4 - Transmission PDF

I
2002 IMPREZA SERVICE MANUAL QUICK REFERENCE INDEX

~
TRANSMISSION SECTION
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
c- - 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.
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

1
CONTROL SYSTEMS
CSr
Page
1. General Description .................................................................................... 2
2. Electrical Component .................................................................................. 6
3. AT Shift Lock System .................................................................................. 8
4. Select Lever .............................................................................................. 23
5. Select Cable .............................................................................................. 26
6. AT Shift Lock Solenoid and “P” Position Switch ........................................ 29
7. Integrated Module ..................................................................................... 31
8. MT Gear Shift Lever .................................................................................. 32
9. General Diagostic...................................................................................... 38
c- .
GENERAL DESCRIPTION
I
CONTROL SYSTEMS
1. General Description
A: SPECIFICATIONS
I Item I Specification -1
I Vibration torque of rod against lever N.m (kgf-m, ft-lb) I 0.7 (0.07, 0.5) or less
cs-2
GENERAL DESCRIPTION
I
CONTROL SYSTEMS
B: COMPONENT
1. AT SELECT LEVER
.‘
‘-
.‘
‘ I
I
. .‘ ‘-A ‘
TR054t
Indicator light bulb Cushion (25) Slider

Detent arm Guide plate (26) Clip
Detent spring Snap pin (27) “P” position switch
Select lever Outer cable (28) Spring
Spring pin Inner cable (29) Button
Arm Nut B
Pin Nut A Tightening torque: N.m (kgf-m, fi-lb)
Plate Clip T1: 7.5 (0.76, 5.5)
Grommet Lock plate T2: 13 (1.3, 9.4)
Packing Shift lock solenoid T3: l S ( 1 . 8 , 13.0)
Grip Clamp T4: 33 (3.4,25)
Indicator cover Cover
cs-3
I CONTROL SYSTEMS
GENERAL DESCRIPTION
2. MT GEAR SHIFT LEVER
TI30594
(1) Gear shift knob (IO) O-ring A (19) Stay

(2) Console boot (11) O-ring B (20) Spacer
(3) Plate complete (12) BushA
(4) Lever (13) Cushion rubber Tightening torque: N-m (kgf-m, ft-lb)
(5) Bush (14) Bush6 T1: 7.5 (0.76, 5.5)
(6) Bush (15 ) Joint T2: 12 (1.2, 8.7)
(7) Locking wire (16) Rod T3: lS(1.8, 13.0)
(8) Boot (17) Bracket
(9) Snap ring (18) Washer
cs-4
GENERAL DESCRIPTION I
CONTROL SYSTEMS
C: CAUTION
Wear working clothing, including a 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.
c. 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
sure to disconnect the negative terminal from bat-
tery.
cs-5
I ELECTRICAL COMPONENT
CONTROL SYSTEMS
2. Electrical Component
A: LOCATION
(1) Inhibitor switch (4) Key warning switch (7) Key lock solenoid
(2) Integrated module (5) Shift lock solenoid
(3) Stop light switch (6) “P” position switch
CS-6
ELECTRICAL COMPONENT
I
CONTROL SYSTEMS
(2)
\ \o\ ' B2M2246E TR0548
TR0549
cs-7
I
AT SHIFT LOCK SYSTEM
CONTROL SYSTEMS
3. AT Shift Lock System

A: ELECTRICAL SPECIFICATION
10 9 8 7 6 5 4 3 2 1
16 15 14 13 12 11 10 9 20 19 18 17 16 15 14 13 12 11
I BO031 1
InpuVOutput signal
Contents Connector No. Terminal No.
Measured value and measuring conditions
Battery power supply 8281 2 9-16V
Ignition power supply B280 19 10 - 15 V when ignition switch is at ON or START.
Ignition power supply 8280 10 10 - 15 V when ignition switch is at ACC.
0 V when select lever is in “ P position.
Inhibitor Switch (“P” position) 8280 5 9 - 16 V when select lever is in other positions than “ P
oosition.
Stop light switch I B280 I 9

9 - 16 V when stop light switch is ON.
0 V when stop light switch is OFF.
I “P” position switch I B280

0 V when select lever is in “ P position.
9 - 16 V when select lever is in other positions than “P”
position.
8.5 - 16 V when shift lock is released.
Shift lock solenoid signal 8281 9
0 V when shift lock is oPeratina.
I
9 - 16 V when key is inserted.

Key warning switch signal 6280 20
0 V when key is removed.
7.5 - 16 V when turning ignition switch to ON, select
Key lock solenoid signal 8281 3 lever is in “P” position and brake switch is ON.
0 V at other conditions than above. .
Ground B281 4 -
Ground B281 13 -
CS-8
I
CONTROL SYSTEMS
B: SCHEMATIC
OQ
(2)
0
0 c----
L
(4)
(1) Ignition switch (4) integrated module (7) Shift lock solenoid
(2) Stop light switch (5) Inhibitor switch (8) “P” position switch
(3) Key warning switch (6) Key lock solenoid (9) Battery
cs-9
CONTROL SYSTEMS
C: INSPECTION
Step Check Yes NO
CHECK SHIFT LOCK. While brake pedal is Go to step 2. Inspect “SELECT
1)Turn the ignition switch ON. depressed, can select lever LEVER CANNOT
2)Move the select lever to “P” position. move from “ P range to other BE SHIFT
positions? LOCKED. <Ref.
to CS-I4, SELECT
LEVER CANNOT
BE SHIFT
LOCKED,
INSPECTION, AT
Shift Lock Sys-
tem.>
! CHECK SHIFT LOCK. While brake pedal is not Inspect “SELECT Go to step 3.
depressed, can select lever LEVER SHIFT
move from “P” range to other LOCK CANNOT
positions? BE RELEASED.
<Ref. to CS-16,
SELECT LEVER
SHIFT LOCK
CANNOT BE
RELEASED,
INSPECTION, AT
Shift Lock Sys-
tem.>
I CHECK KEY INTERLOCK. When select lever is in other Inspect “KEY 4T shift lock sys-
than “P” position, does ignition INTERLOCK em is normal.
switch turn to “LOCK position? DOES NOT BE
Or when select lever is in “ P LOCKED OR
position, does ignition switch RELEASED. <Ref.
turn to “LOCK position? to CS-20, KEY
INTERLOCK
DOES NOT LOCK
OR RELEASE,
INSPECTION, AT
Shift Lock Sys-
tem.>
cs-10
CONTROL SYSTEMS
cs-11
CONTROL SYSTEMS
1. INTEGRATED MODULE POWER SUPPLY AND GROUND LINE

WIRING DIAGRAM:
r 0
P 0
z
I
A: @
I I
-
-
TR0551
cs-12
AT SHIFT LOCK SYSTEM 1
CONTROL SYSTEMS
~
Step Check Yes No

CHECK FUSE (No. 3 , 4 and 11). s the fuse (No. 3,4 or 11) 3eplace the fuse So to step 2.
1)Aemove the fuse (No. 3 , 4 and 11). )lawn out? :No. 3, 4 or 11). If
he replaced fuse
:No. 3,4 or 11)
ias blown out eas
ly, repair short cir-
:uit in harness
letween fuse and
ntegrated module.
! CHECK HARNESS CONNECTOR BETWEEN s the resistance less than 1 30 to step 3. Repair open circuit
INTEGRATED MODULE AND BODY 2? in harness
GROUND. between inte-
1)Turn the ignition switch to OFF. grated module and
2)Measure the resistance of harness between body ground.
integrated module and chassis ground.
Connector & terminal
(8281) No. 4 - Chassis ground:
-
(8281) No. 13 Chassis ground:
I CHECK BATTERY POWER SUPPLY. s the voltage more than 9 V? 30 to step 4. Repair open circuit
1)Turn the ignition switch to ON (engine OFF). harness between
2)Measure the voltages between integrated battery and inte-
module and chassis ground. grated module,
Connector & terminal and poor contact
(8281) No. 1 (+) - Chassis ground (-): in coupling con-
nector.
I CHECK IGNITION POWER SUPPLY CIR- s the voltage more than 9 V? So to step 5. Repair open circuit
CUIT. harness between
1)Tufn the ignition switch to ACC. battery and inte-
2)Measure the voltage between integrated grated module,
module and chassis ground. and poor contact
Connector & terminal in coupling con-
(8280) No. 10 (+) - Chassis ground (-): nector.
> CHECK IGNITION POWER SUPPLY CIR- s the voltage more than 9 V? Go to step 6. Repair open circuit
CUIT. harness between
1)Turn the ignition switch to ON (engine OFF). battery and inte-
2)Measure the voltage between integrated grated module,
module and chassis ground. and poor contact
Connector & terminal in coupling con-
(8281) No. 19 (+) - Chassis ground (-): nector.
i CHECK POOR CONTACT. s there poor contact in power Repair poor con- Replace the inte-
;upply and ground line circuit? tact. grated module.
CS-13
CONTROL SYSTEMS
2. SELECT LEVER CANNOT BE SHIFT LOCKED

WIRING DIAGRAM:
SBF-1
STOP LIGHT
A: @
B: @ INTEGRATED MODULE
I la1
I
1I SHIFT LOCK
I SOLENOID
Is
OC :WITHOUT CRUISE CONTROL MODEL
WC :WITH CRUISE CONTROL MODEL
TR0552
cs-14
CONTROL SYSTEMS
Step Check Yes No

I CHECK STOP LIGHT SWITCH. Does the stop light turn ON? Go to step 2. Inspect the stop
Depress the brake pedal. light system.
2 CHECK HARNESS BETWEEN STOP LIGHT Is the resistance more than 1 Repair open circuit So to step 3.
SWITCH AND INTEGRATED MODULE. MR? in harness
1)Turn the ignition switch to OFF. between inte-
2)Disconnect the integrated and stoplight grated module and
switch connector. stop light switch.
3)Measure the resistance of harness between
stop light switch and integrated module.
Without cruise control model
(864) NO. 1 - (B280) NO. 9:
(B65) NO. 3 - (8280) NO. 9:
3 CHECK HARNESS BETWEEN STOP LIGHT Is the resistance less than 1 Repair short circuit Go to step 4.
SWITCH AND INTEGRATED MODULE. n? in harness
Measure the resistance of harness between between inte-
stop light switch and chassis ground. grated module and
Connector & terminal stop light switch.
(B64) No. 1 - Chassis ground:
4 CHECK HARNESS BETWEENINTEGRATED Is the resistance more than 1 Repair open circuit Go to step 5.
MODULE AND SHIFT LOCK SOLENOID. MR? in harness
1)Disconnect the shift lock solenoid connector between inte-
2)Measure the resistance of harness between grated module and
integrated module and shift lock solenoid.. shift lock solenoid.
(B116) NO. 4 - (8281) NO. 9:
5 CHECK HARNESSBETWEENINTEGRATED Is the resistance less than 1 Repair short circuit Go to step 6.
MODULE AND SHIFT LOCK SOLENOID. Q? in harness
shift lock solenoid and chassis ground. grated module and
Connector & terminal shift lock solenoid.
( B l l 6 ) No. 4 - Chassis ground:
6 CHECK HARNESS BETWEEN SHIFT LOCK Is the resistance more than 1 Repair open circuit Go to step 7.
SOLENOID AND CHASSIS GROUND. MR? in harness
Measure the resistance of harness between between shift lock
shift lock solenoid and chassis ground. solenoid and body
Connector & terminal ground.
7 CHECK SHIFT LOCK SOLENOID. Is the resistance between 10 Go to step 8. Replace the shift
Measure the resistance of shift lock solenoid and 20 R? lock solenoid.
connector terminals.
Terminal
NO. 4 -NO. 5:
8 CHECK SHIFT LOCK SOLENOID. Does the shift lock solenoid Go to step 9. Replace the shift
Connect the battery with shift lock solenoid operate properly? lock solenoid.
connector terminal and operate solenoid.
Terminal
-
NO. 4 (+) NO. 5 (--)I
9 CHECK POOR CONTACT. Is there poor contact in key Repair poor con- Replace the inte-
lock circuit? tact. grated module.
CS-15
CONTROL SYSTEMS
3. SELECT LEVER SHIFT LOCK CANNOT BE RELEASED

WIRING DIAGRAM:
INHIBITOR STOP LIGHT

SWITCH SWITCH
I
A: @
B: @ INTEGRATED MODULE
I SHIFT LOCK
~
I SOLENOID
B
m n
11213]4]516171819110
11~12~13~14]15]16~17~18~19~20
9 10 11 12
TR0553
CS-16
AT SHIFT LOCK SYSTEM I
CONTROL SYSTEMS
~ ~
Step Check Yes No

CHECK INHIBITOR SWITCH. ;ombination meter indicator Go to step 2. 4djust inhibitor
1)Turn the ignition switch to ON (engine OFF). amp and select lever “ P , “R”, ;witch and select
2)Move the select lever from “P”to “1” range. IN”, “ 3 , “ 2 and “1” are cor- :able.
.ectly matched?
CHECK HARNESS BETWEEN INHIBITOR s the resistance less than 1 Repair short circuit 30 to step 3.
SWITCH AND INTEGRATED MODULE. n? in harness
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.
CHECK HARNESS BETWEEN INHIBITOR s the resistance more than 1 Repair open circuit 30 to step 4.
SWITCH AND INTEGRATED MODULE. WR? in harness
integrated module and inhibitor switch. grated module and
Connector & terminal transmission con-
(612) NO. 3 - (6280) NO. 5: nector
CHECK HARNESS BETWEEN INHIBITOR s the resistance less than 1 Go to step 5. Sepair open circuii
SWITCH AND CHASSIS GROUND. n? n harness
Measure the resistance of harness between 2etween inte-
integrated module and chassis ground. Jrated module and
Connector & terminal :hassis ground.
(612) No. 4- Chassis ground:
CHECK INHIBITOR SWITCH. s the resistance more than 1 Repair or replace 30 to step 6.
1)Move the select lever to “ P position. wn? inhibitor switch.
2)Measure the resistance of transmission har-
ness connector terminals.
(T3) NO. 3 - NO. 4:
CHECK OUTPUT SIGNAL FOR INTEGRAT- Is the voltage between 9 and Go to step 7. 30 to step 15.
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.
(6280) 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. iystem.
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 ana
2)Measure the voltage between integrated itop light switch.
CHECK HARNESS BETWEENINTEGRATED Is the resistance more than 1 Repair open circuit Go to step 10.
MODULE AND SHIFT LOCK SOLENOID. MR? in harness
2)Disconnect the connector from shift lock grated module and
solenoid and integrated module. shift lock solenoid.
integrated module and shift lock solenoid.
(6281) NO. 9 - (61161 NO. 4:
CS-17
I AT SHIFT LOCK SYSTEM
CONTROL SYSTEMS
Step Check Yes No

IO CHECK HARNESS BETWEENINTEGRATEC Is the resistance less than 10 Go to step 11. Repair short circui
MODULE AND SHIFT LOCK SOLENOID. R? in harness
shift lock solenoid and chassis ground. grated module an(
Connector & terminal shift lock solenoid
I1 CHECK HARNESS BETWEEN SHIFT LOCK Is the resistance less than 1 Go to step 12. Repair open circui
SOLENOID AND CHASSIS GROUND. n? in harness
Measure the resistance of harness between between shift lock
shift lock solenoid and chassis ground. solenoid and chas
Connector & terminal sis ground.
( 6 1 16) No. 5 - Chassis ground:
12 CHECK SHIFT LOCK SOLENOID. Is the resistance between 10 Go to step 13. Replace the shift
Measure the resistance of shift lock solenoid and 20 R? lock solenoid.
Terminal
NO. 4 - NO. 5:
13 CHECK SHIFT LOCK SOLENOID. Is shift lock solenoid operating So 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. 5I)-(
14 CHECK OUTPUT SIGNAL FOR AT SHIFT Is the voltage more than 8.5 V? 30 to step 15. Replace the inte-
LOCK CONTROL MODULE. grated module.
1)Turnthe ignition switch to ON (engine OFF).
(6281) No. 9 (+) - Chassis groundI)-(
5 CHECK POOR CONTACT. Is there poor contact in key 3epair poor con- Replace the inte-
lock circuit? act. grated module.
CS-18
AT SHIFT LOCK SYSTEM I
CONTROL SYSTEMS
cs-19
CONTROL SYSTEMS
4. KEY INTERLOCK DOES NOT LOCK OR RELEASE

WIRING DIAGRAM:
(D
>
a
si E
$ 0
c.
TR0554
cs-20
I AT SHIFT LOCK SYSTEM
I
CONTROL SYSTEMS
Step Check Yes No

CHECK HARNESS BETWEEN BATTERY s the voltage between 9 and 30 to step 2. 3epair open or
AND KEY WARNING SWITCH. I6 V? short circuit in har-
1)Disconnectthe connector key warning less between bat-
switch. :ery and key
2)Measure the voltage of harness between key Narning switch.
warning switch and chassis ground.
CHECK KEY WARNING SWITCH. Is the resistance more than 1 3eplace key warn- 30 to step 4.
Measure the resistance of stop light switch WR? ng switch.
Terminal
NO. 1 - NO. 2:
CHECK KEY WARNING SWITCH. Is the resistance more than 1 30 to step 4. Replace key warn-
1)Remove the key. MR? ing switch.
2)Measure the resistance of stop light switch
Terminal
NO. 1 - NO. 2:
CHECK HARNESS BETWEEN AT SHIFT Is the resistance more than 9 30 to step 5. Repair open circuit
LOCK CONTROL MODULE AND KEY V? in harness
WARNING SWITCH. between inte-
1)Disconnectthe integrated module connector. grated module and
2)Measure the voltage of harness integrated key warning
module and chassis ground. switch.
CHECK HARNESS BETWEENINTEGRATED Is the resistance more than 1 Repair open circuit Go to step 6.
MODULE AND KEY LOCK SOLENOID. MR? n harness
1)Disconnectthe connector key lock solenoid. setween inte-
2)Measure the resistance of harness between grated module and
integrated module and key lock solenoid. cey lock solenoid.
(873) NO. 2 - (8281) NO. 3:
CHECK HARNESS BETWEEN INTEGRATED Is the resistance more than 1 Go to step 7. Repair short circuit
MODULE AND KEY LOCK SOLENOID. R? in harness
integrated module and chassis ground. grated module and
Connector & terminal key lock solenoid.
CHECK HARNESS BETWEEN KEY LOCK Is the resistance less than 10 Go to step 8. Repair open circuit
SOLENOID AND CHASSIS GROUND. a? in harness
Measure the resistance of harness between between key lock
key lock solenoid and chassis ground. solenoid and chas
Connector & terminal sis ground.
CHECK KEY LOCK SOLENOID. Is the resistance between 4 Go to step 14. Replace the key
Measure the resistance of key lock solenoid and 8 R? lock solenoid.
(873) NO. 1 -NO. 2:
CHECK HARNESS BETWEEN “P” POSI- Is the resistance less than 1 Go to step 10. Repair short circuil
TION SWITCH AND CHASSIS GROUND. R? in harness
Measure the resistance of harness between between “P” posi-
“ P position switch and chassis ground. tion switch and
Connector & terminal integrated module
cs-21
CONTROL SYSTEMS
Step Check Yes No

IO CHECK HARNESS BETWEEN AT SHIFT s the resistance more than 1 Repair open circuit Go to step 11.
LOCK CONTROL MODULE AND “P” POSI- AQ? in harness
TION SWITCH. between inte-
1)Disconnectthe connector from “ P position grated module and
switch. “P” position switch.
integrated module and “ P position switch.
(B116) NO. 2 - (8280) NO. 6:
I1 CHECK HARNESS BETWEEN “P” POSI- s the resistance more than 1 IGo to step 12. Repair open circuit
TlON SWITCH AND CHASSIS GROUND. JIR? in harness
Measure the resistance of harness “P”position between “P” posi-
switch and chassis ground. tion switch and
Connector & terminal shassis ground.
( B l l 6 ) No. 6 - Chassis ground:
I2 CHECK “P” POSITION SWITCH. s the resistance less than 1 Go to step 13. Replace the “P”
1)Move the select lever to “P” position. 2? aosition switch.
2)Measure resistance between “ P position
switch connector terminals.
Terminal
NO. 2 - NO. 6:
k . CHECK “P” POSITION SWITCH. s the resistance more than 1 Go to step 14. Replace the “P”
1)Move the select lever to other than “P” posi- JIQ? position switch.
tion.
Terminal
NO. 2 - NO. 6:
4 CHECK OUTPUT SIGNAL FOR INTEGRAT- s the voltage 7.5 and 16 V? 30 to step 15. Replace the inte-
ED MODULE. grated module.
2)Turn the ignition switch to ON (engine OFF).
3)Move the select lever to “P” position.
4)Press the brake pedal.
module connector and chassis ground.
I5 CHECK POOR CONTACT. s there poor contact in AT shift Repair poor con- Replace the inte-
x k circuit? tact. grated module.
cs-22
SELECT LEVER
I
CONTROL SYSTEMS
4. Select Lever B: INSTALLATION

1) Mount the select lever onto the vehicle body.
A: REMOVAL 2) Tighten the four bolts to install the select lever to
1) Set the vehicle on the lift. the vehicle body, then connect the connector.
2) Disconnect the ground terminal from battery.
Tightening torque:
3) Move the select lever to the “N” position.
13 N.m (1.3 kgf-m, 9.4 ft-lb)
4) Lift-up the vehicle.
5) Remove the rear exhaust pipe and muffler.
6) Remove the heat shield cover. (If equipped)
7) Disconnect the cable from select lever and then
remove the cable bracket.
3) Install the console box. <Ref. to El-39, INSTAL-

LATION, Glove Box.>
4) Set the location of select lever at ‘IN” position.
6) Set the location of range select lever to “N” posi-
(A) Adjusting nuts tion.
(B) Cable bracket 7) Insert the thread portion of the other inner cable
and into the connector hole of the select lever, and
8) Lower the vehicle. fix the other outer cable end to the bracket.
9) Remove the console box. <Ref. to El-41, RE- 8) Adjust the select cable position. <Ref. to CS-27,
MOVAL, Console Box.> ADJUSTMENT, Select Cable.>
10) Disconnect the connectors, then remove the 9) After completion of fitting, make sure that the se-
four bolts to take out the select lever assembly from lect lever operates smoothly all across the operat-
the body. 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 operating 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 ‘W, but not in other positions.
(3) Select lever and indicator positions are
I1510
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
I
CONTROL SYSTEMS
C: DISASSEMBLY 6) Remove the lock plate.

1) Remove the grip.
2) Remove the indicator light and then remove the n
indicator cover.
NOTE:
Be careful not to break the indicator light during re-
moval.
v
TR0556
7) Remove the pattern plate.
B3M1511A
(A) Grip
c. ~ (B) Indicator cover
(C) indicator light
3) Remove the slider. TR0557

4) Remove the clips and then remove the guide
8) Remove the clip and remove the “P” position
plate. switch.
I
I 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.
I TR0555
B3M1797A
(A) Clamp
(A) Straight pin
(B) Shift lock solenoid
(B) Select lever lower
CS-24
I
SELECT LEVER
CONTROL SYSTEMS
10)Remove the select lever lower then take away

the select lever upper from plate.
dA’ B3M1848A
(A) Select lever lower

(B) Select lever upper
(C) Plate
1 1 ) 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. <Ref. to CS-3, AT Select Le-
ver.>
3) Assembly is in the reverse order of disassembly.
4) After completion of fitting, transfer the select le-
ver to range “P” - “l”, 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
I I
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.
3) Prior to removal, set the lever to “N” position.
5) Remove the front and center exhaust pipe. (Non-
turbo model) <Ref. to EX(S0HC)-5, REMOVAL,
Front Exhaust Pipe.>
CAUTION:
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
<Ref. to EX(D0HC TURBO)-8, REMOVAL, Center (B) Cable bracket
Exhaust Pipe.>
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.
(A) Range select lever

(B) Snap pin
(C) Select cable
(D) Clamp
9) Remove the plate assembly from transmission
case
(A) Select cable

(B) Plate ASSY
(C) Clamp
CS-26
I SELECT CABLE
I
CONTROL SYSTEMS
B: INSTALLATION C: INSPECTION
1) Install the select cable to plate assembly. Check the removed cable and replace if damaged,
rusty, or malfunctioning.
Tightening torque:
1) Check for smooth operation of the cable.
32 N.m (3.3 kgf-m, 24 fi-lb)
2) Check the inner cable for damage and rust.
2) Install the select cable to range select lever. 3) Check the outer cable for damage, bends, and
3) Install the plate assembly to transmission. cracks.
Tightening torque: 4) Check the boot for damage, cracks, and deterio-
T: 24.5 N-m (2.5 kgf-m, 18.1 ft-lb) 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
3) Set the lever to “N” position.
c.
(A) Select cable 6) Remove the heat shield cover. (If equipped)
(B) Plate ASSY 7) Loosen the adjusting nut on each side.
4) Install the snap pin to range select lever
I / 03M1792A
(A) Adjusting nut A

(B) Adjusting nut B
(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(S0HC)-6, INSTALLA-
TION, Front Exhaust Pipe.>
8) Install the center exhaust pipe. (Turbo model)
<Ref. to EX(D0HC TURBO)-9, INSTALLATION,
Center Exhaust Pipe.>
CS-27
I SELECT CABLE
CONTROL SYSTEMS
8) Turn the adjusting nut B until it lightly touches the

connector.
(A) Front side

(B) Select lever
(C) Connector
(D) Adjusting nut B
(E) Contact point
(F) Adjusting nut A
S).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-lb)
(A) Adjusting nut A

(B) Adjusting nut B
10) After completion of fitting, make sure that the

select lever operates smoothly all across the oper-
ating range.
11) Install in the reverse order of removal.
CS-28
AT SHIFT LOCK SOLENOID AND “P” POSITION SWITCH I
CONTROL SYSTEMS
6. AT Shift Lock Solenoid and 6 : INSTALLATION

“P” Position Switch Install in the reverse order of removal.
A: REMOVAL
2) Remove the console box. <Ref. to El-41, RE-
MOVAL, Console Box.>
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
I AT SHIFT LOCK SOLENOID AND “P” POSITION SWITCH
CONTROL SYSTEMS
C: INSPECTION
Step Check
1 CHECK SHIFT LOCK SOLENOID.
Measure the resistance of shift lock solenoid and 20 R? lock solenoid and
connector terminals. “ P position switch
Terminal assembly.
NO. 4 - NO. 5
2 CHECK SHIFT LOCK SOLENOID. Is the shift lock solenoid oper- Go to step 3. Replace the shift
Connect the battery with shift lock solenoid ating properly? lock solenoid and
connector terminal, operate solenoid. “ P position switch
Terminal assembly.
NO. 4 (+) - NO. 5 (-)
3 CHECK “P” POSITION SWITCH. Is the resistance less than 1 Go to step 4. Replace the “ P
1)Move the select lever to “ Pposition. n? position switch.
4 CHECK “P” POSITION SWITCH. Is the resistance more than 1 Normal Replace the “P”
1)Move the select lever to other than “P” posi- MR? position switch.
tion.
2)Measure resistance between “P” position
CS-30
INTEGRATED MODULE
I
CONTROL SYSTEMS
7. Integrated Module B: INSTALLATION

Install in the reverse order of removal.
A: REMOVAL
1 ) Disconnect the ground terminal from battery.
2 ) Remove the lower cover.
3) Remove the knee bolster.
4) Disconnect the connector from integrated mod-

ule.
5) Remove the integrated module.
CS-31
I MT GEAR SHIFT LEVER
I
CONTROL SYSTEMS
8. MT Gear Shift Lever 11) Remove the cushion rubber from body.
A: REMOVAL
2) Remove the gear shift knob.
4) Remove the console box. <Ref. to El-41, RE-
MOVAL, Console Box.>
5) Remove the boot plate from body.
(A) Stay
(B) Cushion rubber
12) Remove the joint and then extract the spring
pin.
@.Lift-up the vehicle.

9) Remove the stay from transmission bracket.
(A) Joint
(B) Spring pin
13) Lower the vehicle.

14) Remove the gear shift lever
(A) Stay
(B) Transmission bracket
10) Remove the rod from joint.
CS-32
MT GEAR SHIFT LEVER
I
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, 73.0 ff-lb)
2) Insert the gear shift lever from room side.
NOTE:
After inserting the rod and stay, temporarily put
them onto transmission mount.
(A) Stay
(B) Rod
8) Connect the stay to transmission bracket.

3) Lift-up the vehicle. Tightening torque:
c4) Install the joint to shifter arm.
.
18 N-m (1.8 kgf-m, 13.0 ff-lb)
5) Insert the spring pin.
(A) Stay
(A) Joint
(B) Transmission bracket
(B) Spring pin
6) Mount the cushion rubber on the body. IO) Install the rear exhaust pipe and muffler.
Tightening torque: 1 1 ) Lower the vehicle.
18 N-m (1.8 kgf-m, 13.0 ff-lb) 12) Install the boot plate to body.
Tightening torque:
7.5 N.m (0.76 kgf-m, 5.5 ff-lb)
13) Install the consol box. <Ref. to El-41, INSTAL-
LATION, Console Box.>
(A) Stay
(B) Cushion rubber
cs-33
I
CONTROL SYSTEMS
C: DISASSEMBLY 5) Remove the bush and cushion rubber from stay.

1) Disassemble the locking wire.
B3M08300
' ' B3M0617C

(A) Bushing
(A) Locking wire (B) Stay
(B) Stay (C) Cushion rubber
2) Remove the rod from gear shift lever. 6) Remove the O-ring, then disconnect the bush D.
- B3M1828A
(A) Rod (A) O-ring B

(B) Gear shift lever (B) O-ring A
(C) Stay (C) Bushing B
3) Remove the snap ring from bush B, then discon- 7) Draw out the spring pin, then remove the bush C
nect the stay. from gear shift lever.
B3M0619B 83M0621B
(A) Snap ring (A) Spring pin

(B) Bushing B (B) BushingA
(C) Boot
4) Remove the boot from gear shift lever.
cs-34
MT GEAR SHIFT LEVER
I
CONTROL SYSTEMS
D: ASSEMBLY 4) Insert the gear shift lever into the boot hole.
1) Clean all parts before assembly. 5) Install the snap ring and stay to the bushing B.
2) Mount the bushing B and cushion rubber on the
stay.
B3M0619C
B3M0830C
(A) Snap ring
(6) Bushing B
(A) Bushing
6) Tighten with locking wire to the extent that the
(6) Cushion rubber boot will not come off.
3) Mount each part; boot, O-ring, bush, spacer, CAUTION:
bush A, bush B and straight pin on the gear shift le- Always use new locking wire.
..-
-
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.
L(A)
(6)
(C)
(D)
(E)
(F)
Boot
O-ring B
Bushing
Spacer
BushingA
Bushing E3
B3M0623C
(A) Locking wire
(6) Stay
7) Insert the rod into the boot hole.

8) Connect the rod to gear shift lever.
Tightening torque:
11.8 N.m (1.2 kgf-m, 8.7 fi-lb)
n
(G) Spring pin
(H) O-ring A
(A) Rod
(6) Shift lever
(C) Stay
cs-35
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: Determine defective parts by comparing with new
0.7 N.m (0.07 kgf-m, 0.5 ft-lb) or less parts.
(A) Center of rotation

(6) Swing torque
70) Check that there is no excessive play and that

parts move smoothly.
B3M7 765A
(A) Bushing
(6) Cushion rubber
(C) Spacer
(D) Boot
(E) Stay
(F) Rod
CS-36
MT GEAR SHIFT LEVER 3
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 N-m (0.07 kgf-m, 0.5 ff-lb) or less
(6)
B3M1829C
(A) Center of rotation

(B) Swing torque
cs-37
GENERAL DlAGOSTlC
CONTROL SYSTEMS
9. General Diagostic
A: INSPECTION
Symptom Problem Darts
Stop light switch
Shift lock does not function. Shift lock solenoid
Integrated module
Stop light switch
Shift lock solenoid
Shift lock cannot be released.
Integrated module
Inhibitor switch
Key warning switch
“ P position switch
Key interlock does not function.
Key lock solenoid
Integrated module
Key warning switch
“ P position switch
Key interlock cannot be released.
Key lock solenoid
Integrated module
Inhibitor switch
Starter does not run. Select cable
Starter circuit
Inhibitor switch
Back-up light does not light up. Select cable
Back-up light circuit
CS-38
I
AUTOMATIC TRANSMISSION
AT
1.
Page
General Description .................................................................................... 2
a
2. Automatic Transmission Fluid ..................................................................... 9
3. Differential Gear Oil ................................................................................... 11
4. Road Test .................................................................................................. 12
5. Stall Test ................................................................................................... 13
6. Time Lag Test ........................................................................................... 15
7. Line Pressure Test .................................................................................... 16
8. Transfer Clutch Pressure Test .................................................................. 18
9. Automatic Transmission Assembly ........................................................... 19
C. . 10. Transmission Mounting System ................................................................ 25
11. Extension Case Oil Seal ........................................................................... 27
12. Inhibitor Switch .......................................................................................... 28
13. Front Vehicle Speed Sensor ..................................................................... 32
14. Rear Vehicle Speed Sensor ...................................................................... 35
15. Torque Converter Turbine Speed Sensor ................................................. 36
16. Control Vatve Body ................................................................................... 37
17. Shift Solenoids. Duty Solenoids and ATF Temperature Sensor ...............39
18. ATF Filter .................................................................................................. 44
19. Transmission Control Module (TCM) ........................................................ 45
20 . Dropping Resistor ..................................................................................... 46
21. ATF Cooler Pipe and Hose ....................................................................... 47
I GENERAL DESCRIPTION
I
1. General Description 4. TRANSMISSION GEAR RATIO
A: SPECIFICATIONS Model I Sedan non-turbo

I Except sedan
non-turbo I
1. TORQUE CONVERTER CLUTCH 1st I 3.027 I 2.785 I
Model Non-turbo Turbo
2nd I 1.619 I 1.545 I
3rd 1.ooo
Symmetric, 3 element, single stage, 2 phase
Type 4th 0.694
torwe converter
ratio torque I 1.9 - 2.1 I 1.85-2.15

5. PLANETARY GEAR AND PLATE
Nominal
diameter I 246 mm (9.69 in)
1-1
speed
(at sea level)
2,100 - 2,600 rpm 1 2,600 - 3,300 rpm
Model
I “ 1
Turbo
One-way
clutch
1 Sprague type one-way clutch
Front sun gear number of
teeth
33
Front pinion number of teeth I 21

2. OILPUMP Front internal gear number
75
of teeth
I Type I Pracoid constant-displacementpump I Rear sun gear number of
37 42
LDriving method I Driven by engine teeth
Inner rotor 9 Rear pinion number of teeth I 19 I 17
3. TRANSMISSION CONTROL ELEMENT Drive & driven plate number

4 5
of high clutch
4-forward, 1-reverse, double-row plane- Drive & driven plate number
Type 6 7
tary gears of low clutch
I I
Multi-Dlate clutch 3 sets
I Multi-plate brake I
One-way clutch
(sprague type)
2 sets
1 sets
I
Drive & driven plate number
of 2-4 brake
Drive & driven plate number
of low & reverse brake
1
AT-2
6. SELECTOR POSITION 8. COOLING AND HARNESS
P (Park)
Transmission in neutral, output member immov.
able, and engine start possible
Cooling system
I Liquid-cooledcooler incorpo-
rated in radiator I
Transmission in reverse for backing
(Reverse) I Transmission harness I 20 poles I
tral) 9. TRANSFER
Automatic gear change 1st e + 2nd +_) 3rd
D (Drive) Model Non-turbo Turbo
+ 4th
Multi-plate Variable torque

Automatic gear change 1st e + 2nd +_)3rd t Transfer type transfer distribution
4th (MPT) (VTD)
2nd gear locked (Deceleration possible 2nd t Drive & driven plate
2 (2nd)
3rd c 4th)
1 (1st)
1 1st gear locked (Deceleration possible 1st t
2nd c 3rd t 4th)
number of transfer
clutch
5
I Electronic, hydraulic type

3
Control method I
Control
method I Hydraulic remote control
Lubricant
The same Automatic transmission
fluid used in automatic transmis-
sion
7. HYDRAULIC CONTROL AND LUBRICA- Ist reduction Clear ratio I I.OOO ( 5 ~ 5 3 ) I
JlON
forward speed changes by electri-

cal signals of vehicle speed and
accelerator (throttle) opening]
Fluid
mission fluid
9.3 - 9.6 8 (9.8 - 10.1 US qt,
Fluid capacity
7.4 - 7.7 Imp qt)
Forced feed lubricationwith oil
Lubrication system
,DUmD
,
Automatic transmission fluid
Oil
(above mentioned)
10.FlNAL REDUCTION
I Model Sedan non-turbo Except sedan non-turbo

Front final gear ratio 4.444 (4019) 4.1 11 (37/91
ITEM
Front differential gear oil
API Classification
GL - 5
SAE Viscosity No. and Applicable Temperature
Lubricationoil ("C) -30 -26 -15 -5 0 15 2530
H3M1235A
Front differential oil capacity 1.2 8 (1.3 US qt, 1.1 Imp qt)
AT-3
GENERAL DESCRIPTION
I
B: COMPONENT
NOTE:
For information about other transmission mounting components, refer to “AUTOMATIC TRANSMISSION”
<Pub. No. G0853ZE> a separate publication.
1. TRANSMISSION MOUNTING
’1I
P
t
(1) Pitching stopper Tightening torque: N.m (kgf-m, ft-lb)

(2) Rear cushion rubber T1: 35 (3.6, 26)
(3) Crossmember T2: 39 (4.0,29)
(4) Stopper T3: 50 (5.1, 37)
T4: 58 (5.9, 43)
T5: 70 (7.1, 51)
AT-4
C: CAUTION Use SUBARU genuine gear oil, grease etc. or

Wear working clothing, including a cap, protec- the equivalent. Do not mix gear oil, grease etc. with
tive goggles, and protective shoes during opera- that of another grade or from other manufacturers.
tion. Be sure to tighten fasteners including bolts and
Remove contamination including dirt and corro- nuts to the specified torque.
sion before removal, installation, and disassembly. Place shop jacks or safety stands at the specified
Keep the disassembled parts in order and pro- points.
tect them from dust or dirt. Apply gear oil onto sliding or revolution surfaces
Until the oil pan is removed, do not place with the before installation.
oil pan side facing up to prevent foreign matter from Replace deformed or otherwise damaged snap
entering the valve body. rings with new ones.
Before removal, installation or disassembly, be Before installing O-rings or oil seals, apply suffi-
sure to clarify the failure. Avoid unnecessary re- cient amount of ATF fluid to avoid damage and de-
moval, installation, disassembly and replacement. formation.
When disassembling the-case and other light al- Be careful not to incorrectly install or fail to install
loy parts, use a plastic hammer to force it apart. Do O-rings, snap rings and other such parts.
not pry it apart with a screwdriver or other tool. Before securing a part on a vice, place cushion-
Be careful not to burn your hands, because each ing material such as wood blocks, aluminum plate,
part on the vehicle is hot after running. 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.
D: PREPARATION TOOL
1. SPECIAL TOOLS
~
ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS

398527700 PULLER ASSY Used for removing and installing extension case
roller bearing.
Used for installing extension oil seal.
AT-5
3
I---
498575400 OIL PRESSURE Used for measuring oil pressure.
GAUGE ASSY
I B3M204C
498897200 4DAPTER Used for oil pump housing when measuring
reverse clutch pressure and line pressure.
I B3M2041
498545400 -ILTER WRENCH Jsed for removing and installing ATF filter.
498277200 ;TOPPER SET Jsed for removing and installing automatic trans.
nission assembly to engine.
I B3M2043
AT-6
ILLUSTRATION I TOOLNUMBER DESCRIPTION REMARKS

41099AA020 NGINE SUPPORT Used for supporting engine.
B3M1976 ~
I 41099AA010 INGINE SUPPORT Jsed for supporting engine.

3RACKET
B3M1975
Turbo model :RANK PULLEY Used for removing and installing bolts which hold
499977300 WRENCH torque converter clutch and drive plate.
Non-turbo model
499977100
B2M4157
I 24082AA150
(Newly adopted tool
CARTRIDGE Troubleshooting for electrical systems.
B2M3876
AT-7
GENERAL DESCRIPTION
I

22771AA030 SELECT MONITOR Troubleshooting for electrical systems.
KIT English:
22771AA030 (Without printer)
German:
French:
Spanish:
B2M3877
499267300 STOPPER PIN Used for installing and adjusting inhibitor switch.
B3M2008
2. GENERAL PURPOSE TOOLS
TOOL NAME REMARKS
AT-8
AUTOMATIC TRANSMISSION FLUID I
2. Automatic Transmission (4) Fluid temperature rising speed:

By idling the engine
Fluid Time for temperature rise to 60°C (140°F) with at-
A: INSPECTION mospheric temperature of 0°C (32°F): More than
25 minutes
1) Check the level of the ATF.
<Reference>
(1) Raise the ATF temperature to 60 to 80°C
Time for temperature rise to 30°C (86°F) with atmo-
(140 to 176°F) from 40 to 60°C (104 to 140°F)
spheric temperature of 0°C (32°F): Approx. 8 min-
(when cold) by driving a distance of 5 to 10 km (3
utes
to 6 miles).
By running the vehicle
NOTE: Time for temperature rise to 60°C (140°F) with at-
The level of ATF varies with fluid temperature. Pay mospheric temperature of 0°C (32°F): More than
attention to the fluid temperature when checking oil 10 minutes
level. (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.
B3M1020B B: REPLACEMENT
(A) ATF level gauge 2) Drain the ATF completely.
(B) Upper level CAUTION:
(C) Lower level Directly after the engine has been running, the
(2) Make sure the vehicle is level. After select- ATF is hot. Be careful not to burn yourself.
ing all positions (P, R, N, D, 3, 2, l ) , set the se- NOTE:
lect leveler in “P” range. Measure fluid level with Tighten the ATF drain plug after draining the ATF.
the engine idling. Tightening torque:
NOTE: 25 N-m (2.5 kgf-m, 18.1 ft-lb)
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:
Use care not to exceed the upper limit level. (A) Oil pan
ATF level varies with temperature. Remem- (B) Drain plug
ber that the addition of fluid to the upper limit (C) Differential oil drain plug
mark when the transmission is cold will result 3) Lower the vehicle.
in overfilling of fluid.
AT-9
I AUTOMATIC TRANSMISSION FLUID
I
4) Pour ATF into the oil charge pipe.

