ignition switch to ON engine OFF and Subaru Select Monitor switch to ON 52 0288 A Power switch 6 On the Main Menu display screen select the Each System
251. or and poor contact in coupling connec tor Go to step 65 DIAGNOSTIC PROCEDURE FOR NO DIAGNOSTIC TROUBLE CODE DTC AUTOMATIC TRANSMISSION DIAGNOSTICS CHECK INPUT SIGNAL FOR TCM Measure the voltage between TCM and chas sis ground Connector amp terminal Non turbo model B55 No 8 Chassis ground Turbo model B55 No 4 Chassis ground CHECK D RANGE INDICATOR LIGHT BULB 1 Turn the ignition switch to OFF 2 Remove the combination meter 3 Remove the D range indicator light bulb from combination meter CHECK HARNESS CONNECTOR BETWEEN TCM AND COMBINATION METER 1 Disconnect the connectors from TCM and combination meter 2 Measure the resistance of harness between TCM and combination meter Connector amp terminal Non turbo model B55 No 8 i12 No 11 Turbo model B55 No 4 i12 No 11 CHECK HARNESS CONNECTOR BETWEEN TCM AND INHIBITOR SWITCH 1 Turn the ignition switch to OFF 2 Disconnect the connectors from TCM inhibi tor switch and combination meter 3 Measure the resistance of harness between TCM and chassis ground Connector amp terminal Non turbo model B55 No 8 Chassis ground Turbo model B55 No 4 Chassis ground CHECK HARNESS CONNECTOR BETWEEN TCM AND INHIBITOR SWITCH 1 Turn the ignition switch to OFF 2 Disconnect the connector from TCM and inhibitor switch 3 Measure the resistance of harness between TCM and inhibitor switch connecto
252. or cable rectly matched CHECK HARNESS BETWEEN INHIBITOR Is the resistance less than 1 Repair short circuit Go to step 3 SWITCH AND INTEGRATED MODULE Q in harness 1 Turn the ignition switch to OFF between inte 2 Disconnect the connector transmission har grated module and ness and intgrated module transmission con 3 Measure the resistance of harness between nector integrated module and chassis ground Connector amp terminal B280 No 5 Chassis ground CHECK HARNESS BETWEEN INHIBITOR 15 the resistance more than 1 Repair open circuit Go to step 4 in SWITCH AND INTEGRATED MODULE MQ harness Measure the resistance of harness between between inte integrated module and inhibitor switch grated module and Connector amp terminal transmission con B12 No 3 B280 No 5 nector CHECK HARNESS BETWEEN INHIBITOR 5 the resistance less than 1 Go to step 5 Repair open circuit SWITCH AND CHASSIS GROUND Q in harness Measure the resistance of harness between between inte integrated module and chassis ground grated module and Connector amp terminal chassis ground B12 No 4 Chassis ground CHECK INHIBITOR SWITCH Is the resistance more than 1 Repair or replace Go to step 6 1 Move the select lever to P position MQ inhibitor switch 2 Measure the resistance of transmission har ness connector terminals Connector amp terminal T3 No 3 No 4 CHECK OUTPUT SIGNAL FOR INTEGRAT 15 the voltage betw
253. or Single Range gt 6 Remove the differential assembly CAUTION Be careful not to confuse right and left roller bearing outer races Be careful not to damage retainer oil seal 7 Remove the differential side retainers using ST ST 499787000 WRENCH ASSY B3M1360A MANUAL TRANSMISSION AND DIFFERENTIAL B INSTALLATION 1 Install the differential side retainers using ST ST 499787000 WRENCH ASSY 2 Install the differential assembly CAUTION Be careful not to fold the sealing lip of oil seal NOTE Wrap the left and right splines sections of axle shaft with vinyl tape to prevent scratches 3 Install the main shaft assembly Ref to MT 57 INSTALLATION Main Shaft Assembly for Single Range 4 Install the drive pinion assembly Ref to MT 63 INSTALLATION Drive Pinion Shaft Assembly 5 Install the transmission case Ref to MT 55 IN STALLATION Transmission Case 6 Install the transfer case with extension case as sembly Ref to MT 41 INSTALLATION Transfer Case and Extension Case Assembly 7 Install the manual transmission assembly to ve hicle Ref to MT 30 INSTALLATION Manual Transmission Assembly MT 71 FRONT DIFFERENTIAL ASSEMBLY MANUAL TRANSMISSION AND DIFFERENTIAL C DISASSEMBLY 1 Remove the right and left snap rings from differ ential and then remove the two axle drive shafts NOTE During reassembly reinstall each axle drive shaft in the same
254. ove the heat shield cover If equipped 7 Disconnect the cable from select lever and then remove the cable bracket B3M1795A A Adjusting nuts B Cable bracket 8 Lower the vehicle 9 Remove the console box Ref to El 41 RE MOVAL Console Box 10 Disconnect the connectors then remove the four bolts to take out the select lever assembly from the body B INSTALLATION 1 Mount the select lever onto the vehicle body 2 Tighten the four bolts to install the select lever to the vehicle body then connect the connector Tightening torque 13 N m 1 3 kgf m 9 4 ft Ib 3 Install the console box Ref to El 39 INSTAL LATION Glove Box gt 4 Set the location of select lever at N position 5 Lift up the vehicle 6 Set the location of range select lever to N posi tion 7 Insert the thread portion of the other inner cable and into the connector hole of the select lever and fix the other outer cable end to the bracket 8 Adjust the select cable position Ref to CS 27 ADJUSTMENT Select Cable 9 After completion of fitting make sure that the se lect lever operates smoothly all across the operat ing range 10 Inspect the following items If the following in spection reveals problems adjust the select cable and inhibitor switch Ref to CS 27 ADJUST MENT Select Cable and Ref to AT 28 AD JUSTMENT Inhibitor Switch 1 The engine starts operati
255. p Check Check the ABS switch circuit Ref to ABS 138 DTC 44 ABS AT CONTROL NON CONTROLLED Diagnostics Chart with Subaru Select Monitor and Ref to ABS 140 DTC 44 ABS AT CONTROL CON TROLLED Diag nostics Chart with Subaru Select Monitor Yes Go to step CHECK CRUISE CON TROL SWITCH Ref to AT 113 CHECK CRUISE CONTROL SWITCH Diag nostic Procedure for No Diagnostic Trouble Code DTC No CHECK CRUISE CONTROL SWITCH 4 When cruise control is set does the LED light up AT 113 Go to step CHECK Check the cruise INHIBITOR SWITCH lt Ref to AT 115 CHECK INHIBITOR SWITCH Diag nostic Procedure for No Diagnostic Trouble Code DTC gt control lt Ref to CC 28 Diagnos tics Chart with Diagnostic Trou ble Code gt DIAGNOSTIC PROCEDURE FOR NO DIAGNOSTIC TROUBLE CODE DTC AUTOMATIC TRANSMISSION DIAGNOSTICS AT 114 DIAGNOSTIC PROCEDURE FOR NO DIAGNOSTIC TROUBLE CODE DTC AUTOMATIC TRANSMISSION DIAGNOSTICS F CHECK INHIBITOR SWITCH DIAGNOSIS Input signal circuit of inhibitor switch is open or shorted TROUBLE SYMPTOM Shift characteristics are erroneous Engine brake is not effected when selector lever is in 3 range e Engine brake is not effected when selector lever is in 2 range e Engine brake is not effected when selector lever is in 1 range AT 115 DIAGNOSTIC PROCEDURE FOR NO DIAGNOSTIC TROUBL
256. p Check Yes _ No 1 CHECK HARNESS CONNECTOR BETWEEN the resistance less than 1 Go to step 2 Repair open circuit TCM AND TRANSMISSION Q in harness 1 Turn the ignition switch to OFF between TCM and 2 Disconnect the connector from TCM and transmission con transmission nector 3 Measure the resistance of harness between TCM and transmission connector Connector amp terminal Non turbo model B54 No 15 B11 No 6 Turbo model B54 No 6 B11 No 6 2 CHECK HARNESS CONNECTOR BETWEEN 15 the resistance more than 1 Go to step 3 Repair short circuit TCM AND TRANSMISSION MQ in harness Measure the resistance harness connector between TCM and between TCM and chassis ground transmission con Connector amp terminal nector Non turbo model B54 No 15 Chassis ground Turbo model B54 No 6 Chassis ground ls 3 CHECK TRANSFER DUTY SOLENOID Is the resistance between 10 Gots step 4 Go to step 13 Measure the resistance between transmission and 17 Q connector and transmission terminals Connector amp terminal T4 No 6 No 16 4 PREPARE SUBARU SELECT MONITOR Do you have a Subaru Select Go to step 7 Go to step 5 Monitor 5 CHECK OUTPUT SIGNAL EMITTED FROM 15 the voltage less than 1 V in Go to step 6 Go to step 12 TCM P range 1 Connect the connectors to TCM and trans mission 2 Turn the ignition switch to ON engine OFF 3 Throttle is fully closed 4 Measure the voltage between TCM
257. parate publication 1 TRANSMISSION MOUNTING TR0542 1 Pitching stopper Tightening torque N m kgf m ft Ib 2 Rear cushion rubber Ti 35 3 6 26 3 Crossmember T2 39 4 0 29 4 Stopper 50 5 1 37 4 58 5 9 43 5 70 7 1 51 4 GENERAL DESCRIPTION AUTOMATIC TRANSMISSION C CAUTION Wear working clothing including a cap protec tive goggles and protective shoes during opera tion e Remove contamination including dirt and corro sion before removal installation and disassembly e Keep the disassembled parts in order and pro tect them from dust or dirt e Until the oil pan is removed do not place with the oil pan side facing up to prevent foreign matter from entering the valve body Before removal installation or disassembly be sure to clarify the failure Avoid unnecessary re moval installation disassembly and replacement When disassembling the case and other light al loy parts use a plastic hammer to force it apart Do not pry it apart with a screwdriver or other tool Be careful not to burn your hands because each part on the vehicle is hot after running D PREPARATION TOOL 1 SPECIAL TOOLS ILLUSTRATION 398527700 B3M1977 e Use SUBARU genuine gear oil grease etc or the equivalent Do not mix gear oil grease etc with that of another grade or from other manufacturers e Be sure to tighten fasteners
258. pen circuit TRANSMISSION AND ATF TEMPERATURE Q in harness SENSOR between ATF tem 1 Turn the ignition switch to OFF perature sensor 2 Disconnect the connector from transmission and transmission 3 Remove the transmission connector from connector bracket 4 Lift up the vehicle and place safety stand CAUTION On AWD models raise all wheels off ground 5 Drain the automatic transmission fluid CAUTION Do not drain the automatic transmission flu id until it cools down 6 Remove the oil pan and disconnect the con nector from ATF temperature sensor connec tor 7 Measure the resistance of harness between ATF temperature sensor and transmission con nector Connector amp terminal T4 No 11 AT1 No 2 CHECK HARNESS CONNECTOR BETWEEN TRANSMISSION AND ATF TEMPERATURE SENSOR Measure the resistance of harness between ATF temperature sensor and transmission con nector Connector amp terminal T4 No 12 AT1 No 1 CHECK HARNESS CONNECTOR BETWEEN TRANSMISSION AND ATF TEMPERATURE SENSOR Measure the resistance of harness between transmission connector and transmission ground Connector amp terminal T4 No 11 Transmission ground CHECK HARNESS CONNECTOR BETWEEN TRANSMISSION AND ATF TEMPERATURE SENSOR Measure the resistance of harness between transmission connector and transmission ground Connector amp terminal T4 No 12 Transmission ground
259. pen or shorted input signal circuit Detects open or shorted input signal circuit Detects open or shorted input signal circuit Detects open or shorted input signal circuit Detects open or shorted input signal circuit Detects open or shorted input signal circuit Detects open or shorted out put signal circuit Detects open or shorted out put signal circuit Detects open or shorted out put signal circuit Detects open or shorted put signal circuit Detects open or shorted out put signal circuit Detects open or shorted out put signal circuit Detects open or shorted out put signal circuit Detects open or shorted out put signal circuit Detects open or shorted input signal circuit AT 29 lt Ref to 44 DTC 11 ENGINE SPEED SIGNAL Diagnostic Procedure with Diagnostic Trouble Code DTC gt lt Ref to 46 DTC 23 MASS AIR FROW SIG NAL Diagnostic Procedure with Diagnostic Trou ble Code DTC gt lt Ref to AT 48 DTC 27 ATF TEMPERATURE SENSOR Diagnostic Procedure with Diagnostic Trouble Code DTC gt lt Ref to AT 52 DTC 31 THROTTLE POSITION SENSOR Diagnostic Procedure with Diagnostic Trouble Code DTC gt lt Ref to AT 57 DTC 33 FRONT VEHICLE SPEED SENSOR Diagnostic Procedure with Diagnostic Trouble Code DTC gt Ref to AT 62 36 TORQUE CONVERTER TURBINE SPEED SENSOR Diagnostic Proce dure with Diagnostic Trouble Code DTC Ref
260. place from which it was removed 2 Loosen the twelve bolts and remove hypoid driv en gear B3M0551C A Snap ring B Axle drive shaft C Hypoid driven gear 3 Drive out the straight pin from differential assem bly toward hypoid driven gear ST 899904100 REMOVER 4 Pull out the pinion shaft and remove the differ ential bevel pinion and gear and washer D O B B3M0552C Pinion shaft B Bevel pinion C Bevel gear D Washer 5 Remove the roller bearing using ST ST 399527700 PULLER SET D ASSEMBLY 1 Install the bevel gear and bevel pinion together with washers and insert pinion shaft NOTE Face the chamfered side of washer toward gear B3M0099D A Bevel pinion B Bevel gear C Pinion shaft MT 72 FRONT DIFFERENTIAL ASSEMBLY MANUAL TRANSMISSION AND DIFFERENTIAL 2 Measure the backlash between bevel gear and pinion If it is not within specifications install a suit able washer to adjust it lt Ref to MT 75 ADJUST MENT Front Differential Assembly gt NOTE Be sure the pinion gear tooth contacts adjacent gear teeth during measurement ST1 498247001 MAGNET BASE ST2 498247100 DIAL GAUGE Standard backlash 0 13 0 18 mm 0 0051 0 0071 in 2 KK A 9 952 6 3 Align the pinion shaft and differential case at their holes and drive straight pin into holes from the hypoid driven g
261. poor contact of the con nector or harness may be the cause Repair harness or connector in TCM and transmission Go to step 10 Go to step 10 Repair poor con tact Replace the TCM lt Ref to AT 45 Transmission Con trol Module TCM gt CHECK LOCK UP DUTY SOLENOID IN TRANSMISSION 1 Remove the transmission connector from bracket 2 Drain the automatic transmission fluid CAUTION Do not drain the automatic transmission flu id until it cools down 3 Remove the oil pan and disconnect the con nector from lock up duty solenoid 4 Measure the resistance between lock up duty solenoid connector and transmission ground Terminal No 1 Transmission ground CHECK HARNESS CONNECTOR BETWEEN 15 the resistance less than 1 LOCK UP DUTY SOLENOID AND TRANS MISSION Measure the resistance of harness between lock up duty solenoid and transmission con nector Connector amp terminal T4 No 13 AT3 No 1 CHECK HARNESS CONNECTOR BETWEEN Is the resistance more than 1 LOCK UP DUTY SOLENOID AND TRANS MISSION Measure the resistance of harness between transmission connector and transmission ground Connector amp terminal T4 No 13 Transmission ground Is the resistance between 10 and 17 AT 98 Yes Go to step 12 Go to step 13 Even if the AT OIL TEMP warning lights up the cir cuit has returned to a normal condi tion at this time A temporary poor contact of the
262. que cool oup ional Torque control cut signal ON or OFF 2 4 brake timing control solenoid valve Low clutch timing control solenoid valve ON or OFF o o 5 When the and Turn Ignition Switch OFF For detailed operation procedure refer to the SUB are shown on the display screen turn the Subaru ARU SELECT MONITOR OPERATION MANUAL Select Monitor and ignition switch to OFF 3 CLEAR MEMORY MODE NOTE For detailed operation procedure refer to the SUB 1 On the Main Menu display screen select the ARU SELECT MONITOR OPERATION MANUAL 2 Each System Check and press the YES key 2 On the System Selection Menu display screen select the Transmission Contro System and press the YES key 3 Press the YES key after displayed the informa tion of transmission type 4 On the Transmission Diagnosis display screen select the Clear Memory and press the YES key AT 23 READ DIAGNOSTIC TROUBLE CODE DTC AUTOMATIC TRANSMISSION DIAGNOSTICS 7 Read Diagnostic Trouble Code DTC A OPERATION 1 WITHOUT SUBARU SELECT MONITOR PERFORM READ DIAGNOSTIC TROUBLE Does the indicator light blink at Repair power sup Go to step 2 CODE 4 Hz intervals NOTE Blinks and ground cir 1 Warm up the engine every 0 125 1 8 seconds cuit lt Ref to 36 2 Turn the ignition switch to OFF until ignition switch is turned
263. r Connector amp terminal Non turbo model B55 No 18 T7 No 11 Turbo model B55 No 5 T7 No 11 Is the voltage more than 8 V in to step 65 other ranges Is the D range indicator light bulb OK Is the resistance less than 1 Q Is the resistance more than 1 MQ Is the resistance less than 1 Q AT 122 Go to step 45 Go to step 65 Go to step 47 Go to step 48 Replace the TCM Ref to AT 45 Transmission Con Replace the D range indicator light bulb Ref to IDi 11 Combina tion Meter Assem bly gt Repair open circuit in harness between TCM con nector and combi nation meter and TCM connector Repair ground short circuit in D range circuit Repair open circuit in harness between TCM and inhibitor switch connector and poor contact in coupling connec tor DIAGNOSTIC PROCEDURE FOR NO DIAGNOSTIC TROUBLE CODE DTC AUTOMATIC TRANSMISSION DIAGNOSTICS 0 Nes 48 CHECK INPUT SIGNAL FOR TCM Is the voltage less than 1 Vin Go to step 49 Go to step 65 1 Turn the ignition switch to OFF 3 range 2 Connect the connector to TCM and inhibitor switch 3 Turn the ignition switch to ON 4 Measure the voltage between TCM and chassis ground Connector amp terminal Non turbo model B55 No 18 Chassis ground Turbo model B55 No 5 Chassis ground CHECK INPUT SIGNAL FOR TCM I