Recommended fluid:
Dexron Ill type automatic transmission fluid
Capacity:
Fill the same amount of fluid drained from the
drain plug hole.
Capacity when transmission is overhauled:
9.3-9.6 8 (9.8- 10.1 USqt, 8.2-8.4Imp
qt)
5) Check the level and leaks of the ATF.
<Ref. to AT-9, INSPECTION, Automatic Transmis-
sion Fluid.>
AT-I 0
DIFFERENTIAL GEAR OIL I
3. Differential Gear Oil B: REPLACEMENT

A: INSPECTION 2) Drain the differential gear oil completely.
1) Park the vehicle on a level surface. CAUTION:
2) Remove the oil level gauge and wipe it clean. Directly after the engine has been running, the
3) Reinsert the level gauge all the way. Be sure that differential gear oil is hot. Be careful not to burn
the level gauge is correctly inserted and in the yourself.
proper orientation.
4) Remove it again and note the reading. If the dif- NOTE:
ferential gear oil level is below the “L” line, add oil to Tighten the differential gear oil drain plug after
bring the level up to the “F’ line. draining the differential gear oil.
5) To prevent overfilling the differential gear oil, do Tightening torque:
not add oil above the ‘IF line. 44 N.m (4.5 kgf-m, 32.5 ff-16)
c. .
I s3M0478A
(A) Upper level (A) Oil pan

(B) Lower level (B) Drain plug
(C) Differential oil drain plug

4) Pour gear oil into the gauge hole.
Recommended fluid:
Use GL-5 or equivalent.
Gear oil capacity:
1.2 8 (1.3 US qt, 1.1 Imp qt)
5) Check the level of the differential gear oil.
<Ref. to AT-1 1, INSPECTION, Differential Gear
Oil.>
AT-I 1
ROAD TEST
4. RoadTest
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 a 2nd w 3rd a 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
krick-down shock level.
between D -
5. ENGINE BRAKE OPERATION
Check the 3rd gear engine brake when shifting
3rd range while driving in 4th gear of
D range [50 to 60 km/h (31 to 37 MPH)].
Check the 2nd gear engine brake when shifting
between 3 2 range while driving in the 3 range
3rd gear [40 to 50 km/h (25 to 31 MPH)].
Check the 1st gear engine brake when shifting
between 2 -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 5% 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. CLIMBING 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.
10.01L LEAKS
After the driving test, inspect for oil leaks.
AT-I 2
I STALL TEST
I
5. Stall Test 7) Shift the select lever to Neutral, and cool down
the engine by idling it for more than one minute.
A: INSPECTION 8) Record the stall speed.
9) If the stall speed in “2” range is higher than spec-
1. GENERAL INFORMATION ifications, low clutch slipping and “2-4 brake slip-
The stall test is of extreme importance in diagnos- ping” may occur. To identify it, conduct the same
ing the condition of the automatic transmission and test as above in D range.
the engine. It should be conducted to measure the 10) Perform the stall tests with the select lever in
engine stall speeds in “R” and “2” ranges. the R range.
Purposes of the stall test: NOTE:
1) To check the operation of the automatic trans- Do not continue the stall test for MORE THAN
mission clutch. FIVE SECONDS at a time (from closed throttle, ful-
2) To check the operation of the torque converter ly open throttle to stall speed reading). Failure to
clutch. follow this instruction causes the engine oil and
3) To check engine performance. ATF to deteriorate and the clutch and brake to be
adversely affected.
2. TEST METHODS
Be sure to cool down the engine for at least one
1) Preparations before test: minute after each stall test with the select lever set
(1) Check that the throttle valve opens fully. in the “P’ or ‘IN” range and with the idle speed lower
(2) Check that the engine oil level is correct. than 1,200 rpm.
c _ . (3) Check that the coolant level is correct. If the stall speed is higher than the specified
(4) Check that the ATF level is correct. range, attempt to finish the stall test in as short a
(5) Check that the differential gear oil level is time as possible, in order to prevent the automatic
correct. transmission from sustaining damage.
(6) Increase ATF temperature to 50 to 80°C Stall speed (at sea level):
(122 to 176°F) by idling the engine for approxi- Non-turbo model: 2,100 -2,600 rpm
mately 30 minutes (with select lever set to “N” or Turbo model: 2,600 - 3,300 rpm
lip”).
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 operates
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.
03M1589E
(A) Brake pedal

(B) Accelerator pedal
6) When the engine speed is stabilized, read that

speed quickly and release the accelerator pedal.
AT-1 3
I
STALL TEST
3. EVALUATION
Stall speed (at sea level) Position Cause
Less than specifications Erroneous engine operation

Torque converter clutch's one-way clutch slipping
Line pressure too low
Low clutch slipping
~
One-wav clutch malfunctionim -
Greater than specifications R Reverse clutch slipping
Low & reverse brake slipping
2 Low clutch slipping
I 2-4 brake slipping
AT-I 4
TIME LAG TEST
I
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 &
reverse brake and one-way clutch.
CAUTION:
Perform the test at normal operation fluid
temperature 60 to 80°C (140 to 176°F).
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 (NC 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
“N” + “R”.
Time lag: Less than 1.5 seconds
3. EVALUATION
1) If “N” + ‘ID time lag is longer than specified:
Low clutch worn
One-way clutch not operating properly
2) If “N” + “R” time lag is longer than specified:
Reverse clutch worn
Low & reverse brake worn
AT-I 5
I LINE PRESSURE TEST
7. Line Pressure Test 2. TEST METHODS

1) Temporarily attach the ST to a suitable place in
A: MEASUREMENT the driver’s compartment, remove the blind plug lo-
1. GENERAL INFORMATION cated in front of the toe board and pass the hose of
the ST to the engine compartment.
If the clutch or the brake shows a sign of slippage or ST 498575400 OIL PRESSURE GAUGE
shifting sensation is not correct, the line pressure ASSY
should be checked.
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.
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.
Maintain temperature of ATF at approximate- (A) Pressure gauge hose
ly 50°C (122°F) during measurement. (B) Hole in toe board (blind plug hole)
(ATF will reach the above temperature after (C) Brake pedal
idling the engine for approximately 30 minutes
with select lever in “N” or “P”.) 2) Remove the test plug and install the ST instead.
2) Line pressure measurement (under heavy load):
ST 498897200 OIL PRESSURE GAUGE
ADAPTER
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 when the select le-
ver is in “R”, “2” with engine under stall condi-
tions.
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.) (A) Test plug
Maintain the temperature of ATF at approxi-
mately 50°C (122°F) during measurement. (ATF 3) Connect ST1 with ST2.
will reach the above temperature after idling the ST1 498897200 OIL PRESSURE GAUGE
engine for approximately 30 minutes with the ADAPTER
select lever in “N” or “P”.) ST2 498575400 OIL PRESSURE GAUGE
ASSY
AT-16
LINE PRESSURE TEST
I
4) Check for duty ratio changes by opening and

closing the throttle valve using the Subaru Select
Monitor.
(1) Insert the cartridge to the Subaru Select
Monitor. <Ref. to AT-5, PREPARATION TOOL,
General Description.>
(2) Connect the Subaru Select Monitor to data

link connector.
5 ) Check the line pressure in accordance with the
following chart.
3. EVALUATION
Standard line Dressure 1
Range Line pres- Throttle Line pressure
posi- sure duty position kPa (kgkm’, psi)
tion ratio (Yo)
1,128-1,304
Full open (11.5 - 13.3,
164- 189)
1,520 - 1,716
Full open (15.5 - 17.5,
220 - 249)
304 - 412
D 100 Full closed
(3.1 - 4.2, 44 - 60)
AT-I 7
I TRANSFERCLUTCHPRESSURETEST
8. Transfer Clutch Pressure 2. EVALUATION

Test MTP model
A: INSPECTION NOTE:
If the oil pressure is not produced or if it does not
1. TEST METHODS change in the AWD mode, the transfer duty sole-
noid or transfer valve assembly may be malfunc-
MPT model tioning. If the oil pressure is produced in the FWD
Check the transfer clutch pressure in accordance mode, the problem is similar to that in the AWD
with the following chart in the same manner as with mode.
line pressure. <Ref. to AT-16, Line Pressure Test.>
ST 498897700 OIL PRESSURE ADAPTER Standard transfer clutch Dressure kPa (ka/cm2. Dsi)
SET Duty ratio Throttle
AWD mode
FWD
ST 498575400 OIL PRESSURE GAUGE (%) position mode
ASSY 932 - 1,089
AWD mode: “D” range (9.5-11.1,
closed
FWD mode: “P”range, engine speed 2,000 rpm
2/3 t hrot- 216 - 294
CAUTION: tle (2.2 - 3.0, 31 - 43)
Before setting in FWD mode, install the spare
fuse on FWD mode switch.
c. ~ t 1
Duty ratio Throttle Standard transfer clutch pressure

(Yo) position kPa (kg/cm2,psi)
Full 932 - 1,089
5
closed (9.5-11.1, 135-158)
2/3 throt- 216-294
60
tle (2.2 - 3.0, 31 - 43)
(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 OIL PRESSURE ADAPTER
SET
ST 498575400 OIL PRESSURE GAUGE
ASSY
7
H3M18408
(A) Test plug
AT-I 8
AUTOMATIC TRANSMISSION ASSEMBLY
I
9. Automatic Transmission As- 10) Disconnect the following connectors:

(1) Transmission harness connector
sembly
A: REMOVAL
2) Open the front hood fully, and support it with
stay.
4) Remove the air intake duct. (Non-turbo model)
<Ref. to IN(S0HC)-7, REMOVAL, Air Intake Duct.>
5 ) Remove the air cleaner case. (Non-turbo model)
<Ref. to IN(S0HC)-6, REMOVAL, Air Cleaner
Case.>
6) Remove the air cleaner case stay. (Non-turbo (2) Transmission ground terminal
model) 11) Remove the starter. <Ref. to SC-6, REMOVAL,
Starter.>
12) Install the ST to torque converter clutch case.
ST 498277200 STOPPER SET
7) Remove the intercooler. (Turbo model) <Ref. to

IN(D0HC TURBO)-10, REMOVAL, Intercooler.>
8) Remove the front, center, rear exhaust pipe and
muffler. (Non-turbo model) 13) Remove the pitching stopper.
<Ref. to EX(S0HC)-5, REMOVAL, Front Exhaust
Pipe.>, <Ref. to EX(S0HC)-9, REMOVAL, Rear
Exhaust Pipe.> and <Ref. to EX(S0HC)-1 1, RE-
MOVAL, Muffler.>
9) Remove the center, rear exhaust pipe and
muffer. (Turbo model) <Ref. to EX(D0HC TUR-
BO)-8, REMOVAL, Center Exhaust Pipe.>, <Ref.
to EX(D0HC TURBO)-13, REMOVAL, Rear Ex-
haust Pipe.> and <Ref. to EX(D0HC TURBO)-14,
REMOVAL, Muffler.>
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-I 9
I
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

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

(6) Drain plug
16) Set the ST.
22) Disconnect the ATF cooler hoses from pipes of
NOTE: transmission side, and remove the ATF level gauge
Also is available Part No. 41099AA010. guide.
ST 41 099AA020 ENGINE SUPPORT ASSY
23) Remove the propeller shaft.

<Ref. to DS-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
I
26) Remove the bolt securing ball joint of trans- 30) Remove the transmission rear crossmember
verse link to housing. from vehicle.
S4M0090
27) Remove the spring pins and separate front 31) Remove the transmission.
drive shafts from each side of the transmission. CAUTION:
Move the transmission and torque converter as
a unit away from engine.
Remove the nuts which hold lower side of

transmission to engine.
I 32) Separate transmission assembly and rear
cushion rubber.
v
B3M2047
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.
AT-2 1
I AUTOMATIC TRANSMISSION ASSEMBLY
I
B: INSTALLATION 6) Tighten the nuts and bolts which hold lower side
1) Install the rear cushion rubber to transmission of transmission to engine.
assembly. Tightening torque:
Tightening torque: 50 N-m (5.1 kgf-m, 36.9 ft-lb)
39 N.m (4.0 kgf-m, 29 ft-lb)
2) Install the ST to torque converter clutch case.

8) Connect the engine and transmission.
(1) Remove the ST from torque converter clutch
3) Install the transmission onto engine. case.
-_. (1) Gradually raise the transmission with trans- NOTE:
Be careful not to drop the ST into the torque con-
mission jack.
verter clutch case when removing the ST.
(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-lb)
(2) Engage them at splines.

4) Install the transmission rear crossmember.
Tightening torque:
T1: 35 N-m (3.6 kgf-m, 26 ft-lb)
T2: 70 Nom(7.1 kgf-m, 51.4 ft-lb)
03M2044
5) Take off the transmission jack.
AT-22
1
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:
verter clutch housing. Always use a new spring pin.
Turbo model
Non-turbo model
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.
(3) Clog the service hole with a plug. Tightening torque:
10) Remove the ST. T1: 30 N.m (3.1 kgf-m, 22.4 ft-lb)
T2: 50 N-m (5.1 kgf-m, 37 ft-lb)
11) Install the pitching stopper.

Tightening torque: 15) Install the shift select cable onto select lever.
T1: 50 N.m (5.1 kgf-m, 37 ft-lb) <Ref. to CS-27, INSTALLATION, Select Cable.>
T2: 58 N.m (5.9 kgf-m, 43 ft-lb) 16) Install the ATF level gauge guide, and connect
the ATF cooler hoses to pipe.
AT-23
1
17) Install the propeller shaft. 32) Check the select lever operation.
<Ref. to DS-15, INSTALLATION, Propeller Shaft.> <Ref. to AT-28, INSPECTION, Inhibitor Switch.>
18) Install the heat shield cover. (If equipped) 33) Check the ATF level. <Ref. to AT-9, Automatic
19) Install the front, center, rear exhaust pipes and Transmission Fluid.>
muffler. (Non-turbo model) 34) Check the vehicle on the road tester.
<Ref. to EX(S0HC)-6, INSTALLATION, Front Ex- <Ref. to AT-12, Road Test.>
haust Pipe.>, <Ref. to EX(S0HC)-9, INSTALLA-
TION, Rear Exhaust Pipe.> and <Ref. to
EX(S0HC)-11, INSTALLATION, Muffler.>
20) Install the center, rear exhaust pipes and muf-
fler. (Turbo model) <Ref. to EX(D0HC TURBO)-9,
INSTALLATION, Center Exhaust Pipe.>, <Ref. to
EX(D0HC TURBO)-13, INSTALLATION, Rear Ex-
haust Pipe.>, <Ref. to EX(D0HC TURBO)-14, IN-
STALLATION, Muff ler.>
21) Install the under cover.
23) Install the ATF level gauge.
c. .
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 N.m (1.6 kgf-m, 11.6 ft-16)
26) Install the air cleaner case. (Non-turbo model)
<Ref. to IN(S0HC)-6, INSTALLATION, Air Cleaner
Case.>
27) Install the air intake duct. (Non-turbo model)
<Ref. to IN(S0HC)-7, INSTALLATION, Air Intake
Duct.>
28) Install the intercooler. (Turbo model) <Ref. to
IN(D0HC TURBO)-1 1, 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 Ill type automatic transmission fluid
Fluid capacity:
9.3-9.6 0 (9.8-10.1 USqt, 7.4-7.7lmp
qt)
31) Take off the vehicle from lift arms.
AT-24
TRANSMISSION MOUNTING SYSTEM
I
1O.Transmission Mounting Sys- 6) Set the transmission jack under the transmis-
sion.
tem CAUTION:
A: REMOVAL Make sure that the support plates of trans-
mission jack don't touch the oil pan.
1. PITCHING STOPPER 7) Remove the crossmember.
2) Remove the air intake duct. (Non-turbo model)
3) Remove the air cleaner case. (Non-turbo model)
Case.>
5) Remove the pitching stopper.
8) Remove the rear cushion rubber.

B: INSTALLATION
1. PITCHING STOPPER
Tightening torque:
T I : 50 N.m (5.1 kgf-m, 37 ff-lb)
T2: 58 N.m (5.9 kgf-m, 43 ft-lb)
2. CROSSMEMBER AND CUSHION RUB-
BER
2) Jack-up the vehicle and support it with sturdy
racks.
3) Remove the front, center, rear exhaust pipes
and muffler. (Non-turbo model)
Exhaust Pipe.> and <Ref. to EX(S0HC)-11, RE-
MOVAL, Muffler.>
4) Remove the center, rear exhaust pipes and muf- 2) Install the air intake duct and cleaner case. (Non-
fler. (Turbo model) <Ref. to EX(D0HC TURBO)-8, turbo model) <Ref. to IN(S0HC)-7, REMOVAL, Air
REMOVAL, Center Exhaust Pipe.>, <Ref. to Intake Duct.>, <Ref. to IN(S0HC)-6, REMOVAL,
EX(D0HC TURBO)-13, REMOVAL, Rear Exhaust Air Cleaner Case.>
Pipe.>, <Ref. to EX(D0HC TURBO)-14, REMOV- 3) Install the intercooler. (Turbo model) <Ref. to
AL, Muffler.> IN(D0HC TURBO)-10, REMOVAL, Intercooler.>
CAUTION:
When removing the exhaust pipes, be careful
each exhaust pipe does not drop out.
AT-25
I TRANSMISSION MOUNTING SYSTEM
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 ff-lb) Make sure that the pitching stopper is not bent or
2 ) Install the crossmember. damaged. Make sure that the rubber is not stiff,
cracked, or otherwise damaged.
Tightening torque:
T I : 35 N-m (3.6 kgf-m, 26 ft-lb) 2. CROSSMEMBER AND CUSHION RUB-
T2: 70 N.m (7.1 kgf-m, 51.4 ff-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.
c.
3) Remove the transmission jack.

5 ) Install the front, center, rear exhaust pipes and
the muffler. (Non-turbo model)
<Ref. to EX(S0HC)-6, INSTALLATION, Front Ex-
haust Pipe.>, <Ref. to EX(S0HC)-9, INSTALLA-
TION, Rear Exhaust Pipe.> and <Ref. to
6) Install the center, rear exhaust pipes and muffler.
(Turbo model) <Ref. to EX(D0HC TURBO)-14, IN-
STALLATION, Muffler.>, <Ref. to EX(D0HC TUR-
BO)-13, INSTALLATION, Rear Exhaust Pipe.>,
AT-26
EXTENSION CASE OIL SEAL
11.Extension Case Oil Seal 13) Install the rear exhaust pipe and muffler.
Non-turbo model
A: INSPECTION <Ref. to EX(S0HC)-9, INSTALLATION, Rear Ex-
Make sure that the ATF does not leak from the joint haust Pipe.> and <Ref. to EX(S0HC)-11, INSTAL-
of the transmission and propeller shaft. If so, re- LATION, Muffler.>
place the oil seal. <Ref. to AT-27, REPLACE- Turbo model
MENT, Extension Case Oil Seal.> <Ref. to EX(D0HC TURBO)-14, INSTALLATION,
Muffler.>, <Ref. to EX(D0HC TURBO)-13, IN-
B: REPLACEMENT STALLATION, Rear Exhaust Pipe.>
1) Set the vehicle on the lift. 14) Pour ATF and check the ATF level. <Ref. to AT-
2) Disconnect the ground terminal from battery. 9, Automatic Transmission Fluid.>
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) Oil pan

(B) Drain plug
(C) Differentialoil drain plug

Non-turbo model
<Ref. to EX(S0HC)-9, REMOVAL, Rear Exhaust
Pipe.> and <Ref. to EX(S0HC)-11, REMOVAL,
Muffler.>
Turbo model
<Ref. to EX(D0HC TURBO)-13, REMOVAL, Rear
Exhaust Pipe.>, <Ref. to EX(D0HC TURBO)-14,
REMOVAL, Muffler.>
8) Remove the propeller shaft. <Ref. to DS-14, RE-
MOVAL, Propeller Shaft.>
9) Using the ST, remove the oil seal.
ST 398527700 PULLER ASSY
10) Using the ST, install the oil seal.
ST 498057300 INSTALLER
11) Install the propeller shaft. <Ref. to DS-15, IN-
STALLATION, Prope1ler Shaft.>
AT-27
I INHIBITOR SWITCH
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.<Ref. to AT-28,
ADJUSTMENT, Inhibitor Switch.>
I f-----3
Position Pin No. (A) Continuity does not exist.

P 4-3 (B) Continuity exists.
-. R 4-2 (C) 1.5"
I
N 4-1
Signal sent to TCM
D 4-8 4) Repeat the above checks. If there are abnormal-
3 4-7 ities, adjust the select cable. <Ref. to CS-27, AD-
2 4-6 JUSTMENT, Select Cable.>
I 1 I 4-5 I B: ADJUSTMENT
Starter circuit PIN 12-11 1) Shift the select lever to the N range.
Back-up light circuit R 10-9 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.
Inhibitor switch side connector ST 499267300 STOPPER PIN
B3H0016e
4) Tighten the three inhibitor switch bolts.

Tightening torque:
3.4 N.m (0.35 kgf-m, 2.5 ft-lb)
5 ) Repeat the above checks. If the inhibitor switch
is determined to be "faulty", replace it.
AT-28
INHI BI T 0R SWITCH
I
C: REMOVAL 11) Remove the plate assembly from transmission

1) Set up the vehicle on the lift. case.
2) Move the select lever to neutral position.
Case.>
5) Disconnect the inhibitor switch connector.
(A) Select cable

(B) Plate ASSY
12) Remove the bolts.
c-
(A) Inhibitor switch
6) Remove the inhibitor switch connector from stay.

8) Remove the front exhaust pipe with center ex-
haust pipe. (Non-turbo model)
Pipe.>
9) Remove the center exhaust pipe. (Turbo model)
<Ref. to EX(D0HC TURBO)-8, REMOVAL, Center
Exhaust Pipe.> 13) Move the range select lever to parking position
10) Remove the snap pin from range select lever. (left side).
(A) Snap pin (A) Range select lever

(B) Select cable
(C) Range select lever
AT-29
I INHIBITOR SWITCH
14) Remove the inhibitor switch from transmission. 6) Install the plate assembly to transmission.
Tightening torque:
T: 24.5 N.m (2.50 kgf-m, 18.1 ff-16)
15) Disconnect the inhibitor switch harness from in-

hibitor switch. (A) Select cable
(B) Plate ASSY
D: INSTALLATION
1) Connect the inhibitor switch harness to inhibitor 7 ) Install the snap pin to range select lever
switch.
2) Install the inhibitor switch to transmission case.
c.
(A) Snap ring

(B) Select cable
(A) Inhibitor switch (C) Range select lever
3) Move the range select lever to neutral position. 8) Install the front exhaust pipe with center exhaust
4) Using the ST, tighten bolts of inhibitor switch. pipe. (Non-turbo model)
ST 499267300 STOPPER PIN <Ref. to EX(S0HC)-6, INSTALLATION, Front Ex-
haust Pipe.>
Tightening torque:
3.4 N-m (0.35 kgf-m, 2.5 ff-16)
11) Install the inhibitor switch connector from stay.

(B) Range select lever
5) Install the select cable to range select lever.
AT-30
INHIBITOR SWITCH
1
12) Connect the inhibitor switch connector.
13) Install the air cleaner case. (Non-turbo model)

<Ref. to IN(S0HC)-6, INSTALLATION,Air Cleaner
Case.>
14) Install the intercooler. (Turbo model)
<Ref. to IN(D0HC TURBO)-11, INSTALLATION,
Intercooler.>
1 5 ) Inspect the inhibitor switch. <Ref. to AT-28, IN-
SPECTION, Inhibitor Switch.>
AT-31
I FRONT VEHICLE SPEED SENSOR
AUTOMATIC TRANSM ISSlON
13.Front Vehicle Speed Sensor 9) Drain the ATF completely.

NOTE:
A: REMOVAL Tighten the ATF drain plug after draining the ATF.
1) Set up the vehicle on the lift.
2) Disconnect the ground terminal from battery. Tightening torque:
25 N-m (2.5 kgf-m, 18.1 ft-lb)

<Ref. to IN(SOHC)-6, REMOVAL, Air Cleaner (A) Oil pan
Case.> (B) Drain plug
4) Remove the intercooler. (Turbo model) <Ref. to (C) Differential oil drain plug
W(DOHC TURBO)-10, REMOVAL, Intercooler.>
5) Disconnect the transmission connector. IO) Remove the front, center, rear, exhaust pipes
and muffler.
Exhaust Pipe.> and <Ref. to EX(S0HC)-11, RE-
MOVAL, Muffler.>
11) Remove the center, rear exhaust pipes and
muffler. (Turbo model) <Ref. to EX(D0HC TUR-
BO)-8, REMOVAL, Center Exhaust Pipe.>, <Ref.
to EX(D0HC TURBO)-13, REMOVAL, Rear Ex-
haust Pipe.>, <Ref. to EX(D0HC TURBO)-14, RE-
MOVAL, Muffler.>
12) Remove the shield cover.
(A) Transmission connector 13) Remove the propeller shaft. <Ref. to DS-14,
REMOVAL, Propeller Shaft.>
6) Remove the transmission connector from stay. 14) Place the transmission jack under crossmem-
7) Lift-up the vehicle. ber.
NOTE:
Place a shop cloth or equivalent between the
crossmember and transmission.
15) Remove the transmission rear crossmember
bolts.
AT-32
FRONT VEHICLE SPEED SENSOR I
16) Lower the AT jack. 20) Disconnect the duty solenoids and ATF tem-
NOTE: perature sensor connectors. Remove the connec-
Do not separate the AT jack and transmission. tors from clip and disconnect the connectors.
17) Remove the oil cooler outlet pipe.
CAUTION:
When removing the outlet pipe, 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) 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
(I) Transfer duty solenoid (Brown)
(J) Transmission ground
(A) Front vehicle speed sensor
(B) Torque converter turbine speed sensor 21) Remove the harness assembly.
Rear vehicle speed sensor B: INSTALLATION
1) Pass the harness assembly through the hole in
the transmission case.
(A) Rear vehicle speed sensor

(B) Front vehicle speed sensor
19) Remove the oil pan.
AT-33
I FRONT VEHICLE SPEED SENSOR
2) Connect the harness connectors. 6) Install the oil cooler outlet pipe.
Connect the connectors of same color, and secure CAUTION:
the connectors to valve body sing clips. Be sure to use a new aluminum washer.
Tightening torque (Transmission ground termi- Tightening torque:
nal): 25 N-m (2.5 kgf-m, 18.1 ft-lb)
8 N-m (0.8 kgf-m, 5.8 ft-lb) 7) Install the transmission rear crossmember bolts.
Tightening torque:
75 Nom(7.6 kgf-m, 55 ft-lb)
8 ) Install the propeller shaft. <Ref. to DS-15, IN-
STALLATION, PropeIler Shaft.>
9) Install the shield cover. (If equipped)
10) Install the front, center, rear exhaust pipes and
muffler. (Non-turbo model)
haust Pipe.> and <Ref. to EX(S0HC)-9, INSTAL-
B2M22631 LATION, Rear Exhaust Pipe.> and <Ref. to
(A) Lock-up duty solenoid (Blue) 11) Install the center, rear exhaust pipes and muf-
(B) Low clutch timing solenoid (Gray) fler. (Turbo model) <Ref. to EX(D0HC TURBO)-
Line pressure duty solenoid (Red) 14, INSTALLATION, Muffler.>, <Ref. to EX(D0HC
Shift solenoid 2 (Yellow) TURBO)-13, INSTALLATION, Rear Exhaust
Shift solenoid 1 (Green) Pipe.>, <Ref. to EX(D0HC TURBO)-9, INSTALLA-
2-4 brake timing solenoid (Black) TION, Center Exhaust Pipe.>
2-4 brake duty solenoid (Red) 12) Lower the vehicle.
ATF temperature sensor 13) Install the transmission connector to the stay.
Transfer duty solenoid (Brown) 14) Install the air cleaner case. (Non-turbo model)
Transmission ground
Case.>
3) Apply proper amount of liquid gasket to the en- 15) Install the intercooler. (Turbo model). <Ref. to
tire oil pan mating surface. IN(D0HC TURBO)-11, INSTALLATION, Intercool-
Fluid packing: er.>
Three Bond 12176
I B3M1040
4) Install the oil pan.

Tightening torque:
25 N-m (2.5 kgf-m, 18.1 ff-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)
AT-34
REAR VEHICLE SPEED SENSOR
14.Rear Vehicle Speed Sensor

A: REMOVAL
When removing the rear vehicle speed sensor, re-
fer to “Front Vehicle Speed Sensor.” <Ref. to AT-
32, REMOVAL, Front Vehicle Speed Sensor.>
B: INSTALLATION
When installing the rear vehicle speed sensor, refer
to “Front Vehicle Speed Sensor.” <Ref. to AT-33,
INSTALLATION, Front Vehicle Speed Sensor.>
AT-35
I TORQUE CONVERTER TURBINE SPEED SENSOR
I
15.Torque Converter Turbine

Speed Sensor
A: REMOVAL
When removing the torque converter turbine speed
sensor, refer to “Front Vehicle Speed Sensor.’’
<Ref. to AT-32, REMOVAL, Front Vehicle Speed
Sensor.>
B: INSTALLATION
When installing the torque converter turbine speed
sensor, refer to “Front Vehicle Speed Sensor.”
<Ref. to AT-33, INSTALLATION, Front Vehicle
Speed Sensor.>
AT-36
CONTROL VALVE BODY
I
5) Disconnect the duty solenoids and ATF temper-

16.Control Valve Body ature sensor connectors. Remove the connectors
A: REMOVAL from clip and disconnect the connectors.
3) Drain the ATF completely.
NOTE:
Tightening torque:
25 N.m (2.5 kgf-m, 18.7 ff-16)
B2M2269
(A) Lock-up duty solenoid (Blue)

(A) Oil pan (I) Transfer duty solenoid (Brown)
(B) Drain plug
(C) Differential oil drain plug 6) Remove the control valve. When removing the
control valve body, be careful not to interfere with
4) Remove the oil pan. transfer duty solenoid wiring.
NOTE:
Remove and clean the magnet.
Remove the old gasket on the oil pan and trans-
mission case completely.
I103;
AT-37
I CONTROL VALVE BODY
I
B: INSTALLATION 5) Apply proper amount of liquid gasket to the en-

1) Set the range select lever in ‘IN” position. tire oil pan mating surface.
2) Install the control valve and ground earth con- Fluid packing:
nectors. Tree Bond 12178
Tightening torque:
8 N.m (0.8 kgf-m, 5.8 ft-lb)
B3M1040

Tightening torque:
4.9 N-m (0.5 kgf-m, 3.6 ft-16)
(A) Short bolts 7 ) Pour ATF into the oil charge pipe. <Ref. to AT-9,
(B) Long bolts Automatic Transmission Fluid.>
ij Connect all connector. 8) Check the level of the ATF.
<Ref. to AT-9, Automatic Transmission Fluid.>
C: DISASSEMBLY
Refer to “AUTOMATIC TRANSMISSION” <Pub.
No. G0853ZE> a separate publication.
D: ASSEMBLY
E: INSPECTION
Lock-up duty solenoid (Blue)
Low clutch timing solenoid (Gray)
Line pressure duty solenoid (Red)
Shift solenoid 2 (Yellow)
Shift solenoid 1 (Green)
2-4 brake timing solenoid (Black)
2-4 brake duty solenoid (Red)
ATF temperature sensor
Transfer duty solenoid (Brown)
4) Attach the magnet at the specified position.
AT-38
SHIFT SOLENOIDS, DUTY SOLENOIDS AND ATF TEMPERATURE SENSOR I
17.Shift Solenoids, Duty Sole- 8) Remove the solenoids, duty solenoids and ATF
temperature sensor.
noids and ATF Temperature
Sensor
A: REMOVAL
5) Drain the ATF completely.
NOTE:
Tightening torque: (A) Lock-up duty solenoid (Blue)
25 Nom(2.5 kgf-m, 18.1 ff-lb) (B) Low clutch timing solenoid (Gray)
c- . (G) 2-4 brake duty solenoid (Red)
1. TRANSFER DUTY SOLENOID AND

TRANSFER VALVE BODY
1) Set up the vehicle on the lift.
(A) Oil pan 3) Remove the air intake duct. <Ref. to IN(S0HC)-
(B) Drain plug 7, REMOVAL, Air Intake Duct.>
4) Remove the air cleaner case. <Ref. to IN(S0-
6) Remove the oil pan. HC)-6, REMOVAL, Air Cleaner Case.>
7) Disconnect the solenoid and sensor connectors. 5 ) Remove the intercooler. (Turbo model) <Ref. to
Remove the connectors from clip and disconnect IN(D0HC TURBO)-10, REMOVAL, Intercooler.>
the connectors. 6) Remove the pitching stopper.
I
(G) (F) B2M2263J
Lock-up duty solenoid (Blue) 7) Remove the front exhaust pipe with center ex-
Low clutch timing solenoid (Gray) haust pipe. (Non-turbo model)
Line pressure duty solenoid (Red) With OBD
Pipe.>
8) Remove the center exhaust pipe. (Turbo model)
2-4 brake timing solenoid (Black) <Ref. to EX(D0HC TURBO)-8, REMOVAL, Center
2-4 brake duty solenoid (Red) Exhaust Pipe.>
AT-39
I SHIFT SOLENOIDS, DUTY SOLENOIDS AND ATF TEMPERATURE SENSOR I
9) Raise the vehicle and drain the ATF 14) Remove the select cable nut.
G3M0308
(A) Oil pan

15) Move the gear select cable so that extension
bolts can be removed.
(B) Drain plug
16) Remove the bolts.
(C) Defferential oil drain plug
17) Remove the extension case.
10) Remove the heat shield cover. (If equipped) NOTE:
11) Remove the propeller shaft. <Ref. to DS-14, Use a container to catch oil flowing from extension.
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.
18) Disconnect the transfer duty solenoid connec-

tor.
19) Remove the transfer duty solenoid and transfer
valve body.
13) Remove the rear vehicle speed sensor
B3M1045F
(A) Transfer valve body

(B) Transfer duty solenoid connector
(C) Transfer duty solenoid
AT-40
SHIFT SOLENOIDS, DUTY SOLENOIDS AND ATF TEMPERATURE SENSOR
B: INSTALLATION 3) Apply proper amount of liquid gasket to the en-

1) Install the solenoids and ATF temperature sen- tire oil pan mating surface.
sor. Fluid packing:
Tree Bond 12178
Tightening torque:
T: 8 N-m (0.8 kgf-m, 5.8 ft-lb)
I
B3M 1040

Tightening torque:
(A) Lock-up duty solenoid (Blue) 4.9 N.m (0.50 kgf-m, 3.6 ft-lb)
c- - (D) Shift solenoid 2 (Yellow)
2) Connect the harness connectors.

Connect the connectors of same color, and secure
the connectors to valve body using clips.
(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.>
(G, CF, B2M2263J
Lock-up duty solenoid (Blue)

Low clutch timing solenoid (Gray)
Line pressure duty solenoid (Red)
2-4 brake timing solenoid (Black)
2-4 brake duty solenoid (Red)
AT-4 1
I SHIFT SOLENOIDS, DUTY SOLENOIDS AND ATF TEMPERATURE SENSOR
e
1. TRANSFER DUTY SOLENOID AND 4) Install the rear crossmember.

TRANSFER VALVE BODY (1) Tighten the bolts.
1) Install the transfer duty solenoid and transfer Tightening torque:
valve body. T I : 35 N-m (3.6 kgf-m, 26 ft-lb)
(1) Install the transfer duty solenoid and trans- T2: 70 N.m (7.1 kgf-m, 51.4 ft-lb)
fer valve body.
Tightening torque:
T: 8 N-m (0.8 kgf-m, 5.8 ft-lb)
(2) Connect the transfer duty solenoid connec-
tor.
(2) Lower and remove the transmission jack.

STALLATION, Propeller Shaft.>
6) Install the front exhaust pipe and center exhaust
c.
pipe.
7) Lower and remove the jack.
(A) Transfer valve body 8) Connect the transmission harness connector.
(B) Transfer duty solenoid connector
(C) Transfer duty solenoid
2) Install the extension case to transmission case.

(1) Tighten eleven bolts.
Tightening torque:
25 N-m (2.5 kgf-m, 18.1 ft-lb)
(2) Adjust the select cable. <Ref. to CS-27, AD-
JUSTMENT, Select Cable.>
3) Install the rear vehicle speed sensor.
Tightening torque: 9) Install the pitching stopper.
T: 7 N.m (0.7 kgf-m, 5. t ft-lb)
Tightening torque:
T1: 50 N.m (5.1 kgf-m, 37 ft-lb)
T2: 58 N.m (5.9 kgf-m, 43 ft-lb)
IO) Install the air cleaner case and duct.
AT-42
I SHIFT SOLENOIDS, DUTY SOLENOIDS AND ATF TEMPERATURE SENSOR
I
11) 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.>
12) Check the ATF level. <Ref. to AT-9, Automatic
Transmission Fluid.>
AT-43
ATF FILTER
18.ATF Filter C: INSPECTION

Replace the part if any defect is found from the in-
A: REMOVAL spection.
NOTE: Check for rust, hole, ATF leaks, and other damage.
The ATF filter is maintenance free.
2) Using the ST, remove the ATF filter.
ST 498545400 OIL FILTER WRENCH
Torque wrench length Tightening torque

mm (in) N.m (kgf-m, ft-lb)
100 (3.94) 6 (0.6, 4.3)
150 (5.91) 5 (0.5, 3.6)
200 (7.87) 4 (0.4, 2.9)
250 (9.841 3 (0.3. 2.2)
CAUTION:
Align the ST with torque wrench while tighten-
ing the ATF filter.
ST 498545400 OIL FILTER WRENCH
3) Add ATF.
4) Inspect the level of ATF. <Ref. to AT-9, Automat-
ic Transmission Fluid.>
AT-44
TRANSMISSION CONTROL MODULE (TCM)
I
19.Transmission Control Mod- B: INSTALLATION

1) Install the transmission control module.
ule (TCM)
Tightening torque:
A: REMOVAL 7.5 N-m (0.76 kgf-m, 5.5 ft-lb)
(A) Transmission control module

2) Remove the lower cover and then disconnect the
connector. (B) Brake pedal bracket
2) Connect the connectors to transmission control

c- . module.
3) Disconnect the connectors from transmission

control module.
(A) Transmission control module

(B) Brake pedal bracket
4) Remove the transmission control module.
AT-45
DROPPING RESISTOR
20.Dropping Resistor B: INSTALLATION

A: REMOVAL
Tightening torque:
NOTE: 6.4 N.m (0.65 kgf-m, 4.7 fWb)
The dropping resister is only equipped to Non-turbo
models.
(A
03M2170A
(A) Dropping resistor
2) Remove the air intake duct. <Ref. to IN(S0HC)-

6, REMOVAL, Air Cleaner Case.>
3)Disconnect the connector from dropping resistor.
4) Remove the dropping resistor.
J/
\
i::
I '
(A) Dropping resistor
C: INSPECTION
~~
B3M2170A
Step Check Yes No

1 CHECK RESISTOR. Is the resistance between 9 Go to step 2. Replace the drop-
1)Turn the ignition switch to OFF. and 15 a? ping resistor. <Ref.
2)Disconnect the connector from dropping to AT-46, Dropping
resistor.
3)Measure the resistance between dropping
resistor terminal.
Terminals
NO. 1 - NO. 2:
2 CHECK RESISTOR. Is the resistance between 9 Dropping resistor Replace the drop-
Measure the resistance between dropping and 15 a? is normal. ping resistor.
resistor terminal. <Ref. to AT-46,
Terminals Dropping Resis-
NO. 3 - NO. 4: tor.>
AT-46
ATF COOLER PIPE AND HOSE I
21 .ATF Cooler Pipe and Hose 6) Remove the ATF cooler pipe from cylinder head.
A: REMOVAL
1. NON-TURBO MODEL
4) 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 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.
c-
S2M0895
5) Disconnect the ATF cooler hoses from pipes.

NOTE:
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
I ATF COOLER PIPE AND HOSE
I
2. TURBO MODEL 8) Remove the ATF cooler pipe from frame.

2) Remove the battery and washer tank.
5) Remove the radiator under cover.
EN1063
sconnect the ATF cooler hose from radiator

NOTE:
:- Do not remove with a screwdriver or other point-
ed tools. I'
When the hose is difficult to remove, wrap a shop TR0331
cloth around the hose to protect it. Turn it with pli-
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.
-I TR0329
7) Disconnect the ATF cooler hoses from pipes.