264. r 13 O ring 7 Differential bevel pinion 14 Axle drive shaft MT 12 GENERAL DESCRIPTION MANUAL TRANSMISSION AND DIFFERENTIAL 7 TRANSMISSION MOUNTING 4e 0012 1 Pitching stopper 8 Cushion D Tightening torque N m kgf m ft lb 2 Spacer 9 Center crossmember T1 7 5 0 76 5 5 3 Cushion C 10 Rear plate T2 35 3 6 26 4 Front plate 11 Front crossmember 50 5 1 37 5 Damper T4 58 5 9 43 6 Rear cushion rubber T5 70 7 1 51 7 Rear crossmember T6 140 14 3 103 MT 13 GENERAL DESCRIPTION MANUAL TRANSMISSION AND DIFFERENTIAL C CAUTION Wear working clothing including a cap protec tive goggles and protective shoes during opera tion s Remove contamination including dirt and corro sion before removal installation and disassembly Keep the disassembled parts in order and pro tect them from dust or dirt Before removal installation or disassembly be sure to clarify the failure Avoid unnecessary re moval installation disassembly and replacement When disassembling the case and other light al loy parts use a plastic hammer to force it apart Do not pry it apart with a screwdriver or other tool Be careful not to burn your hands because each part on the vehicle is hot after running Use SUBARU genuine gear oil grease etc or the equivalent Do not mix gear oil grease etc with that of another grade or from other
265. r always appear as noise problems Therefore noise is the first indication of the trouble However noises from the engine muffler tire exhaust gas bear ing 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 Gear noise when driving If noise increases as vehicle speed increases it may be due to insufficient gear oil incor rect gear engagement damaged gears etc Gear noise when coasting Damaged gears due to maladjusted bearings and incorrect shim adjustment Bearing noise when driving or when coasting Cracked broken or damaged bearings Noise which mainly occurs when turn ing Unusual noise from differential side gear differential pinion differential pinion shaft etc conditions Readjust bearing preload and backlash and face contact of gears Adjust Adjust Add recommended oil to specified level Do not use vehicle under severe operat ing conditions f Loose hypoid driven gear clamping bolts Tighten a Insufficient oil Lubricate b Improper adjustment of hypoid driven gear and drive pinion drive pinion Readjust bearing preload ion backlash and check tooth contact ential case f Worn washer and differential pinion shaft MT 85 Check tooth contact
266. r sleeve E INSPECTION Disassembled parts should be washed clean first and then inspected carefully 1 Bearings Replace bearings in the following cases Bearings whose balls outer races and inner rac es are broken or rusty Worn bearings Bearings that fail to tum smoothly or make ab normal noise when turned after gear oil lubrication The ball bearing on the rear side of the drive pin ion shaft should be checked for smooth rotation be fore the drive pinion assembly is disassembled In this case because a preload is working on the bearing its rotation feels like it is slightly dragging unlike the other bearings 0038 A Drive pinion shaft B Ball bearing Bearings having other defects 2 Bushing each gear Replace the bushing in the following cases When the sliding surface is damaged or abnor mally worn When the inner wall is abnormally worn 3 Gears e Replace gears with new ones if their tooth sur faces are broken damaged or excessively worn Correct or replace if the cone that contacts the baulk ring is rough or damaged Correct or replace if the inner surface or end face is damaged 4 Baulk ring Replace the ring in the following cases e When the inner surface and end face are dam aged When the ring inner surface is abnormally or par tially worn down e f the gap between the end faces of the ring and the gear splined part is excessively small when the
267. range circuit Repair open circuit in harness between TCM and inhibitor switch connector and poor contact in coupling connec tor Go to step 65 Replace the TCM Ref to AT 45 Transmission Con trol Module TCM gt Replace the 1 range indicator light bulb lt Ref to IDI 11 Combina tion Meter Assem bly gt DIAGNOSTIC PROCEDURE FOR NO DIAGNOSTIC TROUBLE CODE DTC AUTOMATIC TRANSMISSION DIAGNOSTICS CHECK HARNESS CONNECTOR BETWEEN Is the resistance less than t9 Go to step 65 TCM AND COMBINATION METER 1 Disconnect the connectors from TCM and combination meter 2 Measure the resistance of harness between TCM and combination meter Connector amp terminal Non turbo model B54 No 1 i12 No 5 Turbo model B55 No 7 i12 No 5 CHECK HARNESS CONNECTOR BETWEEN 15 the resistance more than 1 to step 65 TCM AND INHIBITOR SWITCH 1 Turn the ignition switch to OFF 2 Disconnect the connectors from TOM inhibi tor switch and combination meter 3 Measure the resistance of harness between TCM and chassis ground Connector amp terminal Non turbo model B54 No 1 Chassis ground Turbo model B55 No 7 Chassis ground Is there poor contact in inhibi Repair poor con tor switch circuit tact AT 126 Repair open circuit in harnes between TCM and combi nation meter poor contact in TCM connector Repair ground short circuit in 1 range circuit A
268. ransmission connector A gt 7 3M0039B A Transmission connector 6 Remove the transmission connector from stay 7 Lift up the vehicle 8 Clean the transmission exterior 9 Drain the ATF completely NOTE Tighten the ATF drain plug after draining the ATF Tightening torque 25 N m 2 5 kgf m 18 1 ft Ib 2 Ss 1 B3M1036B Drain plug C Differential oil drain plug 10 Remove the front center rear exhaust pipes and muffler lt Ref to EX SOHC 5 REMOVAL Front Exhaust Pipe gt lt Ref to EX SOHC 9 REMOVAL Rear Exhaust Pipe gt and lt Ref to EX SOHC 11 RE MOVAL Muffler gt 11 Remove the center rear exhaust pipes and muffler Turbo model Ref to EX DOHC TUR BO 8 REMOVAL Center Exhaust Pipe gt lt Ref to EX DOHC TURBO 13 REMOVAL Rear Ex haust gt Ref to EX DOHC TURBO 14 RE MOVAL Muffler gt 12 Remove the shield cover 13 Remove the propeller shaft lt Ref to DS 14 REMOVAL Propeller Shaft gt 14 Place the transmission jack under crossmem ber NOTE Place a shop cloth or equivalent between the crossmember and transmission 15 Remove the transmission rear crossmember bolts TRO544 AT 32 FRONT VEHICLE SPEED SENSOR 16 Lower the AT jack NOTE Do not separate the AT jack and transmission 17 Remove the oil cooler outlet pipe CAUTION When removing the outlet pipe
269. rature 3 Engine idling 4 Measure the voltage between TCM connec tor and chassis ground Connector amp terminal B55 No 20 Chassis ground Is the voltage between 1 2 and 1 8V Even if the AT OIL TEMP warning lights up the cir cuit has returned to a normal condi tion at this time A temporary poor contact of the con nector or harness may be the cause Repair harness or connector in the TCM and ECM Go to step 7 CHECK INPUT SIGNAL FOR TCM USING SUBARU SELECT MONITOR 1 Connect the connectors to TCM and ECM 2 Connect the Subaru Select Monitor to data link connector 3 Start the engine and turn the Subaru Select monitor switch to ON 4 Warm up the engine until the engine coolant temperature is above 80 C 176 F 5 Engine idling 6 Read the data of intake manifold pressure signal using Subaru Select Monitor Display shows the intake manifold pressure signal value sent from ECM Is the value between 1 2 and 1 8 V Is there poor contact in intake manifold pressure signal cir cuit AT 69 Even if the AT OIL TEMP warning lights up the cir cuit has returned to a normal condi tion at this time A temporary poor contact of the con nector or harness may be the cause Repair harness or connector in the TCM and ECM Repair poor con tact 30 to step 7 Replace the TCM Ref to AT 45 Transmission Con trol Module TCM gt DIAGNOSTIC PROCEDURE
270. re to disconnect the negative terminal from bat tery CS 5 ELECTRICAL COMPONENT CONTROL SYSTEMS 2 Electrical Component 204 aS ee 7 1 Inhibitor switch 4 warning switch 7 Key lock solenoid 2 Integrated module 5 Shift lock solenoid 3 Stop light switch 6 P position switch os TRO547 CS 6 ELECTRICAL COMPONENT CONTROL SYSTEMS TRO548 4 1747 5 7 AT SHIFT LOCK SYSTEM CONTROL SYSTEMS 3 AT Shift Lock System A ELECTRICAL SPECIFICATION EEE mae BO0311 Input Output signal Contents Connector No Terminal No NDUE SIJ Measured value and measuring conditions Battery power supply B281 pom 9 16V Ignition power supply B280 19 10 15V when ignition switch is at ON or START Ignition power supply B280 1 10 15 V when ignition switch is at ACC 0 V when select lever is in P position B280 9 16 V when select lever is in other positions than P position 9 16 V when stop light switch is ON Stop light switch Beag O V when stop light switch is OFF 0 V when select lever is in P position P position switch B280 9 16 V when select lever is in other positions than P TA 8 5 16 V when shift lock is released Shift lock solenoid signal B281 0 V when shift lock is operating Inhibitor Swit
271. release lever seal 3 Apply grease to the specified points e Spline FX2200 e Shaft SUNLIGHT 2 B2M4222A A Release lever B Release lever seal 4 Install the transmission assembly lt Ref to MT 30 INSTALLATION Manual Trans mission Assembly gt 2 TURBO MODEL 4 Install the release bearing on transmission 2 Insert the release fork into release bearing tab 52 1938 Spline FX2200 B Shaft SUNLIGHT 2 4 Insert the release fork shaft into release fork CAUTION Make sure the cutout portion of the release fork 2M1937A shaft contacts spring pin A Release fork B Release bearing 2 r lt S2M1845A A Release fork B Release shaft C Spring pin 5 Install the transmission assembly Ref to MT 30 INSTALLATION Manual Transmission Assem bly gt CL 16 RELEASE BEARING AND LEVER CLUTCH SYSTEM C INSPECTION 2 RELEASE LEVER 1 RELEASE BEARING 1 Check the lever pivot portion and the point of contact with release bearing case for wear CAUTION Since this bearing is grease sealed and is of a non lubrication type do not wash with gaso line or any solvent when servicing the clutch 1 Check the bearing for smooth movement by ap plying force in the radial direction Radial direction stroke 1 4 0 055 52 1102 Clutch release lever B Pivot C Clutch release bearing B2M0173B A Bearing case
272. return spring and check spring onto reverse check sleeve NOTE Be sure the bent section of reverse check spring is positioned in the groove in check cam B3M1384A A Reverse check spring B Reverse check cam C Return spring 5th Rev D Reverse accent shaft E Return spring cap F Return spring 1st 2nd G Reverse check sleeve 2 Hook the bent section of reverse check spring over reverse check plate 3 Rotate the cam so that the protrusion of reverse check cam is at the opening in plate 4 With cam held in that position install plate onto reverse check sleeve and hold with snap ring 5 Position O ring in groove in sleeve MT 51 REVERSE CHECK SLEEVE MANUAL TRANSMISSION AND DIFFERENTIAL E INSPECTION s Make sure the cutout section of reverse accent shaft is aligned with the opening in reverse check sleeve Spin cam by hand for smooth rotation Move cam and shaft all the way toward plate and release If the cam does not return properly replace reverse check spring if the shaft does not check for scratches on the inner surface of sleeve If the sleeve is in good order replace spring B3M0048D A Snap ring B Reverse check plate C Check spring D Check cam s Select a suitable reverse accent shaft and re verse check plate Ref to MT 52 ADJUSTMENT Reverse Check Sleeve F ADJUSTMENT 1 NEUTRAL POSITION ADJUSTMENT 1 Shift the gear into 3rd gear position 2
273. riven gear bush Used for installing roller bearing outer races to differential case Used for press fitting the 2nd driven gear roller bearings and 5th driven gear onto the driven shaft GENERAL DESCRIPTION MANUAL TRANSMISSION AND DIFFERENTIAL ILLUSTRATION DESCRIPTION INSTALLER REMARKS Used for installing snap ring OUT 25 and ball bearing 25 x 26 x 17 Used for installing bearing cone of transfer driven gear extension core side TOOL NUMBER 499757002 B3M1952 499787000 NRENCH ASSY Used for removing and installing differential side retainer 499827000 Used for installing speedometer oil seal when installing speedometer cable to transmission B3M1954 3TH DRIVEN GEAR REMOVER 499857000 Jsed for removing 5th driven gear B3M1955 MT 18 GENERAL DESCRIPTION MANUAL TRANSMISSION AND DIFFERENTIAL ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 499877000 RACE 4 5 Used for installing 4th needle bearing race and INSTALLER ball bearing onto transmission main shaft Used with REMOVER 899714110 B3M1956 499917500 DRIVE PINION Used for adjusting drive pinion shim GAUGE ASSY Used for fitting transmission main shaft 499937100 TRANSMISSION Stand used for transmission disassembly and STAND SET assembly B3M1959 MT 19 GENERAL DESCRIPTION MANUAL TRANSMISSION AND DIFFERENTIAL ILLUSTRATION TOOL NUMB
274. rmal condi tion at this time A temporary poor contact of the con nector or harness may be the cause Repair harness or connector in line pressure duty solenoid and transmission Is the resistance more than 1 MQ AT 89 Replace the line pressure duty solenoid lt Ref to AT 39 Shift Sole noids Duty Sole noids and ATF Temperature Sen Sor Repair open circuit in harness between line pres sure duty solenoid and transmission connector Repair short circuit in harness between line pres sure duty solenoid and transmission connector DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE DTC AUTOMATIC TRANSMISSION DIAGNOSTICS DTC 76 2 4 BRAKE DUTY SOLENOID DIAGNOSIS Output signal circuit of 2 4 brake duty solenoid is open or shorted TROUBLE SYMPTOM Excessive shift shock WIRING DIAGRAM NON TURBO MODEL TURBO MODEL DROPPING RESISTOR 2 4 BRAKE DUTY SOLENOID 1 2 314115 7 silo 10 11112 13 16 17 18 19 20 21 22 23 24 TRO0586 Check Yes CHECK VEHICLE Is the target non turbo model CHECK RESISTOR Is the resistance between 9 Go to step 3 Replace the dip 1 Turn the ignition switch to OFF and 15 0 ping resistor Ref 2 Disconnect the connector from dropping to AT 46 Dropping resistor Resistor gt 3 Measure the resistance between dropping resistor terminal Terminals No
275. s the voltage more than 8 V in Go to step 65 Measure the hvoltage between and chas other ranges sis ground Connector amp terminal Non turbo model B55 No 18 Chassis ground Turbo model B55 No 5 Chassis ground CHECK 3 RANGE INDICATOR LIGHT Is the 3 range indicator light BULB bulb OK Go to step 65 1 Turn the ignition switch to OFF Go to step 53 Replace the TCM Ref to AT 45 Transmission Con Replace the 3 range indicator light bulb Ref to IDI 11 Combina tion Meter Assem bly gt Repair open circuit in harness between TCM con nector and combi nation meter and poor contact in TCM connector 2 Remove the combination meter 3 Remove the 3 range indicator light bulb from combination meter CHECK HARNESS CONNECTOR BETWEEN Is the resistance more than 1 TCM AND COMBINATION METER 1 Disconnect the connectors from TCM and combination meter 2 Measure the resistance of harness between TCM and combination meter Connector amp terminal Non turbo model B55 No 18 i12 No 10 Turbo model B55 No 5 i12 No 10 CHECK HARNESS CONNECTOR BETWEEN Is the resistance more than 1 TCM AND INHIBITOR SWITCH 1 Turn the ignition switch to OFF 2 Disconnect the connectors from TCM inhibi tor switch and combination meter 3 Measure the resistance of harness between TCM and chassis gro
276. se gt 5 Install the transfer case with extension case as sembly lt Ref to MT 41 INSTALLATION Transfer Case and Extension Case Assembly gt 6 Install the back up light switch and neutral posi tion switch lt Ref to MT 38 INSTALLATION Switches and Harness gt 7 Install the manual transmission assembly to ve hicle lt Ref to MT 30 INSTALLATION Manual Transmission Assembly gt C INSPECTION Check the speedometer gear oil seal and speed ometer shaft for damage Replace if damaged 77 REVERSE IDLER GEAR MANUAL TRANSMISSION AND DIFFERENTIAL 19 Reverse Idler Gear A REMOVAL 1 Remove the manual transmission assembly from vehicle lt Ref to MT 27 REMOVAL Manual Transmission Assembly gt 2 Remove the back up light switch and neutral po sition switch lt Ref to MT 37 REMOVAL Switches and Harness gt 3 Remove the transfer case with extension case assembly lt Ref to MT 41 REMOVAL Transfer Case and Extension Case Assembly gt 4 Remove the transmission case lt Ref to MT 63 REMOVAL Drive Pinion Shaft Assembly gt 5 Remove the drive pinion shaft assembly lt Ref to MT 63 REMOVAL Drive Pinion Shaft Assem bly gt 6 Remove the main shaft assembly lt Ref to MT 57 REMOVAL Main Shaft Assembly for Single Range gt 7 Remove the differential assembly lt Ref to MT 71 REMOVAL Front Differential Assembly 8 Remove the shifter forks and rods Ref to MT 80 REMO
277. selected before is too thick Reduce its thickness B3M0073 MT 76 SPEEDOMETER GEAR 18 Speedometer Gear A REMOVAL 1 Remove the manual transmission assembly from vehicle lt Ref to MT 27 REMOVAL Manual Transmission Assembly gt 2 Remove the back up light switch and neutral po sition switch lt Ref to MT 37 REMOVAL Switches and Harness gt 3 Remove the transfer case with extension case assembly lt Ref to MT 41 REMOVAL Transfer Case and Extension Case Assembly gt 4 Remove the transmission case lt Ref to MT 54 REMOVAL Transmission Case gt 5 Remove the vehicle speed sensor lt Ref to MT 39 REMOVAL Vehicle Speed Sensor gt 6 Remove the outer snap ring and pull out the speedometer driven gear Next remove the oil seal speedometer shaft and washer B3M0525C A Outer snap ring B Speedometer driven gear MANUAL TRANSMISSION AND DIFFERENTIAL B INSTALLATION 1 Install the washer and speedometer shaft and press fit oil seal with ST CAUTION Use new oil seal if it has been removed ST 899824100 or 499827000PRESS 2 Install the vehicle speed sensor lt Ref to MT 39 INSTALLATION Vehicle Speed Sensor gt 3 Install the speedometer driven gear and snap ring CAUTION Use new snap ring if it has been removed B3M0525C A Outer snap ring B Speedometer driven gear 4 Install the transmission case lt Ref to MT 55 IN STALLATION Transmission Ca