NOTE:
Do not remove with a screwdriver or other point-
ed tools.
When the hose is difficult to remove, wrap a shop (A) Inlet pipe
cloth around the hose to protect it. Turn it with pli- (B) Outlet pipe
AT-48
ATF COOLER PIPE AND HOSE
I
B: INSTALLATION 3) Connect the ATF cooler hose to pipe transmis-

sion side.
1. NON-TURBO MODEL NOTE:
1) Install the oil cooler outlet and inlet pipes. Install so that the hose is not folded over, exces-
CAUTION: sively bent, or twisted.
Be sure to use a new aluminum washer. Be careful to insert the hose to the specified po-
sition.
Tightening torque:
T1: 44 N-m (4.5 kgf-m, 32.5 ff-lb)
T2: 25 N-m (2.5 kgf-m, 18.1 ff-lb)
4) Connect the ATF cooler hose to pipe of radiator

side.
NOTE:
(A) Inlet pipe Install so that the hose is not folded over, exces-
(B) Outlet pipe sively bent, or twisted.
Be careful to insert the hose to the specified po-
2) Install the ATF cooler pipe to cylinder head. sition.
Tightening torque:
7.35 N-m (0.75 kgf-m, 5.42 ft-lb)
S2M0895
5) istall the under cover.

6) Fill ATF. <Ref. to AT-9, Automatic Transmission
Fluid.>
NOTE:
Make sure there are no ATF leaks in joints between
the transmission, radiator, pipes, and hoses.
AT-49
I ATF COOLER PIPE AND HOSE
I
2. TURBO MODEL 3) Connect the ATF cooler hose to pipe transmis-

sion side.
1) Install the oil cooler outlet and inlet pipes.
NOTE:
CAUTION: Install so that the hose is not folded over, exces-
Be sure to use a new aluminum washer. sively bent, or twisted.
Tightening torque: Be careful to insert the hose to the specified po-
T l : 44 N.m (4.5 kgf-m, 32.5 ft-lb) sition.
T2: 25 N-m (2.5 kgf-m, 18.1 ft-lb)
4) Connect the ATF cooler hose to pipe of radiator

-- . (A) Inlet pipe
side.
NOTE:
(B) Outlet pipe
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.
L
TR0329
5) Install the radiator under cover.

Tightening torque:
4.9 N.m (0.5 kgf-m, 3.6 ft-lb)
TR0331
EN106:
6) Install the under cover.

7) Install the battery and washer tank.
AT-50
I
8) Fill ATF. <Ref. to AT-9, Automatic Transmission C: INSPECTION

Fluid.> Repair or replace any defective hoses, pipes,
NOTE: clamps, and washers found from the inspection be-
Make sure there are no ATF leaks in joints between low.
the transmission, radiator, pipes, and hoses. 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.
c- .
AT-51
I
AT-52
(DIAGNOSTICS)
Page
1. Basic Diagnostic Procedure ........................................................................ 2
2. Check List for Interview ............................................................................... 4
4. Electrical Components Location.................................................................. 7
5. Transmission Control Module (TCM) I/O Signal ....................................... 11
6. Subaru Select Monitor............................................................................... 22
7. Read Diagnostic Trouble Code (DTC) ...................................................... 24
8. Inspection Mode ........................................................................................ 26
9. Clear Memory Mode.................................................................................. 27
c- . 10. AT OIL TEMP Warning Light Display ........................................................ 28
11. List of Diagnostic Trouble Code (DTC) ..................................................... 29
12. Diagnostic Procedure for AT OIL TEMP Warning Light ............................ 31
13. Diagnostic Procedure for Select Monitor Communication......................... 39
14. Diagnostic Procedure with Diagnostic Trouble Code (DTC) ..................... 44
15. Diagnostic Procedure for No-Diagnostic Trouble Code (DTC) ...............108
16. Symptom Related Diagnostic .................................................................. 127
I BASIC DIAGNOSTIC PROCEDURE
AUTOMATIC TRANSMISSION (DIAGNOSTICS)
1. Basic Diagnostic Procedure

A: PROCEDURE
Step Check Yes No
CHECK PRE-INSPECTION. j the unit that might influence ;o to step 2. 3epair or replace
1)Ask the customer when and how the trouble l e AT problem normal? ?achitem.
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 AT-5, INSPEC-
TION, General Description.>
*Oil leak
*Stall speed test <Ref. to AT-I 3, Stall Test.>
*Line pressure test <Ref. to AT-16, Line Pres-
sure Test.>
*Transfer clutch pressure test <Ref. to AT-I 8,
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. )oes not the AT OIL TEMP $0 to step 3. 30 to step 4.
Turn the ignition switch to ON. iarning light light up?
CHECK AT OIL TEMP WARNING LIGHT. j the AT OIL TEMP warning $0 to step 4. 30 to step 5.
1)Turn the ignition switch to OFF. ght 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.>
CHECK INDICATION OF DTC. j the diagnostic trouble code 20 to step 6. 30 to step 5.
Calling up the diagnostic trouble code (DTC). DTC) displayed? JOTE:
Without SUBARU SELECT MONITOR 3ecord all diag
<Ref. to AT-24, WITHOUT SUBARU SELECT iostic trouble code
MONITOR, Read Diagnostic Trouble Code DTC).
(DTC).>
With SUBARU SELECT MONITOR
<Ref. to AT-25, WITH SUBARU SELECT
MONITOR, Read Diagnostic Trouble Code
(DTC).>
NOTE:
If the communication function of the selec
monitor cannot be executed normally, check
the communication circuit. <Ref. to AT-39
COMMUNICATION FOR INITIALIZING IM.
POSSIBLE, Diagnostic Procedure for Selec
Monitor Communication.>
AT-2
BASIC DIAGNOSTIC PROCEDURE
I
Step Check Yes No

5 PERFORM THE GENERAL DIAGNOSTICS. Is the diagnostic trouble code io to step 6. iomplete the
1NnsDect usina the “Diaqnostic Procedure for (DTC) displayed? iagnosis.
No-Diagnostictrouble Code”.<Ref. to AT-108,
Diagnostic Procedure for No-Diagnostic Trou-
ble Code (DTC).>
2)lnspect using the “Symptom Related Diag-
nostic’’. <Ref. to AT-127, Symptom Related
Diagnostic.>
3)Perform the clear memory mode.
MONITOR, Clear Memory Mode.>
Without SUBARU SELECT MONITOR
<Ref. to AT-27, WITHOUT SUBARU SELECT
4)Perform the inspection mode. <Ref. to AT-26,
Inspection Mode.>
Calling up the diagnostic trouble code (DTC).
MONITOR, Read Diagnostic Trouble Code
(DTC).>
MONITOR, OPERATION, Read Diagnostic
Trouble Code (DTC).>
6 PERFORM THE DIAGNOSIS. 5 the diagnostic trouble code nspect using the :omplete the
1)lnspect using the “Diagnostics Chart with DTC) displayed? Diagnostics Chart hagnosis.
Diahnostic Trouble Code”.<Ref. to AT-44, Diag- vith Diagnostic
nostic Procedure with Diagnostic Trouble Code 2onnector”. <Ref.
(DTC).> o AT-44, Diagnos-
NOTE: ic Procedure with
For trouble code table, refer to the “List of Diag. liagnostic Trou-
nostic Trouble Code”.<Ref. to AT-29, List of Di. ,le Code (DTC).>
agnostic Trouble Code (DTC).>
2)Repair the trouble cause.
3)Perform the clear memory mode.
MONITOR, OPERATION, Clear Memory
Mode.>
4)Perform the inspection mode. <Ref. to AT-26,
Inspection Mode.>
5)Calling up the diagnostic trouble code (DTC)
Trouble Code ( D T C b
AT-3
CHECK LIST FOR INTERVIEW
I
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.
Customer's name I
Data vehicle brought in
Data of repair
Trans. model TRANSMISSION I VIN
Odometer reading km/h or mile
Freauencv D Continuous U Intermittent ( times a day)
~~
Weather CI Fine CI Cloudy U Rainy U Snowy

CI Various/Others
( 1
Place U High 0 Suburbs U Inner city CI Uphill U Rough road
U Others
( 1
Outdoor temperature 0 Hot U Warm c3 Cool U Cold
Vehicle speed km/h (MPH:
Malfunction indicator lamp (MIL) U Continuously lit ] U Not lit
Select lever Dosition CIP UR UN UD C13 U 2 U1
Driving condition U Not affected U At starting CI While idling
U At racing U While accelerating U While cruising
0 While decelerating U While turning (URH/CI
I LH)
SvmDtoms
, * I U No up-shift
I Q No down-shift
CI No kick down
CI Vehicle does not move (UAny position U Particular position)
CI Lock-uD malfunction
I U Noise or vibration
I 0 Shift shock or sliD
I U Select lever does not move
AT-4
GENERAL DESCRIPTION
I
3. General Description 3. ATFLEVEL

Make sure the ATF level is in the specification.
A: CAUTION
Supplemental Restraint System “Airbag”
The airbag system wiring harness is routed near
the transmission control 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. B3M0173B
Measurement
When measuring the voltage and resistance of the (A) Upper level
ECM, TCM or each sensor, use a tapered pin with (B) Lower level
a diameter of less than 0.64 mm (0.025 in) in order
to avoid poor contact. Do not insert the pin more 4. FRONT DIFFERENTIAL OIL LEVEL
than 6.5 mm (0.256 in). Make sure the front differential oil level is in the
a:INSPECTION specification.
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 B3M01748
securely.
Chassis side (A) Upper level
Tightening torque: (B) Lower level
13 N.m (1.3 kgf-m, 9.4 ff-lb)
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.
TR0373
AT-5
GENERAL DESCRIPTION
I
C: PREPARATION TOOL
1. SPECIAL TOOLS
I
ILLUSTRATION TOOLNUMBER I
I
DESCRIPTION REMARKS
Troubleshooting for electrical systems.
(Newly adopted tool)
02M3876
22771AA030 SELECT MONITOR Troubleshootingfor electrical systems.
KIT * English:
German:
French:
Spanish:
B2M3877
TOOL NAME REMARKS

Circuit Tester Used for measuring resistance, voltage and ampere.
Oscilloscope Used for measuring sensor.
AT-6
ELECTRICAL COMPONENTS LOCATION
4. Electrical Components Loca-

tion
A: LOCATION
1. CONTROL MODULE
(1) Engine control module (ECM) (3) Transmission control module (TCM)
(2) ATF temperature warning light (AT diagnostic indicator (4) Data link connector
light)
B3M1575A
TR0563 TR0382
AT-7
I
2. SENSOR
TR0565
(1) Throttle position 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
(3) Inhibitor switch sensor model)
AT-8
I
don-turbo model
--/
S2M0262B TR0387
Turbo model
_J
TR0592
\\ol (3) ' TR0388
(6)
I , ,
TR0390 TR0389
TR0593
AT-9
3. SOLENOID
B3M 1 186A
(1) Solenoid 1 (4) Low clutch timing solenoid (7) 2-4 brake timing solenoid
(2) Solenoid 2 (5) Lock-up duty solenoid (8) Transfer duty solenoid
(3) Line pressure duty solenoid (6) 2-4 brake duty solenoid
.-,
B2M2264E
AT-10
TRANSMISSION CONTROL MODULE (TCM) I/O SIGNAL
I
5. Transmission Control Mod-

ule (TCM) I/O Signal
A: ELECTRICAL SPECIFICATION
1. NON-TURBO MODEL
to @ to @
Check with ignition switch ON.

Con- Resistanceto
Termi-
Content nector Measuring conditions Voltage (V)
nal No. body (ohms)
No.
Back-up power supply B55 6 lanition switch OFF I 10-13 I -
Ignition power supply
854
B54
23
24
Ignition switch ON (with
-
enaine OFF)
Select lever in “ P range
10 - 13
Less than 1
l -
“ P range -
B55 23 Select lever in any other than
switch More than 8
“ P ranae (except “N” ranae)
Select lever in “N” range I Less than 1 I
“ N range
switch
“N” ranae lexceDt “ P ranae)
- “ % I “ I
1
,
Morethan8 1
I
-
“R” range
Select lever in ‘W ranae - I Less than 1
-
655 17 Select lever in any other than
switch More than 8
“R” range
Select lever in “D” range I Less than 1 I
Inhibitor
switch
“ D range
switch
“D ranae I
I
I
More than8 1
I
-
Select lever in “ 3 ranae I

I
Less than 1
“ 3 range 1
-
switch More than 8
“3”ranae
Select lever in “2” range I Less than 1
“ 2 range
switch
854 10 Select lever in any other than
“ 2 ranae
I More than8 I -
“ I ” range
Select lever in “1”ranae I Less than 1 I
654 1 Select lever in any other than -
switch More than 8
“1” range
AT-1 1
I
Check with ignition switch ON.
Termi- Resistanceto
Content nector Measuring conditions Voltage (V)
nal No. body (ohms)
No.
Brake pedal depressed. More than 10.5 -
Brake switch B55 24
Brake pedal released. Less than 1
ABS switch ON Less than 1 -
ABS signal B54 19
ABS switch OFF More than 6.5
Light ON Less than 1 -
AT OIL TEMP light B54 3
+
Light OFF More than 9
I Throttle fully closed.
Throttle position sensor B55 2 Approx. 0.5 -
Throttle fullv open. Approx. 4.3
Throttle position sensor power Ignition switch ON (With -
4.8 - 5.3
SUDDlV engine OFF)
ATF temperature 20°C
1.6 - 2.0 2.1 - 2.9 k
(68°F)
ATF temperature sensor B55 11
0.4 - 0.9 275 - 375
(176°F)
Vehicle stopped. I 0 I
Rear vehicle speed sensor Vehicle speed at least 20 More than (AC range) 450 - 650
km/h (12 MPH)
..
Vehicle stowed 0
Front vehicle speed sensor Vehicle speed at least 20 450 - 650
More than (Ac
km/h (12 MPH)
Engine idling after warm-up I n
u I
Torque converter turbine (D range)
B55 12 450 - 650
speed sensor Engine idling after warm-up
More than (AC
(N range)
Vehicle speed at most 10 Less than I t -
Vehicle speed output signal 855 13
km/h (6 MPH) +More than 5
0
engine OFF) -
Engine speed signal B55 4
0 - 13 or more
engine ON)
When cruise control is set
Less than 1
(SET liaht ON)
Cruise set signal 854 11 ~~
When cruise control is not

More than 6.5
set (SET light OFF)
Torque control signal 1 More than 4.8 -
enaine
" ON)
Ignition switch ON (with -
Torque control signal 2 More than 4.8
enaine ON)
I
~
Toraue control cut simal 854 2 Ignition switch ON I a I -

Intake manifold pressure sig-
Engine idling after warm-up. I .2 - 1.a
nal
1st gear More than 9
Shift solenoid 1 10-16
3rd aear Less than 1
2nd gear More than 9
Shift solenoid 2
4th gear Less than 1
4
Throttle fully closed (with
1.5 - 5.0
Line pressure duty solenoid B54 2.0 - 4.5
Less than 1
engine OFF) after warm-up.
AT-I 2
TRANSMISSION CONTROL MODULE (TCM) 1/0 SIGNAL I
I I
'On-
Termi- Resistanceto
Content Measuring conditions Voltage (V) body (ohms)
nal NO.
No.
More than 8.5
Dropping resistor 854 18
Throttle fully open (with
enaine
a -~OFF) after warm-uD.
I
1 Less than 0.5
I
9- 15
When lock up occurs. More than 8.5

Lock-up duty solenoid B54 16 10- 17
When lock up is released. Less than 0.5
Fuse on FWD switch More than 8.5
~
Fuse removed from FWD

Transfer duty solenoid 854 15 switch (with throttle fully 10- 17
Less than 0.5
open and with select lever in
1st gear).
1.5 - 5.0
2-4 brake duty solenoid B54 8 2.0 - 4.5
Less than 1
enaine OFF) after warm-uD.
d

More than 8.5
--2-4 brake dropping resistor B54 17 9-16 "
Less than 0.5
1st gear Less than 1
2-4 brake timing solenoid B54 5 10- 16
3rd gear More than 9
2nd gear Less than 1
Low clutch timing solenoid B54 14 10- 16
4th gear More than 9
Sensor ground line 1 855 10 - 0 Less than 1
Sensor ground line 2 855 21 - 0 Less than 1
9 -
System ground line 0 Less than 1
B55 19
Fuse removed. More than 9 -
FWD switch B55 14
Fuse installed. Less than 1
Fuse ONFWD switch Less than 1
I FWD indicator light

I B54 I l2
Fuse removed from FWD
switch
More than 9
Less than I t
-
-
AT diagnosis signal B54 4 Ignition switch ON
-+More than 4
Data link signal (Subaru Select
B55 7
Monitor) 16
AT-I 3
2. TURBO MODEL
to @
n n n
I TR0532
Check with ianition switch ON.

Con- Resistance
Content nector Terminal No. Measuring conditions Voltage (V) to body
No. (ohms)
Back-up power supply 856 1 Ignition switch OFF IO- 13 -
B54 23 Ignition switch ON (with IO- 13 -
Ignition power supply
B54 24 engine OFF)
1
I I I I
I Select lever in “ P range I Less than 1

“ P range Select lever in any other
1
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
14
switch than “N” range (except “P” More than 8
range)
“R” range
I Select lever in “R” ranae
“ I Less than 1 t
3 Select lever in any other
switch More than 8
than “R” ranae
I
Inhibitor I I
switch “D” range
I Select lever in “D” range
- Less than 1 I
B55 4 Select lever in any other -
switch More than 8
I I
than “D” ranae“ I I
I
“ 3 range
switch
B55 I 5
I Select lever in “ 3ranae
“
Select lever in any other
than “ 3 range
I Less than 1
More than 8
-
“ 2 range
I I Select lever in “2” range
- I Less than 1 I
switch
B55 I
I
6
I
I
Select lever in any other
than “2” ranae”
Select lever in “1” range
I
I
More than 8
Less than 1
I
-
“1” range
switch
7
1 Select lever in any other
than “1” range
1 More than 8
-
Brake switch B55 I 12

Brake pedal depressed.
Brake Dedal released.
I
I
More than 10.5
Less than 1
-
Light ON Less than 1 -
AT OIL TEMP warning light 856 10
Liaht OFF More than 9
AT-I 4
TRANSMISSION CONTROL MODULE (TCM) I/O SIGNAL I
I Check with ianition switch ON.

Con- Resistance
No. (ohms)
Throttle fully closed. Approx. 0.5 -
Throttle position sensor 654 3
Throttle fullv- open.
. Auprox.
.. 4.3
Throttle position sensor
654 2 Ignition switch ON (With Approx. 5.0 -
engine OFF)
1.6 - 2.0 2.1 k - 2.9 k
(68°F)
ATF temperature sensor 654 11
0.4 - 0.9 275 - 375
(176°F)
I Vehicle stopped.
. . I 0 I
Rear vehicle speed sensor 655 24 Vehicle speed at least 20 More than (Ac range) 450 - 650
km/h (12 MPH)
Vehicle stotmed.
,. 0
Front vehicle speed sensor 655 18 Vehicle speed at least 20 More than (AC range) 450 - 650
km/h (12 MPH)
I Engine idling after warm- I n
V
I
Torque converter turbine - up. (D-range)
655 8 450 - 650
speedsensor Engine idling after warm-
More than 1 (AC range)
UP. (N ranae)
~
Vehicle speed at most 10 Less than I t -

Vehicle speed output signal 656 17
km/h (6 MPH) +More than 5
0
engine OFF) -
Engine speed signal 655 17
0- 13 or more
engine ON)
When cruise control is set
Less than 1
(SET lamp ON) -
Cruise set signal 655 22
When cruise control is not
More than 6.5
set (SET lamp OFF)
I Torque control signal 1 656

~~
5
engine ON)
More than 4 -
Torque control signal 2 656 14 Ignition switch ON (with More than 4 -

enaine ON)
655 10 lanition switch ON 8 -
654 1
I Engine idling after warm-
UD.
--r
0.5 - 1.2
l -
I Shift solenoid 1 654 22 -
1st or 4th gear
2nd or 3rd gear
1st or 2nd gear
More than 9
Less than 1
More than 9
10-16
Shift solenoid 2 654 5 ' 10-16

-
3rd or 4th gear Less than 1
engine OFF)
1.5 - 5.0
Throttle fully closed after
warm-up.
Line pressure duty solenoid 654 9 2.0 - 4.5
engine OFF) Less than 1
Throttle fully open after
warm-up.
When lock up occurs. More than 8.5
Lock-up duty solenoid 654 7 10-17
When lock up is released. Less than 0.5
- More than 8.5
Transfer duty solenoid 654 6 Throttle fully open and with 10 - 17
Less than 0.5
select lever in 1st gear.
AT-15
Check wi I ignition switch ON.

Con- Resistance
No. (ohms)
engine OFF) after warm- 1.5 - 5.0
2-4 brake duty solenoid B54 18 UP.
2.0 - 4.5
engine OFF) after warm- Less than 1
UP.
1st gear Less than 1
2-4 brake timing solenoid 854 16 10-16
3rd gear More than 9
2nd gear Less than 1
-ow clutch timing solenoid 854 15 10-16
4th gear More than 9
ABS switch ON Less than 1
4BS signal 855 21
ABS switch OFF More than 6.5
Sensor around line 1 854 20 Less than 1
Sensor ground line 2 B55 9 - 0 Less than 1
B56 19 I
-
System ground line
B54 21
-
I
I
0 Less than 1
:.ensor ground line 3 854 10 0 Less than 1

Sensor ground line 4 B54 19 - I 0 Less than 1
Less than 1 t
AT diagnosis signal B56 21 Ignition switch ON
+ More than 4
lata link signal (Subaru 15
856
Select Monitor) 6
AT-I 6
AT-1 7
TRANSMISSION CONTROL MODULE (TCM) I10 SIGNAL I
B: SCHEMATIC
1. NON-TURBO MODEL
I
TR0566
AT-I 8
TRANSMISSION CONTROL MODULE (TCM) I/O SIGNAL E
Transmission control module “ 2 range indicator light ATF temperature sensor

Data link connector ”1” range indicator light Torque converter turbine speed
Cruise set switch “ P range switch sensor
ABS control module “R” range switch Front vehicle speed sensor
Ignition switch “N” range switch Rear vehicle speed sensor
Brake switch “ D range switch Shift solenoid 1
Brake light “ 3 range switch Shift solenoid 2
Battery “ 2 range switch 2-4 brake timing solenoid
Combination meter “1” range switch Line pressure duty solenoid
AT OIL TEMP warning light Throttle position sensor Line pressure dropping resistor
FWD indicator light Engine speed signal 2-4 brake duty solenoid
FWD switch Torque control cut signal 2-4 brake dropping resistor
“ P range indicator light Torque control signal 2 Lock-up duty solenoid
“R” range indicator light Torque control signal 1 Low clutch timing solenoid
“N” range indicator light AT load signal Transfer duty solenoid
“ D range indicator light AT diagnostics signal
“ 3 range indicator light Engine control module
AT-19
I TRANSMISSION CONTROL MODULE (TCM) I10 SIGNAL I
2. TURBO MODEL
r-
r"" 1 -
(4)
c- "
m
(9)
TR0567
AT-20
Transmission control module (16) “ D range indicator light Engine control module
Cruise control module (17) “ D range switch ATF temperature sensor
ABS control module (18) “ 3 range indicator light Torque converter turbine speed
Ignition switch (19) “ 3 range switch sensor
Brake switch (20) “2” range indicator light Rear vehicle speed sensor
Brake light (21) “ 2 range switch Front vehicle speed sensor
Battery (22) “1” range indicator light Shift solenoid 1
Combination meter (Speedome- (23) “1” range switch Shift solenoid 2
ter circuit) (24) Data link connector 2-4 brake timing solenoid
AT OIL TEMP light (25) Throttle position sensor Line pressure duty solenoid
“ P range indicator light (26) Engine speed signal 2-4 brake duty solenoid
“P” range switch (27) Torque control cut signal Lock-up duty solenoid
“R” range indicator light (28) Torque control signal 2 Low clutch timing solenoid
“R” range switch (29) Torque control signal 1 Transfer duty solenoid
“N” range indicator light (30) Mass air flow signal
“N” range switch (31) AT diagnostics signal
AT-21
I SUBARU SELECT MONITOR
6. Subaru Select Monitor (2) Connect the diagnosis cable to data link
connector.
A: OPERATION CAUTION:
1. READ DIAGNOSTIC TROUBLE CODE Do not connect scan tools except for Subaru
Select Monitor and OBD-ll general scan tool.
(DTC)
5) Turn the ignition switch to ON (engine OFF) and
1) Prepare the Subaru Select Monitor kit. Subaru Select Monitor switch to ON.
.
I S2M0285
2) Connect the diagnosis cable to Subaru Select

Monitor.
3 Insert the cartridge into Subaru Select Monitor.
<Ref. to AT-6, PREPARATION TOOL, General De-
scription.>
(A) Power switch
’’ S2M0288C
6) On the ((Main Menu,) display screen, select the

{Each System 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@) Display}
10) On the ((Diagnostic Code(s) Display)) display
screen, select the {Latest Diagnostic Code(s)} or
{Memorized Diagnostic Code(s)} and press the
1 S2M028E
[YES] key.
4) Connect the Subaru Select Monitor to dati link NOTE:
connector. For detailed operation procedure, refer to the
(1) Data link connector located in the lower por- SUBARU SELECT MONITOR OPERATION MAN-
tion of the instrument panel (on the driver’s UAL.
side). For detailed concerning diagnostic trouble
codes, refer to the DIAGNOSTIC TROUBLE CODE
LIST (DTC). <Ref. to AT-29, List of Diagnostic
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
(A) Data link connector
4) On the ((Transmission Diagnosis,, display
screen, select the {Current Data Display & Save}
AT-22
SUBARU SELECT MONITOR
Contents Display Unit of measure

Batterv voltaae I Batterv Voltaae V
I Rear vehicle speed sensor signal 1 Rear Wheel Speed I km/h or MPH I
I Front vehicle speed sensor signal I Front Wheel Speed I km/h or MPH I
Engine speed signal Engine Speed rPm
Automatic transmission fluid temperature signal ATF Temp. "Cor OF
Throttle position signal Throttle Sensor Voltage V
Gear Dosition Gear Position -
I &ne pressure control dutv ratio 1 Line Pressure Dutv Ratio I YO I
I Lock up clutch control duty ratio I Lock Up Duty Ratio I O/O I
I Transfer clutch control duty ratio 1 Transfer Duty Ratio I % I
Power supply for throttle position sensor Throttle Sensor Power V
Torque converter turbine speed signal Turbine Revolution Speed rPm
2-4 brake timina Dressure control dutv ratio Brake Clutch Dutv Ratio - -
YO
-
IMass air flow sensor sianal (Turbo model) I Air Flow Sensor Voltaae -1 V -1
-4 -Intake manifold pressure sensor voltage (Non-turbo model) I Mani. Pressure Voltage I V I
I 2 wheel drive switch signal (Non-turbo model) 1 FWD Switch I ON or OFF I
-Stop lamp switch signal Stop Light Switch ON or OFF
Anti lock brake system signal ABS Signal ON or OFF
Cruise control system signal Cruise Control Signal ON or OFF
NeutraVParkina ranae sianal N/P RanQeSianal ON or OFF
I Reverse range signal I R Range Signal I ON or OFF I
I Drive range signal 1 D Range Signal I ON or OFF I
3rd range signal 3rd Range Signal ON or OFF
2nd range signal 2nd Range Signal ON or OFF
1st range signal 1st Range Signal ON or OFF
Shift control solenoid A Shift Solenoid #1 ON or OFF
Shift control solenoid B Shift Solenoid #2 ON or OFF
Torque control output signal #I Torque Control Signal 1 ON or OFF
Torque control output signal #2 Torque Control Signal 2 ON or OFF
Torque control cut signal Torque Control Cut Sig. ON or OFF
2-4 brake timing control solenoid valve 2-4 Brake Timing Sol. ON or OFF
Low clutch timing control solenoid valve Low Clutch Timing Sol. ON or OFF
Automatic transmission diagnosis indicator lamp Diagnosis Lamp ON or 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.
12.Each System Check} and press the [YES] key.
2) On the ((System Selection Menu), display
4) On the ((Transmission Diagnosis)) display
screen, select the {Clear Memory} and press the
[YES] key.
AT-23
I READ DIAGNOSTIC TROUBLE CODE (DTC)
7. Read Diagnostic Trouble

Code (DTC)
A: OPERATION
1. WITHOUT SUBARU SELECT MONITOR
~~
Step Check Yes No

PERFORM READ DIAGNOSTIC TROUBLE Does the indicator light blink at Repair power sup- 30 to step 2.
CODE. 4-Hz intervals? NOTE: Blinks ply and ground cir-
1)Warm-up the engine. every 0.125 (1/8) seconds cuit.<Ref. to AT-36,
2)Turn the ignition switch to OFF. (until ignition switch is turned CHECK 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.
1O)Move the select lever 2 range.
11)Move the select lever 1 range.
12)Movethe select lever 2 range.
13)Movethe select lever 3 range.
14)Move the select lever D range.
CHECK INDICATOR LIGHT. Does the indicator light blink at AT system is nor- 30 to step 3.
2-Hz intervals? NOTE: Blinks mal.
every 0.25 (1/4) seconds (until
ignition switch is turned OFF).
CHECK INDICATOR LIGHT. Is a trouble code outputted? Inspect the prob- 30 to step 4.
lem correspond-
ing with diagnostic
trouble code
(DTC).
NOTE:
Record all diag-
iostic trouble code
(DTC).
CHECK INDICATOR LIGHT. Does the indicator light remain Repair the AT OIL 2alling up the
illuminated? TEMP warning liagnostic trouble
ight circuit <Ref. :ode (DTC) again.
to AT-31, Diagnos-
:ic Procedure for
4T OIL TEMP
Uarning Light.>,
3r Inspect inhibitor
switch, wiring,
TCM, etc.
AT-24
READ DIAGNOSTIC TROUBLE CODE (DTC) I
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 “one”
Normal code
0.25
DTC 11
0.3 0.2
\ /
Unit: Seconds
TR056!
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
I INSPECTION MODE
~~
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.
Secure a rope or wire to the front and rear
towing or tie-down hooks to prevent the lateral
runout of front wheels.
Do not abruptly depresshelease 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
%landsand 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.
(B)
B2M2969C
(A) Safety stand

(B) Free rollers
AT-26
CLEAR MEMORY MODE I
9. Clear Memory Mode

A: OPERATION
1. WITHOUT SUBARU SELECT MONITOR
Current trouble 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)
The 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
-+he 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
AT OIL TEMP WARNING LIGHT DISPLAY
I
10.AT OIL TEMP Warning Light determined by a trouble code during the on-board
diagnostics operation. Problems which occurred
Display previously can also be identified through the mem-
ory function. If the AT OIL TEMP warning does not
A: INSPECTION show a problem (although a problem is occurring),
When any on-board diagnostics item is malfunc- the problem can be determined by checking the
tioning, the display on the Power indicator light performance characteristics of each sensor using
blinks from the time the malfunction is detected af- the selectmonitor. indicator signal is as shown in
ter starting the engine until the ignition switch iS the figure.
turned OFF. The malfunctioning part or unit can be
Normal
ON
2 secs
I .
OFF -
ON
-_ -_ -
0.25 secs
_ _
2 secs
OFF -- _ _ _ _ __
Normal (power switch ON)
I I-
Blink
I
Power indicator light ON
S3M0062A
AT-28
I
LIST OF DIAGNOSTIC TROUBLE CODE (DTC)
11.List of Diagnostic Trouble

Code (DTC)
A: LIST
DTC No. Item Content of diagnosis Index
<Ref. to AT-44, DTC 11 ENGINE SPEED SIGNAL,
Detects open or shorted input
11 Engine speed signal Diagnostic Procedure with Diagnostic Trouble
signal circuit.
Code (DTC).>
<Ref. to AT-46, DTC 23 MASS AIR FROW SIG-
Detects Open Or shorted input
23 Mass air flow signal NAL, Diagnostic Procedure with Diagnostic Trou-
signal circuit.
ble Code (DTC).>
<Ref. to AT-48, DTC 27 ATF TEMPERATURE
27 ATF temperature sensor signal
Detectscircuit,
Open Or shorted input SENSOR, Diagnostic Procedure with Diagnostic
<Ref. to AT-52, DTC 31 THROTTLE POSITION
31 Throttle position sensor signal
Detectscircuit,
Open Or shorted input SENSOR, Diagnostic Procedure with Diagnostic
<Ref. to AT-57, DTC 33 FRONT VEHICLE SPEED
Front vehicle speed Detects Open Or shorted input
33 SENSOR, Diagnostic Procedure with Diagnostic
sensor signal circuit.
<Ref. to AT-62, DTC 36 TORQUE CONVERTER
Torque converter tur- Detects Open Or shorted input
36 TURBINE SPEED SENSOR, Diagnostic Proce-
bine speed sensor signal circuit.
dure with Diagnostic Trouble Code (DTC).>
<Ref. to AT-66, DTC 38 TORQUE CONTROL SIG,
38 Torque control signal Detects Open Or shorted input NAL, Diagnostic Procedure with Diagnostic Trou-
signal circuit.
ble Code (DTC).>
~
Intake manifold pres-

<Ref. to AT-68, DTC 45 INTAKE MANIFOLD
sure Detects open or shorted input
45 PRESSURE SIGNAL, Diagnostic Procedure with
signal (Non-turbo signal circuit.
Diagnostic Trouble Code (DTC).>
model)
<Ref. to AT-70, DTC 71 SHIFT SOLENOID 1,
Detects open or shorted out-
71 Shift solenoid 1 Diagnostic Procedure with Diagnostic Trouble
put signal circuit.
Code (DTC).>
<Ref. to AT-74, DTC 72 SHIFT SOLENOID 2,
72 Shift solenoid 2 Diagnostic Procedure with Diagnostic Trouble
put signal circuit.
Code (DTC).>
<Ref. to AT-78, DTC 73 LOW CLUTCH TIMING
Low clutch timing sole- Detects open or shorted out-
73 SOLENOID, Diagnostic Procedure with Diagnostic
noid put signal circuit.
<Ref. to AT-82, DTC 74 2-4 BRAKE TIMING
2-4 brake timing sole- Detects open or shorted out-
Trouble
_ _ _
Code
~
(DT
~ ~
Cb
<Ref. to AT-86, DTC 75 LINE PRESSURE DUTY
Line pressure duty sole- Detects open or shorted out-
<Ref. to AT-90, DTC 76 2-4 BRAKE DUTY SOLE-
76 2-4 brake duty solenoid NOID, Diagnostic Procedure with Diagnostic Trou.
put signal circuit.
ble Code (DTC).>
<Ref. to AT-94, DTC 77 LOCK-UP DUTY SOLE-
77 Lock-up duty solenoid NOID, Diagnostic Procedure with Diagnostic Trou,
put signal circuit.
ble Code ( D T C b
~~
<Ref. to AT-100, DTC 79 TRANSFER DUTY

79 Transfer duty solenoid SOLENOID, Diagnostic Procedure with Diagnostic
put signal circuit.
<Ref. to AT-104, DTC 93 REAR VEHICLE SPEED
Rear vehicle speed Detects open or shorted input
93 SENSOR, Diagnostic Procedure with Diagnostic
sensor signal circuit.
AT-29
LIST OF DIAGNOSTIC TROUBLE CODE (DTC)
r.
AT-30
DIAGNOSTIC PROCEDURE FOR AT OIL TEMP WARNING LIGHT
a
12.Diagnostic Procedure for AT OIL TEMP Warning Light