278. side of transmission to the engine 20 Disconnect the stabilizer link from the trans verse link 721 Remove the bolt securing ball joint of trans verse link to housing Except sedan turbo model 24 Place the transmission jack under transmis sion CAUTION GAMO491 Always support transmission case with a trans mission jack MT 29 MANUAL TRANSMISSION ASSEMBLY MANUAL TRANSMISSION AND DIFFERENTIAL 25 Remove the transmission rear crossmember from the vehicle G2M0831 26 Remove the transmission CAUTION Move transmission jack toward rear until main shaft is withdrawn from clutch cover 27 Separate the transmission assembly and rear cushion rubber B INSTALLATION 1 Install the rear cushion rubber to the transmis sion assembly Tightening torque 35 3 6 kgf m 26 3 ft lb 2 Install the clutch release lever and bearing onto the transmission Turbo model lt Ref to CL 15 INSTALLATION Release Bearing and Lever gt 3 Install the transmission onto the engine 1 Gradually raise the transmission with trans mission jack 2 Engage them at splines CAUTION Be careful not to strike main shaft against clutch cover 4 Install the transmission rear crossmember Tightening torque T1 70 7 1 kgf m 51 ft lb T2 140 N m 14 3 kgf m 103 ft Ib 5 Take off the transmission jack 6 Tighten the nuts which hold lower side of trans mission to the engine T
279. sor 2 Measure the resistance between throttle CHECK THROTTLE POSITION SENSOR Is the resistance between 0 35 Go to step 5 Replace the throt Measure the resistance between throttle posi 0 5 kQ tle position sensor tion sensor connector receptacle s terminals Terminals No 2 No 3 CHECK HARNESS CONNECTOR BETWEEN s the resistance less than 1 Go to step 6 TCM AND THROTTLE POSITION SENSOR 02 B54 No 3 E13 No 3 CHECK HARNESS CONNECTOR BETWEEN 15 the resistance less than 1 Go to step 7 TCM AND THROTTLE POSITION SENSOR 02 a Repair open circuit in harness between TCM and throttle position sensor connector and poor contact in coupling con nector nals Terminals Non turbo model 2 Measure the resistance of harness between TCM and throttle position sensor connector Connector amp terminal Repair open circuit in harness between TCM and throttle position sensor connector and poor contact in coupling con nector position sensor connector receptacle s termi 1 Disconnect the connector from TCM Measure the resistance of harness between TCM and throttle position sensor connector Connector amp terminal Non turbo model B55 No 1 E13 No 4 Turbo model B54 No 2 E13 No 4 AT 54 DIAGNOSTIC PROCEDURE WITH DIAGN
280. ssis ground Turbo model B54 No 22 Chassis ground CHECK OUTPUT SIGNAL EMITTED FROM TCM 1 Move the select lever to 2 range 2 Measure the voltage between TCM connec tor and chassis ground Connector amp terminal Non turbo model B54 No 7 Chassis ground Turbo model B54 22 Chassis ground AUTOMATIC TRANSMISSION DIAGNOSTICS Is the resistance less than 1 Q Go to step 2 Repair open circuit in harness between TCM and transmission con nector Is the resistance more than 1 MQ Repair short circuit in harness between TCM and transmission con nector Is the resistance between 10 and 16 Q Go to step 7 Is the voltage more than 9V step 5 Go to step 6 Even if the AT OIL TEMP warning lights up the cir cuit has returned to a normal condi tion at this time A temporary poor contact of the con nector or harness may be the cause Repair harness or contact in the TCM Repair poor con tact Is the voltage less than 1V Go to step 6 Is there poor contact in shift solenoid 1 circuit Replace the TCM Ref to AT 45 Transmission Con trol Module TCM gt AT 71 CHECK SHIFT SOLENOID 1 IN TRANSMIS 15 the resistance between 10 SION 1 Remove the transmission connector from bracket 2 Lift up or raise the vehicle and support with safety stand CAUTION On AWD models raise all whee
281. st A INSPECTION 1 GENERAL PRECAUTION Road tests should be conducted to properly diag nose the condition of the automatic transmission CAUTION When performing the test do not exceed post ed speed limit 2 D RANGE SHIFT FUNCTION Check shifting between 1st lt gt 2nd lt gt 3rd lt gt 4th while driving on normal city streets 3 D RANGE SHIFT SHOCK Check the shock level when shifting up during nor mal driving 4 KICK DOWN FUNCTION Check kick down for each gear Also check the kick down shock level 5 ENGINE BRAKE OPERATION Check the 3rd gear engine brake when shifting between D lt gt 3rd range while driving in 4th gear of D range 50 to 60 km h 31 to 37 MPH J Check the 2nd gear engine brake when shifting between 3 lt gt 2 range while driving in the 3 range 3rd gear 40 to 50 km h 25 to 31 MPH J Check the 1st gear engine brake when shifting between 2 lt 1 range while driving in the 2 range 2nd gear 20 to 30 km h 12 to 19 MPH 6 LOCK UP FUNCTION Check that rpm does not change sharply when the axle pedal is lightly depressed when driving on flat roads at normal speed in the lock up range 7 P RANGE OPERATION Stop the vehicle on an uphill grade of 596 or more and shift to P range Check that the vehicle does not move when the parking brake is released 8 UNUSUAL SOUNDS AND VIBRATION Check for unusual sounds and vibration while driv ing and during shifting 9 CLIM
282. switch Select lever in any other than More thans P range except N range arrange Select lever in N range Less than 1 B55 22 i switch Select lever in any other than More than 8 N range except P range R range Select lever in R range Less than 1 55 17 switch Select s ae 2 than More than 8 Select lever D range Less than 1 Inhibitor D range switch switch B59 Select ooo R More than 8 3 range Select lever in 3 range Less than 1 18 switch 55 Select xs More than 8 2 range Select lever in 2 range Less than 1 54 10 witch Select s a SS than More than 8 1 range Select lever in 1 range Less than 1 B54 1 i switch 5 Select aa 22 than More than 8 AT 11 TRANSMISSION CONTROL MODULE TCM I O SIGNAL AUTOMATIC TRANSMISSION DIAGNOSTICS Content Brake switch ABS signal AT OIL TEMP light Throttle position sensor supply ATF temperature sensor Rear vehicle speed sensor Front vehicle speed sensor Torque converter turbine speed sensor Engine speed signal Cruise set signal Torque control signal 1 Torque control signal 2 Torque control cut signal Intake manifold pressure sig nal Shift solenoid 1 Shift solenoid 2 Line pressure duty solenoid Throttle position sensor power Vehicle speed output signal e A as
283. t the ground terminal from battery 2 Remove the air intake duct Non turbo model lt Ref to IN SOHC 7 REMOVAL Air Intake Duct gt 3 Remove the air cleaner case Non turbo model lt Ref to IN SOHC 6 REMOVAL Air Cleaner Case gt 4 Remove the intercooler Turbo model lt Ref to IN DOHC TURBO 10 REMOVAL Intercooler gt 5 Remove the pitching stopper ET I 2 CROSSMEMBER AND CUSHION RUB BER 1 Disconnect the ground terminal from battery 2 Jack up the vehicle and support it with sturdy racks 3 Remove the front center rear exhaust pipes and muffler Non turbo model lt Ref to EX SOHC 5 REMOVAL Front Exhaust Pipe gt lt Ref to EX SOHC 9 REMOVAL Rear Exhaust Pipe gt and lt Ref to EX SOHC 11 RE MOVAL Muffler gt 4 Remove the center rear exhaust pipes and muf fler Turbo model lt Ref to EX DOHC TURBO 8 REMOVAL Center Exhaust Pipe gt lt Ref to EX DOHC TURBO 13 REMOVAL Rear Exhaust Pipe gt lt Ref to EX DOHC TURBO 14 REMOV AL Muffler gt CAUTION When removing the exhaust pipes be careful each exhaust pipe does not drop out 5 Remove the heat shield cover If equipped AUTOMATIC TRANSMISSION 6 Set the transmission jack under the transmis sion CAUTION e Make sure that the support plates of trans mission jack don t touch the oil pan 7 Remove the crossmember 8 Remove the rear cushion rubber B INSTALLATIO
284. t the out er circumference of facing repair or replace ST 499747100 CLUTCH DISC GUIDE Limit for deflection Non turbo model 1 0 mm 0 039 in at R 107 mm 4 21 in Turbo model 0 8 mm 0 031 in at R 110 mm 4 33 in WS 5 Worn spline loose rivets and torsion spring fail ure Replace defective parts TRO441 Spline B Rivet C Torsion spring CL 12 CLUTCH DISC AND COVER CLUTCH SYSTEM 2 CLUTCH COVER NOTE Visually check for the following items without disas sembling and replace or repair if defective 1 Loose thrust rivet 2 Damaged or worn bearing contact area at the center of diaphragm spring A Thrust rivet E B Diaphragm spring 3 Damaged or worn disc contact surface of pres sure plate 4 Loose strap plate setting bolt 5 Worn diaphragm sliding surface A Pressure plate B Strap plate CL 13 FLYWHEEL CLUTCH SYSTEM 3 Flywheel A REMOVAL 1 Remove the transmission assembly lt Ref to MT 27 REMOVAL Manual Transmission Assem bly gt 2 Remove the clutch cover and clutch disc lt Ref to CL 11 REMOVAL Clutch Disc and Cover gt CAUTION e Take care not to allow oil on the clutch disc facing e Do notdisassemble either the clutch cover or clutch disc 3 Using ST remove the flywheel ST 498497100 CRANKSHAFT STOPPER A Flywheel B INSTALLATION 1 Install the flywheel and ST ST 498497100 CRANKSHAF