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:
When the ignition switch is turned to ON (engine OFF), AT OIL TEMP warning light does not illuminate.
When the on-board diagnostics is performed, AT OIL TEMP warning light remains illuminated.
--
AT-31
I
WIRING DIAGRAM:
IGNITION
SWITCH
SBF-1 SBF-4
I i
COMBINATION
METER
B AT OIL
INHIBITOR SWITCH
r- ~
3 3
I A: @
3
B: @ TCM
7 8 9101112
dR\
9 101112
A: @ B: @
TR0570
AT-32
1
~~~ ~
Step Check Yes No

CHECK AT OIL TEMP WARNING LIGHT. )oes the AT OIL TEMP warn- Go to step 3. 30 to step 2.
Turn the ignition switch to ON (engine OFF). i g light illuminate?
CHECK AT OIL TEMP WARNING LIGHT. ;the AT OIL TEMP warning Go to step 4. 3eplace the AT
1)Turn the ignition switch to OFF. ght bulb OK? 31L TEMP warn-
2)Remove the combination meter. ng light bulb.
3)Remove the ATF temp warning light bulb
from combination meter.
CHECK AT OIL TEMP WARNING LIGHT. )oes the AT OIL TEMP warn- A temporary poor 30 to step 10.
Perform “Read Diagnostic Trouble Code”. i g light blink? contact of the con-
<Ref. to AT-24, WITHOUT SUBARU SELECT nector or harness
MONITOR, OPERATION, Read Diagnostic may be the cause.
Trouble Code (DTC).> Repair the har-
ness or connector
in TCM, inhibitor
switch and combi-
nation meter.
CHECK FUSE (No. 13). 5 the fuse (No. 13) blown out? Replace the fuse 30 to step 5.
Remove the fuse (No. 13). (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.
CHECK HARNESSCONNECTOR BETWEEN 5 the voltage more than 9 V? Go to step 6. 3epair open or
COMBINATION METER AND IGNITION short circuit in har-
SWITCH. less between
1)Turnthe ignition switch to ON (engine OFF). :ombination meter
2)Measure the voltage between combination md battery.
meter connector and chassis ground.
(il0) No. 7 (+) - Chassis ground (-):
CHECK COMBINATION METER. 3 the voltage less than 1 V? Go to step 7 . 3epair the combi-
Measure the voltage between combination iation meter.
meter connector and chassis ground. :Ref. to IDI-11,
Connector & terminal zombination
( i l l ) No. 5 (+) - Chassis ground (-): Meter Assembly.>
CHECK OPEN CIRCUIT OF HARNESS. s the resistance less than 1 Go to step 8. 3epair open circuit
1)Turn the ignition switch to OFF. l? n harness
2)Disconnect the connector from combination ietween TCM and
meter connector. :ombination
3)Measure the resistance of harness between neter, and poor
combination meter. :ontact in cou-
Connector & terminal iling connector.
Non-turbo model
(854) NO. 3 - ( i l l ) NO. 5:
Turbo model
(856) NO. 11 - ( i l l ) NO. 5:
AT-33
I DIAGNOSTIC PROCEDURE FOR AT OIL TEMP WARNING LIGHT
Step Check Yes No

I CHECK INPUT SIGNAL FOR TCM. 5 the voltage less than 1 V? Even if the AT OIL Replace the TCM.
1)Connectthe 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- to a normal condi- (TCM).>
tor and chassis ground. tion at this time. A
Connector & 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.
1 CHECK SUBARU SELECT MONITOR. 10 you have a SUBARU Go to step 10. Go to step 11.
SELECT MONITOR?
0 CHECK INHIBITOR SWITCH. Vhen each range is selected, Go to step 11. Check the inhibi-
1)Connect the Subaru Select Monitor to data loes the LED of Subaru Seleci tor switch circuit.
link connector. Aonitor light up? <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 w OFF. nostic Trouble
Code (DTC).>
1 CHECK SHORT CIRCUIT OF HARNESS. s the resistance less than 1 Replace the TCM. Repair short circuil
1)Disconnectthe connector from TCM. AR? <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).> tor and TCM
4)Measure the resistance of harness connec- connector.
tor between TCM and chassis ground.
Connector & terminauspecified resistance
Non-turbo model
(854)No. 3 (+) - Chassis ground (-):
Turbo model
(B56)No. 11 (+) - Chassis ground (-):
AT-34
I DIAGNOSTIC PROCEDURE FOR AT OIL TEMP WARNING LIGHT
I
AT-35
I I
B: CHECK POWER SUPPLY AND GROUND LINE

WIRING DIAGRAM:
BATTERY
n
I -
i
m
(I)
INITION DATALINK
NITCH CONNECTOR
by
TB
m,@ : NON-TURBO MODEL
m, :TURBO MODEL
9 110 11 111211 311 411 511 6
112131415] 16171819110111
1211311411511 611 711 8119120121122123124
TR0571
AT-36
I DIAGNOSTIC PROCEDURE FOR AT OIL TEMP WARNING LIGHT I
AUTOMATIC TRANSMISSION (DIAGNOSTICSI
Step Check Yes No

1 CHECK IGNITION SWITCH. Is the ignition switch ON? Go to step 2. Turn the ignition
switch ON.
2 CHECK GENERATOR. Is the voltage between 10 and Go to step 3. Repair the genera
1)Start the engine. 15 V? tor. <Ref. to SC-
2)ldle the engine. 13, Generator.>
3)Measure the voltage between generator and
chassis ground.
Terminal
Generator B terminal (+) - Chassis
ground (-):
3 CHECK BATTERY TERMINAL. Is there poor contact at battery Repair the battery Go to step 4.
Turn the ignition switch to OFF. terminal? terminal.
I CHECK POWER SUPPLY OF TCM. Is the voltage between 10 and Go to step 6. Go to step 5.
1)Disconnectthe connector from TCM. 15 V?
3)Measure the voltage between TCM connec-
tor and chassis ground.
Non-turbo model
Turbo model
(B56) No. 1 (+)- Chassis ground (-):
5 CHECK FUSE (NO. 4). Is the fuse (No. 4) blown out? Replace the fuse Repair open circuii
Remove fuse (No. 4). (No. 4). If the in harness
replaced fuse (No. between fuse (No.
4) has blown out 4) and TCM, or
easily, repair short fuse (No. 4) and
circuit in harness battery, and poor
between fuse (No. sontact in cou-
4) and TCM. pling connector.
5 CHECK IGNITION POWER SUPPLY CIR- Is the voltage more than 10 V? Go to step 8. Go to step 7.
CUIT.
2)Measure the ignition power supply voltage
between TCM connector and chassis ground.
(B54) No. 23 (+) - Chassis ground (-):
(654) No. 24 (+)- - Chassis ground (-):
7 CHECK FUSE (NO. 11). Is the fuse (No. 11) blown out? Replace the fuse Repair open circuii
Remove the fuse (No. 11). (No. 11). If the in harness
replaced fuse (No. Detween fuse (No.
11) has blown out 4) and TCM, or
easily, repair short fuse (No. 4) and
circuit in harness Dattery, and poor
between fuse (No. :ontact in cou-
11) and TCM. Dling connector.
3 CHECK HARNESSCONNECTOR BETWEEN Is the resistance less than 1 Go to step 9. Repair open circuii
TCM AND TRANSMISSION. n? n harness
1)Turn the ignition switch to OFF: Detween TCM,
2)Disconnect the connector from TCM and ransmission har-
transmission. less connector,
3)Measure the resistance of harness between and poor contact
TCM and transmission connector. n coupling con-
Connector & terminal lector.
Non-turbo model
(B55) NO. 9 - (B1 1) NO. 16
(B55) NO. 19 - (Bl 1) NO. 16
Turbo model
(B56) NO. 19 - ( B l l ) NO. 16
(654) NO.21 - (611) NO. 16
AT-37
I
Step Check Yes No

9 CHECK HARNESS CONNECTOR BETWEEN Is the resistance less than 1 30 to step 10. Repair open circuit
TRANSMISSION AND TRANSMISSION n? in harness
GROUND. between transmis-
Measure the resistance of harness between sion and transmis-
transmission and transmission ground. sion ground.
(T4) No. 16 - Transmission ground:
10 CHECK POOR CONTACT IN CONNECTORS. Is there poor contact in control Repair the con- Replace the TCM.
module power supply, ground lector. <Ref. to AT-45,
line and data link connector? Transmission Con-
trol Module
(TCM).>
AT-38
I DIAGNOSTIC PROCEDURE FOR SELECT MONITOR COMMUNICATION
E
13.Diagnostic Procedure for Select Monitor Communication

A: COMMUNICATION FOR INITIALIZING IMPOSSIBLE
DIAGNOSIS:
Faulty harness connector
TROUBLE SYMPTOM:
Select the monitor communication failure
AT-39
DIAGNOSTIC PROCEDURE FOR SELECT MONITOR COMMUNICATION
I
WIRING DIAGRAM:
BATTERY
P
0
5 DATALINK
=
12
CONNECTOR
-
13
r- ~
1 A:@ B:@
m
2 2
m *
9 2
C @ : m
*
TCM
TRANSMISSION
m,@ : NON-TURBO MODEL
TR0571
AT-40
I
~~
Step Check Yes No

CHECK SUBARU SELECT MONITOR POW- s the voltage more than lOV? 30 to step 2. 3epair harness
ER SUPPLY CIRCUIT. and connector
Measure the voltage between data link con- 3etween battery
nector and chassis ground. and data link con-
Connector & terminal lector, and poor
(840) No. 1 - Chassis ground: :ontact in cou-
Dling connector.
CHECK SUBARU SELECT MONITOR Is the resistance less than In? 30 to step 3. Repair open circuii
GROUND CIRCUIT. in harness
Measure the resistance of harness between between data link
data link connector and chassis ground. sonnector and
Connector & terminal ground terminal,
(840) No. 12 - Chassis ground: and poor contact
(840) No. 13 - Chassis ground: in coupling con-
nector.
CHECK COMMUNICATIONOF SELECT Are the name and year of the 30 to step 8. Go to step 4.
MONITOR. system displayed on the select
1)Turn the ignition switch to ON. monitor?
2)Using the select monitor, check whether
communication to other systems (such as
engine, ABS etc.) can be executed normally.
CHECK COMMUNlCATtON OF SELECT Are the name and year of the So to step 10. Go to step 5.
MONITOR. system displayed on the select
1)Turn the ignition switch to OFF. monitor?
2)Disconnect the TCM connector.
3)Check whether communication to other sys-
tems (such as ABS etc.) can be executed nor-
mally.
CHECK COMMUNICATIONOF SELECT Are the name and year of the Inspect the ECM. Go to step 6.
MONIT0R . system displayed on the select
1)Turnthe ignition switch to OFF. monitor?
2)Connect the TCM connector.
3)Disconnect the ECM connector.
tems (such as ABS etc.) can be executed nor-
mally.
CHECK COMMUNICATIONOF SELECT Are the name and year of the Inspect the Go to step 7.
MONITOR. system displayed on the select ABSCM&H/U.
2)Connect the ECM connector.
3)Disconnect the ABSCM&H/U connector.
tems (such as engine etc.) can be executed
normally.
CHECK COMMUNICATIONOF SELECT Are the name and year of the Inspect the cruise Go to step 8.
MONITOR. system displayed on the select control module.
2)Connect the ABSCM&H/U module connec-
tor.
3)Disconnect the cruise control module con-
nector.
tems (such as engine etc.) can be executed
normally.
NOTE:
If the vehicle is not equipped with cruise contro
Go to step 8.
AT-41
I DIAGNOSTIC PROCEDURE FOR SELECT MONITOR COMMUNICATION
Step Check
R? and connector
between each con.
trol module and
data link connec-
tor.
(840) No. 4-Chassis ground:

I CHECK OUTPUT SIGNAL FOR TCM. Is the voltage more than 1 V? 3epair harness A temporary poor
ind connector contact or har-
letween each con- ness may be the
rol module and case. Repair har-
jata link connec- ness or connector
or. in the select moni-
tor communication
circuit.
0 CHECK HARNESSKONNECTORBETWEEN Is the resistance less than 0.5 i o to step 11. Repair harness
TCM AND DATA LINK CONNECTOR. R? and connector
Measure the resistance between TCM connec- between TCM and
tor and data link connector. data link connec-
Connector & terminal tor.
Non-turbo model
-
(855) NO. 7 (840) NO. 5:
(855) NO. 16 - (840) NO. 4:
Turbo model
(856) NO. 6 - (840) NO. 5:
(856) NO. 15 - (840) NO. 4:
1 CHECK INSTALLATION OF TCM CONNEC- Is TCM connector inserted into i o to step 12. Insert the TCM
TOR. TCM? connector into
Turn the ignition switch to OFF. TCM.
2 CHECK POOR CONTACT IN CONNECTORS. Is there poor contact in control 3epair the poor Replace the TCM.
module and data link connec- :ontact. <Ref. to AT-45,
tor? Transmission Con-
trol Module
(TCM).>
AT-42
AT-43
I
DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
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:
No lock-up (after engine warm-up).
AT OIL TEMP warning light remains on when the vehicle speed is ''0'.
WIRING DIAGRAM:
1
@TCM
: NON-TURBO MODEL
: TURBO MODEL
I ECM I
TR0572
AT-44
DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) I
Step Check Yes No

CHECK HARNESS CONNECTOR BETWEEN s the resistance less than 1 io to step 2. 3epair open circuit
TCM AND ECM. 2? n harness
1)Turn the ignition switch to OFF. letween TCM and
2)Disconnect the connectors from TCM and X M connector.
ECM.
TCM and ECM connector.
Non-turbo model
(B55) NO. 4 - (8134) NO. 30:
Turbo model
(B55) NO. 17 - (8136) NO. 9:
CHECK HARNESSCONNECTOR BETWEEN s the resistance more than 1 i o to step 3. 3epair short circuit
TCM AND ECM. VlR? n harness
Measure the resistance of harness between ietween TCM and
TCM connector and chassis ground. ICM connector.
Non-turbo model
Turbo model
PREPARE SUBARU SELECT MONITOR. l o you have a Subaru Select i o to step 5. 30 to step 4.
Vlonitor?
CHECK INPUT SIGNAL FOR TCM. s the voltage 0 V? gven if the AT OIL 30 to step 6.
1)Connect the connectors to TCM and ECM. rEMP warning
2)Turn the ignition switch to ON (engine OFF). ights up, the cir-
3)Measure the voltage between TCM connec- :uit has returned
tor and chassis ground. o a normal condi-
Connector & terminal ion at this time. A
Non-turbo model emporary poor
(B55) No. 4 (+) - Chassis ground (-): :ontact of the con
Turbo model lector or harness
(B55) No. 17 (+) - Chassis ground (-): nay be the cause
3epair harness or
:onnector in the
E M and ECM.
I CHECK INPUT SIGNAL FOR TCM USING Is the revolution value the Iven if the AT OIL 30 to step 6.
SUBARU SELECT.MONITOR. same as the tachometer read- rEMP warning
1)Connect the connectors to TCM and ECM. ng shown on the combination ights up, the cir-
2)Connect the Subaru Select Monitor to data neter? x i t has returned
link connector. o a normal condi.
3)Start the engine, and turn the Subaru Select ion at this time. A
Monitor switch to ON. emporary poor
4)Warm-up the engine until engine coolant :ontact of the con
temperature is above 80°C (176°F). lector or harness
5)Engine idling. nay be the cause
6)Read the data of engine speed using the qepair harness or
Subaru Select Monitor. :onnector in the
-Display shows engine speed signal value sent TCM and ECM.
from ECM.
i CHECK POOR CONTACT. Is there poor contact in engine qepair poor con- Go to step 7.
speed signal circuit? :act.
I CONFIRM DTC 11. Replace the ECM with a new Replace the TCM. Replace the ECM.
one. Does the trouble code <Ref. to AT-45,
appear again, after the mem- Transmission Con
ory has been cleared? :rol Module
[TCM).>
AT-45
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:
TR0573
Step Check Yes No

Repair ground ter- Go to step 2.
I
I 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).>
2 CHECK HARNESS CONNECTOR BETWEEN s the resistance less than 1 Go to step 3. Repair open circuit
TCM AND ECM. n? in harness
1)Turn the ignition switch to OFF. between TCM and
2)Disconnect the connectors from TCM and ECM connector.
~ ECM.
(B54) NO. 1 - (8135) NO. 28:
3 CHECKHARNESSCONNECTORBETWEEN s the resistance more than 1 Go to step 4. Repair short circuit
TCM AND ECM. M1R? in harness
Measure the resistance of harness between between TCM and
TCM connector and chassis ground. ECM connector.
4 PREPARE SUBARU SELECT MONITOR. l o you have a Subaru Select Go to step 6. Go to step 5.
vlonitor?
AT-46
Step Check Yes No

1 CHECK INPUT SIGNAL FOR TCM. s the voltage between 0.4 and Even if the AT OIL ;o to step 7.
1)Connect the connectors to TCM and ECM. I .8 V? TEMP warning
2)Start the engine, and warm-up the transmis- lights up, the cir-
sion until ATF temperature is above 80°C cuit has returned
(176°F). to a normal condi-
NOTE: tion at this time. A
If ambient temperature is below 0°C (32°F) temporary poor
drive the vehicle until the ATF reaches its oper contact of the con-
ating temperature. nector or harness
3)Engine idling. may be the cause.
4)Measure the voltage between TCM connec- Repair harness or
tor and chassis ground. connector in the
Connector & terminal TCM and ECM.
i CHECK INPUT SIGNAL FOR TCM USING s the value between 0.4 and Even if the AT OIL 30 to step 7.
SUBARU SELECT MONITOR. 1.8 V? TEMP warning
1)Connect the connectors to TCM and ECM. lights up, the cir-
2)Connect the Subaru Select Monitor to data cuit has returned
link connector. to a normal condi-
3)Start the engine, and turn the Subaru Seleci tion at this time. A
monitor switch to ON. temporary poor
4)Warm-upthe engine until the engine coolani contact of the con-
temperature is above 80°C (176°F). nector or harness
6)Read the data of intake manifold pressure Repair harness or
signal using Subaru Select Monitor. connector in the
*Display shows the intake manifold pressure TCM and ECM.
signal value sent from ECM.
r CHECK POOR CONTACT. s there poor contact in intake Repair the poor 3eplace the TCM.
nanifold pressure signal cir- contact. :Ref. to AT-45,
rransmission Con-
rot Module
'TCMb
AT-47
I
C: DTC 27 ATF TEMPERATURE SENSOR

DIAGNOSIS:
Input signal circuit of TCM to ATF temperature sensor is open or shorted.
TROUBLE SYMPTOM:
WIRING DIAGRAM:
TCM
w o
a m
w w
:TURBO MODEL
LL
+
4:
TRANSMISSION
TR0574
AT-48
DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) 1
~~~ ~
Step Check Yes No

CHECK HARNESSCONNECTOR BETWEEN ;the resistance less than 1 io to step 2. Repair open circuit
TCM AND ATF TEMPERATURE SENSOR. 1? in harness
2)Disconnect the connector from transmission transmission con-
and TCM. nector.
TCM and transmission connector.
Non-turbo model
(655) NO. 10 - (61 1) NO. 12:
Turbo mode
(654) NO.20 - ( 6 1 1) NO. 12:
CHECK HARNESSCONNECTOR BETWEEN 3 the resistance less than 1 io to step 3. Repair open circuit
TCM AND ATF TEMPERATURE SENSOR. I? in harness
TCM and transmission connector. transmission con-
Connector & terminal nector.
Non-turbo model
(655) No. 11 - (611) NO. 11:
Turbo mode
(654) NO. 11 - (611) NO. 11:
c .- CHECK HARNESSCONNECTOR BETWEEN ;the resistance more than 1 io to step 4. Repair short circuit
TCM AND ATF TEMPERATURE SENSOR. AR? in harness
TCM connector and chassis ground. transmission con-
Non-turbo model
Turbo mode
I CHECK HARNESS CONNECTOR BETWEEN s the resistance more than 1 So to step 5. Repair short circuil
TCM AND ATF TEMPERATURE SENSOR. An? in harness
TCM connector and chassis ground. transmission con-
Non-turbo model
Turbo mode
1 CHECK ATF TEMPERATURE SENSOR. s the resistance between 275 So to step 6. Go to step 11.
1)Turn the ignition switch to OFF. md 375 n?
2)Connect the connectors to transmission and
TCM.
3)Turn the ignition switch to ON and start
engine.
4)Warm-up the transmission until the ATF tern
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.
(T4) NO. 11 - NO. 12:
AT-49
I DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
~~
Step Check Yes No

6 CHECK ATF TEMPERATURE SENSOR. Does the resistance value Go to step 7. So to step 11.
1)Turn the ignition switch to ON (engine OFF). ncrease while the ATF temper
2)Measure the resistance between transmis- 3ture decreases?
sion connector terminals.
(T4) NO. 11 - NO. 12:
7 PREPARE SUBARU SELECT MONITOR. 30 you have a Subaru Select Go to step 9. 30 to step 8.
Monitor?
CHECK INPUT SIGNAL FOR TCM. s the voltage between 0.4 and Even if the AT OIL 30 to step 10.
1)Connect the connector to transmission. 1.9 V? TEMP warning
2)Warm-up the transmission 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. :ontact of the con.
3)Measure the voltage between TCM connec- lector or harness
tor terminal. nay be the case.
Connector & terminal Repair harness or
Non-turbo model :ontact in the ATF
(B55)NO. 11 (+) - NO. 10 (-): :emperatwe sen-
r. ~ Turbo model ;or and transmis-
(B54) NO. 11 (+) - NO. 20 (-): sion connector.
9 CHECK INPUT SIGNAL FOR TCM USING 1oes the ATF temperature Even if the AT OIL 50 to step 10.
SUBARU SELECT MONITOR. jradually decrease? rEMP warning
1)Connect the connector to transmission. ights up, the cir-
2)Turn the ignition switch to ON (engine OFF). :uit has returned
o a normal condi-
ion at this time.
remporary poor
:ontact of the con-
lector or harness
nay be the case.
3epair harness or
:ontact in the ATF
emperature sen-
ior and transmis-
;ion connector.
3 there poor contact in ATF Iepair poor con- ieplace the TCM.
smperature sensor circuit? act. :Ref. to AT-45,
tansmission Con-
'01 Module
TCM).>
AT-50
Step Check Yes No

I1 CHECK HARNESS CONNECTOR BETWEEN s the resistance less than 1 ;o to step 12. lepair open circuit
TRANSMISSION AND ATF TEMPERATURE 2? 1 harness
SENSOR. letween ATF tem-
1)Turnthe ignition switch to OFF. lerature sensor
2)Disconnect the connector from transmission. .nd transmission
3)Remove the transmission connector from onnector.
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.
ATF temperature sensor and transmission con.
nector. I

(T4) NO. 11 - (AT1) NO. 2:
12 CHECK HARNESSCONNECTOR BETWEEN s the resistance less than 1 50 to step 13. iepair open circuit
TRANSMISSION AND ATF TEMPERATURE n? iharness
SENSOR. letween ATF tem-
Measure the resistance of harness between Ierature sensor
ATF-temperaturesensor and transmission con. ind transmission
nector. :onnector.
(T4) NO. 12 - (ATl) NO. 1:
13 CHECK HARNESSCONNECTOR BETWEEN Is the resistance more than 1 20 to step 14. iepair short circuit
TRANSMISSION AND ATF TEMPERATURE Ma? iharness
SENSOR. jetween ATF tem-
Measure the resistance of harness between erature sensor
transmission connector and transmission nd transmission
ground. onnector.
(T4) No. 11 - Transmissionground:
4 CHECK HARNESS CONNECTOR BETWEEN s the resistance more than 1 leplace the ATF lepair short circuit
TRANSMISSION AND ATF TEMPERATURE An? mperature sen- 1 harness
SENSOR. ,or. <Ref. to AT- etween ATF tem-
Measure the resistance of harness between 19,Shift Sole- erature sensor
transmission connector and transmission ioids, Duty Sole- nd transmission
ground. ioids and ATF onnector.
Connector & terminal emperature Sen-
-
(T4) No. 12 Transmissionground: ,or.>
AT-51
I DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) I
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
@ TCM 000
A. 6134 B 8135 C 6136 ECM
L
THROTTLE
POSITION SENSOR
SHIELD AND
SENSOR GROUND
JOINT CONNECTOR
AT-52
I
TURBO MODEL
@ TCM
A: 8134
C:@
'O
B 6135
D:@
ECM
I
I I
r. .
SHIELD AND
THROTTLE SENSORGROUND
POSITION SENSOR JOINT CONNECTOR
TR0576
AT-53
Step Check Yes No

I CHECK ENGINE GROUND TERMINALS. -lave engine ground terminals 20 to step 2. righten the engine
ieen tightened? ground terminals.
! CHECK GROUND CIRCUIT OF ECM. s the resistance less than 5 :o to step 3. 3epair open circuit
1)Turn the ignition switch to OFF. 3? n harness
2)Disconnect the connector from ECM. letween ECM
3)Measure the resistance of harness between :onnector and
ECM and engine ground. mgine grounding
Connector & terminal erminal.
Non-turbo model
(6134) No. 27 - Engine ground:
( 6 134)No. 8 - Engine ground:
(6136) No. 21 -Engine ground:
Turbo model
_I
~

t CHECK THROTTLE POSITION SENSOR. s the resistance between 3.0 20 to step 4. 3eplace the throt-
1)Disconnect the connector from throttle posi- 2nd 4.2 kfi? le position sensor.
tion sensor.
2)Measure the resistance between throttle
position sensor connector receptacle's termi-
nals.
Terminals
Non-turbo model
NO. 4 - NO. 2:
Turbo model
NO. 1 - NO. 2:
I CHECK THROTTLE POSITION SENSOR. s the resistance between 0.35 ;o to step 5. 3eplace the throt-
Measure the resistance between throttle posi- md 0.5 kR? le position sensor.
tion sensor connector receptacle's terminals.
Terminals
NO. 2 - NO. 3:
> CHECK HARNESS CONNECTOR BETWEEN s the resistance less than 1 20 to step 6. 3epair open circuit
TCM AND THROTTLE POSITION SENSOR. n? n harness
1)Disconnect the connector from TCM. ietween TCM and
2)Measure the resistance of harness between hrottle position
TCM and throttle position sensor connector. sensor connector,
Connector & terminal 3nd poor contact
Non-turbo model n coupling con-
-
(655) NO. 2 (€13) NO. 3: lector.
Turbo model
-
(B54) NO. 3 (E13) NO. 3:
i CHECK HARNESS CONNECTOR BETWEEN s the resistance less than 1 ;o to step 7. 3epair open circuit
TCM AND THROlTLE POSITION SENSOR. n? n harness
TCM and throttle position sensor connector. hrottle position
Connector & terminal sensor connector,
Non-turbo model md poor contact
-
(655) NO. 1 (€13) NO. 4: n coupling con-
Turbo model lector.
-
(654) NO. 2 (€13) NO. 4:
AT-54
I
Step Check Yes No

CHECK HARNESSCONNECTOR BETWEEN s the resistance more than 1 o step 8. Repair short circuit
TCM AND THROTTLE POSITION SENSOR. An? n harness
Measure the resistance of harness between Detween TCM and
TCM connector and chassis ground. throttle position
Connector & terminal sensor connector.
Non-turbo model
Turbo model
CHECK HARNESSCONNECTOR BETWEEN s the resistance more than 1 o step 9. Repair short circuit
TCM AND THROTTLE POSITION SENSOR. dR? in harness
TCM connector and chassis ground. throttle position
Connector & terminal sensor connector.
Non-turbo model
Turbo model
I CHECK HARNESS CONNECTOR BETWEEN s the resistance less than 1 o step 10. Repair open circuit
TCM AND ECM. 2? in harness
TCM and ECM connector. ECM connector.
Non-turbo model
(655) NO.2 - (6136) NO. 17:
Turbo model
(654) NO. 3 - (6135) NO. 7:
0 CHECK HARNESSCONNECTOR BETWEEN Is the resistance less than 1 to step 11. Repair open circuit
TCM and ECM connector. ECM connector.
Non-turbo model
(655) NO. 1 - (6136) NO. 15:
Turbo model
(654) NO. 2 - (6135) NO. 9:
I1 PREPARE SUBARU SELECT MONITOR. Do you have a Subaru Select to step 14. Go to step 12.
Monitor?
12 CHECK INPUT SIGNAL FOR TCM. Is the voltage between approx. 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.
Non-turbo model
Turbo model
13 CHECK INPUT SIGNAL FOR TCM. Is the voltage between approx. to step 16.
1)Open the throttle completely. 4.3 V with throttle fully open?
Non-turbo model
Turbo model
AT-55
AUTOMATIC TRANSMISSION [DIAGNOSTICS)
Step Check Yes No

4 CHECK INPUT SIGNAL FOR TCM USING s the value voltage between 30 to step 15. 20 to step 18.
SUBARU SELECT MONITOR. ipprox. 0.5 V?
1)Connect the connectors to TCM, throttle
position sensor and ECM.
2)Connect the Subaru Select Monitor to data
link connector.
4)Turn the Subaru Select Monitor switch to ON.
5)Throttle fully closed.
6)Read the data of throttle position sensor
using Subaru Select Monitor.
*Throttle position sensor input signal is indi-
cated.
5 CHECK INPUT SIGNAL FOR TCM USING s the value voltage between 30 to step 17. i o to step 18.
SUBARU SELECT MONITOR. ipprox. 4.3 V?
Throttle fully open.
NOTE:
Must be changed correspondingly with acceler-
ator pedal operation (from “released” to “de-
pressed” position).
6 CHECK INPUT SIGNAL FOR TCM (THROT- s the voltage between 4.8 and Even if the AT OIL i o to step 18.
.- TLE POSITION SENSOR POWER SUPPLY). i.3 V? rEMP warning
Measure the voltage between TCM connector ights up, the cir-
and chassis ground. :uit has returned
Connector & terminal o a normal condi-
Non-turbo model ion at this time. A
(855)No. 1 (+) - Chassis ground (-): emporary poor
Turbo model :ontact of the con-
(B54) No. 2 (+) - Chassis ground (-): lector or harness
nay be the cause.
3epair harness or
:onnector in throt-
le position sensor
:ircuit.
7 CHECK INPUT SIGNAL FOR TCM USING s the value voltage between Even if the AT OIL i o to step 18.
SUBARU SELECT MONITOR (THROTTLE ..8 and 5.3 V? rEMP warning
POSITION SENSOR POWER SUPPLY). ights up, the cir-
Read the data of throttle position sensor power :uit has returned
supply using Subaru Select Monitor. o a normal condi-
*Throttle position sensor power supply voltage ion at this time. A
is indicated. emporary poor
:ontact of the con-
lector or harness
nay be the cause.
3epair harness or
:onnector in throt-
le position sensor
:ircuit.
8 CHECK POOR CONTACT. s there poor contact in throttle
losition sensor circuit? :ontact. <Ref. to AT-45,
Transmission Con-
trol Module
AT-56
3
E: DTC 33 FRONT VEHICLE SPEED SENSOR

DIAGNOSIS:
The vehicle speed signal is abnormal.
The circuit in combination meter is faulty.
The harness connector between TCM and vehicle speed sensor is in short or open.
TROUBLE SYMPTOM:
Erroneous idling.
Engine stalls.
Poor driving performance.
--
AT-57
I
WIRING DIAGRAM:
TCM
SHIELD AND
SENSORGROUND
JOINT CONNECTOR
I
I
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I I
I I
..
I I
I I
I I
I
I I
1
I
I
JI
I I
I I
I I
I I
I I
I I
I
r *I
(I II COMBINATON FRONT
VEHICLE SPEED
SENSOR
A: a
TR0577
AT-58
I
Step Check Yes No

CHECK HARNESS CONNECTOR BETWEEN Is the resistance less than 1 20 to step 2. Repair open circuit
TCM AND TRANSMISSION. R? in harness
2)Disconnect the connector from TCM and transmission con-
transmission. nector.
Non-turbo model
(B55) NO. 5 - (B11)NO. 17:
Turbo model
(B55) NO. 18 - (B11)NO. 17:
CHECK HARNESS CONNECTOR BETWEEN Is the resistance less than 1 30 to step 3. Repair open circuit
TCM AND TRANSMISSION. R? in harness
Connector & terminal nector, and poor
Non-turbo model contact in cou-
(B55) NO. 21 - (Bll)NO. 18: pling connector.
Turbo model
(854) NO. 10 - (B 1 1) NO. 18:
1 CHECK HARNESS CONNECTOR BETWEEN Is the resistance more than 1 30 to step 4. Repair short circuit
TCM AND TRANSMISSION. MR? in harness
Non-turbo model
Turbo model
(854) No, 10 - Chassis ground:
CHECK HARNESS CONNECTOR BETWEEN Is the resistance more than 1 30 to step 5. Repair short circuit
TCM AND TRANSMISSION. MR? in harness
(B55) No. 5 - Chassis ground: pling connector.
Turbo model
I CHECK FRONT VEHICLE SPEED SENSOR. Is the resistance between 450 30 to step 6. Replace the front
Measure the resistance between transmission and 650 R? vehicle speed sen.
connector receptacle's terminals. sor. <Ref. to AT-32,
'
Connector & terminal Front Vehicle

(T4) NO. 17- NO. 18: Speed Sensor.>
i PREPARE OSCILLOSCOPE. Do you have an oscilloscope? 30 to step 9. Go to step 7.
I PREPARE SUBARU SELECT MONITOR. Do you have a Subaru Select 30 to step 10. Go to step 8.
Monitor?
AT-59
Step Check Yes No

CHECK INPUT SIGNAL FOR TCM. Is the voltage more than AC 1 %en if the AT OIL 20 to step 11.
1)Connect all connectors. V? rEMP warning
2)Lift-up or raise the vehicle and place safety ights up, the cir-
stands. :uit has returned
CAUTION: o a normal condi-
On AWD models, raise all wheels off floor. ion at this time. A
3)Start the engine and set the vehicle in 20 km emporary poor
h (12 MPH) condition. :ontactor or har-
less may be the
NOTE:
The speed difference between front and real :ase. Repair har-
wheels may light the ABS warning light, but thk less or connector
indicates no malfunction. When the AT contro n the front vehicle
diagnosis is finished, perform the ABS memorq ;peed sensor cir-
clearance procedure of on-board diagnostic5 :uit.
system. <Ref. to ABS-22, Clear Memor)
Mode.>
tor terminals.
i
Non-turbo model
(655) NO. 5 (+) - (654) NO. 21 (-):
Turbo model
(655) NO. 18 (+) - (654) NO. 10 (-):
CHECK FRONT VEHICLE SPEED SENSOR s the voltage more than AC 4 h e n if the AT OIL ;o to step 11.
USING OSCILLOSCOPE. J? rEMP warning
1)Connect all connectors. ights up, the cir-
2)Lift-up the vehicle and place safety stands. :uit has returned
CAUTION: o a normal condi-
On AWD models, raise all wheels off ion at this time. A
ground. emporary poor
3)Set the oscilloscope to TCM connector ter- :ontactor or har-
minals. less may be the
Non-turbo model :ase. Repair har-
Positive probe; (855) No. 18 less or connector
Earth lead; (B54) No. 10 Ithe front vehicle
Turbo model ;peed sensor cir-
Positive probe; (855) No. 5 :uit.
Earth lead; (854) No. 21
4)Start the engine, and drive the wheels slowly,
NOTE:
The speed difference between front and real
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.
<Ref. to ABS-22, Clear Memory Mode.>
5)Measure the signal voltage indicated on
oscilloscope.
AT-60
I
Step Check Yes No

0 CHECK INPUT SIGNAL FOR TCM USING Does the speedometer indica- Even if the AT OIL ;o to step 11.
SUBARU SELECT MONITOR. tion increase as the Subaru TEMP warning
1)Connect all connectors. Select Monitor data increases? lights up, the cir-
3)Lift-up or raise the vehicle and place safety tion at this time. A
stands. temporary poor
CAUTION: connector or har-
On AWD models, raise all wheels off floor. ness may be the
4)Turn the ignition switch to ON and turn the case. Repair har-
Subaru Select Monitor switch to ON. ness or connector
5)Start the engine. in the front vehicle
6)Read the data of vehicle speed using Subaru speed sensor cir-
Select Monitor. cuit.
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
indicates no malfunction. When the AT control
clearance procedure of on-board diagnostics
system. <Ref. to ABS-22, Clear Memory
Mode.>
1 CHECK POOR CONTACT. IS there poor contact in front Repair poor con- Replace the TCM.
vehicle speed sensor circuit? tact. <Ref. to AT-45,
Transmission Con-
trol Module
(TCM).>
AT-61
I
DIAGNOSTIC P 3OCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
AUTOMATIC TRANSMISSI( IN (DIAGNOSTICS)
F: DTC 36 TORQUE CONVERTER TURBINE SPEED SENSOR

DIAGNOSIS:
Input signal circuit of TCM is open or shorted.
TROUBLE SYMPTOM:
WIRING DIAGRAM:
: NON-TURBO MODEL
: TURBO MODEL
SHIELD AND
SENSOR GROUND
JOINT CONNECTOR
r.
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t
*a
4
la
1I
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\
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-
I
TORQUE
CONVERTER
TURBINE SPEED
SENSOR
TRQ570
AT-62
I
Step Check Yes No

I CHECK TORQUE CONVERTER TURBINE Is the resistance between 450 ;o to step 2. Replace the tur-
SPEED SENSOR. and 650 Q? bine speed sensor.
1)Turn the ignition switch to OFF. <Ref. to AT-36,
2)Disconnect the connector from transmission. Torque Converter
3)Measure the resistance between transmis- Turbine Speed
sion connector receptacle's terminals. Sensor.>
(T4) NO. 14 - NO. 15:
! CHECK HARNESS CONNECTOR BETWEEN Is the resistance less than 1 ;o to step 3. Repair open circuit
TCM AND TRANSMISSION. Q? in harness
1)Disconnectthe connector from TCM. between TCM and
2)Measure the resistance of harness between transmission con-
TCM and transmission connector. nector.
Non-turbo model
(B55) NO. 12 - (Bll)NO. 14:
Turbo model
-
(B55) NO. 8 (Bll)NO. 14:
t CHECK HARNESS CONNECTOR BETWEEN Is the resistance less than 1 $0 to step 4. Repair open circuit
TCM AND TRANSMISSION. Q? in harness
(B55) NO. 21 - (Bll)NO. 15: pling connector.
Turbo model
(B55) NO. 9 - (B11) NO. 15:
I CHECK HARNESS CONNECTOR BETWEEN Is the resistance more than 1 ;o to step 5. Repair short circuit
TCM AND TRANSMISSION. MQ? in harness
TCM and chassis ground. transmission con-
Non-turbo model
Turbo model
I CHECK HARNESS CONNECTOR BETWEEN Is the resistance more than 1 20 to step 6. Repair short circuit
TCM AND TRANSMISSION. MQ? in harness
(B55) No. 12 - Chassis ground: pling connector.
Turbo model
5 PREPARE OSCILLOSCOPE. Do you have an oscilloscope? ;o to step 10. Go to step 7.
7 PREPARE SUBARU SELECT MONITOR. Do you have a Subaru Select o
; to step 9. Go to step 8.
Monitor?
AT-63
Step Check Yes f

8 CHECK INPUT SIGNAL FOR TCM. s the voltage more than AC 1 Even if the AT OIL 20 to stc
1)Connect the connectors to TCM and trans- I? TEMP warning
mission. lights up, the cir-
2)Start the engine and move select lever to “P” cuit has returned
or “N” range. to a normal condi-
3)Measure the voltage between TCM connec- tion at this time. A
tor terminals. temporary poor
Connector & terminal contact of the con-
Non-turbo model nector or harness
(855) NO. 12 (+) - NO. 21 (-): may be the cause.
Turbo model Repair harness or
(855) NO. 8 (+) - NO. 9 (-): connector in the
TCM and trans-
mission.
9 CHECK INPUT SIGNAL FOR TCM USING s the revolution value same as Even if the AT OIL 20 to ste
SUBARU SELECT MONITOR. he tachometer reading shown TEMP warning
1)Connect the connectors to TCM and trans- In the combination meter? lights up, the cir-
mission. cuit has returned
2)Connect the Subaru Select Monitor to data to a normal condi-
link connector. tion at this time. A
3)Turn the ignition switch to ON and turn the temporary poor
r. - Subaru Select Monitor switch to ON. contact of the con-
4)Start the engine. nector or harness
5)Move the select lever to “P” or “N” range. may be the cause.
6)Read the data of turbine speed using Subaru Repair harness or
Select Monitor. connector in the
Compare the tachometer with Subaru Select TCM and trans-
Monitor indications. mission.
10 CHECK INPUT SIGNAL FOR TCM USING s the signal voltage more than Even if the AT OIL 30 to stt
OSCILLOSCOPE. 4c 1 V? TEMP warning
1)Connect the connectors to TCM and trans- lights up, the cir-
mission. cuit has returned
2)Set the oscilloscope to TCM connector ter- to a normal condi-
minals. tion at this time. A
Turbo model temporary poor
Positive probe; (B55) No. 8 contact of the con-
Earth lead; (B55) No. 9 nector or harness
Non-turbo model may be the cause.
Positive probe; (B55) No. 12 Repair harness or
Earth lead; (B55) No. 21 connector in the
3)Start the engine and move the select lever to TCM and trans-
“P” or “N” range. mission.
11 CHECK POOR CONTACT. s there poor contact in torque Repair poor con- z$5EG
:onverter turbine speed sensor tact. :Ref. to
:ircuit? rransmi:
rol Modi
I I TCM).>
AT-64
I
AT-65
G: DTC 38 TORQUE CONTROL SIGNAL

DIAGNOSIS:
The signal circuit is open or shorted.
TROUBLE SYMPTOM:
WIRING DIAGRAM:
I : NON-TURBO MODEL
.TURBO MODEL
I TR0579
1
TCM AND ECM.
Step
1)Turnthe ignition switch to OFF.

2)Disconnect the connectors from TCM and
ECM.
Check
CHECK HARNESSCONNECTOR BETWEEN I Is the resistance less than 1
t
Go to step 2. Repair open circuit
in harness
between TCM and
ECM connector.
Non-turbo model
(854) NO. 21 - (8134) NO. 17:
(854) NO. 13 - (8134) NO. 16:1
Turbo model
(B56) NO. 14 - (8135) NO. 18:
(856) NO. 5 -(8135) NO. 19:
AT-66
I
Step Check Yes No

CHECK HARNESS CONNECTOR BETWEEN s the resistance more than 1 Go to step 3. 3epair short circuit
TCM AND ECM. An? I harness
TCM connector and chassis ground. ICM connector.
Non-turbo model
Turbo model
CHECK OUTPUT SIGNAL EMITTED FROM s the voltage more than 4.8 V' Even if the AT OIL ;o to step 4.
TCM. TEMP warning
2)Turn the ignition switch to ON (engine OFF). cuit has returned
3)Measure the voltage between TCM connec- to a normal condi-
tor terminals. tion at this time. A
Non-turbo model contact of the con-
(B54) No. 21 (+) - Chassis ground (-): nector or harness
(B54) No. 13 (+) - Chassis ground (-): may be the cause.
Turbo model Repair harness or
(B56) No. 14 (+) - Chassis ground (-): connector in the
(B56) No. 5 (+) - Chassis ground (-): TCM and ECM.
I CHECK POOR CONTACT. s there poor contact in torque Repair poor con- ;o to step 5.
:ontrol signal circuit? tact.
1 CHECK GROUND LINE BETWEEN TRANS- s there any dirt or rust at Remove dirt and ;o to step 6.
MISSION AND BODY. lround line installing point? rust.
Check the installing condition of ground line in
transmission and body.
i CHECK GROUND LINE BETWEEN TRANS- s the tightening torque value Go to step 7. 7ghten to speci-
MISSION AND BODY. vithin specification? ied torque.
Check the installing condition of ground line in
transmission and body.
Tightening torque:
13f3 N.m (1.3i0.3 kgf-m, 9.4i9.2 ft-lb)
, CHECK GROUND LINE INSIDE TRANSMIS- s the tightening torque value Go to step 9. 7ghten to speci-
SION. vithin specification? ied torque.
1)Drain the AT fluid and remove the oil pan.
2)Check the tightening torque value of ground
line installing bolt.
Tightening torque:
T: Bfl N-m (O.BiO.l kgf-m, 5.8i0.7 ft-lb)
I CHECK GROUND CIRCUIT OF ECM. s there any trouble? Repair ground ter- So to step 9.
<Ref. to AT-52, DTC 31 THROTTLE POSITION minal and/or
SENSOR, Diagnostic Procedure with Diagnos, ground circuit of
tic Trouble Code (DTC).> ECM.
1 RECHECK OUTPUT SIGNAL EMITTED s each voltage more than 4.8 Replace the TCM. 3eplace the ECM.
FROM TCM. I? <Ref. to AT-45,
Measure the voltage between TCM connector Transmission Con-
and chassis ground. trol Module
Connector & terminal (TCM).>
Non-turbo model
Turbo model
AT-67
I
H: DTC 45 INTAKE MANIFOLD PRESSURE SIGNAL

DIAGNOSIS:
Input signal circuit of TCM from ECM is open or shorted.
TROUBLE SYMPTOM:
WIRING DIAGRAM:
TR0580
~~
Step Check Yes No

1 CHECK ENGINE GROUND TERMINALSAND Is there any trouble? 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).>
2 CHECK HARNESSCONNECTOR BETWEEN Is the resistance less than 1 Go to step 3. Repair open circuit
2)Disconnect the connectors from TCM and
ECM.
Connector 81terminal
(B55)NO. 20 -(8136) NO. 11:
3 CHECK HARNESSCONNECTOR BETWEEN
TCM AND ECM. in harness
TCM connector and chassis ground. ECM connector.
(B55)No. 20 - Chassis ground:
1 PREPARE SUBARU SELECT MONITOR. Do you have a Subaru Select Go to step 6. Go to step 5.
Monitor?
AT-68
Step Check Yes No

CHECK INPUT SIGNAL FOR TCM. s the voltage between 1.2 and Even if the AT OIL 30 to step 7.
1)Connect the connectors to TCM and ECM. i.8 V? TEMP warning
2)Start the engine, and warm-up the transmis- lights up, the cir-
sion until the ATF temperature is above 80°C cuit has returned
(176°F). to a normal condi-
NOTE: tion at this time. A
If ambient temperature is below 0°C (32"F), temporary poor
drive the vehicle until the ATF reaches its oper- contact of the con-
ating temperature. nector or harness
4)Measure the voltage between TCM connec- Repair harness or
tor and chassis ground. connector in the
Connector & terminal TCM and ECM.
CHECK INPUT SIGNAL FOR TCM USING s the value between 1.2 and Even if the AT OIL o ; to step 7.
SUBARU SELECT MONITOR. 1.8 V? TEMP warning
3)Start the engine, and turn the Subaru Select tion at this time. A
monitor switch to ON. temporary poor
4)Warm-up the engine until the engine coolant contact of the con-
temperature is above 80°C (176°F). nector or harness
6)Read the data of intake manifold pressure Repair harness or
signal using Subaru Select Monitor. connector in the
*Display shows the intake manifold pressure TCM and ECM.
signal value sent from ECM.
CHECK POOR CONTACT.
<Ref. to AT-45,
%it? Transmission Con-
trol Module
AT-69
I
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:
TRANSMISSION
TR0581
AT-70
I
Step Check Yes No

CHECK HARNESS CONNECTOR BETWEEN j the resistance less than 1 ;o to step 2. iepair open circuit
TCM AND TRANSMISSION. 1? 1 harness
2)Disconnect the connector from TCM and *ansmissioncon-
transmission. lector.
TCM and shift solenoid 1 connector.
Non-turbo model
(854) NO. 7 - (B 1 1) NO. 1:
Turbo model
(B54) NO.22 - (B1 1) NO. 1:
CHECK HARNESS CONNECTOR BETWEEN 3 the resistance more than 1 ;o to step 3. iepair short circuit
TCM AND TRANSMISSION. An? i harness
Measure the resistance of harness between letween TCM and
TCM connector and chassis ground. ransmission con-
Non-turbo model
Turbo model
b CHECK SHIFT SOLENOID 1. s the resistance between 10 30 to step 4. ;o to step 7.
Measure the resistance between transmission ind 16 Q?
(T4) NO. 1 - NO. 16:
I CHECK OUTPUT SIGNAL EMITTED FROM s the voltage more than 9V? 30 to step 5. ;o to step 6.
TChk
1)Connect the connectors to TCM and trans-
mission.
3)Move the select lever to “ D range.
Non-turbo model
Turbo model
1 CHECK OUTPUT SIGNAL EMIlTED FROM s the voltage less than l V ? Even if the AT OIL 20 to step 6.
TCM. rEMP warning
1)Move the select lever to “ 2 range. ights up, the cir-
2)Measure the voltage between TCM connec- :uit has returned
tor and chassis ground. :o a normal condi-
Connector & terminal :ion at this time. A
Non-turbo model :emporary poor
(854) No. 7 (+) - Chassis ground (-): :ontact of the con.
Turbo model lector or harness
(B54) No. 22 (+) - Chassis ground (-): nay be the cause.
qepair harness or
:ontact in the
TCM.
i CHECK POOR CONTACT. s there poor contact in shift Repair poor con- 3eplace the TCM.
;olenoid 1 circuit? :act. :Ref. to AT-45,
rransmission Con,
rol Module
TCM).>
AT-71
AUTOMATIC TRANSMISSION [DIAGNOSTICSI
Step Check Yes No

r CHECK SHIFT SOLENOID 1 (IN TRANSMIS- s the resistance between 10 Go to step 8. 3eplace the shift
SION). ind 16 Q? ;olenoid 1. <Ref.
1)Remove the transmission connector from o AT-39, Shift
bracket. Solenoids, Duty
2)Lift-up or raise the vehicle and support with Solenoids and ATF
safety stand. remperature Sen-
CAUTION: ior.>
ground.
CAUTION:
Do not drain the automatic transmission flu-
nector from shift solenoid 1.
5)Measure the resistance between shift sole-
noid 1 connector and transmission ground.
Terminal
No. 1 - Transmissionground:
I CHECK HARNESS CONNECTOR BETWEEN s the resistance less than 1 [Go to step 9. 3epair open circuit
SHIFT SOLENOID 1 AND TRANSMISSION. 2? n harness
.. Measure the resistance of harness between )etween shift sole-
shift solenoid 1 and transmission connector. ioid 1 and trans-
Connector & terminal nission connector.
(AT5) NO. 1 - (T4) NO. 1:
1 CHECK HARNESS CONNECTOR BETWEEN s the resistance more than 1 Even if the AT OIL 3epair short circuit
SHIFT SOLENOID 1 AND TRANSMISSION. An? TEMP warning iarness between
Measure the resistance of harness between lights up, the cir- ;hift solenoid 1
shift solenoid 1 connector and transmission cuit has returned ind transmission
ground. to a normal condi- :onnector.
Connector & terminal tion at this time. A
(T4) No. 1 - Transmissionground: temporary poor
contact of the con-
nector or harness
may be the cause.
Repair harness or
connector in shift
solenoid 1 and
transmission.
AT-72
r.
AT-73
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:
<
z (D
m v)
I-
TR0582
AT-74
1
~~
Step Check Yes No

CHECK HARNESSCONNECTOR BETWEEN s the resistance less than 1 ;o to step 2. 3epair open circuit
TCM AND TRANSMISSION. l? n harness
2)Disconnect the connector from TCM and ransmission con-
TCM and shift solenoid 2 connector.
Non-turbo model
(654) NO. 6 - (611) NO. 2:
Turbo model
(B54) NO. 5 - (611) NO. 2:
! CHECK HARNESSCONNECTOR BETWEEN s the resistance more than 1 30 to step 3. 3epair short circuit
TCM AND TRANSMISSION. VlQ? n harness
Measure the resistance of harness between letween TCM and
TCM connector and chassis ground. ransmission con-
Non-turbo model
Turbo model
1- CHECK SHIFT SOLENOID 2. s the resistance between 10 30 to step 4. 30 to step 6.
Measure the resistance between transmission ind 16 Q?
connector & terminal
(T4) NO.2 - NO. 16:
AT-75
~~
Step Check Yes No

I CHECK OUTPUT SIGNAL EMITTED FROM I Is the voltage less than 1 V? Even if the AT OIL 30 to step 5.
TCM. TEMP warning
1)Connect the connectors to TCM and trans- lights up, the cir-
mission. suit has returned
2)Lift-up or raise the vehicle and support with to a normal condi-
safety stand. tion at this time. A
CAUTION: temporary poor
On AWD models, raise all wheels off :ontact of the con-
ground. lector or harness
3)Start the engine and warm-up the transmis- nay be the cause.
sion until the ATF temperature is above 80°C 3epair harness or
(176°F). :onnector in the
NOTE: TCM and trans-
If the ambient temperature is below 0°C (32°F) nission.
ating temperature.
4)Move the selector lever to “D”, and slowly
increase the vehicle speed to 50 km/h (31
MPH).
NOTE:
wheels may light the ABS warning light, but thi:
indicates no malfunction. When the AT contro
diagnosis is finished, perform the ABS memo0
Mode.>
Non-turbo model
Turbo model
CHECK POOR CONTACT. IS there poor contact in shift 3eoair Door con-
-3.- I----- denlace the TCM
I. . - ~ .
solenoid 2 circuit? act. <Ref. to AT-45,
Transmission Con.
trol Module
(TCM).>
CHECK SHIFT SOLENOID 2 (IN TRANSMIS- Is the resistance between 10 $0to step 7. Replace the shift
SION). and 16 !2? solenoid 2 assem-
1)Remove the transmission connector from bly. <Ref. to AT-39
bracket. Shift Solenoids,
2)Drain the automatic transmission fluid. Duty Solenoids
CAUTION: and ATF Tempera-
Do not drain the automatic transmission flu- ture Sensor.>
nector from shift solenoid 2.
4)Measure the resistance between shift sole-
noid 2 connector and transmission ground.
CHECK HARNESS CONNECTOR BETWEEN s the resistance less than 1
SHIFT SOLENOID 2 AND TRANSMISSION. R? in harness
Measure the resistance of harness between between shift sole.
shift solenoid 2 and transmission connector. noid 2 and trans-
Connector & terminal mission connector,
(AT6) NO. 1 - (T4) NO.2:
AT-76
I DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) I
Step Check Yes

I CHECK HARNESS CONNECTOR BETWEEN s the resistance more than 1 Even if the AT OIL
SHIFT SOLENOID 2 AND TRANSMISSION. An? TEMP warning harness between
Measure the resistance of harness between lights up, the cir- shift solenoid 2
shift solenoid 2 connector and transmission cuit has returned and transmission
ground. to a normal condi- connector.
i tion at this time. A
(T4) No. 2 - Transmissionground: temporary poor
contact of the con-
nector or harness
may be the cause.
Repair harness or
connector in shift
solenoid 2 and
transmission.
-. .
AT-77
K: DTC 73 LOW CLUTCH TIMING SOLENOID

DIAGNOSIS:
Output signal circuit of low clutch timing solenoid is open or shorted.
TROUBLE SYMPTOM:
WIRING DIAGRAM:
TCM
I
LOW CLUTCH
TIMING
SOLENOID
TRANSMISSION
AT-78
~
Step Check Yes No

CHECK HARNESSCONNECTOR BETWEEN s the resistance less than 1 o
; to step 2. 3epair open circuit
TCM AND TRANSMISSION. 2? n harness
1)Turn the ignition switch to OFF ietween TCM and
2)Disconnect the connector from TCM and .ransmissioncon-
Non-turbo model
(954) NO. 14 - (91 1) NO. 3:
Turbo model
(954) NO. 15 - (91 1) NO. 3:
CHECK HARNESS CONNECTOR BETWEEN Is the resistance more than 1 30 to step 3. 3epair short circuit
TCM AND TRANSMISSION. MR? n harness
Measure the resistance of harness between 3etween TCM and
TCM connector and transmission ground. transmission con-
Non-turbo model
Turbo model
CHECK LOW CLUTCH TIMING SOLENOID. Is the resistance between 10 30 to step 4. Go to step 7.
Measure the resistance between transmission and 16 R?
(T4) NO. 3 - NO. 16:
CHECK OUTPUT SIGNAL EMITTED FROM Is the voltage more than 9V? 30 to step 5. Go to step 6.
TCM.
mission.
3)Move the select lever to “ D range.
Non-turbo model
Turbo model
CHECK OUTPUT SIGNAL EMITTED FROM Is the voltage less than 1V? Even if the AT OIL Go to step 6.
TCM. TEMP warning
1)Move the select lever to “ 2 range. lights up, the cir-
2)Measure the voltage between TCM connec- cuit has returned
tor and chassis ground. to a normal condi-
Connector & terminal tion at this time. A
Non-turbo model temporary poor
(954) No. 14 (+) - Chassis ground (-): contact of the con-
Turbo model nector or harness
(954) No. 15 (+) - Chassis ground (-): may be the cause.
Repair harness or
contact in the TCM
and transmission.
1 CHECK POOR CONTACT. Is there poor contact in low Repair poor con- Replace the TCM.
clutch timing solenoid circuit? tact. <Ref. to AT-45,
Transmission Con
trol Module
(TCM).>
AT-79
Step Check Yes No

r CHECK LOW CLUTCH TIMING SOLENOID s the resistance between 10 i o to step 8. 3eplace the low
(IN TRANSMISSION). md 16 R? :lutch timing sole-
1)Remove the transmission connector from ioid. <Ref. to AT-
bracket. 39,Shift Sole-
2)Lift-up or raise the vehicle and support with ioids, Duty Sole-
safety stands. ioids and ATF
CAUTION: remperature Sen-
On AWD models, raise all wheels off ior.>
ground.
CAUTION:
Do not drain the automatic transmission flu-
nector from low clutch timing solenoid.
5)Measure the resistance between low clutch
timing solenoid connector and transmission
ground.
Terminal
No. 1 - Transmission ground:
I CHECK HARNESSCONNECTOR BETWEEN s the resistance less than 1 i o to step 9. 3epair open circuit
LOW CLUTCH TIMING SOLENOID AND 2? n harness
TRANSMISSION. )etween low clutch
Measure the resistance of harness between iming solenoid
low clutch timing solenoid and transmission md transmission
connector. :onnector.
(ATS) NO. 7 - (T4) NO. 3:
1 CHECK HARNESSCONNECTOR BETWEEN s the resistance more than 1 hen if the AT OIL 3epair short circuit
LOW CLUTCH TIMING SOLENOID AND dR? -EMP warning iarness between
TRANSMISSION. ghts up, the cir- OW clutch timing
Measure the resistance of harness between :uit has returned ;olenoid and
low clutch timing solenoid connector and trans- 3 a normal condi- ransmission con-
mission ground. ion at this time. A lector.
Connector & terminal smporary poor
(T4) No. 3 - Transmission ground: :ontact of the con-
iector or harness
nay be the cause.
lepair harness or
:onnector in low
:lutchtiming sole-
ioid and transmis-
,ion.
AT-80
r.
AT-81
L: DTC 74 2-4 BRAKE TIMING SOLENOID

DIAGNOSIS:
Output signal circuit of 2-4 brake timing solenoid is open or shorted.
TROUBLE SYMPTOM:
WIRING DIAGRAM:
I
2-4 BRAKE
TIMING
SOLENOID
TRANSMISSION
TR0584
AT-82
I
Step Check
CHECK HARNESSCONNECTOR BETWEEN Is the resistance less than 1 ) to step 2.
in harness
between TCM and
1)Turnthe ignition switch to OFF.
transmission con-
2)Disconnect the connector from TCM and
nector.
transmission.
Non-turbo model
(B54) NO. 5- (B11) NO. 4:
Turbo model
(854) NO. 16 - (81I ) NO. 4:
CHECK HARNESSCONNECTOR BETWEEN Is the resistance more than 1
MQ? in harness
TCM AND TRANSMISSION.
between TCM and
Measure the resistance of harness between
+---
transmission con-
TCM connector and transmission ground.
nector.
Non-turbo model
Turbo model
Is the resistance between 10 o to step 4. Go to step 7.
CHECK 2-4 BRAKE TIMING SOLENOID.
Measure the resistance between transmission and 16 Q?
CHECK OUTPUT SIGNAL EMllTED FROM 1 Is the voltage less than 1 V?

TCM.
mission.
2)Lift-up or raise the vehicle and support with
safety stands.
CAUTION:
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 “l”,and slowly
increase vehicle speed to 10 km/h (6 MPH).
NOTE:
The speed difference between front and rea
wheels may light the ABS warning light, but thi!
indicates no malfunction. When the AT contrc
diagnosis is finished, perform the ABS memo?
clearance procedure of on-board diagnostic!
system. <Ref. to ABS-22, Clear Memor
Mode.>
Non-turbo model
Turbo model
AT-83
Step Check Yes No

1 CHECK OUTPUT SIGNAL EMITTED FROM I Is the voltage more than 9 V? Zven if the AT OIL 30 to step 6.
TCM. rEMP warning
1)Move the select lever to “D”, and slowly ights up, the cir-
increase vehicle speed to 65 km/h (40 MPH). :uit has returned
NOTE: o a normal condi-
The speed difference between front and rear ion at this time. A
wheels may light the ABS warning light, but this emporary poor
indicates no malfunction. When the AT control :ontact of the con-
diagnosis is finished, perform the ABS memory lector or harness
clearance procedure of on-board diagnostics nay be the cause.
system. <Ref. to ABS-22, Clear Memory qepair harness or
Mode.> :ontact in the
2)Measure the voltage between TCM connec- ransmission.
Non-turbo model
Turbo model
I CHECK POOR CONTACT. Is there poor contact in 2-4 3epair poor con- Replace the TCM.
brake timing solenoid circuit? act. <Ref. to AT-45,
Transmission Con.
trol Module
(TCM).>
I
CHECK 2-4 BRAKE TIMING SOLENOID (IN I Is the resistance between 10 30 to step 8. Replace the 2-4
TRANSMISSION). and 16 R? brake timing sole-
1)Remove the transmission connector from noid. <Ref. to AT-
‘20 ChiH Crrln.
bracket.
2)Lift-up or raise the vehicle and support with noids, Duty Sole-
safety stands. noids and ATF
CAUTION: Temperature Sen-
On AWD models, raise all wheels off sor.>
ground.
3)Drain the automatic transmission fluid. I
CAUTION:
Do not drain the automatic transmission flu,
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
I CHECK HARNESSCONNECTOR BETWEEN Is the resistance less than 1 30 to step 9. Repair open circuit
2-4 BRAKE TIMING SOLENOID AND R? in harness
TRANSMISSION. between 2-4 brake
Measure the resistance of harness between 2- timing solenoid
4 brake timing solenoid and transmission con- and transmission
nector. connector.
(AT8) NO. 1 - (T4) NO. 4:
AT-84
Step Check Yes No

9 CHECK HARNESSCONNECTOR BETWEEN Is the resistance more than 1 Even if the AT OIL Repair short circuit
2-4 BRAKE TIMING SOLENOID AND MR? TEMP warning harness between
TRANSMISSION. lights up, the cir- 2-4 brake timing
Measure the resistance of harness between 2- cuit has returned solenoid and
4 brake timing solenoid connector and trans- to a normal condi- transmission con-
mission ground. tion at this time. A nector.
(T4) No. 4 - Transmissionground: 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.
AT-85
I
M: DTC 75 LINE PRESSURE DUTY SOLENOID

DIAGNOSIS:
Output signal circuit of line pressure duty solenoid is open or shorted.
TROUBLE SYMPTOM:
WIRING DIAGRAM:
: NON-TURBO MODEL
U
DROPPING
RESISTOR
Ir""lB L
TRANSMISSION
TR0585
Step Check Yes No

I CHECK VEHICLE. - I
Go to step 7.
! CHECK RESISTOR. s the resistance between 9 I Go to step 3. Replace the drop-
1)Turn the ignition switch to OFF. ping resistor. <Ref.
resistor. Resistor.>
resistor terminal.
Terminals
NO. 1 -NO. 2:
AT-86
Step Check Yes No

3 CHECK HARNESS CONNECTOR BETWEEN Is the resistance less than 1 i o to step 4. Repair open circuit
TCM AND DROPPING RESISTOR. n? in harness
2)Measure the resistance of harness between dropping resistor
TCM connector and dropping resistor connec- connector.
tor.
(B54) NO. 18 - (84) NO. 1:
4 CHECK HARNESS CONNECTOR BETWEEN Is the resistance more than 1 ;o to step 5. Repair short circuit
TCM AND DROPPING RESISTOR. MR? in harness
dropping resistor connector and chassis dropping resistor
ground. connector.
5 CHECK HARNESS CONNECTOR BETWEEN Is the resistance less than 1 ;o to step 6. Repair open circuit
TRANSMISSION AND DROPPING RESIS- Q? in harness
TOR. between dropping
1 )Disconnect the connector from transmission. resistor and trans-
2)Measure the resistance of harness between mission connector.
transmission and dropping resistor connector.
(B4) NO. 2 - ( B l l ) NO. 5:
6 CHECK HARNESSCONNECTOR BETWEEN Is the resistance more than 1 ;o to step 7. Repair short circuit
TRANSMISSION AND DROPPING RESIS- MQ? in harness
Measure the resistance of harness between resistor and trans-
dropping resistor connector and chassis mission connector.
I
ground.
7 CHECK HARNESSCONNECTOR BETWEEN Is the resistance less than 1 i o to step 8. Repair open circuit
TCM AND TRANSMISSION. n? in harness
and TCM. nector.
-
(B54) NO. 9 (B1 1) NO. 5:
8 CHECK HARNESSCONNECTOR BETWEEN Is the resistance more than 1 ;o to step 9. Repair short circuit
TCM AND CHASSIS GROUND. MR? in harness
9 CHECK LINE PRESSURE DUTY SOLENOID. Is the resistance between 2.0 20 to step 10. Go to step 16.
Measure the resistance between transmission and 4.5 R?
connector receptacle's terminals.
Terminal
(T4) NO. 5 - NO. 16:
10 PREPARE SUBARU SELECT MONITOR. Do you have a Subaru Select ;o to step 13. Go to step 11.
Monitor?
AT-87
Step Check Yes No

1 CHECK OUTPUT SIGNAL EMITTED FROM s the voltage between 1.5 and Go to step 12. ;o to step 15.
TCM.
(176°F).
NOTE:
If the ambient temperature is below 0°C (32°F:
drive the vehicle until the ATF reaches its ope1
ating temperature.
4)Move the select lever to “N”.
-
2 CHECK OUTPUT SIGNAL EMITTED FROM s the voltage less than 1 V Even if the AT OIL ;o to step 15.
TCM. iith throttle fully open? TEMP warning
Measure the voltage between TCM connector lights up, the cir-
and chassis ground. cuit has returned
Connector & terminal to a normal condi-
.. ~
(B54) No. 9 (+) - Chassis ground (-): tion at this time. A
temporary poor
contact of the con-
nector or harness
may be the cause.
Repair harness or
connector in trans-
mission.
3 CHECK OUTPUT SIGNAL EMITTED FROM j the value 1OO%? Go to step 14. io to step 15.
TCM USING SUBARU SELECT MONITOR.
mission.
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:
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
*Line pressure duty solenoid is indicated in
“o/o”,
1)Throttle is fully closed.
AT-88
I
Step Check Yes No

4 CHECK OUTPUT SIGNAL EMITTED FROM s the value less than 25%? lven if the AT OIL ;o to step 15.
TCM USING SUBARU SELECT MONITOR. 'EMP warning
1)Turnthe ignition switch to ON (Engine OFF). ghts up, the cir-
2)Throttle is fully open. uit has returned
3 a normal condi-
on at this time. A
zmporary poor
ontact of the con-
lector or harness
lay be the cause.
iepair harness or
onnector in trans-
nission.
5 CHECK POOR CONTACT. s there poor contact in line Iepair poor con- 3eplace the TCM.
)ressure duty solenoid circuit? act. :Ref. to AT-45,
rransmissionCon-
rol Module
TCM).>
6 CHECK LINE PRESSURE DUTY SOLENOID s the resistance between 2.0 io to step 17. 3eplace the line
(IN TRANSMISSION). ind 4.5 Q? )ressure duty
1)Remove the transmission connector from ;olenoid. <Ref. to
bracket. 4T-39, Shift Sole-
2)Drain the automatic transmission fluid. ioids, Duty Sole-
CAUTION: \aids and ATF
Do not drain the automatic transmission flu- Temperature Sen-
id until it cools down. ;or.>
nector from line pressure duty solenoid.
4)Measure the resistance between line pres-
sure duty solenoid connector and transmission
ground.
Terminal
17 CHECK HARNESSCONNECTOR BETWEEN s the resistance less than 1 ;o to step 18. 3epair open circuit
TRANSMISSION AND LINE PRESSURE a? n harness
DUTY SOLENOID. )etween line pres-
Measure the resistance of harness between jure duty solenoid
line pressure duty solenoid and transmission md transmission
connector. :onnector.
(T4) NO. 5 - (AT2) NO. 1:
18 CHECK HARNESS CONNECTOR BETWEEN s the resistance more than 1 iven if the AT OIL 3epair short circuit
TRANSMISSION AND LINE PRESSURE dQ? -EMP warning n harness
DUTY SOLENOID. ghts up, the cir- jetween line pres-
Measure the resistance of harness between :uit has returned ;ure duty solenoid
transmission connector and transmission D a normal condi- ind transmission
ground. ion at this time. A :onnector.
Connector & terminal emporary poor
(T4) No. 5 - Transmissionground: :ontact of the con-
lector or harness
nay be the cause.
3epair harness or
:onnector in line
)ressure duty
;olenoid and
ransmission.
AT-89
N: DTC 76 2-4 BRAKE DUTY SOLENOID

DIAGNOSIS:
Output signal circuit of 2-4 brake duty solenoid is open or shorted.
TROUBLE SYMPTOM:
WIRING DIAGRAM:
$ m
I-
m a
2
Ey*-
_.
SOLENOID
~
TI30586
Step Check Yes No