285. tance less than 1 TCM AND ATF TEMPERATURE SENSOR 1 Turn the ignition switch to OFF 2 Disconnect the connector from transmission and TCM 3 Measure the resistance of harness between TCM and transmission connector Connector amp terminal Non turbo model B55 No 10 B11 No 12 Turbo mode B54 No 20 B11 No 12 Repair open circuit in harness between TCM and transmission con nector to step 2 CHECK HARNESS CONNECTOR BETWEEN TCM AND ATF TEMPERATURE SENSOR Measure the resistance of harness between TCM and transmission connector Connector amp terminal Non turbo model B55 No 11 B11 No 11 Turbo mode B54 No 11 B11 No 11 Is the resistance less than 1 Q 166 to step 3 Repair open circuit in harness between TCM and transmission con nector CHECK HARNESS CONNECTOR BETWEEN TCM AND ATF TEMPERATURE SENSOR Measure the resistance of harness between TCM connector and chassis ground Connector amp terminal Non turbo model B55 No 10 Chassis ground Turbo mode B54 No 20 Chassis ground CHECK HARNESS CONNECTOR BETWEEN TCM AND ATF TEMPERATURE SENSOR Measure the resistance of harness between TCM connector and chassis ground Connector amp terminal Non turbo model B55 No 11 Chassis ground Turbo mode B54 No 11 Chassis ground CHECK ATF TEMPERATURE SENSOR 1 Turn the ignition switch to OFF 2 Connect the connectors to transmissio
286. ter Align the tip end of key with key groove on the end of speedometer shaft during installation 1 Hand tighten the vehicle speed sensor 2 Tighten the vehicle speed sensor using suitable tool Tightening torque 5 9 N m 0 6 kgf m 4 3 ft Ib 3 Connect the connector to vehicle speed sensor 4 Install the front and center exhaust pipes 5 Lower the vehicle 6 Connect the battery ground terminal C INSPECTION Inspect the vehicle speed sensor Non Turbo model Ref to EN SOHC 238 DTC P0500 VEHICLE SPEED SENSOR MALFUNCTION Diagnostic Procedure with Diagnostic Trouble Code DTC Turbo model Ref to EN DOHC TURBO 246 DTC P0500 VEHICLE SPEED SENSOR MALFUNCTION Diagnostic Procedure with Diagnostic Trouble Code DTC gt MT 39 MANUAL TRANSMISSION AND DIFFERENTIAL PREPARATION FOR OVERHAUL MANUAL TRANSMISSION AND DIFFERENTIAL 8 Preparation for Overhaul A PROCEDURE 1 Clean the oil grease dirt and dust from trans mission 2 Remove the drain plug to drain oil After draining retighten it as before CAUTION Replace gasket with a new one Tightening torque 44 4 5 kgf m 32 5 3 Attach the transmission to ST ST 499937100 TRANSMISSION STAND G3M0517 4 Rotating parts should be coated with oil prior to assembly 5 All disassembled parts if to be reused should be reinstalled in the original positions and direc tions 6 G
287. ter Exhaust Pipe gt Ref to EX DOHC TURBO 13 INSTALLATION Rear Ex haust Pipe gt Ref to EX DOHC TURBO 14 IN STALLATION Muffler gt 21 Install the under cover 22 Lower the vehicle 23 Install the ATF level gauge 24 Connect the following connectors 1 Transmission harness connectors 2 Transmission ground terminal 25 Install the air cleaner case stay Non turbo model Tightening torque 16 1 6 kgf m 11 6 ft lb 26 Install the air cleaner case Non turbo model Ref to 6 INSTALLATION Air Cleaner Case 27 Install the air intake duct Non turbo model Ref to IN SOHC 7 INSTALLATION Air Intake Duct 28 Install the intercooler Turbo model Ref to IN DOHC TURBO 11 INSTALLATION Intercool er 29 Connect the battery ground terminal 30 Fill ATF up to the middle of the COLD side on level gauge by using the gauge hole Recommended fluid Dexron lli type automatic transmission fluid Fluid capacity 9 3 9 6 0 9 8 10 1 US qt 7 4 7 7 Imp qt 31 Take off the vehicle from lift arms 32 Check the select lever operation Ref to AT 28 INSPECTION Inhibitor Switch 33 Check the ATF level Ref to AT 9 Automatic Transmission Fluid 34 Check the vehicle on the road tester Ref to AT 12 Road Test AT 24 TRANSMISSION MOUNTING SYSTEM 10 Transmission Mounting Sys tem A REMOVAL 1 PITCHING STOPPER 1 Disconnec
288. terminal CHECK POWER SUPPLY OF TCM 1 Disconnect the connector from TCM 2 Turn the ignition switch to ON 3 Measure the voltage between TCM connec tor and chassis ground Connector amp terminal Non turbo model B54 No 6 Chassis ground Turbo model B56 No 1 Chassis ground is the voltage between 10 and 15 V Go to step 6 Go to step 5 CHECK FUSE NO 4 Remove fuse No 4 2 Measure the ignition power supply voltage between TCM connector and chassis ground Connector amp terminal B54 No 23 Chassis ground B54 No 24 Chassis ground Is the fuse No 4 blown out Replace the fuse No 4 If the replaced fuse No 4 has blown out easily repair short circuit in harness between fuse No 4 and TCM Is the voltage more than 10 V Go to step 8 Repair open circuit in harness between fuse No 4 and TCM or fuse No 4 and battery and poor contact in cou pling connector Go to step 7 CHECK FUSE NO 11 Remove the fuse No 11 Is the fuse No 11 blown Suir Beplace the fuse No 11 If the replaced fuse No 11 has blown out easily repair short circuit in harness between fuse No 11 and TCM Repair open circuit in harness between fuse No 4 and TCM or fuse No 4 and battery and poor contact in cou pling connector CHECK HARNESS CONNECTOR BETWEEN TCM AND TRANSMISSION 1 Turn the ignitio
289. than 1 Go to step 3 TCM AND ECM Measure the resistance of harness between TCM connector and chassis ground Connector amp terminal Non turbo model B55 No 4 Chassis ground Turbo model B55 No 17 Chassis ground Repair short circuit in harness between TCM and ECM connector PREPARE SUBARU SELECT MONITOR CHECK INPUT SIGNAL FOR TCM 1 Connect the connectors to TCM and ECM 2 Turn the ignition switch to ON engine OFF 3 Measure the voltage between TCM connec tor and chassis ground Connector amp terminal Non turbo model B55 No 4 Chassis ground Turbo model B55 No 17 Chassis ground CHECK INPUT SIGNAL FOR TCM USING SUBARU SELECT MONITOR 1 Connect the connectors to TCM and ECM 2 Connect the Subaru Select Monitor to data link connector 3 Start the engine and turn the Subaru Select Monitor switch to ON 4 Warm up the engine until engine coolant temperature is above 80 C 176 F 5 Engine idling 6 Read the data of engine speed using the Subaru Select Monitor Display shows engine speed signal value sent from ECM Do you have a Subaru Select Monitor 8o to step 5 lao to step 4 Is the voltage 0 V Is the revolution value the same as the tachometer read ing shown on the combination meter TEMP warning lights up the cir cuit has returned to a normal condi tion at this time A temporary poor contact of the con nector or harness
290. the con nector or harness may be the cause Repair harness or connector in throt tle position sensor circuit CHECK POOR CONTACT Is there poor contact in throttle position sensor circuit AT 56 Repair the poor contact Go to step 15 Go to step 18 Go to step 18 Go to step 18 Go to step 18 Replace the TCM Ref to AT 45 Transmission Con trol Module TCM gt DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE DTC AUTOMATIC TRANSMISSION DIAGNOSTICS E DTC 33 FRONT VEHICLE SPEED SENSOR DIAGNOSIS The vehicle speed signal is abnormal The circuit in combination meter is faulty e The harness connector between and vehicle speed sensor is in short or open TROUBLE SYMPTOM Erroneous idling Engine stalls e Poor driving performance AT 57 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE DTC AUTOMATIC TRANSMISSION DIAGNOSTICS WIRING DIAGRAM TCM lt 868 T volo a B o E SHIELD AND SENSOR GROUND JOINT CONNECTOR Made TURBO MODEL BE NON TURBO MODEL Mp FRONT VEHICLE SPEED SENSOR COMBINATON METER L 112 Ts 4s Te T7 Te Te 91112 1772 5 Ta T Te T7 Ts Ts 19 1 1 1 0 1 0 C 1 2 8 T4 8 Te 2818 T2 T8 4 Ts Je 7 8 9 1 2 T T4 Ts Te 7T 8 19
291. the manual transmission assembly to ve hicle Ref to MT 30 INSTALLATION Manual Transmission Assembly C DISASSEMBLY NOTE Do not disassemble center differential because it is a non disassemble part Remove ball bearing using ST CAUTION Do not reuse ball bearing ST 498077300 CENTER DIFFERENTIAL BEARING REMOVER D ASSEMBLY Install the ball bearing to center differential assem bly CAUTION Do not apply pressure in excess of 10 kN 1 ton 1 1 US ton 1 0 mp ton B3M1399B A Ball bearing E INSPECTION 1 Bearings Replace the bearings in the following cases e Broken or rusty bearings e Worn or damaged e Bearings that fail to turn smoothly or make ab normal noise when turned after gear oil lubrication Bearings having other defects 2 Center differential Replace the center differential assembly in the fol lowing case e Worn or damaged MT 49 REVERSE CHECK SLEEVE MANUAL TRANSMISSION AND DIFFERENTIAL 13 Reverse Check Sleeve A REMOVAL 1 Remove the manual transmission assembly from vehicle lt Ref to MT 27 REMOVAL Manual Transmission Assembly gt 2 Remove the transfer case with extension case assembly lt Ref to MT 41 REMOVAL Transfer Case and Extension Case Assembly gt 3 Remove the shifter arm 4 Remove the plug spring washer and reverse check ball B3M1376 B INSTALLATION 1 Install the reverse check sleeve Tight