1 CHECK VEHICLE. Is the target non-turbo model? Go to step 2. Go to step 7.
2 CHECK RESISTOR. Is the resistance between 9 Go to step 3. Replace the drop-
1)Turnthe ignition switch to OFF. and 15 Q? ping resistor. <Ref.
resistor. Resistor.>
resistor terminal.
Terminals
NO. 3 - NO. 4:
AT-90
I
~~~ ~~
Step Check Yes No

CHECK HARNESSCONNECTOR BETWEEN s the resistance less than 1 Go to step 4. Repair open circuit
TCM AND DROPPING RESISTOR. 2? in harness
2)Measure the resistance of harness between dropping resistor
TCM connector and dropping resistor connec- connector.
tor.
(B54) NO. 17 - (B4) NO. 3:
CHECK HARNESSCONNECTOR BETWEEN s the resistance more than 1 Go to step 5. Repair short circuit
TCM AND DROPPING RESISTOR. VlQ? in harness
dropping resistor connector and chassis dropping resistor
ground. connector.
CHECK HARNESS CONNECTOR BETWEEN s the resistance less than 1 Go to step 6. Repair open circuit
TRANSMISSION AND DROPPING RESIS- n? in harness
1)Disconnect the connector from transmission. resistor and trans-
2)Measure the resistance of harness between mission connector.
transmission and dropping resistor connector.
(B4) NO. 4 - ( B l l ) NO. 9:
CHECK HARNESSCONNECTOR BETWEEN s the resistance more than 1 Go to step 7. Repair short circuit
TRANSMISSION AND DROPPING RESIS- Ua? in harness
Measure the resistance of harness between resistor and trans-
dropping resistor connector and chassis mission connector.
ground.
CHECK HARNESS CONNECTOR BETWEEN s the resistance less than 1 Go to step 8. Repair open circuit
TCM AND TRANSMISSION. n? in harness
1)Turnthe ignition switch to OFF. between TCM and
and TCM. nector.
Non-turbo model
(B54) NO. 8 - ( B l l ) NO. 9:
Turbo model
(B54) NO. 18 - ( B l l ) NO. 9:
CHECK HARNESS CONNECTOR BETWEEN Is the resistance more than 1 Go to step 9. Repair short circuii
TCM AND CHASSIS GROUND. Ma? in harness
Non-turbo model
Turbo model
CHECK 2-4 BRAKE DUTY SOLENOID. Is the resistance between 2.0 Go to step 10. Go to step 16.
Measure the resistance between transmission and 4.5 R?
Terminal
(T4) NO. 16 - NO. 9:
I PREPARE SUBARU SELECT MONITOR. Do you have a Subaru Select Go to step 13. Go to step 11.
Monitor?
AT-9 1
~~
Step Check Yes No

1 CHECK OUTPUT SIGNAL EMITTED FROM ;the voltage between 1.5 and 30 to step 12. i o to step 15.
TCM. i.0 V with throttle fully closed?
(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 "N".
Non-turbo model
(B54) No. 8 (+) - Chassis groundI)-(
Turbo model
2 CHECK OUTPUT SIGNAL EMITTED FROM s the voltage less than 1 V Even if the AT OIL io to step 15.
TCM. with throttle fully open? rEMP warning
._ Measure the voltage between TCM connector ights up, the cir-
(B54) No. 8 (+) - Chassis ground (-): emporary poor
Non-turbo model :ontact of the con-
(B54) No. 18 (+) - Chassis ground (-): lector or harness
nay be the cause.
3epair harness or
:onnector in TCM
2nd transmission.
3 CHECK OUTPUT SIGNAL EMIlTED FROM s the value 1OO%? 30 to step 14. ;o to step 15.
link connector.
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 2-4 brake duty solenoid
*2-4 brake duty solenoid is indicated in "%".
AT-92
I
Step- Check Yes No
5 CHECK POOR CONTACT. Is there poor contact in 2-4 3epair poor con- Heplace the TCM.
brake duty solenoid circuit? act. <Ref. to AT-45,
Transmission Con-
trol Module
(TCM).>
6 CHECK 2-4 BRAKE DUTY SOLENOID (IN Is the resistance between 2.0 30 to step 17. Replace the 2-4
TRANSMISSION). and 4.5 R? brake duty sole-
1)Remove the transmission connector from noid. <Ref. to AT-
bracket. 39, Shift Sole-
2)Drain the automatic transmission fluid. . noids, Duty Sole-
CAUTION: noids and ATF
Do not drain the automatic transmission flu- Temperature Sen-
id until it cools down. sor.>
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
7 CHECK HARNESS CONNECTOR BETWEEN IS the resistance less than 1 30 to step 18. Repair open circuil
TRANSMISSION AND 2-4 BRAKE DUTY SO- Q? in harness
LENOID. between 2-4 brake
Measure the resistance of harness between 2- duty solenoid and
4 brake duty solenoid and transmission con- transmission con-
nector. nector.
(T4) NO. 9 - (AT7) NO. 1:
8 CHECK HARNESSCONNECTOR BETWEEN Is the resistance more than 1 Even if the AT OIL Repair short circuil
TRANSMISSION AND 2-4 BRAKE DUTY SO- MQ? rEMP warning in harness
LENOID. ights up, the cir- between 2-4 brake
Measure the resistance of harness between :uit has returned duty solenoid and
transmission connector and transmission o a normal condi- transmission con-
ground. ion at this time. A nector.
(T4) No. 9 - Transmissionground: :ontact of the con-
lector or harness
nay be the cause.
3epair harness or
:onnector in line
3ressure duty
solenoid and
ransmission.
AT-93
0: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:
@ TCM
TRANSMISSION
TR0587
AT-94
I
Step Check Yes No

I CHECK DTC. l o multiple trouble codes So to another trou- Go to step 2.
ippear in the on-board diag- )le code.
iostics test mode?
! CHECK HARNESS CONNECTOR BETWEEN s the resistance less than 1 o
; to step 3. Repair open circui
TCM AND TRANSMISSION. 2? in harness
1)Turn the ignition switch to OFF. between TCM anc
Non-turbo model
(654) NO. 16 - (61 1) NO. 13:
Turbo model
(654) NO. 7 - (61 1) NO. 13:
i CHECK HARNESS CONNECTOR BETWEEN s the resistance more than 1 ;o to step 4. Repair short circui
TCM AND TRANSMISSION. fin? in harness
Measure the resistance of harness connector between TCM anc
between TCM and chassis ground. transmission con-
Non-turbo model
Turbo model
I CHECK LOCK-UP DUTY SOLENOID. s the resistance between 10 ;o to step 5. Go to step 11.
Measure the resistance between transmission 2nd 17 Q?
(T4) NO. 13 - NO. 16:
) PREPARE SUBARU SELECT MONITOR. l o you have a Subaru Select ;o to step 8. Go to step 6.
donitor?
AT-95
I
Step Check Yes

, CHECK OUTPUT SIGNAL EMITTED FROM j the voltage more than 8.5 V? 30 to step 7.
TCM.
mission.
CAUTION:
ground.
(176°F).
NOTE:
drive the vehicle until the ATF reaches its oper.
ating temperature.
4)Move the select lever to “D” and slowly
MPH). Wheels will lock-up.
NOTE:
.. wheels may light the ABS warning light, but thiz
diagnosis is finished, perform the ABS memoq
clearance procedure of on-board diagnostic:
system. <Ref. to ABS-22, Clear Memoq
Mode.>
Non-turbo model
(B54)No. 16 (+) - Chassis ground (-):
Turbo model
(44)No. 7 (+) - Chassis ground (-):
CHECK OUTPUT SIGNAL EMITTED FROM s the voltage less than 0.5 V? :veri if the AT OIL
TCM. rEMP warning
1)Return the engine to idling speed and move ights up, the cir-
the select lever to “N”. :uit has returned
2)Measure the voltage between TCM connec- o a normal condi-
tor and chassis ground. ion at this time. A
Non-turbo model :ontact of the con-
(854)No. 16 (+) - Chassis ground (-): lector or harness
Turbo model nay be the cause.
(B54)No. 7 (+) - Chassis ground (-): 3epair harness or
:onnector in TCM
and transmission.
AT-96
I
Step Check Yes No

CHECK OUTPUT SIGNAL EMllTED FROM Is the value 95%? 30 to step 9. 30 to step 10.
mission.
CAUTION:
ground.
link connector.
(176°F).
NOTE:
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 “Yo”.
1)Move the select lever to “ D and slowly
MPH). Wheels will lock-up.
NOTE:
diagnosis is finished, perform the ABS memor)
system. <Ref. to ABS-22, Clear Memor),
Mode.>
CHECK OUTPUT SIGNAL EMllTED FROM Is the value 5%? Even if the AT OIL 30 to step 10.
TCM USING SUBARU SELECT MONITOR. TEMP warning
Return the engine to idling speed and move lights up, the cir-
the select lever to “N”. cuit has returned
NOTE: to a normal condi-
The speed difference between front and real tion at this time. A
wheels may light the ABS warning light, but this temporary poor
indicates no malfunction. When AT control di- contact of the con-
agnosis is finished, perform the ABS memor) nector or harness
clearance procedure of on-board diagnostics may be the cause.
system. <Ref. to ABS-22, Clear Memor) Repair harness or
Mode.> connector in TCM
and transmission.
CHECK POOR CONTACT. Is there poor contact in lock-up Repair poor con- 3eplace the TCM.
duty solenoid circuit? tact. :Ref. to AT-45,
rransmission Con-
rol Module
I I
TCM).>
AT-97
I
Step No
CHECK LOCK-UP DUTY SOLENOID (IN Replace the lock-
TRANSMISSION). ind 17 R? up duty solenoid.
1)Remove the transmission connector from <Ref. to AT-39,
bracket. Shift Solenoids,
2)Drain the automatic transmission fluid. Duty Solenoids
CAUTION: and ATF Tempera-
Do not drain the automatic transmission flu- ture Sensor.>
nector from lock-up duty solenoid.
4)Measure the resistance between lock-up
ground.
Terminal
CHECK HARNESSCONNECTOR BETWEEN s the resistance less than 1 IGo to step 13. Repair open circuit
LOCK-UP DUTY SOLENOID AND TRANS- 2? in harness
MISSION. between TCM and
Measure the resistance of harness between transmission con-
lock-up duty solenoid and transmission connector.
nector.
(T4) NO. 13 - (AT3) NO. 1:
CHECK HARNESSCONNECTOR BETWEEN s the resistance more than 1 Even if the AT OIL Repair short circuit
LOCK-UP DUTY SOLENOID AND TRANS- dR? TEMP warning in harness
MISSION. lights up, the cir- between lock-up
Measure the resistance of harness between cuit has returned duty solenoid and
transmission connector and transmission to a normal condi- transmission con-
ground. tion at this time. A nector.
(T4) No. 13 - Transmission ground: contact of the con.
nector or harness
may be the cause.
Repair harness or
connector in lock-
up duty solenoid
and transmission.
AT-98
r- .
AT-99
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:
@ TCM
I -
-
TRANSMISSION
TR0588
AT-I 00
I
Step Check Yes No

1 CHECK HARNESSCONNECTOR BETWEEN s the resistance less than 1 i o to step 2. 3epair open circuit
TCM AND TRANSMISSION. 2? n harness
1)Turn the ignition switch to OFF. setween TCM and
2)Disconnect the connector from TCM and [ransmissioncon-
Non-turbo model
-
(B54) NO. 15 (Bl 1) NO. 6:
Turbo model
(B54) NO. 6 - (811) NO. 6:
2 CHECK HARNESS CONNECTOR BETWEEN s the resistance more than 1 i o to step 3. Repair short circuii
TCM AND TRANSMISSION. An? in harness
Measure the resistance harness connector between TCM and
between TCM and chassis ground. transmission con-
Non-turbo model
-
Turbo model
.3 CHECK TRANSFER DUTY SOLENOID. s the resistance between 10 ;o to step 4. Go to step 13.
Measure the resistance between transmission ind 17 R?
connector and transmission terminals.
(T4) NO. 6- NO. 16:
4 PREPARE SUBARU SELECT MONITOR. 10 you have a Subaru Select ;o to step 7 . Go to step 5.
A o nito r?
CHECK OUTPUT SIGNAL EMITTED FROM s the voltage less than 1 V in ;o to step 6. Go to step 12.
TCM. P” range?
mission.
Non-turbo model
Turbo model
CHECK OUTPUT SIGNAL EMITTED FROM s the voltage between 5 and 7 iven if the AT OIL Go to step 12.
TCM. J in “D” range? -EMP warning
Measure the voltage between TCM connector ights up, the cir-
(854) No. 15 (+) - Chassis ground (-): emporary poor
Turbo model :ontact of the con.
(854) No. 6 (+) - Chassis ground (-): rector or harness
nay be the cause.
Iepair harness or
:onnector in the
TCM and trans-
nission.
7 CHECK VEHICLE s the taraet non-turbo model S o
; to step 8. Go to step 10.
AT-I 01
Step Check Yes No

CHECK OUTPUT SIGNAL EMITTED FROM s the value between 5 and Go to step 9. 30 to step 12.
TCM USING SUBARU SELECT MONITOR. I O%?
mission.
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
*Transfer duty solenoid is indicated in “ O h ” .
CHECK OUTPUT SIGNAL EMITTED FROM s the value between approx. Even if the AT OIL 30 to step 12.
TCM USING SUBARU SELECT MONITOR. SO% and approx. 70%? TEMP warning
1)Move the select lever to “D” with throttle fully lights up, the cir-
closed (vehicle speed 0 km/h or 0 MPH). cuit has returned
2)Rear the data of transfer duty solenoid using to a normal condi-
Subaru Select Monitor. tion at this time. A
*Transfer duty solenoid is indicated in “%”. temporary poor
contact of the con-
nector or harness
may be the cause.
Repair harness or
connector in the
TCM and trans-
mission.
I CHECK OUTPUT SIGNAL EMITTED FROM s the value between 80 and Go to step 11. 30 to step 12.
TCM USING SUBARU SELECT MONITOR. )5%?
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
*Transfer duty solenoid is indicated in ‘Yo”.
CHECK OUTPUT SIGNAL EMllTED FROM s the value approx. 40%? Even if the AT OIL 30 to step 12.
TCM USING SUBARU SELECT MONITOR. TEMP warning
1)Move select lever to “N” with throttle fully lights up, the cir-
close (vehicle speed 0 km/h or 0 MPH). cuit has returned
2)Rear data of transfer duty solenoid using to a normal condi-
Subaru Select Monitor. tion at this time. A
*Transfer duty solenoid is indicated in “Yo”. 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.
AT-I 02
Step Check Yes No

2 CHECK POOR CONTACT. Is there poor contact in transfer lepair poor con- 3eplace the TCM.
duty solenoid circuit? act. :Ref. to AT-45,
rransmission Con-
rol Module
'TCM).r
3 CHECK TRANSFER DUTY SOLENOID (IN Is the resistance between 10 ;o to step 14. 3eplace the trans-
TRANSMISSION). and 17 Q? er duty solenoid.
CAUTION:
ground.
CAUTION:
Do not drain the automatic transmission flu.
3)Remove the extension case, and disconnect
the connector from transfer duty solenoid.
4)Measure the resistance between transfer
ground.
(AT4) No. 1 - Transmissionground:
4 CHECK HARNESS CONNECTOR BETWEEN IS the resistance less than 1 o; to step 15. 3epair open circuit
TRANSFER DUTY SOLENOID AND TRANS- Q? n harness
MISSION. ietween transfer
Measure the resistance of harness between juty solenoid and
transfer duty solenoid and transmission con- ransmission con-
nector. lector.
(T4) NO. 6 - (AT4) NO. 1:
5 CHECK HARNESS CONNECTOR BETWEEN Is the resistance more than 1 %en if the AT OIL 3epair short circuit
TRANSFER DUTY SOLENOID AND TRANS- MQ? rEMP warning n harness
MISSION. ights up, the cir- ietween transfer
Measure the resistance of harness between :uit has returned luty solenoid and
transmission connector and transmission o a normal condi- ransmission con-
ground. ion at this time. A lector.
(T4) No. 6 - Transmissionground: :ontact of the con,
lector or harness
nay be the cause.
3epair harness or
:ontact in the
ransfer duty sole-
ioid and transmis.
;ion.
AT-I 03
I
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:
: NON-TURBO MODEL
: TURBO MODEL
REAR VEHICLE
SPEED SENSOR
TR0589
AT-I 04
Step Check Yes No

CHECK HARNESSCONNECTOR BETWEEN s the resistance less than 1 20 to step 2. Repair open circuit
Non-turbo model
(B55)NO. 3 - (B11)NO. 19:
Turbo model
(B55)NO.24 - (B11)NO. 19:
CHECK HARNESS CONNECTOR BETWEEN s the resistance less than 1 o
; to step 3. Repair open circuit
TCM and transmission connector. transmission, and
Connector & terminal poor contact in
Non-turbo model coupling connec-
(B55)NO.21 - (B11)NO.20: tor.
Turbo model
(B54)NO. 19 - ( 6 1 1) NO. 20:
CHECK HARNESSCONNECTOR BETWEEN s the resistance more than 1 30 to step 4. Repair short circuit
TCM AND TRANSMISSION. Uln? in harness
Non-turbo model
Turbo model
(655)No. 24 - Chassis ground:
CHECK HARNESS CONNECTOR BETWEEN s the resistance more than 1 30 to step 5. Repair short circuit
TCM AND TRANSMISSION. wn? in harness
Non-turbo model
(655)No. 21 - Chassis ground:
Turbo model
CHECK REAR VEHICLE SPEED SENSOR. s the resistance between 450 30 to step 6. Replace the rear
Measure the resistance between transmission and 650 Q? vehicle speed sen.
connector receptacle'sterminals. sor. <Ref. to AT-
Connector & terminal 35, Rear Vehicle
(T4) NO. 19 - NO.20: Speed Sensor.>
PREPARE OSCILLOSCOPE. l o you have an oscilloscope? 30 to step 10. Go to step 7.
PREPARE SUBARU SELECT MONITOR. 30 you have a Subaru Select 30 to step 9. Go to step 8.
Monitor?
AT-I 05
Step Check Yes No

CHECK INPUT SIGNAL FOR TCM. s the voltage more than AC 1 Even if the AT OIL 30 to step 11.
1)Connect the connectors to TCM and trans- /? TEMP warning
mission. ights up, the cir-
2)Lift-up or raise the vehicle and place safety :uit has returned
stands. :o a normal condi-
CAUTION: :ion at this time. A
On AWD models, raise all wheels off floor. :emporary poor
3)Start the engine and set vehicle in 20 km/h :ontact of the con-
(12 MPH) condition. lector or harness
NOTE: nay be the cause.
The speed difference between front and rea 3epair harness or
wheels may light the ABS warning light, but thi: :onnector in the
indicates no malfunction. When the AT contro TCM and trans-
diagnosis is finished, perform the ABS memor) nission.
clearance procedure of on-board diagnostic5
Mode.>
tor terminals.
Non-turbo model
(655) NO. 3 (+) - (654) NO. 21 (-):
Turbo model
(655) NO.24 (+) - (654) NO. 19 (-):
CHECK INPUT SIGNAL FOR TCM USING )oes the speedometer indica- Even if the AT OIL i o to step 11.
SUBARU SELECT MONITOR. on increase as the Subaru rEMP warning
1)Connect the connectors to TCM and trans- ielect Monitor data increases? ights up, the cir-
mission. :uit has returned
2)Connect the Subaru Select Monitor to data o a normal condi-
link connector. ion at this time. A
3)Lift-up or raise the vehicle and place safety emporary poor
stands. :ontact of the con-
CAUTION: lector or harness
Raise all wheels off floor. nay be the cause.
4)Turn the ignition switch to ON and turn the 3epair harness or
Subaru Select Monitor switch to ON. :onnector in the
5)Start the engine. T M and trans-
6)Read the data of vehicle speed using Subaru nission.
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
indicates no malfunction. When the AT control
Mode.>
AT-106
~ ~
Step Check Yes No

IO CHECK INPUT SIGNAL FOR TCM USING s the signal voltage more than Even if the AT OIL 30 to step 11.
OSCILLOSCOPE. 4c 1 V? rEMP warning
1)Connect the connectors to TCM and trans- ights up, the cir-
mission. :uit has returned
2)Lift-up or raise the vehicle and place safety o a normal condi-
stands. ion at this time. A
CAUTION: emporary poor
Raise all wheels off floor. :ontact of the con-
3)Set the oscilloscope to TCM connector ter- lector or harness
minals. nay be the cause.
Turbo model 3epair harness or
Positive probe; (655) No. 24 :onnector in the
Earth lead; (855) No. 19 TCM and trans-
Non-turbo model nission.
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:
diagnosis is finished, perform the ABS memoq
clearance procedure of on-board diagnostic:
system. <Ref. to ABS-22, Clear Memoq
Mode.>
5)Measure the signal voltage indicated on
oscilbscope.
I1 CHECK POOR CONTACT. s there poor contact in rear 3epair poor con- 3eplace the TCM.
iehicle speed sensor circuit? act. :Ref. to AT-45,
rransmission Con-
rol Module
'TCM).>
AT-1 07
I DIAGNOSTIC PROCEDURE FOR NO-DIAGNOSTIC TROUBLE CODE (DTC)
15.Diagnostic Procedure for No-Diagnostic Trouble Code (DTC)

A: CHECK GEAR POSITION.
Step Check Yes No
CHECK GEAR POSITION. Does the transmission gear 30 to step 2. Check shift sole-
1)Lift-up the vehicle and place safety stand. correspond to the gear which noid 1 and shift
CAUTION: is shown on display? solenoid 2 signal
On AWD models, raise all wheels off circuit. <Ref. to AT-
ground. 70, DTC 71 SHIFT
2)Start the engine. SOLENOID 1,
3)Move the select lever to “D”, and drive the Diagnostic Proce-
vehicle. dure with Diagnos-
4)Read the data of gear position using Subaru tic Trouble Code
Select Monitor. (DTC).> and <Ref.
*Gear position is indicated. to AT-74, DTC 72
SHIFT SOLE-
NOTE:
The speed difference between front and rear NOID 2, Diagnos-
wheels may light the ABS warning light, but this tic Procedure with
indicates no malfunction. When the AT control Diagnostic Trou-
diagnosis is finished, perform the ABS memory ble Code (DTC).>
Mode.>
I CHECK VEHICLE. s the target no6turbo model? 30 to step CHECK Go to step CHECK
=WD BRAKE SWITCH.
;WITCH.<Ref. to <Ref. to AT-1 12,
4T-110, CHECK CHECK BRAKE
IWD SWITCH., SWITCH., Diag-
liagnostic Proce- nostic Procedure
lure for No-Diag- for No-Diagnostic
iostic Trouble Trouble Code
;ode (DTC).> (DTC).>
AT-I 08
DIAGNOSTIC PROCEDURE FOR NO-DIAGNOSTIC TROUBLE CODE (DTC)
ALJTOMATIC TRANSMISSION (DIAGNOSTICS)
AT-I 09
I
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:
2
z
0
- 0
IGNITION
SWITCH
0
SBF-4 SEF-1
BATTERY
3 0
1
I
-
E
FWD SWITCH
COMBINATION
METER
) FWD
r.
A: @
B:@
B:@ A:@
4- 8 11 12 16 19 20 24 27 28 30
TI30590
AT-I 10
DIAGNOSTIC PROCEDURE FOR NO-DIAGNOSTIC TROUBLE CODE (DTC) 1
~~
Step Check Yes No

I CHECK FWD SWITCH. When the fuse is inserted to Go to step CHECK Go to step 2.
FWD switch, does the LED BRAKE
light up? SWITCH.<Ref. to
AT-1 12, CHECK
BRAKE SWITCH.,
Diagnostic Proce-
dure for No-Diag-
nostic Trouble
Code (DTC).>
! CHECK FWD INDICATOR LIGHT. Is the FWD indicator light bulb Go to step 3. Replace the FWD
1)Turnthe ignition switch to OFF. indicator light bulb.
2)Remove the combination meter. <Ref. to IDI-11,
3)Remove the FWD indicator light bulb from Combination
I
combination meter.
TCM AND FWD SWITCH.

r---f-
CHECK HARNESSCONNECTOR BETWEEN Is the resistance less than 1 Go to step 4.
Meter Assembly.>
Repair open circuit
in harness
2)Disconnect the connector from TCM and FWD switch con-
FWD switch. nector.
I
TCM and FWD switch connector.
-
(B55) NO. 14 (F67) NO. 30:
I CHECK HARNESSCONNECTOR BETWEEN Is the resistance less than 1 Go to step 5. Repair open circuit
FWD SWITCH AND CHASSIS GROUND. D? in harness
Measure the resistance of harness between between FWD
FWD switch and chassis ground. switch connector
Connector & terminal and chassis
-
(F67) No. 29 Chassis ground: ground.
CHECKHARNESSCONNECTORBETWEEN Is the resistance more than 1 1 Go to step 6. Repair short circuit
TCM AND FWD SWITCH. MQ? in harness
Measure the resistance of harness connector between TCM and
between TCM and body to make sure that cir- FWD switch con-
cuit does not short. nector.
-
(B55) No. 14 Chassis ground:
i CHECK INPUT SIGNAL FOR TCM. Go to step 12.
1)Turn the ignition switch to OFF. FWD switch while installing?
2)Connect the connector to TCM and FWD
switch.
4)Measure the signal voltage for TCM while
installing the fuse to FWD switch connector.
r CHECK INPUT SIGNAL FOR TCM. Replace the TCM.
Measure the signal voltage for TCM while FWD switch while removing? <Ref. to AT-45,
removing the fuse from FWD switch connector. Transmission Con-
I
TCM AND COMBINATION METER.

7j--
CHECK HARNESS CONNECTOR BETWEEN Is the resistance less than 1 Go to step 9.
trol Module
(TCM).>
Repair open circuit
in harness
between TCM and
2)Disconnect the connector from TCM and combination meter
combination meter. and poor contact
3)Measure the resistance of harness between in coupling con-
TCM and diagnosis connector. nector.
-
(B54) No. 12 ( i l l ) No. 4:
~~ ~
Step Check Yes No

9 CHECK HARNESS CONNECTOR BETWEEN the resistance more than 1 30 to step 1Q. Repair short circuii
TCM AND COMBINATION METER. n? ,n harness
Measure the resistance of harness connector between TCM and
between TCM and chassis ground to make :ombination meter
sure that circuit does not short. zonnector.
-
10 CHECK OUTPUT SIGNAL EMITTED FROM the voltage less than 1 V in 30 to step 11. So to step 12.
TCM. YD switch while installing?
2)Connect the connector to TCM and combina-
tion meter.
4)Measure the signal voltage for TCM while
installing and removing the fuse to FWD switch
connector.
11 CHECK OUTPUT SIGNAL EMITTED FROM the voltage more than 9 V in 30 to step 12. Replace the TCM.
TCM. 'VDswitch while removing? <Ref. to AT-45,
Measure the signal voltage for TCM while Transmission Con.
_.. removing the fuse from FWD switch connector. trol Module
Connector & terminal [TCM).>
-
12 CHECK POOR CONTACT. there poor contact in FWD 3epair poor con- Replacethe TCM.
[itch circuit? act. <Ref. to AT-45,
Transmission Con.
trol Module
(TCM).>
C: CHECK BRAKE SWITCH.
I
Check Yes No
CHECK BRAKE SWITCH. When the brake pedal is Go to step CHECK Check the brake
depressed, does the LED light ABS SWITCH. switch circuit.
up? <Ref. to AT-113,
CHECK ABS
SWITCH., Diag-
nostic Procedure
for No-Diagnostic
Trouble Code
(DTC).>
AT-1 12
DIAGNOSTIC PROCEDURE FOR NO-DIAGNOSTIC TROUBLE CODE (DTC) I
D: CHECK ABS SWITCH.

Step Check Yes No
Go to step CHECK
1 light up? [switch circuit. CRUISE CON-
<Ref. to ABS1 38, TROL SWITCH.
DTC 44 ABS-AT <Ref. to AT-113,
CONTROL (NON CHECK CRUISE
CONTROLLED), CONTROL
Diagnostics Chart SWITCH., Diag-
with Subaru Select nostic Procedure
Monitor.> and for No-Diagnostic
<Ref. to ABS-140, Trouble Code
DTC 44 ABS-AT (DTC).>
CONTROL (CON-
TROLLED), Diag-
nostics Chart with
Subaru Select
Monitor.>
E: CHECK CRUISE CONTROL

r- SWITCH.
~
Step Check Yes No

1 CHECK CRUISE CONTROL SWITCH. When cruise control is set, Go to step CHECK Check the cruise
does the LED light up? INHIBITOR control. <Ref. to
SWITCH. <Ref. to CC-28, Diagnos-
AT-1 15, CHECK tics Chart with
INHIBITOR Diagnostic Trou-
SWITCH., Diag- ble Code.>
nostic Procedure
for No-Diagnostic
Trouble Code
(DTC).>
AT-I 13
I
r. .
AT-I 14
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.
Engine brake is not effected when selector lever is in “2” range.
Engine brake is not effected when selector lever is in “1” range.
AT-1 15
WIRING DIAGRAM:
IGNITION
SWITCH
SBF-1 SBF-4 0 No 13
0 c
COMBINATION
METER
I - A@
I @" C@
TR0591
AT-I 16
DIAGNOSTIC PROCEDURE FOR NO-DIAGNOSTIC TROUBLE CODE (DTC) 3
Step Check Yes No

CHECK “P” RANGE SWITCH. When “ P range is selected, i o to step 2. 20 to step 22.
loes the LED light up?
CHECK INDICATOR LIGHT. >oes the combination meter ;o to step 3. o
; to step 26.
P” range indicator illuminate?
CHECK “P” RANGE SWITCH. When the “R” range is io to step 28. o
; to step 4.
;elected, does the “ P range
.ED light up?
CHECK “R” RANGE SWITCH. Nhen the “R” range is ;o to step 5. 30 to step 29.
;elected, does the LED light
lp?
CHECK INDICATOR LIGHT. loes the combination meter ;o to step 6. 30 to step 32.
R” range indicator illuminate?
CHECK “R” RANGE SWITCH. Nhen the “N” range is 20 to step 34. 30 to step 7.
;elected, does the “R” range
-ED light up?
CHECK “N” RANGE SWITCH. Nhen the “N” range is 30 to step 8. 30 to step 35.
;elected, does the LED light
JP?
CHECK INDICATOR LIGHT. loes the combination meter 30 to step 9. 30 to step 38.
‘N” range indicator illuminate?
CHECK “N” RANGE SWITCH. Nhen the “ D range is o
; to step 40. 30 to step 10.
selected, does the “N” range
-ED light up?
1 CHECK “D” RANGE SWITCH. Nhen the “D” range is o; to step 11. 30 to step 41.
selected, does the LED light
Jp?
I CHECK INDICATOR LIGHT. I o e s the combination meter 30 to step 12. 30 to step 44.
‘D” range indicator illuminate?
? CHECK “D” RANGE SWITCH. Nhen the “ 3 range is selected, 30 to step 46. 30 to step 13.
joes the “D” range LED light
Jp?
3 CHECK “3” RANGE SWITCH. When the “ 3 range is selected, 30 to step 14. 30 to step 47.
joes the LED light up?
I CHECK INDICATOR LIGHT. Does the combination meter 30 to step 15. Go to step 50.
‘3” range indicator illuminate?
> CHECK “3” RANGE SWITCH. When the “ 2 range is selected, 30 to step 52. Go to step 16.
does the “ 3 range LED light
up?
5 CHECK “2” RANGE SWITCH. When the “2” range is selected, 30 to step 17. Go to step 53.
does the LED light up?
7 CHECK INDICATOR LIGHT. Does the combination meter 30 to step 18. Go to step 56.
“2” range indicator illuminate?
3 CHECK “2” RANGE SWITCH. When the “1” range is selected, So to step 58. Go to step 19.
does the “2” range LED light
up?
9 CHECK “1” RANGE SWITCH. When the “ I ” range is selected, Go to step 20. Go to step 59.
does the LED light up?
D CHECK INDICATOR LIGHT. Does the combination meter Go to step 21. Go to step 62.
“1” range indicator illuminate?
1 CHECK “1” RANGE SWITCH. When the “P” range is Go to step 64. Go to step Symp-
selected, does the “1” range tom Related Diag-
LED light UP? nostic. <Ref. to A1
127, Symptom
Related Diagnos-
tic.>
AT-I 17
Step Check Yes No

2 CHECK HARNESS CONNECTOR BETWEEN Is the resistance less than 1 Go to step 23. Repair open circui
INHIBITOR SWITCH AND CHASSIS R? 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.
(T7) No. 5 - Chassis ground:
3 CHECK HARNESS CONNECTOR BETWEEN Is the resistance less than 1 Go to step 24. Repair open circuil
TCM AND INHIBITOR SWITCH. R? in harness
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-
Non-turbo model
(655) NO. 23 - (T7) NO. 9
Turbo model
._ (655) NO. 1 - (T?’) NO. 9
4 CHECK INPUT SIGNAL FOR TCM. Is the voltage less than 1 V in Go to step 25. Go to step 65.
1)Turnthe ignition switch to OFF. ‘P” range?
2)Connect the connector to TCM and inhibitor
switch.
4)Measure the voltage between TCM and
chassis ground.
Non-turbo model
Turbo model
5 CHECK INPUT SIGNAL FOR TCM. Is the voltage more than 8 V in Go to step 65. Replace the TCM.
Measure the voltage between TCM and chas- 2ther ranges? <Ref. to AT-45,
sis ground. Transmission Con-
Connector & terminal :rol Module
Non-turbo model :TCM).>
Turbo model
6 CHECK “P” RANGE INDICATOR LIGHT s the “ P range indicator light Go to step 27. qeplace the “ P
BULB. iulb OK? ange indicator
1)Turn the ignition switch to OFF. ight bulb. <Ref. to
2)Remove the combination meter. DI-11, Combina-
3)Remove the “ P range indicator light bulb ion Meter Assem-
from combination meter. ilY.>
7 CHECKHARNESSCONNECTORBETWEEN s the resistance more than 1 Go to step 65. 3epair open circuit
TCM AND COMBINATION METER. n? n harness
1)Disconnectthe connectors from TCM and ietween TCM con.
combination meter. lector and combi-
2)Measure the resistance of harness between iation meter, and
TCM and combination meter. ioor contact in
Connector & terminal :oupling connec-
Non-turbo model or.
(655) NO.23 -(112) NO. 14:
Turbo model
(655) NO. 1 - (i12) NO. 14:
AT-I 18
Step Check Yes No

CHECK HARNESS CONNECTOR BETWEEN s the resistance less than 1 30 to step 29. lepair ground
TCM AND INHIBITOR SWITCH. AR? ,hart circuit in “ P
1)Turn the ignition switch to OFF. ange circuit.
2)Disconnect the connectors from TCM, inhibi.
tor switch and combination meter.
TCM and chassis ground.
Non-turbo model
-
(B55) No. 23 Chassis ground:
Turbo model
CHECK HARNESS CONNECTOR BETWEEN s the resistance less than 1 30 to step 30. lepair open circui
TCM AND INHIBITOR SWITCH. 2? I harness
1)Turn the ignition switch to OFF. between TCM anc
2)Disconnect the connectors from TCM and ihibitor switch
inhibitor switch. :onnector,and
3)Measure the resistance of harness between ioor contact in
TCM and inhibitor switch connector. :oupling connec-
Connector & terminal Dr.
Non-turbo model
(B55) NO. 17 - (V) NO. 8:
Turbo model
(B55) NO. 3- (V) NO. 8:
CHECK INPUT SIGNAL FOR TCM. s the voltage less than 1 V in 30 to step 31. ;o to step 65.
1)Turn the ignition switch to OFF. R” range?
switch.
chassis ground.
Non-turbo model
Turbo model
(B55) No. 3 (+)- Chassis ground (-):
CHECK INPUT SIGNAL FOR TCM. s the voltage more than 8 V in 30 to step 65. leplace the TCM.
Measure the voltage between TCM and chas- )ther ranges? :Ref. to AT-45,
sis ground. -ransmissionCon
Connector & terminal rol Module
Non-turbo model TCM).>
Turbo model
CHECK “R” RANGE INDICATOR LIGHT s the “R” range indicator light 30 to step 33. leplace the “R”
BULB. )ulb OK? ange indicator
1)Turn the ignition switch to OFF. ght bulb. <Ref. tc
3)Remove the “R” range indicator light bulb ion Meter Assem,
from combination meter. )lY.>
AT-I 19
~ ~~ ~~~~
Step Check Yes No

3 CHECK HARNESS CONNECTOR BETWEEN s the resistance less than 1 30 to step 65. Repair open circuii
TCM AND COMBINATION METER. 2? in harness
1)Disconnectthe connectors from TCM and between TCM con
combination meter. nector and combi-
2)Measure the resistance of harness between nation meter, and
TCM and combination meter. poor contact in
Connector & terminal TCM connector.
Non-turbo model
(B55) NO. 17 - (i12) NO. 13:
Turbo model
(B55) NO. 3 - (i12) NO. 13:
4 CHECK HARNESS CONNECTOR BETWEEN s the resistance more than 1 30 to step 35. Repair ground
TCM AND INHIBITOR SWITCH. AR? short circuit in “R”
1)Turn the ignition switch to OFF. range circuit.
2)Disconnect the connectors from TCM, inhibi.
Non-turbo model
._ .. Turbo model
5 CHECK HARNESSCONNECTOR BETWEEN s the resistance less than 1 30 to step 36. Repair open circuit
TCM AND INHIBITOR SWITCH. 2? in harness
TCM and inhibitor switch connector, coupling connec-
Non-turbo model
(B55) NO. 22 - (T?) NO. IO:
Turbo model
(B55) NO. 14 - (T7) NO. 10:
6 CHECK INPUT SIGNAL FOR TCM. 5 the voltage less than 1 V in 20 to step 37. Go to step 65.
1)Turn the ignition switch to OFF. N” range?
switch.
chassis ground.
Non-turbo model
Turbo model
7 CHECK INPUT SIGNAL FOR TCM. 5 the voltage more than 8 V in 20 to step 65. Replace the TCM.
Measure the voltage between TCM and chas- ither ranges? <Ref. to AT-45,
Connector & terminal trol Module
Non-turbo model (TCM).>
Turbo model
AT-I 20
I
Step Check Yes No

8 CHECK “N” RANGE INDICATOR LIGHT s the “N” range indicator light i o to step 39. Replace the “N”
BULB. wlb OK? range indicator
1)Turn the ignition switch to OFF. light bulb. <Ref. to
2)Remove the combination meter. IDI-11, Combina-
3)Remove the “N” range indicator light bulb tion Meter Assem-
from combination meter. bly.>
9 CHECK HARNESS CONNECTOR BETWEEN s the resistance less than 1 i o to step 65. Repair open circuit
1)Disconnect the connectors from TCM and between TCM con-
Non-turbo model
(B55) NO.22 - (i12) NO. 12:
Turbo model
(B55) NO. 14 - (i12) NO. 12:
0 CHECK HARNESS CONNECTOR BETWEEN s the resistance more than 1 30 to step 41. Repair ground
TCM AND INHIBITOR SWITCH. dQ? short circuit in “N”
1)Turnthe ignition switch to OFF. range circuit.
2)Disconnect the connectors from TCM, inhibi-
Non-turbo model
Turbo model
,1 CHECK HARNESSCONNECTOR BETWEEN s the resistance less than 1 i o to step 42. Repair open circuit
TCM AND INHIBITOR SWITCH. n? in harness
Non-turbo model
(B55) NO. 8 - (T7) NO. 3:
Turbo model
(B55) NO. 4 - (T7) NO. 3:
12 CHECK INPUT SIGNAL FOR TCM. Is the voltage less than 1 V in 30 to step 43. Go to step 65.
1)Turn the ignition switch to OFF. ‘ D range?
switch.
chassis ground.
Non-turbo model
Turbo model
AT-I 21
Step Check Yes No

CHECK INPUT SIGNAL FOR TCM. s the voltage more than 8 V in I Go to step 65. 3eplace the TCM.
Measure the voltage between TCM and chas- Ither ranges? :Ref. to AT-45,
sis ground. rransmission Con-
Connector & terminal ro1 Module
Turbo model
CHECK “D” RANGE INDICATOR LIGHT s the “ D range indicator light ;o to step 45. 3eplace the “ D
BULB. lulb OK? ange indicator
1)Turnthe ignition switch to OFF. ight bulb. <Ref. to
3)Remove the “ D range indicator light bulb ion Meter Assem-
from combination meter. llY.>
TCM AND COMBINATION METER. 2? n harness
1)Disconnectthe connectors from TCM and letween TCM con-
combination meter. lector and combi-
2)Measure the resistance of harness between ration meter, and
TCM and combination meter. TCM connector.
Non-turbo model
(B55) NO. 8 - (i12) NO. 11:
Turbo model
(B55) NO. 4 - (i12) NO. 11:
CHECK HARNESS CONNECTOR BETWEEN s the resistance more than 1 20 to step 47. 3epair ground
TCM AND INHIBITOR SWITCH. dQ? ;hort circuit in “ D
1)Turnthe ignition switch to OFF. ange circuit.
Non-turbo model
Turbo model
TCM AND INHIBITOR SWITCH. 2? n harness
2)Disconnect the connector from TCM and nhibitor switch
inhibitor switch. :onnector, and
3)Measure the resistance of harness between loor contact in
Connector & terminal or.
Non-turbo model
(655) NO. 18 - (P) NO. 11:
Turbo model
(655) NO. 5 - (R) NO. 1 1:
AT-I 22
I
3
Step Check
18 CHECK INPUT SIGNAL FOR TCM. s the voltage less than 1 V in 30 to step 49. Go to step 65.
1)Turn the ignition switch to OFF. 3 range?
switch.
chassis ground.
Non-turbo model
Turbo model
I9 CHECK INPUT SIGNAL FOR TCM. s the voltage more than 8 V in 30 to step 65. Replace the TCM.
Measure the hvoltage between TCM and chas- )ther ranges? <Ref. to AT-45,
Turbo model
io CHECK “3” RANGE INDICATOR LIGHT s the “3” range indicator light 30 to step 51. Replace the “ 3
BULB. ulb OK? range indicator
3)Remove the “ 3 range indicator light bulb tion Meter Assem-
il CHECK HARNESSCONNECTOR BETWEEN s the resistance more than 1 30 to step 65. Repair open circuii
1)Disconnectthe connectors from TCM and between TCM con
Non-turbo model
(B55) NO. 18 - (i12) NO. 10:
Turbo model
(B55) NO. 5 - (i12) NO. 10:
i2 CHECK HARNESSCONNECTOR BETWEEN s the resistance more than 1 30 to step 53. Repair ground
TCM AND INHIBITOR SWITCH. del? short circuit in “ 3
Non-turbo model
Turbo model
AT-I 23
Step Check Yes No

13 CHECK HARNESS CONNECTOR BETWEEN s the resistance less than 1 30 to step 54. 3epair open circuit
TCM AND INHIBITOR SWITCH. n? n harness
2)Disconnect the connector from TCM and nhibitor switch
inhibitor switch. :onnector, and
3)Measure the resistance of harness between ioor contact in
Connector & terminal ‘or.
Non-turbo model
(854) NO. 10 - (T7) NO. 4:
Turbo model
(B55) NO. 6 - (T7) NO. 4:
14 CHECK INPUT SIGNAL FOR TCM. s the voltage less than 1 V in o
; to step 55. 30 to step 65.
1)Turn the ignition switch to OFF. ‘2” range?
switch.
chassis ground.
Non-turbo model
.. .. (854) No. 10 (+) - Chassis groundI)-(
Turbo model
5 CHECK INPUT SIGNAL FOR TCM. s the voltage more than 8 V in 30 to step 65. 3eplace the TCM.
Measure the voltage between TCM and chas- ither ranges? :Ref. to AT-45,
sis ground. rransmission Con-
Connector & terminal rol Module
Turbo model
8
6 CHECK “2” RANGE INDICATOR LIGHT s the “2” range indicator light 30 to step 57. 3eplace the “ 2
BULB. iulb OK? ‘ange indicator
1)Turn the ignition switch to OFF. ight bulb. <Ref. to
3)Remove the “2” range indicator light bulb ion Meter Assem-
from combination met,er. ilY.>
7 CHECK HARNESSCONNECTOR BETWEEN s the resistance less than 1 ;o to step 65. 3epair open circuit
TCM AND COMBINATION METER. 2? n harness
1)Disconnectthe connectors from TCM and letween TCM and
combination meter. :ombination
2)Measure the resistance of harness between neter, and poor
TCM and combination meter. :ontact in TCM
Connector & terminal :onnector.
Non-turbo model
(854) No. 10 - (i12) No. 4:
Turbo model
(B55) No. 6 - (i12) No. 4:
AT-I 24
I
~ ~~
Step Check Yes No

3 CHECK HARNESS CONNECTOR BETWEEN s the resistance more than 1 ;o to step 59. Repair ground
TCM AND INHIBITOR SWITCH. do? short circuit in “ 2
2)Disconnect the connectors from TCM, inhibi
Non-turbo model
Turbo model
3 CHECK HARNESS CONNECTOR BETWEEN s the resistance less than 1 ;o to step 60. Repair open circuit
TCM AND INHIBITOR SWITCH. 1? in harness
Non-turbo model
(854) NO. 1 - (P) NO. 6:
Turbo model
(B55) NO. 7 - (P) NO. 6:
3 CHECK INPUT SIGNAL FOR TCM. s the voltage less than 1 V in 30 to step 61. Go to step 65.
1)Turnthe ignition switch to OFF. 1” range?
switch.
chassis ground.
Non-turbo model
Turbo model
-
(B55) No. 7 (+) Chassis ground (-):
1 CHECK INPUT SIGNAL FOR TCM. s the voltage more than 8 V in ;o to step 65. Replace the TCM.
Measure the voltage between TCM and chas- ither ranges? <Ref. to AT-45,
-
(854) No. 1 (+) Chassis ground (-):
Turbo model
-
(B55) No. 7 (+) Chassis ground (-):
2 CHECK “1” RANGE INDICATOR LIGHT s the “1” range indicator light 20 to step 63. Replace the “1”
BULB. iulb OK? range indicator
3)Remove the “1” range indicator light bulb tion Meter Assem-
AT-1 25
Step Check Yes No

i3 CHECK HARNESS CONNECTOR BETWEEN s the resistance less than 1RS i o to step 65. Repair open circuit
TCM AND COMBINATION METER. in harnes between
1)Disconnectthe connectors from TCM and TCM and combi-
combination meter. nation meter, poor
2)Measure the resistance of harness between contact in TCM
TCM and combination meter. connector.
Non-turbo model
(B54) No. 1 - (i12) No. 5:
Turbo model
(B55) No. 7 - (i12) No. 5:
i4 CHECK HARNESS CONNECTOR BETWEEN s the resistance more than 1 ;o to step 65. Repair ground
TCM AND INHIBITOR SWITCH. dsz? short circuit in “1”
Non-turbo model
-. Turbo model
i5 CHECK POOR CONTACT. s there poor contact in inhibi- 3epair poor con- Adjust the inhibi-
or switch circuit? act. tor switch and
select cable. <Ref.
to AT-28, ADJUST-
MENT, Inhibitor
Switch.> and
<Ref. to CS-26,
Select Cable.>
AT-I 26
I
SYMPTOM RELATED DIAGNOSTIC
16.Symptom Related Diagnostic

A: INSPECTION
Svmptom Problem parts I
Inhibitor switch
Starter does not rotate when the select lever is in “P” 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
Abnormal noise when the select lever is in “ P or “N” Oil pump
Drive plate
ATF level too high or too low
Strainer
Hissing noise occurs during standing start.
ATF level too high or too low
Noise occurs while driving in “Dl”. Final gear
Planetary gear
Noise occurs while driving in “ 0 2 . Reduction gear
Differential gear oil level too high or too low
Final gear
Low & reverse brake
Noise occurs while driving in “ D 3
Reduction gear
Final gear
Low & reverse brake
Noise occurs while driving in ‘ID4 Planetary gear
Reduction gear
Control valve
Lock-up damper
Engine stalls while shifting from one range to another.
Engine performance
Input shaft
TCM
Vehicle moves when the select lever is in “N”.
Low clutch
TCM
Harness
Shock occurs when the select lever is moved from “N” to “ D .
Control valve
ATF deterioration
Control valve
Low clutch
Excessive time lag occurs when the select lever is moved from
Line pressure duty solenoid
“N” to “ D .
Seal ring
Front gasket transmission case
TCM
Harness
Shock occurs when the select lever is moved from “N” to “R”.
Control valve
ATF deterioration
Control valve
Low & reverse clutch
Excessive time lag occurs when the select lever is moved from Reverse clutch
“N” to “R”. Line pressure duty solenoid
Seal ring
Parking brake mechanism
Vehicle does not start in any shift range (engine stalls).
Planetarv aear
AT-127
I
~~
Symptom ’roblem parts

Strainer
1 Line pressure duty solenoid
I Control valve
1 Drive pinion
1 Hypoid gear
1 Axle shaft
1 Differential gear
Vehicle does not start in any shift range (engine revving up).
1 Oil pump
1 Input shaft
b Output shaft
b Planetary gear
b Drive plate
b ATF level too low
b Front gasket transmission case

b Select cable
Vehicle does not start in “R” range only (engine rewing up).
b
.Select lever
Control valve
b
.Low & reverse clutch

Reverse clutch
,Vehicle does not start in “R” range only (engine stalls).

..
Low clutch
2-4 brake
.
-
Planetary gear
Parking brake mechanism
Low clutch
Vehicle does not start in “D”, “ 3 range only (engine rewing up).
* One-wav clutch
Vehicle does not start in “D”, “ 3or “2” range only (engine rev- Low clutch
vina up).
Vehicle does not start in “D”, “ 3 or “ 2 range only (engine
stalls).
.Reverse clutch
Vehicle starts in “R” range only (engine revving up). Control valve
Control valve
Low clutch
Reverse clutch
Acceleration during standing starts is poor (high stall rpm).
ATF level too low
Oil pump
Acceleration during standing starts is poor (low stall rpm). Torque converter one-way clutch
Engine performance
TCM
Control valve
Acceleration is poor when the select lever is in “D”, “ 3 or “ 2
High clutch
range (normal stall rpm).
2-4 brake
Planetary gear
I
Control valve
Acceleration is poor when the select lever is in “R” (normal stall High clutch
rpm). 2-4 brake
Planetary gear
TCM
Rear vehicle speed sensor
Front vehicle speed sensor
No shift occurs from 1st to 2nd gear. Throttle position sensor
Shift solenoid 1
Control valve
2-4 brake
TCM
Control valve
No shift occurs from 2nd to 3rd gear.
High clutch
Shift solenoid 2
I
Problem parts
TCM
B Shift solenoid 1
No shift occurs from 3rd to 4th gear. B ATF temperature sensor
r
Control valve
B 2-4 brake
B Inhibitor switch
Engine brake is not effected when the select lever is in “ 3 TCM
range. * Throttle position sensor
* Control valve
‘Engine brake is not effected when the select lever is in “ 3 or “2” 0 Control valve
range.
Engine brake is not effected when the select lever is in “1” * Control valve
range. Low & reverse brake
Inhibitor switch
TCM
Shift characteristics are erroneous. Rear vehicle speed sensor
Control valve
Ground earth
TCM
Control valve
Lock-up facing
Engine speed signal
m n u brake is not effected. Select cable
Select lever
Shift lever cannot be moved or is hard to move from “P” range. Parkinu mechanism
ATF spurts out. ATF level too high
Differential oil swrts out. Differential gear oil too high
Seal pipe
Differential oil level changes excessively.
Double oil seal
High clutch
2-4 brake
Low & reverse clutch
Odor is produced from ATF supply pipe.
Reverse clutch
Lock-up facing
ATF deterioration
TCM
2-4 brake duty solenoid
Shock occurs from 1st to 2nd gear.
Control valve
2-4 brake
ATF deterioration
Engine performance
2-4 brake timing solenoid
TCM
Control valve
2-4 brake
Hiah clutch
I
Symptom Problem parts

TCM
Shock occurs from 2nd to 3rd gear. Control valve
High clutch
2-4 brake
r
ATF deterioration
Engine performance
TCM
Slippage occurs from 2nd to 3rd gear. Line pressure duty solenoid
Control valve
High clutch
2-4 brake
TCM
Control valve
2-4 brake
ATF deterioration
Engine performance
Low clutch timing solenoid
Low clutch
TCM
Slippage occurs from 3rd to 4th gear. Line pressure duty solenoid
Control valve
2-4 brake
TCM
Shock occurs when the select lever is moved from “ 3 to “ 2 Control valve
2-4 brake
ATF deterioration
TCM
I Shock occurs when the select lever is moved from “ 0to “1” Line pressure duty solenoid
Control valve
range. ATF deterioration
Low clutch timinu solenoid
AT-I 30
3vmPtom Problem parts

TCM
Shock occurs when the select lever is moved from “2” to “1” Control valve
.ange. Low & reverse clutch
ATF deterioration
TCM
Shock occurs when the accelerator pedal is released at Control valve
nedium speeds. Lock-up damper
Engine performance
TCM
Lock-up duty solenoid
Vibration occurs during straight-forwardoperation.
Lock-up facing
Lock-up damper
TCM
Rear vehicle speed sensor
Vibration occurs during turns (tight corner “braking” phenome- ATF temperature sensor
non). Transfer clutch
Transfer valve
ATF deterioration
Harness
TCM
Front wheel slippage occurs during standing starts. Control valve
Transfer clutch
Transfer valve
Transfer pipe
Transfer dutv solenoid
TCM
Transfer clutch
Vehicle is not set in FWD mode.
Transfer valve
Select cable
Select lever
Select lever is hard to move.
Detent spring
Manual date
Detent spring
Select lever is too high to move (unreasonable resistance).
Manual plate
Select cable
Select lever slips out of operation during acceleration or while Select lever
driving on rough terrain. Detent spring
Manual plate
AT-1 31
I SYMPTOM RELATED DIAGNOSTIC
I
AT-I 32
MANUAL TRANSMISSION AND
DIFFERENTIAL
MT
Page
2. Transmission Gear Oil .............................................................................. 26
3. Manual Transmission Assembly ............................................................... 27
4. Transmission Mounting System ................................................................ 34
5. Oil Seal ...................................................................................................... 36
6. Switches and Harness .............................................................................. 37
7. Vehicle Speed Sensor ............................................................................... 39
8. Preparation for Overhaul ........................................................................... 40
9. Transfer Case and Extension Case Assembly .......................................... 41
r . 10. Transfer Drive Gear .................................................................................. 45
11. Transfer Driven Gear ................................................................................ 47
12. Center Differential ..................................................................................... 49
13. Reverse Check Sleeve .............................................................................. 50
14. Transmission Case ................................................................................... 54
15. Main Shaft Assembly for Single-Range .................................................... 57
16. Drive Pinion Shaft Assembly ..................................................................... 63
17. Front Differential Assembly ....................................................................... 71
18. Speedometer Gear .................................................................................... 77
19. Reverse Idler Gear .................................................................................... 78
20. Shifter Fork and Rod ................................................................................. 80
21 . General Diagnostic.................................................................................... 84
GENERAL DESCRIPTION
3
MANUAL TRANSMISSION AND DIFFERENTIAL
A: SPECIFICATIONS
1. MANUAL TRANSMISSION AND DIFFERENTIAL
Sedan Wagon
Type 5-forward speeds with synchromesh and 1-reverse
1st 3.454 3.454
2nd 2.062 1.947
3rd 1.448 1.366
Transmission gear ratio
F I 1.088 I 0.972
15th I 0.780 I 0.738
I Reverse I 3.333
Type of gear Hypoid
Gear ratio 4.1 11 I
3.900
Type of gear Helical
Transfer
Gear ratio 1.ooo 1.100
Rear reduction gear
C. ~
Type of gear Hypoid
Final
Gear ratio 4.1 11 3.900 3.545
Front differential 1 Type and number of gear Straight bevel gear (Bevel pinion: 2, Bevel gear: 2)
Center differential I Type and number of gear

I Straight bevel gear
(Bevel Dinion: 2, Bevel aear: 2 and viscous couplina)
Transmission aear
" .
oil I
GL-5
Transmission aear oil caeacitv I 3.5 8 (3.7 US qt, 3.1 Imp qt)
2. TRANSMISSION GEAR OIL

Recommended oil
Transmission gear oil

API Classification
SAE Viscosity No and Applicable Temperature
(OF) -22 -15
MT-2
GENERAL DESCRIPTION
3
3. TRANSMISSION CASE ASSEMBLY 4. DRIVE PINION ASSEMBLY

Drive pinion shim adjustment Preload adjustment of thrust bearing
Hypoid gear backlash Starting torque
0.13 - 0.18 mm (0.0051 - 0.0071 in) 0.3 - 0.8 N-m (0.03 - 0.08 kgf-m, 0.2 - 0.6 ft-
Drive pinion shim Ib)
Part No.
Thickness
mm (in)
1 Part No.
mm (in) Part No. Thickness mm (in)
32295AA031
I 803025052 I 3.950 (0.1555) I
0.275 803025053
32295AA041
32295AA051 803025055
(0.0079) (0.01 18)
32295AA061 I 32295AAlOl
Selection of main shaft rear plate

I Main shaft rear date I
bimension"Amm (in) I Part No. I Mark I 803025059 3.850 (0.1516)
. . 4.00-4.13
32294AA041 1
(0.1575 - 0.1626)
3.87 - 3.99
32294AA051 2 5. MAIN SHAFT
(0.1524 - 0.1571)
Input shaft holder adjustment Snap ring (Outer-25) to synchronizer hub clear-
ance
I Dimension " D mm (in) I Number of shim I 0.060 - 0.100 mm (0.0024 - 0.0039 in)
52.50 - 53.1 1
(2.0669 - 2.0909)
- I SnaD rina (Outer-25) 1
Thickness Part No, Thickness
52.00 - 52.49 Part No.
1 mm (in) mm (in)
(2.0472 - 2.0665)
- 805025051 2.42 (0.0953) 805025055 2.62 (0.1031)
51.26 - 51.99
2 805025052 2.47 (0.0972) 805025056 2.67 (0.1051)
(2.0181 - 2.0468)
805025053
_________- - - (0.0992)
2.52 ,- ,
805025057 2.72 (0.1071)
1
I
I
- - - - I
805025054 I 2.57 (0.1012) I 805025058 I 2.37 (0.0933)
MT-3
GENERAL DESCRIPTION
I
6. REVERSE IDLER GEAR 7. SHIFTER FORK AND ROD

Adjustment of reverse idler gear position Select suitable shifter forks so that both coupling
Reverse idler gear to transmission case (LH) wall sleeve and reverse driven gear are positioned in
clearance the center of their synchromesh mechanisms.
6.0 - 7.5 mm (0.236 - 0.295 in) Rod end clearance
A: 1st-2nd - 3rd-4th
0.4 - 1.4 mm (0.016 - 0.055 in)
Part No. Mark Remarks
B: 3rd-4th - 5th
0.5 - 1.3 mm (0.020 - 0.051 in)
I 32820AA080 I 8 I Standard I
I 32820AA090 I 9 I Closer to the case wall I I 1st-2nd shifter fork I
I Part No. I Mark I Remarks I
After installing a suitable reverse shifter lever, ad-
just reverse idler gear to transmission case wall I 32804AA060 1 Approach to 1st gear
by 0.2 mm (0.008 in)
clearance to within 0 to 0.5 mm (0 to 0.020 in) using 32804AA070 I No mark I Standard
1
washers.
I
I 32804AA080 I 3 I Approach to 2nd gear
by 0.2 mm (0.008 in) I
I Part No.
I Thickness
mm (in)
I
Washer (20.5 x 26 x t)
Part No, I
y; : ;T I
I
803020151 0.4 (0.016) 803020154 1.9 (0.075) Part No. Mark Remarks
--803020152 1.1 (0.043) 803020155 2.3 (0.091) Approach to 4th gear
32810AA061 1
803020153 1.5 (0.059) - - bv 0.2 mm (0.008 in)
I 32810AA071 I No mark I Standard I
I 32810AA101 I 3 I Approach to 3rd gear
bv 0.2 mm (0.008 in)
I 5th shifter fork (Non-turbo)

I 32812AA201 I 4 I
Approach to 5th gear
bv 0.2 mm (0.008 in) I
Become distant from
32812AA221 5th gear by 0.2 mm
(0.008 in)
I 32812AA231 I ' 1 Approach to 5th gear

by 0.2 mm (0.008 in) I
32812AA241 No mark Standard
Become distant from
32812AA251 9 5th gear by 0.2 mm
(0.008 in)
MT-4
GENERAL DESCRIPTION
8. TRANSFER CASE 9. EXTENSION ASSEMBLY

Neutral position adjustment 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)
Part No. Thickness mm (in)
32190AA000 0.15 (0.0059) NOTE:
T: Tight
I 32190AA010 I 0.30 (0.0118) I

Part No. Mark Remarks 803050060 0.50 (0.0197)
Neutral position is 803050061 0.55 (0.0217)
32188AA090 3
closer to 1st.
I 803050062 I 0.60 (0.0236) I
I 32188AA100 I 0 I Standard I 803050063 0.65 (0.0256)
I 32188AA110 I 1 I Neutral position is
closer to reverse aear. I 803050064
803050065
0.70 (0.0276)
0.75 (0.0295)
Reverse check plate adjustment 803050066 0.80 (0.0315)
803050067 0.85 (0.0335)
I -
Reverse check plate I
I Part No. Mark1 Angle
e I I
Remarks
I I
803050068
803050069 I
0.90 (0.0354)
0.95 (0.0374) I
.-.. Arm stops closer to I 803050070 I 1.OO (0.0394) I
32189AA000 0 803050071 1.05 (0.0413)
I I I
280
I
-
5th qear.
I
Arm stops closer to 803050072 1.10 (0.0433)
32189AA010 1
31" 5th gear. 803050073 1.15 (0.0453)
Arm stops in the cen- 803050074 1.20 (0.0472)
33189AA020 2
340 ter. I 803050075 I 1.25 (0.0492) I
Arm stops closer to I 803050076 I 1.30 (0.0512) I
32189AA030 3
370 reverse gear. 803050077 1.35 (0.0531)
I 32189AA040 I 4 I 40" I Arm stops closer to
reverse aear. I 803050078
803050079
1.40 (0.0551)
1.45 (0.0571)

I 803036050 I 0.9 (0.035) I
803036054 1.O (0.039)
803036051 1.1 (0.043)
803036055 1.2 (0.047)
803036052 1.3 (0.051 )
803036056 1.4 (0.055)
803036053 1.5 (0.059)
I 803036057 I 1.6 (0.063) I
803036058 1.7 (0.067)
MT-5
GENERAL DESCRIPTION
1O.FRONT DIFFERENTIAL 11.TRANSFER DRIVE GEAR
Snap ring (Outer-30)

Washer (38.1 x 50 x t)
Thickness Part No, Thickness
Part No. 805030041 1.53 (0.0602)
mm (in) mm (in)
0.925 - 1.025 - 805030042 1.65 (0.0650)
I I 0.0374) I I 0.0413) I
I
I 803038022
I
I
0.975-
l.ooo
(0.0384-
I
I
- 1
I
- II
Thickness Part No. Thickness

Part No.
mm (in) mm (in)
805028011 I 1.05 (0.0413) 1 805028012 I 1.20 (0.0472)
MT-6
GENERAL DESCRIPTION
I
B: COMPONENT
1. TRANSMISSION CASE
(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 model)
(3) Drain plug (9) Oil seal
(4) Snap ring (Outer) (10) Clamp Tightening torque: N.m (kgf-m, ff-lb)
(5) Speedometer driven gear (11) Pitching stopper bracket T: 44 (4.5, 32.5)
(6) Washer (12) Clip
Size All models Tightening torque: N.m (kgf-m, ft-lb)

8 mm bolt <5> - <I 5> 25 (2.5, 18.1)
< I > - <4>
10 mm bolt 39 (4.0, 28.9)
<16> - <17>
MT-7
2. DRIVE PINION ASSEMBLY
/
/’
/
/’
S3M0423B
(1) Drive pinion shaft (15) Baulk ring (29) Locknut

(2) Roller bearing (16) 1st-2nd synchronizer hub (30) Washer
(3) Washer (17) Insert key (31) Thrust bearing
(4) Thrust bearing (18) Reverse driven gear (32) Differential bevel gear sleeve
(5) Needle bearing (19) Outer baulk ring (33) Washer
(6) Driven shaft (20) Synchro cone (34) Lock washer
(7) Key (21) Inner baulk ring (35) Locknut
(8) Woodruff key (22) 2nd driven gear
(9) Drive pinion collar (23) 2nd driven gear bush Tightening torque: N.m (kgf-m, ft-lb)
(10) Needle bearing (24) 3rd-4th driven gear T1: 29 (3.0, 21.7)
(11) Snap ring (Outer) (25) Driven pinion shim T2: 118 (12.0, 86.8)
(12) Washer (26) Roller bearing T3: 265 (27, 195)
(13) Subgear (27) 5th driven gear
(14) 1st driven gear (28) Lock washer
MT-8
3. MAIN SHAFT ASSEMBLY
Oil seal Needle bearing Ball bearing

Needle bearing 4th gear thrust washer Synchro cone stopper
Transmission main shaft Ball bearing Snap ring
Needle bearing 5th gear thrust washer Lock washer
3rd drive gear 5th needle bearing race Lock nut
Inner baulk ring Needle bearing Reverse idler gear shaft
Synchro cone (3rd) Main shaft rear plate Straight pin
Outer baulk ring 5th drive gear Reverse idler gear
Coupling sleeve (3rd-4th) 5th baulk ring Washer
Synchronizer hub (3rd-4th) Shifting insert key (5th-Rev)
Shifting insert key (3rd-4th) Synchronizer hub (5th-Rev) Tightening torque: N.m (kgf-m, ft-lb)
4th baulk ring Coupling sleeve (5th-Rev) T: 118 (12.0, 86.8)
4th drive gear Rev baulk ring
4th needle bearing race Synchro cone (Rev)
MT-9
I
4. SHIFTER FORK AND SHIFTER ROD
r-
(1) Shifter arm (9) 3rd-4th fork rod (17) Reverse fork rod arm
(2) 5th shifter fork (10) Interlock plunger (18) Reverse shifter lever
(3) Straight pin (1 1) 1st-2nd fork rod
(4) Reverse fork rod (12) 3rd-4th shifter fork Tightening torque: N-m (kgf-m, ft-lb)
(5) Checking ball plug (13) 1st-2nd shifter fork T: 19.6(2.0, 14.5)
(6) Gasket (14) Ball
(7) Checking ball spring (15) Spring
(8) Ball (16) Snap ring (Outer)
MT-10
GENERAL DESCRIPTION
I
5. TRANSFER CASE AND EXTENSION

I .
TROOO
Oil guide Return spring (31) Transfer drive gear

Gasket O-ring (32) Ball bearing
Transfer case Adjusting select shim (33) Extension
Ball Reverse check sleeve (34) Oil seal
Reverse accent spring Gasket (35) Dust cover
Gasket Neutral switch (36) Shift bracket
Plug Gasket (37) Snap ring
Oil seal Back-up light switch
Snap ring (Inner) Roller bearing Tightening torque: N.m (kgf-myft-lb)
Reverse check plate Transfer driven gear T1: 6.4 (0.65, 4.7)
Reverse check spring Roller bearing T2: lO(1.0, 7.2)
Reverse return spring Adjusting washer T3: 25 (2.5, 18.1)
Reverse check cam Ball bearing T4: 26 (2.7, 20)
Reverse accent shaft Center differential T5: 40 (4.1, 29.7)
Return spring cap Adjusting washer
MT-11
I GENERAL DESCRIPTION I
6. FRONT DIFFERENTIAL
H3M1967A
(1) Drive pinion shaft (8) Snap ring (Outer) (15) Retainer lock plate
(2) Hypoid driven gear (9) Roller bearing
(3) Pinion shaft (10) Differentialcase Tightening torque: N.m (kgf-m, ft-lb)
(4) Straight pin (1 1) Oil seal T1: 25(2.5, 18.1)
(5) Washer (12) Differential side retainer T2: 62 (6.3, 45.6)
(6) Differential bevel gear (13) O-ring
(7) Differential bevel pinion (14) Axle drive shaft
MT-12
7. TRANSMISSION MOUNTING
“i, @
I
’\
TROOl:
(1) Pitching stopper (8) Cushion D Tightening torque: N.m (kgf-m, ft-lb)
(2) Spacer (9) Center crossmember T l : 7.5 (0.76, 5.5)
(3) Cushion C (10) Rear plate T2: 35 (3.6,26)
(4) Front plate (1 1) Front crossmember T3: 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
C: CAUTION Be sure to tighten fasteners including bolts and

Wear working clothing, including a cap, protec- nuts to the specified torque.
tive goggles, and protective shoes during opera- Place shop jacks or safety stands at the specified
tion. points.
Remove contamination including dirt and corro- Apply gear oil onto sliding or revolution surfaces
sion before removal, installation, and disassembly. before installation.
Keep the disassembled parts in order and pro- Replace deformed or otherwise damaged snap
tect them from dust or dirt. rings with new ones.
Before removal, installation or disassembly, be Before installing O-rings or oil seals, apply suffi-
sure to clarify the failure. Avoid unnecessary re- cient amount of gear oil to avoid damage and defor-
moval, installation, disassembly and replacement. mation.
When disassembling the case and other light al- Be careful not to incorrectly install or fail to install
loy parts, use a plastic hammer to force it apart. Do O-rings, snap rings and other such parts.
not pry it apart with a screwdriver or other tool. Before securing a part on a vice, place cushion-
Be careful not to burn your hands, because each ing material such as wood blocks, aluminum plate,
part on the vehicle is hot after running. or shop cloth between the part and the vice.
Use SUBARU genuine gear oil, grease etc. or Avoid damaging the mating surface of the case.
the equivalent. Do not mix gear oil, grease etc. with Before applying sealant, completely remove the
that of another grade or from other manufacturers. old seal.
D: PREPARATION TOOL
r. ~
1. SPECIAL TOOLS
ILLUSTRATION I TOOLNUMBER DESCRIPTION REMARKS

398791700 REMOVER Used for removing and installing spring pin (6
mm).
B3M1938
39941 1700 ACCENT BALL Used for installing reverse shifter rail arm.
INSTALLER
B3M1939
MT-14
GENERAL DESCRIPTION 1
--t ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS

399527700 'ULLER SET k e d for removing and installing roller bearing
Differential).
1) BOLT (899521412)
2) PULLER (399527702)
3) HOLDER (399527703)
4) ADAPTER (398497701)
5 ) BOLT (899520107)
6) NUT (021008000)
I B3M1940A
399780104 VEIGHT Jsed for measuring preload on roller bearing.
I B3M1941
498077000 3EMOVER Used for removing roller bearing of drive pinion
shaft.
I B3M194;
498077300 CENTER DIFFER- Used for removing the center differential cover
ENTIAL BEARING ball bearing.
REMOVER
I B3M194:
MT-15

498147000 DEPTH GAUGE Used for adjusting main shaft axial end play.
~~
498247001 MAGNET BASE Used for measuring backlash between side

gear and pinion, and hypoid gear.
Used with DIAL GAUGE (498247100).
-t B3M1945
498247100 31AL GAUGE m Used for measuring backlash between side
.
gear and pinion, and hypoid gear.
Used with MAGNET BASE (498247001).
r--- B3M1946
498427100 STOPPER Jsed for securing the drive pinion shaft assem-
3ly and driven gear assembly when removing the
jrive pinion shaft assembly lock nut.
I B3M1947
MT-16
GENERAL DESCRIPTION 3
ILLUSTRATION TOOL NUMBER DESCRIPTION

_ _ _- I REMARKS
498787100 JlAlN SHAFT Used for removing and installing transmission
;TOPPER main shaft lock nut.
B3M1948
498937000 rRANSMlSSlON Jsed for removing and installing transmission
i0LDER nain shaft lock nut.
B3M1945
499277100 BUSH 1-2 1 Used for installing 1st driven gear thrust plate
INSTALLER and 1st-2nd driven gear bush.
1 Used for installing roller bearing outer races to
jifferential case.
B3M195l
499277200 INSTALLER Used for press-fittingthe 2nd driven gear, roller
bearings, and 5th driven gear onto the driven
shaft.
B3M195
MT-17
GENERAL DESCRIPTION

499757002 INSTALLER 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).
B3M1952
499787000 NRENCH ASSY Used for removing and installing differential side
retainer.
B3M1953
499827000 WESS Used for installing speedometer oil seal when
Installing speedometer cable to transmission.
B3M1954
499857000 jTH DRIVEN GEAR Jsed for removing 5th driven gear.
3EMOVER
B3M1955
MT-18
IL
TOOL NUMBER DESCRIPTION L
REMARKS
499877000 3ACE 4-5 1 Used for installing 4th needle bearing race and
NSTALLER ,all bearing onto transmission main shaft.
1 Used with REMOVER (8997141IO).
I
B3M1956
499917500 ]RIVE PINION Used for adjusting drive pinion shim.
3AUGE ASSY
+ B3M1957
499927100 HANDLE Used for fitting transmission main shaft.
I B3M1958
~
499937100 TRANSMISSION Stand used for transmission disassembly and

STAND SET assembly.
I B3M1959
MT-19

499987003 SOCKET WRENCH Used for removing and installing driven pinion
(35) lock nut and main shaft lock nut.
B3M1960
499987300 SOCKET WRENCH Used for removing and installing driven gear
(50) assembly lock nut.
...
B3M1961
8997141 10 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

899884100 iOLDER Jsed for tightening lock nut on sleeve.
B3M1964
899904100 3 EMOVER Used for removing and installing straight pin.
B3M1965
899988608 SOCKET WRENCH Used for removing and installing drive pinion lock
?7) nut.
B3M1966
398497701 ADAPTER Used for installing roller bearing onto differen-
tial case.
Used with INSTALLER (499277100).
B3M1967
MT-21
GENERAL DESCRIPTION

499587000 INSTALLER Used for installing driven gears to driven shaft.
B3M1968
899824100 PRESS Used for installing speedometer shaft oil seal.
B3M1969
499987100 SOCKET WRENCH Llsed for removing and installing drive pinion lock
(35) IUt.
B3M1970
899984103 SOCKET WRENCH Jsed for removing and installing drive pinion lock
(35) IUt.
B3M1971
MT-22
GENERAL DESCRIPTION
I

498057300 NSTALLER Jsed for installing extension oil seal.
B3M1972
498255400 'LATE 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 Used for supporting engine.
BRACKET
B3M1975
MT-23
GENERAL DESCRIPTION
I
r------
ILLUSTRATION TOOL NUMBER
41099AA020
DESC R IPTION
ENGINE SUPPORT
REMARKS
Jsed for supporting engine.
398527700 PULLER ASSY Jsed for removing and installing extension case
*oiler bearing.
I-
B3M1977
398643600 GAUGE Jsed for measuring total end play, extension end
2lay and drive pinion height.
I B3M1978
38177700 INSTALLER 1 Used for installing bearing cone of transfer
driven gear (transfer case side).

1 Used for installing ball bearing of transfer drive
gear.
B3M1905
MT-24
GENERAL DESCRIPTION
1
TOOL NAME REMARKS

MT-25
I TRANSMISSION GEAR OIL
2. Transmission Gear Oil B: REPLACEMENT

1) Pull out oil level gauge.
A: INSPECTION 2) Lift-up the vehicle.
1) Park vehicle on a level surface. 3) Drain the transmission gear oil completely.
2) Turn the ignition switch to OFF, and wait until the
CAUTION:
engine cools. Directly after the engine has been running, the
3) Remove the oil level gauge and wipe it clean. transmission gear oil is hot. Be careful not to
4) Reinsert the level gauge all the way. Be sure burn yourself.
that the level gauge is correctly inserted and in the
proper direction. NOTE:
5) Pull out the oil level gauge again and check the Tighten the transmission gear oil drain plug after
oil level on it. If it is below the lower level, add oil draining transmission gear oil.
through the oil level gauge hole to bring the level up Tightening torque:
to the upper level. 44 N.m (4.5 kgf-m, 325 ft-lb)
e' A S3M0470A
(A) Drain plug

(B) Gasket

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 9t, 3.1 Imp 9t)
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 gauge hole.
NOTE:
The level should be within the specified range
marked on the gauge.
MT-26
I
MANUAL TRANSMISSION ASSEMBLY
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(S0HC)-7, REMOV-
AL, Air Intake Duct.> and <Ref. to IN(S0HC)-6,
REMOVAL, Air Cleaner Case.>
4) Remove the air cleaner case stay. (Non-turbo
model)
7) Remove the starter. <Ref. to SC-6, REMOVAL,
Starter.>
8) Remove the operating cylinder from the trans-
mission.
Non-turbo model
5 ) Remove the intercooler (Turbo model) <Ref. to

6) Disconnect the following connectors.
(1) Neutral position switch connector
(2) Back-up light switch connector
Non-turbo model Turbo model
9) Remove the pitching stopper.

(A) Neutral switch (Brown)
(B) Back-up light switch (Gray)
Turbo model
MT-27
I MANUAL TRANSMISSION ASSEMBLY
10) Separate the clutch release fork from the re- 11) Set ST.
lease bearing. (Turbo model) NOTE:
(1) Remove the clutch operating cylinder from Also is available Part No. 927670000.
the transmission.
ST 41099AA020 ENGINE SUPPORT ASSY
(2) Remove the plug using 10 mm hexagon
wrench.
S2M1935 I 12) Remove the bolt which holds right upper side of
transmission to the engine.
(3) Screw the 6 mm dia. bolt into the release
fork shaft, and remove it.
B2M2791
13) Remove the front and center exhaust pipes.

(Non-turbo model) with OBD <Ref. to EX(S0HC)-
5, REMOVAL, Front Exhaust Pipe.>
14) Remove the center exhaust pipe. (Turbo mod-
el). <Ref. to EX(D0HC TURBO)-8, REMOVAL,
CAUTION:
When removing exhaust pipes, be careful each
exhaust pipe does not drop out.
S2M1936A 17) Remove the hanger bracket from right side of
transmission.
(A) Shaft
(B) Bolt I I W ' I
(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.
I rJl \\ 0 B2M0032
18) Remove the propeller shaft. <Ref. to DS-14,

MT-28
1
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.
2M0325
(4 Stay
(6) Rod 23) Remove the nuts which hold lower side of
transmission to the engine.
20) Disconnect the stabilizer link from the trans-
verse link.
2 1 ) Remove the bolt securing ball joint of trans-
verse link to housing.
Except sedan turbo model
B2M2790
24) Place the transmission jack under transmis-

sion.
CAUTION:
G4M0491 Always support transmission case with a trans-
mission jack.
Sedan turbo model
u
G2M0326
MT-29
I
25) Remove the transmission rear crossmember 6) Tighten the nuts which hold lower side of trans-
from the vehicle. mission to the engine.
Tightening torque:
50 N.m (5.1 kgf-m, 36.9 ft-lb)
26) Remove the transmission.

CAUTION: I 82M2790
Move transmission jack toward rear until main 7) Connect the engine and transmission.
shaft is withdrawn from clutch cover. (1) Install the starter.
27) Separate the transmission assembly and rear <Ref. to SC-7, INSTALLATION, Starter.>
cushion rubber. (2) Tighten the bolt which holds right upper side
of transmission to the engine.
B-:INSTALLATION
1) Install the rear cushion rubber to the transmis- Tightening torque:
sion assembly. 50 N.m (5.1 kgf-m, 36.9 ft-lb)
Tightening torque: I
35 N.m (3.6 kgf-m, 26.3 ft-lb)
2) Install the clutch release lever and bearing onto
the transmission. (Turbo model) <Ref. to CL-15,
INSTALLATION, Release Bearing and Lever.>
3) Install the transmission onto the engine.
(1) Gradually raise the transmission with trans-
mission jack.
(2) Engage them at splines.
CAUTION: B2M2791
Be careful not to strike main shaft against 8) Remove ST.

clutch cover.
4) Install the transmission rear 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)
5) Take off the transmission jack.
MT-30
I
9) Push the clutch release lever to fit bearing into 14) Drive the spring
. - .pin into the chamfered hole of
clutch cover. drive shaft.

CAUTION:
Always use a new spring pin.
/
H2M1818
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 Plug
(B) Transmission ASSY
- B2M3402A
Tightening torque: (A) Transverse link
T7: 50 Nom(5.7 kgf-m, 37 ft-lb) (B) Ball joint
T2: 58 N.m (5.9 kgf-m, 43 ft-lb)

13) Install the front drive shaft into the transmis-
sion.
MT-31
16) Install the stabilizer link from the transverse (2) Connect the stay to the transmission brack-
link. et.
Except sedan turbo model Tighfening torque:
Tightening torque: 18 N.m (1.8 kgf-m, 13.0 ft-lb)
30 N.m (3.1 kgf-m, 22.1 ft-lb)
(A) Stay
Sedan turbo model (B) Transmission bracket
Tightening torque:
45 N-m (4.6 kgf-m, 33.2 ft-lb)
20) Install the rear exhaust pipe and muffler.
21) Install the hanger bracket on the right side of
transmission.
17) Install the gear shift rod and stay.

(1) Connect the rod to the joint.
Tightening torque: (4, B2M0032
18 N-m (1.8 kgf-m, 13.0 ft-lb)
Install the front exhaust .pipe
. and center ex-
haust pipe. (Non-turbo model)
haust Pipe.>
24) install the under cover.
MT-32
I MANUAL TRANSMISSION ASSEMBLY 1
25) Install the operating cylinder.

Tightening torque:
37 N-m (3.8 kgf-m, 27.5 ft-lb)
Non-turbo model
Turbo model
26) Connect the following connectors.

(1) Transmission ground terminal
Tightening torque:
73 N-m (7.3 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:
76 N-m (7.6 kgf-m, 7 7.6 ft-lb)
28) Install the air cleaner case and intake duct.
(Non-turbo model) <Ref. to IN(S0HC)-6, INSTAL-
LATION, Air Cleaner Case.> and <Ref. to IN(S0-
HC)-7, INSTALLATION, Air Intake Duct.>
<Ref. to IN(D0HC TURBO)-1 1, INSTALLATION,
I ntercooler.>
31) Take off the vehicle from lift arms.
MT-33
I TRANSMISSION MOUNTING SYSTEM
I
4. Transmission Mounting Sys- 8) Remove the rear crossmember.

tem
A: REMOVAL
1. PITCHING STOPPER
3) Remove the air intake duct (Non-turbo model).
4) Remove the air cleaner case (Non-turbo model).
7 C J \ ' G2M0831
Case.> 9) Remove the rear cushion rubber.

5) Remove the inter cooler (Turbo model). <Ref. to
B: INSTALLATION
6) Remove the pitching stopper. 1. PITCHING STOPPER
Tightening torque:
T1: 50 N-m (5.1 kgf-m, 37 ff-lb)
T2: 58 N.m (5.9 kgf-m, 43 ff-lb)
2. CROSSMEMBER AND CUSHION RUB-

BER
2) Jack-up the vehicle and support it with sturdy
racks.
2) Install the air intake duct and cleaner case. (Non-
3) Remove the front, center exhaust pipes. (Non-
turbo model)
turbo model)
Case.> and <Ref. to IN(S0HC)-7, INSTALLATION,
Pipe.>
Air Intake Duct.>
CAUTION: 3) Install the intercooler. (Turbo model)
When removing exhaust pipes, be careful each <Ref. to IN(D0HC TURBO)-11, INSTALLATION,
exhaust pipe does not drop out. Intercooler.>
4) Remove the center exhaust pipe. (Turbo model) 4) Connect the battery ground terminal.
<Ref. to EX(D0HC TURBO)-8, REMOVAL, Center
Exhaust Pipe.>
7) Set the transmissionjack under the transmission
body.
CAUTION:
Always support transmission case with a trans-
mission jack.
MT-34
TRANSMISSION MOUNTING SYSTEM
I
2. CROSSMEMBER AND CUSHION RUB- C: INSPECTION

BER Repair or replace parts if the results of the inspec-
1) Install for rear cushion rubber. tion below are not satisfactory.
Tighfening torque: 1. PITCHING STOPPER
35 N-m (3.6 kgf-m, 26 ff-lb) Make sure that the pitching stopper is not bent or
2 ) Install the crossmember. damaged. Make sure that the rubber is not stiff,
cracked, or otherwise damaged.
Tighfening torque:
T I : 70 N.m (7.1 kgf-m, 51 ff-lb) 2. CROSSMEMBER AND CUSHION RUB-
T2: 140 N-m (14.3 kgf-m, 103 ff-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.

5) Install the front and center exhaust pipes. (Non-
turbo model)
<Ref. to EX(-S0HC)-6, INSTALLATION, Front Ex-
haust Pipe.>
MT-35
I OIL SEAL
I
5. Oil Seal 7 ) Using ST, install the oil seal.

ST 4$8057300 INSTALLER
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
2) Drain the gear oil completely.
NOTE:
Tighten the drain plug after draining gear oil.
\ B3M1982
Tightening torque:
44 N.m (4.5 kgf-m, 32.5 ff-lb) 8) Install the propeller shaft. <Ref. to DS-15, IN-
11) Pour the gear oil and check the oil level. <Ref.
to MT-26, Transmission Gear Oil.>
1 g B3M0037
3) Remove the rear exhaust pipe and muffler,

5) Remove the propeller shaft. <Ref. to DS-14, RE-
MOVAL, Propeller Shaft.>
6) Using ST, remove the oil seal.
ST 398527700 PULLER ASSY
B3M2135A
(A) Oilseal
MT-36
SWITCHES AND HARNESS
I
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-
TION SWITCH
1) Disconnect the connector battery ground termi-
nal.
AL, Air Cleaner Case.> and <Ref. to IN(S0HC)-7,
REMOVAL, Air Intake Duct.>
3) Remove the intercooler (Turbo model). <Ref. to
IN(D0HC TURBO)-I0, REMOVAL, Intercooler.>
(A) Neutral switch (Brown connector)
4) Disconnect the connector back-up light switch
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
MT-37
I SWITCHES AND HARNESS
B: INSTALLATION C: INSPECTION
1. BACK-UP LIGHT SWITCH AND NEU- 1. BACK-UP LIGHT SWITCH
TRAL POSITION SWITCH Inspect the back-up light switch. <Ref. to LI-6, IN-
1) Install the back-up light switch and neutral posi- SPECTION, Back-up Light System.>
tion switch with harness.
2. NEUTRAL POSITION SWITCH
Tightening torque: 1) Turn the ignition switch to OFF.
24.5 N.m (2.5 kgf-m, 18.1 fi-lb)
2) Disconnect the connector neutral position
switch.
3) Measure the resistance between neutral position
switch terminal.
Non-turbo model
I Gear shift position I Terminal No. I Specified resistance I
Neutral position Less than 1R
1 and2 .
Other positions More than 1MR
Gear shift position Terminal No. Specified resistance

--- (A) Neutral switch
Neutral position
1 and 3
Less than 1R
Other positions More than 1MR
(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(S0HC)-6, INSTALLA-
TION, Air Cleaner Case.> and <Ref. to IN(S0HC)-
7, INSTALLATION, Air Intake Duct.>
<Ref. to IN(D0HC TURBO)-I 1, INSTALLATION,
Intercooler.>
5 ) Connect the battery ground terminal.
Turbo model
TROlOl
4) Replace defective parts.
MT-38
VEHICLE SPEED SENSOR I
7. Vehicle Speed Sensor

A: REMOVAL
3) Remove the front and center exhaust pipes.
4) Disconnect the connector from vehicle speed
sensor.
5 ) Turn and remove the vehicle speed sensor.
-8: 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 matter.
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 ff-lb)
3) Connect the connector to vehicle speed sensor.
4) Install the front and center exhaust pipes.
5 ) Lower the vehicle.
C: INSPECTION
Inspect the vehicle speed sensor.
Non-Turbo model
<Ref. to EN(S0HC)-238, DTC PO500 - VEHICLE
SPEED SENSOR MALFUNCTION -, Diagnostic
Procedure with Diagnostic Trouble Code (DTC).>
Turbo model
<Ref. to EN(D0HC TURBO)-246, DTC PO500 -
VEHICLE SPEED SENSOR MALFUNCTION -,
Diagnostic Procedure with Diagnostic Trouble
Code (DTC).>
MT-39
I PREPARATION FOR OVERHAUL
I
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 N.m (4.5 kgf-m, 32.5 ft-lb)
3) Attach the transmission to ST.

ST 499937100 TRANSMISSION STAND
j 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) Gaskets, 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
I
2j Remove the bearing cone from the extension

9. Transfer Case and Extension case assemblv, and install to taper roller bearing of
Case Assembly the transfer d h e n gear.
A: REMOVAL
1) Remove the manual transmission assembly
from vehicle. <Ref. to MT-27, REMOVAL, Manual
Transmission Assembly.>
2) Remove the back-up light switch and neutral po-
sition switch. <Ref. to MT-37, REMOVAL, Switches
and Harness.>
3) Remove the transfer case with extension case
assembly.
(A) Bearing cone (Extensioncase)

(B) Extension case
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.
4) Remove the shifter arm.

5) Remove the extension case assembly.
5 ) Measure the depth “X’.

NOTE:
Measure with bearing cone and thrust washer re-
B3M1374 I moved.
B INSTALLATION
1) Install the center differential and transfer driven
gear into transfer case.
6) Calculate space “t” using the following equation:

t = X - W + 0.2 to 0.3 mm (0.008 to 0.012 in)
MT-41
TRANSFER CASE AND EXTENSION CASE ASSEMBLY
I
7) Select the nearest washer in the following table: 10) Measure the depth “T” between extension case
and transfer drive gear.
-
Standard clearance between thrust washer and
taper roller bearing: ST 398643600 GAUGE
0.2 - 0.3 mm T (0.008 - 0.012 in T)
NOTE:
T: Tight
I Thrust washer (50 x 61 x t) I
I Part No. I Thickness” (in) I
803050060 0.50 (0.01 97)
803050061 0.55 (0.0217)
803050062 0.60 (0.0236)
803050063 0.65 (0.0256) 3951
I 803050064 I 0.70 (0.0276) I 11) Calculate the space “U” using the following
803050065
equation: U = S - T
12) Select the suitable washer in the following ta-
803050067 ble:
Standard clearance:
I. 803050070 I 1.OO (0.0394) -10.15 - 0.35 mm (0.0059 - 0.0138 in)
803050071 1.05 (0.041 3) I Thrust washer I
803050072 1.10 (0.0433) Part No. Thickness mm (in)
803050073 1.15 (0.0453) 803036050 0.9 (0.035)
803050074 1.20 (0.0472) 803036054 1.O (0.039)
803050075 1.25 (0.0492) 803036051 1.1 (0.043)
803050076 1.30 (0.0512) 803036055 1.2 (0.047)
I 803050077 I 1.35 (0.0531) 1 803036052 1.3 (0.051)
803050078 1.40 (0.0551) I 803036056 I 1.4 (0.055) ~ -1
803050079 1.45 (0.0571) 803036053 1.5 (0.059)
803036057 1.6 (0.063)
803036058 1.7 (0.067)
407A
-
MT-42
I TRANSFER CASE AND EXTENSION CASE ASSEMBLY I
16) Install the extension assembly into the transfer C: DISASSEMBLY

case.
1. TRANSFER CASE
Tightening torque:
40N.m (4.1 kgf-m, 29.7 ff-lb) 1) Remove the reverse check assembly. <Ref. to
MT-50, REMOVAL, Reverse Check Sleeve.>
r 2) Remove the oil guide.
B3M 1374
17) Install the shifter arm to the transfer case. 83M1378

I
2. EXTENSION CASE
1) Remove the transfer drive gear assembly. <Ref.
to MT-45, REMOVAL, Transfer Drive Gear.>
2) Remove the shift bracket.
- w
B3M1396
18) Hang the shifter arm on the 3rd-4th fork rod.
B3M1381
3) Remove the oil seal from the extension case.

<Ref. to MT-36, OIL SEAL, .>
I B3M1397B I
19) Install the transfer case with extension case as-
sembly to the transmission case.
Tightening torque:
25N-m (2.5 kgf-m, 18.1 ff-lb)
/ B3M 1373
MT-43
I TRANSFER CASE AND EXTENSION CASE ASSEMBLY
D: ASSEMBLY
1. EXTENSION CASE
1) Using ST, install the oil seal to the extension
case. <Ref. to MT-36, Oil Seal.>
CAUTION:
Use new oil seal.
2) Install the shift bracket to the extension case.
Tightening torque:
25 N-m (2.5 kgf-m, 18.1 ff-lb)
3) Install the transfer drive gear to the extension

case. <Ref. to MT-45, INSTALLATION, Transfer
Drive Gear.>
2. TRANSFER CASE
1) Install the oil guide to the transfer case.
Tightening torque:
6.4 Nom(0.65 kgf-m, 4.7 ff-lb)
B3M137E
2) Install the reverse check sleeve assembly to the

transfer case. <Ref. to MT-50, INSTALLATION,
Reverse Check Sleeve.>
MT-44
TRANSFER DRIVE GEAR I
1O.Transfer Drive Gear C: DISASSEMBLY

1) Remove the snap ring.
A: REMOVAL
@
from vehicle. <Ref. to MT-27, REMOVAL, Manual C
and Harness.>
3) Remove the transfer case with extension case C
assembly. <Ref. to MT-41, REMOVAL, Transfer
Case and Extension Case Assembly.>
4) Remove the extension case assembly. B3M 198E
5) Remove the transfer driven gear.
2) Remove the ball bearing.
6) Remove the transfer drive gear.
B3M1986
INSTALLATION D: ASSEMBLY
1) Set the ST applying to inner race of bearing and
1) Install the transfer drive gear.
instal to drive shaft.
Tightening torque: ST 398177700 INSTALLER
26 N.m (2.7 kgf-m, 20 fi-lb) CAUTION:
Do not apply pressure in excess of 10 kN (1 ton,
1.1 US ton, 1.O Imp ton)
B3M198E
2) Install the transfer driven gear.

3) Install the extension case assembly.
4) Install the transfer case and extension case as- 2) Install the snap ring on transfer drive shaft.
sembly. <Ref. to MT-41, INSTALLATION, Transfer 3) Inspect the clearance between snap ring and in-
Case and Extension Case Assembly.> ner race of ball bearing. <Ref. to MT-46, INSPEC-
5 ) Install the back-up light switch and neutral posi- TION, Transfer Drive Gear.>
tion switch. <Ref. to MT-38, INSTALLATION,
Switches and Harness.>
6) Install the manual transmission assembly from
vehicle. <Ref. to MT-30, INSTALLATION, Manual
MT-45
I TRANSFER DRIVE GEAR
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:
0.0 1 - 0.15 mm (0.0004 - 0.0059 in)
B3M1991
If the measurement is not within the specification,

select suitable snap ring.
I Snap ring (Outer-30) I
805030041 1.53 (0.0602)
805030042 1.65 (0.0650)
805030043 1.77 (0.0697)
MT-46
TRANSFER DRIVEN GEAR I
11.Transfer Driven Gear B: INSTALLATION

1) Install the bearing cup to extension case and
A: REMOVAL transfer case.
and Harness.>
4) Remove the extension case assembly.
5) Remove the transfer driven gear.
6) Remove the bearing cup from extension case

and transfer-case. (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.<Ref. to MT-41, INSTALLATION, Transfer
4) Install the back-up light switch and neutral posi-
5) Install the manual transmission assembly to ve-
(A) Bearing cup (transfer case) hicle. <Ref. to MT-30, INSTALLATION, Manual
(B) Bearing cup (extension case) Transmission Assembly.>
MT-47
I TRANSFER DRIVEN GEAR
C: DISASSEMBLY D: ASSEMBLY
1) Using ST, remove the roller bearing (extension 1) Using ST, install the roller bearing (extension
case side). case side).
ST 498077000 REMOVER ST1 398177700 INSTALLER
ST2 899864100 REMOVER
CAUTION:
1.1 US ton, 1.0 Imp ton)
(A) Roller bearing
2) Using ST1 and ST2, remove the roller be&,ing

(transfer case side).
ST1 498077000 REMOVER
sJ2 899864100 REMOVER (A) Roller bearing
2) Using ST, install the roller bearing (transfer case

side).
CAUTION:
1.1 US ton, 1.O Imp ton)
(A) Roller bearing
(A) Roller bearing
E: INSPECTION
1) Bearings
Replace the bearings in the following cases:
Worn or damaged
2) Driven gear
Replace drive gear in the following cases:
If their tooth surfaces and shaft are excessively
broken or damaged.
MT-48
CENTER DIFFERENTIAL I
12.Center Differential C: DISASSEMBLY

NOTE:
A: REMOVAL Do not disassemble center differential because it is
1) Remove the manual transmission assembly a non-disassemble part.
Transmission Assembly.> Remove ball bearing using ST.
2) Remove the transfer case with extension case CAUTION:
assembly.<Ref. to MT-41, REMOVAL, Transfer Do not reuse ball bearing.
Case and Extension Case Assembly.> ST 498077300 CENTER DIFFERENTIAL
3) Remove the extension case assembly. <Ref. to BEARING REMOVER
MT-41, REMOVAL, Transfer Case and Extension 1
Case Assembly.>
4) Remove the transfer driven gear. <Ref. to MT-
47, REMOVAL, Transfer Driven Gear.>
5) Remove the center differential.
B: INSTALLATION
1) Install the center differential into transfer case.
2) Install the transfer driven gear. <Ref. to MT-47,
INSTALLATION, Transfer Driven Gear.>
3) Install the extension case assembly. <Ref. to
“MT-41, INSTALLATION,Transfer Case and Exten-
sion Case Assembly.> D: ASSEMBLY
4) Install the transfer case with extension case as- Install the ball bearing to center differential assem-
sembly. <Ref. to MT-41, REMOVAL, Transfer bly.
Case and Extension Case Assembly.> CAUTION:
5) Install the back-up light switch and neutral posi- Do not apply pressure in excess of 10 kN (1 ton,
tion switch. <Ref. to MT-37, REMOVAL, Switches 1.1 US ton, 1.O Imp ton).
and Harness.>
I
hicle. <Ref. to MT-30, INSTALLATION, Manual
B3M13998
(A) Ball bearing
E: INSPECTION
1) Bearings
Worn or damaged
Bearings having other defects
2) Center differential
Replace the center differential assembly in the fol-
lowing case:
Worn or damaged
MT-49
I REVERSE CHECK SLEEVE
I
13.Reverse Check Sleeve B: INSTALLATION

1) Install the reverse check sleeve.
A: REMOVAL
1) Remove the manual transmission assembly Tightening torque:
from vehicle. <Ref. to MT-27, REMOVAL, Manual 6.4 N-m (0.65 kgf-m, 4.7 ff-16)
3) Remove the shifter arm.
4) Remove the plug, spring washer and reverse
check ball.
B3M 1377 I
2) Install the ball, spring, washer and plug to trans-

fer case.
Tightening torque:
10 N-m (1.0 kgf-m, 7.2 ff-16)
5) Remove the reverse check sleeve.
3) Install the shifter arm to transfer case assembly.

I
. .
B3M1377 I
sembly. <Ref. to MT-41, INSTALLATION,Transfer
MT-50
REVERSE CHECK SLEEVE I