292. the operating cylinder for fluid leakage or T1 18 N m 1 8 kgf m 13 0 ft lb damage on boot If any leakage or damage is T2 37 N m 3 8 kgf m 27 5 ft lb found replace the operating cylinder Non turbo model NOTE Be sure to install the clutch hose with the mark side facing upward Be careful not to twist the clutch hose during in stallation H2M2666B A Marking B Clutch hose C Operating cylinder CL 19 MASTER CYLINDER CLUTCH SYSTEM 6 Master Cylinder A REMOVAL 1 Thoroughly drain the brake fluid from reservoir tank 2 Remove the snap pin clevis pin and separate the push rod of master cylinder from clutch pedal A S AE B4M1189E A pin B Snap pin 77 Push rod D Lock nut 3 Remove the air cleaner case and air intake duct Non turbo model Ref to IN SOHC 6 RE MOVAL Air Cleaner Case and Ref to IN SO HC 7 REMOVAL Air Intake Duct 4 Remove the intercooler Turbo model Ref to IN DOHC TURBO 10 REMOVAL Intercooler gt 5 Remove the clutch pipe from master cylinder 6 Remove the master cylinder with reservoir tank CAUTION Be extremely careful not to spill the brake fluid Brake fluid spilt on the vehicle body will harm the paint surface wipe it off quickly if spilt Master cylinder B Clutch pipe B INSTALLATION 1 Install the master cylinder to body and install the
293. the resistance between transmission and 650 Q DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE DTC AUTOMATIC TRANSMISSION DIAGNOSTICS Go to step 2 Repair open circuit in harness between TCM and transmission con nector Is the resistance less than 1 Q Is the resistance more than 1 MQ Go to step 3 Go to step 4 Repair open circuit in harness between TCM and transmission con nector and poor contact in cou pling connector Repair short circuit in harness between TCM and transmission con nector Is the resistance more than 1 MQ Is the resistance between 450 AT 59 Go to step 5 6 PREPARE OSCILLOSCOPE Do you have an oscilloscope PREPARE SUBARU SELECT MONITOR Do you a Subaru Select Go to step 10 Monitor Go to step 6 Front Vehicle Repair short circuit in harness between TCM and transmission con nector and poor contact in cou pling connector Replace the front vehicle speed sen sor Ref to AT 32 Speed Sensor DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE DTC AUTOMATIC TRANSMISSION DIAGNOSTICS Step CHECK INPUT SIGNAL FOR TCM 1 Connect all connectors 2 Lift up or raise the vehicle and place safety stands CAUTION On AWD models ra
294. to AT 66 DTC 38 TORQUE CONTROL SIG NAL Diagnostic Procedure with Diagnostic Trou ble Code DTC gt Ref to AT 68 45 INTAKE MANIFOLD PRESSURE SIGNAL Diagnostic Procedure with Diagnostic Trouble Code DTC Ref to AT 70 DTC 71 SHIFT SOLENOID 1 Diagnostic Procedure with Diagnostic Trouble Code DTC Ref to AT 74 DTC 72 SHIFT SOLENOID 2 Diagnostic Procedure with Diagnostic Trouble Code DTC gt Ref to AT 78 DTC 73 LOW CLUTCH TIMING SOLENOID Diagnostic Procedure with Diagnostic Trouble Code DTC gt Ref to AT 82 DTC 74 2 4 BRAKE TIMING SOLENOID Diagnostic Procedure with Diagnostic Trouble Code DTC Ref to AT 86 DTC 75 LINE PRESSURE DUTY SOLENOID Diagnostic Procedure with Diagnostic Trouble Code DTC gt Ref to AT 90 DTC 76 2 4 BRAKE DUTY SOLE NOID Diagnostic Procedure with Diagnostic Trou ble Code DTC gt Ref to AT 94 DTC 77 LOCK UP DUTY SOLE NOID Diagnostic Procedure with Diagnostic Trou ble Code DTC Ref to AT 100 79 TRANSFER DUTY SOLENOID Diagnostic Procedure with Diagnostic Trouble Code DTC Ref to AT 104 DTC 93 REAR VEHICLE SPEED SENSOR Diagnostic Procedure with Diagnostic Trouble Code DTC LIST OF DIAGNOSTIC TROUBLE CODE DTC AUTOMATIC TRANSMISSION DIAGNOSTICS AT 30 DIAGNOSTIC PROCEDURE FOR AT OIL TEMP WARNING LIGHT AUTOMATIC TRANSMISSION DIAGNOSTICS 12 Diagnostic Procedure for AT OIL TEMP Warning Light
295. tor from stay 7 Lift up the vehicle 8 Remove the front exhaust pipe with center ex haust pipe Non turbo model Ref to EX SOHC 5 REMOVAL Front Exhaust Pipe 9 Remove the center exhaust pipe Turbo model Ref to EX DOHC TURBO 8 REMOVAL Center Exhaust Pipe 10 Remove the snap pin from range select lever A 8 gt FB B3M1029C A Snap pin B Select cable C Range select lever 11 Remove the plate assembly from transmission case A Select cable B Plate ASSY 12 Remove the bolts al B3M1031B A Inhibitor switch 13 Move the range select lever to parking position left side B3M1032B A Range select lever AT 29 INHIBITOR SWITCH AUTOMATIC TRANSMISSION 14 Remove the inhibitor switch from transmission SS SS aSS B3M1033B Inhibitor switch 15 Disconnect the inhibitor switch harness from in hibitor switch D INSTALLATION 1 Connect the inhibitor switch harness to inhibitor switch 2 Install the inhibitor switch to transmission case B3M1033B Inhibitor switch 3 Move the range select lever to neutral position 4 Using the ST tighten bolts of inhibitor switch ST 499267300 STOPPER PIN Tightening torque 3 4 0 35 kgf m 2 5 ft lb Inhibitor switch B Range select lever 5 Install the select cable to range select lever 6 Install the plate assembly
296. uble codes shown on the display are cleared by turning the ignition switch OFF after conducting the on board diagnostics operation Previous trouble codes however cannot be cleared since they are stored in the TCM memory which is operating on the back up power supply These trouble codes can be cleared by removing the specified fuse located under the light or left lower position of the instrument panel CLEAR MEMORY Removal of No 4 fuse for at least one minute No 4 fuse is located in the line to the mem ory back up power supply of the TCM Removal of this fuse clears the previous trouble codes stored in the TCM memory Be sure to remove the No 4 fuse for at least the specified length of time Otherwise trouble codes may not be cleared 2 WITH SUBARU SELECT MONITOR Refer to SUBARU SELECT MONITOR for informa tion about how to clear trouble codes Ref to AT 23 CLEAR MEMORY MODE OPER ATION Subaru Select Monitor AT 27 AUTOMATIC TRANSMISSION DIAGNOSTICS AT OIL TEMP WARNING LIGHT DISPLAY AUTOMATIC TRANSMISSION DIAGNOSTICS 10 AT OIL TEMP Warning Light Display INSPECTION When any on board diagnostics item is malfunc tioning the display on the power indicator light blinks from the time the malfunction is detected af ter starting the engine until the ignition switch is turned OFF The malfunctioning part or unit can be Ignition switch engine OFF determined by a trouble code during
297. ug 6 Remove the oil pan 7 Disconnect the solenoid and sensor connectors Remove the connectors from clip and disconnect the connectors B2M2263J Lock up duty solenoid Blue Low clutch timing solenoid Gray C Line pressure duty solenoid Red Shift solenoid 2 Yellow Shift solenoid 1 Green F 2 4 brake timing solenoid Black G 2 4 brake duty solenoid Red H ATF temperature sensor Transfer duty solenoid Brown 8 Remove the solenoids duty solenoids and ATF temperature sensor Lock up duty solenoid Blue Low clutch timing solenoid Gray C Line pressure duty solenoid Red 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 1 TRANSFER DUTY SOLENOID AND TRANSFER VALVE BODY 1 Set up the vehicle on the lift 2 Disconnect the ground terminal from battery 3 Remove the air intake duct Ref to IN SOHC 7 REMOVAL Air Intake Duct 4 Remove the air cleaner case lt Ref to IN SO HC 6 REMOVAL Air Cleaner Case 5 Remove the intercooler Turbo model Ref to IN DOHC TURBO 10 REMOVAL Intercooler gt 6 Remove the pitching stopper 7 Remove the front exhaust pipe with center ex haust pipe Non turbo model With OBD Ref to EX SOHC 5 REMOVAL Front Exhaust Pipe 8 Remove the center exhaust pipe Turbo model Ret to EX DOHC
298. ully open and with 7 More than 9 Less than 1 Less than 1 More than 8 5 Less than 0 5 More than 8 5 Less than 0 5 select lever in 1st gear AT 15 10 16 1st or 2nd gear More than 9 B54 istor2ndgear E 3rd or 4th gear Less than 1 10 17 10 17 TRANSMISSION CONTROL MODULE TCM I O SIGNAL AUTOMATIC TRANSMISSION DIAGNOSTICS Check with ignition switch ON Con Resistance Content nector Terminal No Measuring conditions Voltage V to body No ohms Throttle fully closed with engine OFF after warm 1 5 5 0 up Throttle fully open with engine OFF after warm Less than 1 up 1st gear Less than 1 3rd gear More than 9 2 4 brake duty solenoid 2 4 brake timing solenoid Low clutch timing solenoid ABS signal Sensor ground line 1 B54 20 0 Less than 1 Sensor ground line 2 fF 0 0 Less than 1 5 System ground line Less than 1 2 19 0 1 Sensor ground line 3 10 0 Less than 1 Sensor ground line 4 19 mou 0 Less than 1 1 AT diagnosis signal 2 Ignition switch ON Data link signal Subaru B56 15 Select Monitor 18 16 15 2nd gear Less than 1 4th gear More than 9 ABS switch ON Less than 1 ABS switch OFF More than 6 5 Less than 1 lt More than 4 AT 16 TRANSMISSION CONTROL MODULE TCM I O SIGNAL AUTOMATIC TRANSMISSION DIAGNOSTICS AT 17 TRANSMISSION CONTROL MODULE TCM I O SIGNAL AU
299. und Connector amp terminal Non turbo model B55 No 18 Chassis ground Turbo model B55 No 5 Chassis ground Repair ground short circuit in 3 range circuit AT 123 DIAGNOSTIC PROCEDURE FOR NO DIAGNOSTIC TROUBLE CODE DTC AUTOMATIC TRANSMISSION DIAGNOSTICS Step Yes No CHECK HARNESS CONNECTOR BETWEEN 15 the resistance less than 1 TCM AND INHIBITOR SWITCH 1 Turn the ignition switch to OFF 2 Disconnect the connector from TCM and inhibitor switch 3 Measure the resistance of harness between TCM and inhibitor switch connector Connector amp terminal Non turbo model B54 No 10 T7 No 4 Turbo model B55 No 6 T7 No 4 CHECK INPUT SIGNAL FOR TCM 1 Turn the ignition switch to OFF 2 Connect the connector to TCM and inhibitor switch 3 Turn the ignition switch to ON 4 Measure the voltage between TCM and chassis ground Connector amp terminal Non turbo model B54 No 10 Chassis ground Turbo model B55 No 6 Chassis ground Is the voltage less than 1 V in 2 range Go to step 54 Go to step 55 Repair open circuit in harness between TCM and inhibitor switch connector and poor contact in coupling connec tor Go to step 65 CHECK INPUT SIGNAL FOR TCM Measure the voltage between TCM and chas sis ground Connector amp terminal Non turbo model B54 N
300. ve shift shock WIRING DIAGRAM NA NON TURBO MODEL TURBO MODEL DROPPING RESISTOR TRANSMISSION f en em 884 11213141 se Le o 10111112113 16 1920121 po Step 12 Check O Is the target non turbo model Go to step 2 Go to step 7 CHECK VEHICLE 2 CHECK RESISTOR Is the resistance between 9 Replace the drop 1 Turn the ignition switch to OFF and 15 ping resistor Ref 2 Disconnect the connector from dropping to AT 46 Dropping resistor Resistor gt 3 Measure the resistance between dropping resistor terminal Terminals No 1 No 2 AT 86 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE DTC AUTOMATIC TRANSMISSION DIAGNOSTICS Xe Ns 7 30 to step 4 Repair open circuit Is the resistance less than 1 TCM AND DROPPING RESISTOR 0 1 Disconnect the connector from TCM 2 Measure the resistance of harness between TCM connector and dropping resistor connec tor Connector amp terminal B54 No 18 B4 1 CHECK HARNESS CONNECTOR BETWEEN TCM AND DROPPING RESISTOR MQ Measure the resistance of harness between dropping resistor connector and chassis ground Connector amp terminal B4 No 1 Chassis ground CHECK HARNESS CONNECTOR BETWEEN TRANSMISSION AND DROPPING RESIS TOR 1 Disconnect the connector from transmission 2 Measure the resistance of harness betwe
301. ve the select lever to N 7 Read the data of 2 4 brake duty solenoid using Subaru Select Monitor 2 4 brake duty solenoid is indicated in 1 Throttle is fully closed Is the voltage between 1 5 and Go to step 12 5 0 V with throttle fully closed Go to step 15 Is the voltage less than 1 V Even if the AT OIL Go to step 15 with throttle fully open TEMP warning lights up the cir cuit has returned to a normal condi tion at this time A temporary poor contact of the con nector or harness may be the cause Repair harness or connector in TCM and transmission Go to step 14 Is the value 100 Go to step 15 AT 92 CHECK OUTPUT SIGNAL EMITTED FROM TCM USING SUBARU SELECT MONITOR 1 Turn the ignition switch to ON Engine OFF 2 Throttle is fully open CHECK POOR CONTACT CHECK 2 4 BRAKE DUTY SOLENOID IN TRANSMISSION 1 Remove the transmission connector from bracket 2 Drain the automatic transmission fluid CAUTION Do not drain the automatic transmission flu id until it cools down 3 Remove the oil pan and disconnect the con nector from 2 4 brake duty solenoid 4 Measure the resistance between 2 4 brake duty solenoid connector and transmission ground Terminal No 1 Transmission ground CHECK HARNESS CONNECTOR BETWEEN TRANSMISSION AND 2 4 BRAKE DUTY SO LENOID Measure the resistance of harness between 2 4 brake duty solenoid and transmission con nector
302. vel does not increase or push rod does not retract clutch pedal must be readjust ed CL 28 CLUTCH PEDAL CLUTCH SYSTEM 10 Check the fluid level on the outside of the res ervoir tank If the level is below MIN add clutch fluid to bring it up to MAX Recommended clutch fluid FMVSS No 116 fresh DOT 3 or DOT 4 brake fluid A Max level B Min level Reservoir tank CL 29 CLUTCH SWITCH CLUTCH SYSTEM 11 Clutch Switch A REMOVAL 1 Disconnect the ground terminal from battery 2 Disconnect the connector from clutch switch 3 Remove the clutch switch B INSTALLATION 1 Move the clevis pin of the push rod right and left and hold where it moves smoothly then measure stroke of clutch pedal Specified clutch pedal full stroke A 130 135 mm 5 12 5 31 Tightening torque T 8 N m 0 8 kgf m 5 8 ft Ib 4 1190 2 If the clutch pedal stroke is out of specification adjust the stroke lt Ref to CL 27 ADJUSTMENT Clutch Pedal gt 3 Connect the clutch switch connector C INSPECTION 1 If the clutch switch does not operate properly or if it does not stop at the specified position replace with a new one Specified position L 2 0 079 058 G4M0327 2 Check the clutch switch continuity If continuity is not as specified replace the switch 1 Disconnect the clutch switch connector 2 Measure the resistance between
303. ween 450 and 650 0 20 you have an oscilloscope 20 you have a Subaru Select Vonitor AT 105 30 to step 2 30 to step 3 30 to step 4 30 to step 5 3o to step 6 3o to step 10 to step 9 Repair open circuit in harness between TCM and transmission con nector Repair open circuit in harness between TCM and transmission and poor contact in coupling connec tor Repair short circuit in harness between TCM and transmission con nector Repair short circuit in harness between TCM and transmission con nector Replace the rear vehicle speed sen sor Ref to AT 35 Rear Vehicle Speed Sensor Go to step 7 Go to step 8 CHECK INPUT SIGNAL FOR TCM 1 Connect the connectors to TCM and trans mission 2 Lift up or raise the vehicle and place safety stands CAUTION On AWD models raise all wheels off floor 3 Start the engine and set vehicle in 20 km h 12 MPH condition NOTE The speed difference between front and rear wheels may light the ABS warning light but this indicates no malfunction When the AT control diagnosis is finished perform the ABS memory clearance procedure of on board diagnostics lt Ref to ABS 22 Clear Memory system Mode gt 4 Measure the voltage between TCM connec tor terminals Connector amp terminal Non turbo model B55 No 3 B54 21 Turbo model B55 No 24 B54 19 CHE
304. y all across the oper ating range 11 Install in the reverse order of removal CS 28 AT SHIFT LOCK SOLENOID AND P POSITION SWITCH CONTROL SYSTEMS 6 AT Shift Lock Solenoid and B INSTALLATION P Position Switch Install in the reverse order of removal A REMOVAL 1 Disconnect the ground terminal from battery 2 Remove the console box lt Ref to El 41 RE MOVAL Console Box gt 3 Disconnect the connector 4 Remove the grip 5 Remove the indicator cover 6 Remove the slider 7 Remove the cushion 8 Remove the clip and remove the P position Switch A Clip B P position switch 9 Remove the clamp and remove the shift lock so lenoid A Clamp B Shift lock solenoid CS 29 AT SHIFT LOCK SOLENOID AND P POSITION SWITCH CONTROL SYSTEMS C INSPECTION CHECK SHIFT LOCK SOLENOID Measure the resistance of shift lock solenoid connector terminals Terminal No 4 No 5 CHECK SHIFT LOCK SOLENOID Connect the battery with shift lock solenoid connector terminal operate solenoid Terminal No 4 No 5 CHECK P POSITION SWITCH 1 Move the select lever to P position 2 Measure resistance between P position switch connector terminals CHECK P POSITION SWITCH 1 Move the select lever to other than P posi tion 2 Measure resistance between P position switch connector terminals Is the resistance between
305. y solenoid is indicated in 95 CHECK OUTPUT SIGNAL EMITTED FROM TCM USING SUBARU SELECT MONITOR 1 Move the select lever to D with throttle fully closed vehicle speed 0 km h or 0 MPH 2 Rear the data of transfer duty solenoid using Subaru Select Monitor Transfer duty solenoid is indicated in 96 Is the value between 5 and 10 Is the value between approx 60 and approx 70 cuit has returned to a normal condi tion at this time A temporary poor contact of the con nector or harness may be the cause Repair harness or connector in the TCM and trans mission Go to step 11 Even if the AT OIL Go to step 12 TEMP warning Go to step 12 lights up the cir Go to step 12 CHECK OUTPUT SIGNAL EMITTED FROM TCM USING SUBARU SELECT MONITOR 1 Connect connectors to TCM and transmis sion 2 Connect Subaru Select Monitor to data link connector 3 Turn ignition switch to ON engine OFF and turn Subaru Select Monitor switch to ON 4 Move select lever to D with throttle fully open vehicle speed 0 km h or 0 MPH 5 Read data of transfer duty solenoid using Subaru Select Monitor Transfer duty solenoid is indicated in 96 CHECK OUTPUT SIGNAL EMITTED FROM TCM USING SUBARU SELECT MONITOR 1 Move select lever to N with throttle fully close vehicle speed 0 km h or 0 MPH 2 Rear data of transfer duty solenoid using Subaru Select Monitor

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