1) Cover the reverse check sleeve with a rag, and 1) Install the return spring (lst-2nd), return spring
remove snap ring using a screwdriver. cap, reverse accent shaft, check cam, return spring
NOTE: and check spring onto reverse check sleeve.
Replace the snap ring with a new one if deformed NOTE:
or weakened. Be sure the bent section of reverse check spring is
positioned in the groove in check cam.
B3M1383C
I B3M 1384A
(A) Snap ring
(A) Reverse check spring
2) Remove the reverse check plate, reverse check (B) Reverse check cam
‘spring, reverse check cam, return spring (5th-Rev), (C) Return spring (5th-Rev)
reverse accent shaft, return spring cap and return
(D) Reverse accent shaft
spring (1st-2nd).
(E) Return spring cap
I 1 (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.
I B3M1384A I
(A) Reverse check plate
(8) 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:
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.
MT-51
I REVERSE CHECK SLEEVE
E: INSPECTION F: ADJUSTMENT
Make sure the cutout section of reverse accent
shaft is aligned with the opening in reverse check 1. NEUTRAL POSITION ADJUSTMENT
sleeve. 1) Shift the gear into 3rd gear position.
Spin cam by hand for smooth rotation. 2) Shifter arm turns lightly toward the lst/2nd gear
Move cam and shaft all the way toward plate and side but heavily toward the reverse gear side be-
release. cause of the function of the return spring, until arm
If the cam does not return properly, replace reverse contacts the stopper.
check spring; if the shaft does not, check for 3) Make adjustment so that the heavy stroke (re-
scratches on the inner surface of sleeve. If the verse side) is a little more than the light stroke (lst/
sleeve is in good order, replace spring. 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:
r. - , B3M0048D
When the shim is removed, the neutral position
will move closer to reverse; when the shim is add-
(A) Snap ring ed, the neutral position will move closer to 1st gear.
If the shims alone cannot adjust the clearance,
(6) Reverse check plate
(C) Check spring
replace the reverse accent shaft and re-adjust.
(D) Checkcam
Select a suitable reverse accent shaft and re- Part No. Thickness mm (in)
verse check plate.<Ref. to MT-52, ADJUSTMENT, I 32190AA000 I 0.15 (0.0059) I
Reverse Check Sleeve.> I 32190AA010 I 0.30 (0.0118) I

Neutral position is closer to 1st
32188AA090 3
gear.
-
I 32188AA100 I 0 1 Standard I
1 32188AA110 I 1 I Neutral position is closer to
reverse aear. I
MT-52
REVERSE CHECK SLEEVE I
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 properly, replace reverse check
plate.
Reverse check plate I
I Part No. (A):
No.
Angle
0
Remarks
Arm stops closer to

32189AA000 0 280
5th gear.
Arm stops closer to
32189AA010 1 310
5th gear.
Arm stops in the cen-
32 189AA020 2 340
ter.
Arm stops closer to
32189AA030 3 370
reverse gear.
Arm stops closer to
32 189AA040 4 400
reverse gear.
B3M00540
MT-53
I TRANSMISSION CASE I
14.Transmission Case 7) Separate the transmission case into the right

and left cases by loosening coupling bolts and nuts.
A: REMOVAL
2) Remove the clutch release lever. <Ref. to CL-
15, REMOVAL, Release Bearing and Lever.>
4) Remove the bearing mounting bolts.
1 03M 1359
8) Remove the drive pinion shaft assembly from left

side transmission case.
NOTE:
Use a hammer handle, etc. to remove if too tight.
5 ) Remove the main shaft rear plate.
(A) Main shaft assembly

(B) Drive pinion shaft assembly
9) Remove the main shaft assembly.
10) Remove the differential assembly.
I I S3M0100C 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 the right and Be careful not to damage retainer oil seal.
left axle drive shafts to prevent damage to oil seal.
I I I \\ \
B3M14050
(A) Vinyl tape
MT-54
TRANSMISSION CASE
I
B: INSTALLATION 8) Backlash adjustment of hypoid gear and preload

1) Wipe off grease, oil and dust on the mating sur- adjustment of roller bearing
faces of transmission cases with white gasoline. NOTE:
2) Install the front differential assembly. Support the drive pinion assembly with ST. (AWD
3) Install the main shaft assembly. model)
Install the needle bearing knock pin hole into trans- ST 4984271 00 STOPPER
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. L - I
B3M1362A
NOTE:
Insert the bolts from the bottom and tighten nuts 9) Place the transmission with case left side facing
at the top. downward and put ST1 on bearing cup.
- 0 - Put the cases together so that the drive pinion
10) Screw the retainer assembly into left case from
shim and input shaft holder shim are not caught up the bottom with ST2. Fit ST3 on the transmission
in between. main shaft. Shift gear into 4th or 5th and turn the
Confirm that speedometer gear is meshed. shaft several times. Screw in the retainer while
turning ST3 until a slight resistance is felt on ST2.
Tightening torque: This is the contact point of hypoid gear and drive
8 mm bolt pinion shaft. Repeat the above sequence several
25 Nom(2.5 kgf-m, 18.1 ft-16) times to ensure the contact point.
*10 mm bolt
39 N.m (4.0 kgf-m, 28.9 ft-lb)
ST1 399780104 WEIGHT
ST2 499787000 WRENCH ASSY
ST3 4999271 00 HANDLE
03M1361A
7) Tighten the ball bearing attachment bolts.
Tightening torque:
29 N-m (3.0 kgf-m, 21.7 ft-16)
MT-55
I TRANSMISSION CASE
11) Remove weight and screw in retainer without 17) After checking the tooth contact of hypoid
O-ring on the upper side and stop at the point gears, remove the lock plate. Then loosen the re-
where slight resistance is felt. tainer until the O-ring groove appears. Fit O-ring
NOTE: into the groove and tighten the retainer into the po-
At this point, the backlash between the hypoid gear sition where retainer has been tightened in.
and drive pinion shaft is zero. Tighten the lock plate.
ST 499787000 WRENCH ASSY NOTE:
Carry out this job on both upper and lower retain-
ers.
Tightening torque:
T: 25 N-m (2.5 kgf-m, 18.1 fi-lb)
12) Fit lock plate. Loosen the retainer on the lower

side by 1-112 notches of lock plate and turn in the
6tainer on the upper side by the same amount in
order to obtain the backlash. S3M0014C
NOTE: 18) Selecting of main shaft rear plate <Ref. to MT-

The notch on the lock plate moves by 1/2 notch if 62, ADJUSTMENT, Main Shaft Assembly for Sin-
the plate is turned upside down. gle-Range.>
13) Turn in the retainer on the upper side addtion- 19) Install the clutch release lever and bearing.
ally by 1 notch in order to apply preload on taper <Ref. to CL-15, INSTALLATION, Release Bearing
roller bearing. and Lever.>
14) Tighten temporarily both the upper and lower 20) Install the transfer case with extension case as-
lock plates and mark both holder and lock plate for sembly. <Ref. to MT-41, INSTALLATION, Transfer
later readjustment. Case and Extension Case Assembly.>
15) Turn the transmission main shaft several times 21) Install the manual transmission assembly into
while tapping around retainer lightly with plastic the vehicle.<Ref. to MT-30, INSTALLATION, Man-
hammer. ual Transmission Assembly.>
16) Inspect and adjust backlash and tooth contact C: INSPECTION
of hypoid gear. <Ref. to MT-74, INSPECTION,
Front Differential Assembly.> Check the transmission case for cracks, damage,
and oil leaks.
MT-56
MAIN SHAFT ASSEMBLY FOR SINGLE-RANGE
I
15.Main Shaft Assembly for Sin- C: DISASSEMBLY

1) Put the vinyl tape around main shaft splines to
gle-Range protet oil seal from damage. Then pull out the oil
A: REMOVAL seal and needle bearing by hand.
1) Remove the manual transmission assembly 2) Remove the lock nut from transmission main
from vehicle. <Ref. to MT-27, REMOVAL, Manual shaft assembly.
Transmission Assembly.> NOTE:
2) Remove the transfer case with extension case Remove the caulking before off lock nut.
assembly. <Ref. to MT-41, REMOVAL, Transfer ST1 499987000 TRANSMISSION HOLDER
Case and Extension Case Assembly.> ST2 498937003 SOCKET WRENCH (35)
3) Remove the transmission case. <Ref. to MT-41,
REMOVAL, Transfer Case and Extension Case
Assembly.>
4) Remove the drive pinion shaft assembly. <Ref.
to MT-63, REMOVAL, Drive Pinion Shaft Assem-
bly.>
B: INSTALLATION
1) Install the needle bearing and oil seal onto the
front of transmission main shaft assembly.
r.
CAUTION:
Wrap clutch splined section with vinyl tape to 3) Remove the 5th-Rev sleeve and hub assembly,
prevent damage to oil seal. baulk ring, 5th drive gear and needle bearing.
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.
I
A// / 03MQ4378
(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.
B3M0528A
3) Install the drive pinion assembly. <Ref. to MT-63,

INSTALLATION, Drive Pinion Shaft Assembly.>
4) Install the transmission case. <Ref. to MT-55, IN-
STALLATION, Transmission Case.>
sembly. <Ref. to MT-41, INSTALLATION, Transfer
6) Install the manual transmission assembly to ve- w B3M0435E
Transmission Assembly.> (A) Synchro cone stopper
(B) Snap ring
MT-57
I MAIN SHAFT ASSEMBLY FOR SINGLE-RANGE
5) Using ST1, ST2 and a press, remove the ball 6) Using ST1 and ST2, remove the rest of parts.
bearing, synchro cone and baulk ring (Rev). NOTE:
NOTE: Replace sleeve and hub with new ones. Do not at-
Replace the sleeve and hub with new ones. Do tempt to disassemble because they must engage
not attempt to disassemble because they must en- at a specified point. If they should be disassem-
gage at a specified point. If they should be disas- bled, marking engagement point on splines before-
sembled, mark engagement point on the splines hand.
beforehand. ST1 899864100 REMOVER
Do not reuse the ball bearing. ST2 8997141 10 REMOVER
ST1 499757002 INSTALLER
ST2 498077400 SYNCHRO CONE REMOV- Press
ER n
fl
(A) Ball bearing
(B) Synchro cone
(C) Baulk ring
03MQ035A
MT-58
I
D: ASSEMBLY 3) Install the 4th needle bearing race onto transmis-

1) Assemble each sleeve and hub assembly. sion main shaft using ST1, ST2 and a press.
NOTE: CAUTION:
Position open ends of spring 120" apart. Do not apply pressure in excess of 10 kN (1 ton,
1.1 US ton, 1.0 Imp ton).
3rd-4th hub ASSY ST1 8997141 10 REMOVER
ST2 499877000 RACE 4-5 INSTALLER
3rd gear
5th-Rev hub ASSY
- vyY//-'/ B3M0543C
(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 & hub assembly with
B3M1366A
key groove.
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.
S3M0045P
(A) Groove
7 d-r- (B) 4th gear side
(A) 3rd needle bearing

(B) 3rd drive gear
(C) Inner baulk ring
(D) Synchro cone
(E) Outer baulk ring
(F) Sleeve and hub ASSY
MT-59
5) Drive the ball bearing onto the rear section of 7) Install the bearing onto synchro cone.
transmission main shaft using ST1, ST2 and a 8) Install the baulk ring and synchro cone onto 5th-
press. Rev sleeve and hub assembly using ST and a
CAUTION: press.
Do not apply pressure in excess of 10 kN (1 ton, CAUTION:
1.1 US ton, 1.O Imp ton). Do not apply pressure in excess of 10 kN (1 ton,
ST1 8997141 10 REMOVER 1.1 US ton, 1.0 Imp ton).
ST2 499877000 RACE 4-5 INSTALLER NOTE:
Use new ball bearing.
After press fitting, make sure synchro cone ro-
tates freely.
6) Using ST1 and ST2, install the 5th gear thrus

iasher 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, (A) Baulk ring
1.1 US ton, 1.O Imp ton).
(B) Synchro cone
NOTE: (C) Ball bearing
Face the thrust washer in the correct direction.
ST1 8997141 10 REMOVER 9) Install the synchro cone stopper and snap ring to
ST2 499877000 RACE 4-5 INSTALLER 5th-Rev sleeve and hub assembly.
B3M0091D u B3M04358
(A) Face this surface to 5th gear side. (A) Synchro cone stopper
(B) Snap ring
MT-60
1
10) Install the rest parts to the rear section of trans- E: INSPECTION
mission main shaft. Disassembled parts should be washed clean first
NOTE: and then inspected carefully.
Align the groove in baulk ring with shifting insert. 1) Bearings
Bearings whose balls, outer races and inner rac-
es are broken or rusty.
Worn bearings
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.
(A) Needle bearing 3) Gears
(B) 5th drive gear Replace the gears with new ones if their tooth
(C) Baulk ring surfaces are broken, damaged, or excessively
(D) 5th-Rev sleeve and hub ASSY worn.
r. (E) Lock washer Correct or replace if the cone that contacts the
(F) Lock nuts baulk ring is rough or damaged.
Correct or replace if the inner surface or end face
11) Tighten the lock nuts to the specified torque us- is damaged.
ing ST1 and ST2. 4) Baulk ring
NOTE: Replace the ring in the following cases:
Secure the lock nuts in two places after tightening. When the inner surface and end face are dam-
ST1 499987003 SOCKET WRENCH aged.
ST2 498937000 TRANSMISSION HOLDER When the ring inner surface is abnormally or par-
tially worn down.
Tightening torque: When the contact surface of the synchronizer
118 N.m (12.0 kgf-m, 86.8 ff-lb) 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.
MT-61
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
~ _ _ _ _~
Dimension (A)
Part No. Mark
mm (in)
4.00 - 4.13
I
e*
(0.1575 -
0.1626)
3.87- 3.99
I 32294AA041 I 1
(0.1524 - 32294AA051 2
0.1571)
MT-62
DRIVE PINION SHAFT ASSEMBLY 3
16.Drive Pinion Shaft Assembly 4) Inspection and adjustment of ST

NOTE:
A: REMOVAL Loosen the two bolts and adjust so that the scale
1) Remove the manual transmission assembly indicates 0.5 correctly when the plate end and the
from vehicle. <Ref. to MT-27, REMOVAL, Manual scale end are on the same level.
Transmission Assembly.> Tighten the two bolts.
2) Remove the transfer case with extension case ST 499917500 DRIVE PINION GAUGE
assembly. <Ref. to MT-41, REMOVAL, Transfer ASSY
3) Remove transmission case. <Ref. to MT-54, RE-
MOVAL, Transmission Case.>
4) Remove the drive pinion shaft assembly.
NOTE:
Use a hammer handle, etc. to remove if too tight.
*- (A) Plate
(B) Scale
5 ) Position the ST by inserting the knock pin of ST

into the knock hole in the transmission case.
ST 49991 7500 DRIVE PINION GAUGE
ASSY
(A) Main shaft assembly
6) Slide the drive pinion gauge scale with finger tip
(B) Drive pinion shaft assembly
and read the value at the point where it matches
with the end face of drive pinion.
B: INSTALLATION ST 499917500 DRIVE PINION GAUGE
1) Remove the differential assembly. ASSY
2) Alignment markshumbers 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.
11. B3M0065C I
(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 ST. (Add if the number on
G3M0554 drive pinion is prefixed by + and subtract if the num-
ber is prefixed by -.)
3) Place the drive pinion shaft assembly on right
ST 499917500 DRIVE PINION GAUGE
hand transmission main case without shim and
ASSY
tighten the bearing mounting bolts.
MT-63
I DRIVE PINION SHAFT ASSEMBLY
I
8) Select one to three shims from the next table for C: DISASSEMBLY
the value determined as described above and take
a shim thickness which is closest to the said value. CAUTION:
Attach a cloth to the end of driven shaft (on the
frictional side of thrust needle bearing) during
Part No. Thickness mm (in) disassembly or reassembly to prevent damage.
I 32295AA031 I 0.1 50 (0.0059) 1) Straighten the lock nut at staked portion. Re-
I 32295AA041 I 0.175 (0.0069) move the lock nut using S T l , ST2 and ST3.
32295AA051 0.200 (0.0079) ST1 899884100 HOLDER
32295AA061 0.225 (0.0089) ST2 4984271 00 STOPPER
32295AA071 0.250 (0.0098) ST3 899988608 SOCKET WRENCH (27)
32295AA081 0.275 (0.0108)
I 32295AA091 I 0.300 (0.0118)
I 32295AA101 I 0.500 (0.0197)
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 G3M0595
and reverse driven gear are positioned in the cen- 2) Withdraw the drive pinion from driven shaft.
ter of their cynchronizing mechanisms. <Ref. to
Remove the differential bevel gear sleeve, adjust-
MT-68, INSPECTION, Drive Pinion Shaft Assem-
ing washer No. 1, adjusting washer No. 2, thrust
bly.> bearing, needle bearing, drive pinion collar, needle
11) Install the transmission case. <Ref. to MT-55, bearing and thrust bearing.
INSTALLATION, Transmission Case.>
hicle.<Ref. to MT-27, Manual Transmission As-
sembly.>
Differential bevel gear sleeve

Washer No. 1 (25 x 37.5 x t)
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)
MT-64
DRIVE PINION SHAFT ASSEMBLY
I
3) Remove the roller bearing and washer using ST 7) Remove the roller bearing, 3rd-4th driven gear
and press. using ST1 and ST2.
CAUTION: ST1 499757002 INSTALLER
Do not reuse roller bearing. ST2 8997141 10 REMOVER
ST 498077000 REMOVER
I
G3M060; 8) Remove the key.

9) Remove the 2nd driven gear, inner baulk ring,
4) Straighten the lock nut at staked portion. Re-
synchro cone and outer baulk ring.
move the lock nut using ST1 and ST2.
ST1 499987300 SOCKET WRENCH (50)
ST2 899884100 HOLDER
c.
(A) 2nd driven gear

(B) Inner baulk ring
5) Remove the 5th driven gear using ST. (C) Synchro cone
ST 499857000 5TH DRIVEN GEAR REMOV- (D) Outer baulk ring
ER
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.
STl 499757002 INSTALLER
ST2 8997141 10 REMOVER
6) Remove the woodruff key.
G3M0611
MT-65
11) Remove the sub gear for 1st driven gear. ST1 499277200 INSTALLER
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.
5) Install the 2nd driven gear, inner baulk ring, syn-

chro cone, outer baulk ring and insert onto driven
shaft.
B3M0077E n n
(A) 1st gear side
-+ (B) 2nd gear side
(C) Flush surface
(D) Stepped surface
2) Install the washer, snap ring and sub gear to 1st

driven gear. ( ) ( S3M0445A
3) Install the 1st driven gear, 1st baulk ring, gear
and hub assembly onto driven shaft.
(A) 2nd driven gear
NOTE: (B) Inner baulk ring
Take care to install gear and hub assembly in (C) Synchro cone
proper direction. (D) Outer baulk ring
Align the baulk ring and gear & hub assembly
with key groove. 6) After installing key on driven shaft, install the
4) Install the 2nd driven gear bushing onto driven 3rd-4th driven gear using ST and press.
shaft using ST1, ST2 and press. CAUTION:
CAUTION: Do not apply pressure in excess of 10 kN (1 ton,
Attach a cloth to the end of driven shaft to 1.1 US ton, 1.0 Imp ton).
prevent damage. NOTE:
Do not apply pressure in excess of 10 kN (1 Align the groove in baulk ring with insert.
ton, 1.1 US ton, 1.0 Imp ton). ST 499277200 INSTALLER
NOTE:
When press fitting, align the oil holes of shaft and
bush.
G3M061.5
MT-66
DRIVE PINION SHAFT ASSEMBLY il
7) Install a set of roller bearings onto the driven NOTE:

shaft using ST and press. Stake the lock nut at two points.
CAUTION: Using spring balancer, check that starting torque
Do not apply pressure in excess of 10 kN (1 ton, of roller bearing is 0.1 to 1.5 N (0.01 to 0.15 kgf,
1.1 US ton, 1.O Imp ton). 0.02 to 0.33ft).
I I
G3M0616 10) Install the roller bearing onto drive pinion.

8) Position the woodruff key in groove on the rear of NOTE:
driven shaft. Install 5th driven gear onto drive shaft When installing roller bearing, note its directions
using ST and press. (front and rear) because the knock pin hole in outer
r.
CAUTION: race is offset.

1.1 US ton, 1.O Imp ton).
' \
(B) B3M1661A
(A) Roller bearing

(B) Knock pin hole
G3M0617
9) Install the lock washer. Install lock nut and tight- 11) Install the washer using STI, ST2 and press.
en to the specified torque using ST. CAUTION:
ST 499987300 SOCKET WRENCH (50) Discard old lock nuts, replace with new ones.
Tightening torque: Secure lock nut in four places.
265 N.m (27 kgf-m, 195 ff-lb) STI 4992771 00 BUSH 1-2 INSTALLER
I .
(A) Washer
MT-67
12) Install the thrust bearing and needle bearing. The ball bearing on the rear side of the drive pin-
Install the driven shaft assembly. 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
r-:-- bearing, its rotation feels like it is slightly dragging

unlike the other bearings.
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
B3M0038E
that order.
NOTE: (A) Drive pinion shaft
Be careful because the spacer must be installed in (B) Ball bearing
proper direction.
r- - I
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
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
(A) Driven shaft is damaged.
(B) Drive shaft 4) Baulk ring
(C) Drive pinion collar Replace the ring in the following cases:
(D) Needle bearing (25 x 30 x 20) When the inner surface and end face are dam-
(E) Washer No. 2 (25 x 36 x 4) aged.
(F) Thrust bearing (25 x 37.5 x 3) When the ring inner surface is abnormally or par-
(G) Washer No. 1 (25 x 36 x t) tially worn down.
(H) Differential bevel gear sleeve
If the gap between the end faces of the ring and
the gear splined part is excessively small when the
E: INSPECTION ring is pressed against the cone.
Disassembled parts should be washed clean first Clearance (A):
and then inspected carefully. 0.5 - 1.0 mm (0.020 - 0.040 in)
1) Bearings
Replace bearings in the following cases:
Bearings whose balls, outer races and inner rac-
es are broken or rusty.
Worn bearings
/I \

I
S3M0188A
MT-68
DRIVE PINION SHAFT ASSEMBLY I
When the contact surface of the synchronizer 2) Using ST1, ST2 and ST3, tighten the lock nut to
ring insert is scored or abnormally worn down. the specified torque.
5) Shifting insert key ST1 899884100 HOLDER
Replace the insert if deformed, excessively worn, ST2 498427100 STOPPER
or defective in any way. ST3 899988608 SOCKET WRENCH (27)
7- I Tightening torque:
118 N.m (12 kgf-m, 86.8 ft-16)
6) Oil seal
Replace the oil seal if the lip is deformed, hard- G3M0626
ened, damaged, worn, or defective in any way.
3) After removing ST2, measure the starting torque
7) O-ring
using torque driver.
&place the O-ring if the sealing face is deformed,
ST1 899884100 HOLDER
hardened, damaged, worn, or defective in any way.
ST3 899988608 SOCKET WRENCH (27)
F: ADJUSTMENT Starting torque:
1. THRUST BEARING PRELOAD 0.3 - 0.8 N-m
(0.03 - 0.08 kgf-m, 0.2 - 0.6 ft-16)
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).
4) If starting torque is not within specified limit, se-

lect new adjusting washer No. 1 and recheck start-
ing torque.
\-,
B3M05361
(A) Adjusting washer No.1

(B) Adjusting washer No.2
MT-69
DRIVE PINION SHAFT ASSEMBLY
I
I Adjusting washer No. 1 I

Part No.
803025052 3.950 (0.1555)
803025055 4.025 (0.1585)

803025056 4.050 (0.1594)
803025057 4.075 (0.1604)
I B3M05361
(A) Adjusting washer No. 1

(B) Adjusting washer No. 2
I Starting torque I Dimension H I Washer No. 2 1

I Low I Small I Select thicker one. I
I Part No. I Thickness mm

I 803025059 I 3.850 (0.1516) I
803025054 4.000 (0.1575)
803025058 4.150 (0.1634)
MT-70
FRONT DIFFERENTIAL ASSEMBLY
1
17.Front Differential Assembly B: INSTALLATION

1) Install the differential side retainers using ST.
A: REMOVAL ST 499787000 WRENCH ASSY
1) Remove the manual transmission assembly 2) Install the differential assembly.
Be careful not to fold the sealing lip of oil seal.
assembly. <Ref. to MT-41, REMOVAL, Transfer NOTE:
Case and Extension Case Assembly.> Wrap the left and right splines sections of axle shaft
3) Remove the transmission case. <Ref. to MT-54, with vinyl tape to prevent scratches.
REMOVAL, Transmission Case.>
4) Removes the drive pinion shaft assembly. <Ref.
bly.>
<Ref. to MT-57, REMOVAL, Main Shaft Assembly
for Single-Range.>
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. 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.>
STALLATION, Transmission Case.>
7) Remove the differential side retainers using ST.
ST 499787000 WRENCH ASSY
MT-71
I FRONT DIFFERENTIAL ASSEMBLY
C: DISASSEMBLY 4) Pull out the pinion shaft, and remove the differ-
1) Remove the right and left snap rings from differential bevel pinion and gear and washer.
ential, and then remove the two axle drive shafts.
NOTE:
During reassembly, reinstall each axle drive shaft
in the same place from which it was removed.
2) Loosen the twelve bolts and remove hypoid driv-
en gear.
(A) Pinion shaft

(B) Bevel pinion
(C) Bevel gear
(D) Washer
5) Remove the roller bearing using ST.

ST 399527700 PULLER SET
G3M0668
(A) Snap ring D: ASSEMBLY

(B) Axle drive shaft
1) Install the bevel gear and bevel pinion together
(C) Hypoid driven gear with washers, and insert pinion shaft.
3) Drive out the straight pin from differential assem- NOTE:
bly toward hypoid driven gear. Face the chamfered side of washer toward gear.
+I
A'L G3M0667
(A) Bevel pinion
(B) Bevel gear
(C) Pinion shaft
MT-72
FRONT DIFFERENTIAL ASSEMBLY 1
2) Measure the backlash between bevel gear and 4) Install the roller bearing to differential case.
pinion. If it is not within specifications, install a suit- CAUTION:
able washer to adjust it. <Ref. to MT-75, ADJUST- Do not apply pressure in excess of 10 kN (1 ton,
MENT, Front Differential Assembly.> 1.1 US ton, 1.O Imp ton).
NOTE: NOTE:
Be sure the pinion gear tooth contacts adjacent Be careful because roller bearing outer races are
gear teeth during measurement. used as a set.
STl 498247001 MAGNET BASE STl 499277100 BUSH 1-2 INSTALLER
ST2 4982471 00 DIAL GAUGE ST2 398497701 ADAPTER
Standard backlash:
0.73 - 0.78 mm (0.0057 - 0.0077 in)
I I
\- / I
I ST2 y
G3M0671
5) Install the hypoid driven gear to differential case

G3M0670 using twelve bolts.
3) Align the pinion shaft and differential case at Tightening torque:
their holes, and drive straight pin into holes from T: 62 N.m (6.3 kgf-m, 45.6 ft-lb)
the hypoid driven gear side, using ST.
I
NOTE:
Lock the straight pin after installing.
. .
B3M0554C
(A) Hypoid driven gear

(B) Differential case
B3M0609C
(A) Pinion shaft

(B) Differential case
(C) Straight pin
MT-73
E: INSPECTION 1. BEVEL PINION GEAR BACKLASH

Repair or replace the differential gear in the follow- Measure the backlash between bevel gear and pin-
ing cases: ion. If it is not within specifications, install a suitable
The hypoid drive gear and drive pinion shaft washer to adjust it.
tooth surface are damaged, excessively worn, or
NOTE:
seized.
Be sure the pinion gear tooth contacts adjacent
The roller bearing on the drive pinion shaft has a
gear teeth during measurement.
worn or damaged roller path.
There is damage, wear, or seizure of the differ- ST1 498247001 MAGNET BASE
ential bevel pinion, differential bevel gear, washer, ST2 498247100 DIAL GAUGE
pinion shaft, and straight pin. Standard backlash:
The differential case has worn or damaged slid-
ing surfaces.
0.13 - 0.18 mm (0.0051 - 0.0071 in)
2. HYPOID GEAR BACKLASH

Set the STI, 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.
STI 498247001 MAGNET BASE
ST2 498247100 DIAL GAUGE
ST3 498255400 PLATE
Backlash:
B3M0558C
0.13 - 0.18 mm (0.0051 - 0.0071 in)
(A) Drive pinion shaft
(6) 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) Differential case
NOTE:
If the backlash is outside specified range, adjust it
by turning holder in right side case.
MT-74
FRONT DIFFERENTIAL ASSEMBLY I
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. <Ref. to MT-75, ADJUSTMENT, Front Differ- Thickness mm (in)
Part No.
ential Assembly.>
Tooth contact is correct. I 803038021
1 0.925- 0.950
(0.0364
~~-
\ -
- 0.0374)
~~
0.975- I .OOO
I
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
(A) Toe case.
(B) Coast side
ST 499787000 WRENCH ASSY
(C) Heel I
(D) Drive side
NOTE:
Each time holder rotates one tooth, backlash
changes by 0.05 mm (0.020 in).
MT-75
3. TOOTH CONTACT OF HYPOID GEAR The drive pinion shim selected before is too thin.
Increase its thickness.
Adjust until the teeth contact is correct.
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.
B3MOQ74
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.
B3MQO72
The drive pinion shim selected before is too

thick.
Reduce its thickness.
03M0073
MT-76
SPEEDOMETER GEAR I
18.Speedometer Gear B: INSTALLATION

1) Install the washer and speedometer shaft, and
A: REMOVAL press fit oil seal with ST.
1) Remove the manual transmission assembly CAUTION:
from vehicle. <Ref. to MT-27, REMOVAL, Manual Use new oil seal, if it has been removed.
2) Remove the back-up light switch and neutral po- ST 899824100 or 499827000PRESS
sition switch. <Ref. to MT-37, REMOVAL, Switches 2) Install the vehicle speed sensor. <Ref. to MT-39,
and Harness.> INSTALLATION, Vehicle Speed Sensor.>
3) Remove the transfer case with extension case 3) Install the speedometer driven gear and snap
assembly. <Ref. to MT-41, REMOVAL, Transfer ring.
Case and Extension Case Assembly.> CAUTION:
4) Remove the transmission case. <Ref. to MT-54, Use new snap ring, if it has been removed.
5) Remove the vehicle speed sensor. <Ref. to MT-
39, REMOVAL, Vehicle Speed Sensor.>
6) Remove the outer snap ring and pull out the
speedometer driven gear. Next, remove the oil
seal, speedometer shaft and washer.
r.
/ (A) Outer snap ring

(B) Speedometer driven gear

B3M0525C STALLATION, Transmission Case.>
(A) Outer snap ring sembly. <Ref. to MT-41, INSTALLATION, Transfer
(B) Speedometer driven gear Case and Extension Case Assembly.>
hicle.<Ref. to MT-30, INSTALLATION, Manual
C: INSPECTION
Check the speedometer gear, oil seal and speed-
ometer shaft for damage. Replace if damaged.
MT-77
REVERSE IDLER GEAR
19.Reverse Idler Gear B: INSTALLATION

1) Install the reverse shifter lever, reverse idler gear
A: REMOVAL and reverse idler gear shaft, and secure with
1) Remove the manual transmission assembly straight pin.
from vehicle. <Ref. to MT-27, REMOVAL, Manual NOTE:
Transmission Assembly .> Be sure to install the reverse idler shaft from the
2) Remove the back-up light switch and neutral po- rear side.
and Harness.>
REMOVAL, Drive Pinion Shaft Assembly.>
5) Remove the drive pinion shaft assembly. <Ref.
bly.>
6) Remove the main shaft assembly. M0526C
for Single-Range.> (A) Reverse shifter lever
7) Remove the differential assembly. <Ref. to MT- (B) Reverse idler gear
A , REMOVAL, Front Differential Assembly.>
(C) Reverse idler gear shaft
8) Remove the shifter forks and rods. <Ref. to MT-
(D) Straight pin
80, REMOVAL, Shifter Fork and Rod.>
9) Pull out the straight pin, and remove the idler 2) Inspect and adjust the clearance between re-
gear shaft, reverse idler gear and washer. verse idler gear and transmission case wall. <Ref.
to MT-78, INSTALLATION, Reverse Idler Gear.>
and <Ref. to MT-79, ADJUSTMENT, Reverse Idler
Gear.>
3) Install the shifter forks and rods. <Ref. to MT-80,
INSTALLATION,Shifter Fork and Rod.>
4) Install the differential assembly. <Ref. to MT-71,
INSTALLATION, Front Differential Assembly.>
5) Install the main shaft assembly.
<Ref. to MT-57, INSTALLATION, Main Shaft As-
sembly for Single-Range.>
6) Install the drive pinion shaft assembly. <Ref. to
MT-63, INSTALLATION, Drive Pinion Shaft As-
(A) Straight pin sembly.>
(8) Idler gear shaft 7) Install the transmission case. <Ref. to MT-55, IN-
(C) Idler gear STALLATION, Transmission Case.>
(D) Washer 8) Install the transfer case with extension case as-
IO) Remove the reverse shifter lever. Case and Extension Case Assembly.>
IO) Install the manual transmission assembly to ve-
MT-78
REVERSE IDLER GEAR I
C: INSPECTION D: ADJUSTMENT
1) Move the reverse shifter rod toward the reverse 1) Select the appropriate reverse shifter lever from
side. Inspect the clearance between reverse idler the table below, and adjust until the gap between
gear and transmission case wall. the reverse idler gear and transmission case wall is
If out of specification, select the appropriate re- within specification.
verse shifter lever and adjust.
Clearance A:
Clearance A: 6.0 - 7.5 mm (0.236 - 0.295 in)
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-
32820AA070 7 Further from case wall
verse idler gear and transmission case wall.
If out of specification, select the appropriate washer 32820AA080 8 Standard
and adjust. 32820AA090 9 Closer to case wall
Clearance:
0 - 0.5 mm (0 - 0.020 in)
3) Check the reverse idler gear and shaft for dam-

age. Replace if damaged.

803020151 0.4 (0.016)
803020152 1.1 (0.043)
803020153 1.5 (0.059)
803020154 1.9 (0.075)
803020155 2.3 (0.091)
MT-79
I MANUAL TRANSMISSION AND DIFFERENTIAL
SHIFTER FORK AND ROD
20.Shifter Fork and Rod 10) Drive out the straight pin, and pull out 3-4 fork
rod and shifter fork.
A: REMOVAL NOTE:
1) Remove the manual transmission assembly When removing rod, keep other rods in neutral. Al-
from vehicle. <Ref. to MT-27, REMOVAL, Manual so, when pulling out straight pin, remove it toward
Transmission Assembly.> the inside of the case so that it does not hit against
2) Remove the back-up light switch and neutral po- the case.
and Harness.>
5) Removes the drive pinion shaft assembly. <Ref.
bly.>
for Single-Range.> (A) Straight pin
7) Remove the differential assembly. <Ref. to MT- (B) 3-4 fork rod
7.4,~REMOVAL, Front Differential Assembly.> (C) Shifter fork
8) Drive out the straight pin with ST, and 5th shifter
fork. 11) Drive out the straight pin, and pull out the 1-2
ST 398791700 STRAIGHT PIN REMOVER 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
B3M03331 1) Install the reverse arm fork spring, ball and inter-
lock plunger to reverse fork rod arm. Insert the re-
(A) Straight pin verse fork rod into hole in reverse fork rod arm, and
(6) 5th shifter fork hold it with outer snap ring using ST.
9) Remove the plugs, springs and checking balls. CAUTION:
Apply grease to plunger to prevent it from fall-
ing.
ST 39941 1700 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 I
4) Align the holes in rod and fork, and drive straight 9) Position the balls, checking ball springs and gas-
pin into these holes using ST. kets into 3-4 and 1-2 rod holes, and install plugs.
CAUTION: CAUTION:
Replace straight pin with a new one. Replace gasket with a new one.
NOTE:
Set other rods to neutral.
Make sure interlock plunger is on the 3-4 fork rod
side.
ST 398791700 STRAIGHT PIN REMOVER
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 33J
hole on the rear of transmission case.
7) Align the holes in rod and fork, and drive straight (A) 5th shifter fork
pin into these holes. (B) Reverse fork rod
(C) Straight pin
CAUTION:
Replace straight pin with a new one. 10) Install the differential assembly. <Ref. to MT-
** NOTE: 1
71 INSTALLATION, Front Differential Assembly.>
Set the reverse fork rod to neutral. 11) Install the main shaft assembly.
Make sure the interlock plunger (installing be- Single-range model:
fore) is on the reverse fork rod side. <Ref. to MT-57, INSTALLATION, Main Shaft As-
ST 398791700 STRAIGHT PIN REMOVER sembly for Single-Range.>
8) Install the 5th shifter fork onto the rear of reverse 12) Install the drive pinion shaft assembly. <Ref. to
fork rod. Align the holes in the two parts and drive MT-63, INSTALLATION, Drive Pinion Shaft As-
straight pin into place. sembly.>
13) Install the transmission case. <Ref. to MT-55,
CAUTION: INSTALLATION, Transmission Case.>
Replace straight pin with a new one. 14) Install the transfer case with extension case as-
ST 398791700 STRAIGHT PIN REMOVER sembly. <Ref. to MT-41, INSTALLATION, Transfer
15) Install the back-up light switch and neutral po-
( sition switch. <Ref. to MT-38, INSTALLATION,
B3M0333J
(A) 5th shifter fork

(B) Reverse fork rod
(C) Straight pin
MT-81
C: INSPECTION 4) Inspect the clearance between 3rd, 4th drive

1) Check the shift shaft and shift rod for damage. gear and coupling sleeve. If any clearance is not
Replace if damaged. within specifications, replace shifter fork as re-
2) Gearshift mechanism quired.
Repair or replace the gearshift mechanism if ex- Clearance (a) and (b):
cessively worn, bent, or defective in any way. 9.3 mm (0.366 in)
3) Inspect the clearance between lst, 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)
B3M1411A
(A) 3rd drive gear

(B) Coupling sleeve
(C) 4th drive gear
L I
I 3rd-4th shifter fork
I Part No. I Mark I Remarks
(A) 1st driven gear
(B) Reverse driven gear
I 32810AA061 I Approach to 4th gear
by 0.2 mm (0.008 in).
(C) 2nd driven gear 3281OAA071 - Standard
Become distant from
3281OAAI 01 3 3rd gear by 0.2 mm
(0.008 in).
I 32804AA060 I 1 I Approach to 1st gear

by 0.2 mm (0.008 in). I
32804AA070 - Standard
Become distant from
32804AA080 3 2nd gear by 0.2 mm
(0.008 in).
MT-82
I
5) Inspect the clearance between 5th drive gear 6) Inspect the rod end clearances (A) and (B). 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 "(0.016 - 0.055 in)
Clearance (B):
3rd - 4th to 5th:
0.5 - 1.3 "(0.020 - 0.051 in)
r
(A) 5th drive gear
S3M0191A
(B) Coupling sleeve

W
B3M0530A
-4- - 5th shifter fork (Non-turbo) I
I 32812AA201 I 4 I Approach to 5th gear
bv 0.2 mm 10.008 ink I
32812AA211 5 Standard
Become distant from
32812AA221 6 5th gear by 0.2 mm
I (0.068 in).- I
I 32812AA231 1 7 I Approach to 5th gear

by 0.2 mm (0.008 in). I
32812AA241 - Standard
Become distant from
32812AA251 9 5th gear by 0.2 mm
(0.008 in).
MT-83
I GENERAL DIAGNOSTIC
I
21 .General Diagnostic
A: INSPECTION
1. MANUAL TRANSMISSION
Symptom Possible cause ~~

Remedv
1. Gears are difficult to intermesh. (a) Worn, damaged or burred chamfer of Replace.
VOTE: internal spline of sleeve and reverse
The cause for difficulty in shifting gears driven gear
:an be classified into two kinds: one is (b) Worn, damaged or burred chamfer of Replace.
malfunction of the gear shift system and spline of gears
:he other is malfunction of the transmis- Redace.
(c) Worn or scratched bushinas
sion. However, if the operation is heavy
and engagement of the gears is difficult, (d) Incorrect contact between synchro- Correct or replace.
jefective clutch disengagement may also nizer ring and gear cone or wear
De responsible. Check whether the clutch
s correctly functioning, before checking
the gear shift system and transmission.
2. Gear slips out. (a) Defective pitching stopper adjustment Adjust.
Gear slips out when coasting on rough (b) Loose engine mounting bolts Tiahten
u or redace.
.-
road.
Gear slips out during acceleration.
(c) Worn fork shifter, broken shifter fork
rail spring
Replace.
Id) Worn or damaaed ball bearina Replace.

(e) Excessive clearance between splines Replace.
of synchronizer hub and synchronizer
sleeve
(f) Worn tooth step of synchronizer hub Replace.
(resDonsible for slipout of 3rd clear)
(9) Worn 1st driven gear, needle bearing Replace.
and race
(h) Worn 2nd driven gear, needle bearing Replace.
and race
Ii) Worn 3rd drive aear and bushinn Replace.
(i) Worn 4th drive gear and bushing Replace.
(k) Worn reverse idler gear and bushing Replace.
3. Unusual noise comes from transmis- (a) Insufficient or improper lubrication Lubricate or replace with specified oil.
sion. (b) Worn or damaged gears and bearings Replace.
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
I
2. DIFFERENTIAL
Symptom Possible cause Remedy

1 . Broken differential (case, gear, bear- (a) Insufficient or improper oil 3isassemble differential and replace bro-
ng, etc.) ten components and at the same time
VOTE: :heck other components for any trouble,
4bnormal noise will develop and finally it 3nd replace if necessary.
Mill become impossible to continue to run (b) useof vehicle under Severe con& Readjust bearing preload and backlash
h e to broken pieces obstructing the gear tions such as load and m d face contact of gears.
,evolution. improper use of clutch
(c) Improper adjustment of taper roller 4djust.
bearing
(d) Improper adjustment of drive pinion 4djust.
and hvlsoid driven aear
(e) Excessive backlash due to worn dif- 4dd recommended oil to specified level.
ferential side gear, washer or differential Do not use vehicle under severe operat-
pinion vehicle under severe operating ng conditions.
conditions
2. Differential and hypoid gear noises

I (f) Loose hypoid driven gear clamping
bolts
(a) Insufficient oil
Tighten.
-ubricate.
r
b u b l e s of the differential and hYPoid (b) Improper adjustment of hypoid driven :heck tooth contact.
p a r always appear as nOiSe problems. sear and drive Dinion
rherefore noise is the first indication of I vi I iypuiu ui ivci I ycai ai iu Replace as a set.
:he trouble. However noises from the Readjust bearing preload.
mgine, muffler, tire, exhaust gas, bear-
,e roller bearing Readjust hypoid driven gear to drive pin-
ng, body, etc. are easily mistaken for the
on backlash and check tooth contact.
jifferential noise. Pay special attention to
:he hypoid gear noise because it is easily (e) Distorted hypoid driven gear or differ- Replace.
:onfused with other gear noises. There ential case
we the following four kinds of noises. (f) Worn washer and differential pinion Replace.
1 Gear noise when driving: If noise shaft
ncreases as vehicle speed increases it
nay be due to insufficient gear oil, incor-
Oect gear engagement, damaged gears,
2tc.
1 Gear noise when coasting: Damaged
jears due to maladjusted bearings and

ncorrect shim adjustment
1 Bearing noise when driving or when
:oasting: Cracked, broken or damaged

3earings
1 Noise which mainly occurs when turn-
ng: Unusual noise from differential side

jear, differential pinion, differential pinion
;haft. etc.
MT-85
I GENERAL DIAGNOSTIC
MT-86
a
CLUTCH SYSTEM
CL
Page
2. Clutch Disc and Cover .............................................................................. i1
3. Flywheel .................................................................................................... 14
4. Release Bearing and Lever ....................................................................... 15
5. Operating Cylinder .................................................................................... 18
6. Master Cylinder ......................................................................................... 20
7. Clutch Pipe and Hose ............................................................................... 22
8. Clutch Fluid ............................................................................................... 23
9. Clutch Fluid Air Bleeding ........................................................................... 24
... 10. Clutch Pedal .............................................................................................. 26
11. Clutch Switch ............................................................................................ 30
12. General Diagnostic Table .......................................................................... 31
CLUTCH SYSTEM
A: SPECIFICATIONS
Model NON-TURBO TURBO
Clutch cover Type Push type Pull type
Diaphraam set load ka Ob) 580 (1 -279) 830 (1,830)
Clutch disk I Facinq material I Woven (Non asbestos)
O.D. x I.D. x thickness mm (in) 225 x 150 x 3.5 230 x 150 x 3.5
(8.86 x 5.91 x 0.138) (9.06 x 5.91 x 0.138)
Spline O.D. mm (in) 25.2 (0.992), (No. of teeth: 24)
Clutch release lever ratio 1.6 1.7
I Release bearina Grease-Dacked self-alianina
I Clutch Dedal
I
II Full stroke . ,I
mm (in) 130 - 135 (5.12 - 5.31) I
I Free play mm (in) 1 10 - 20 (0.39 - 0.79) 3 - 13 (0.12 - 0.51)
1
Clutch disk Depth of rivet head mm (in) Standard 1.3 - 1.9 (0.051 - 0.075)
Limit of 0.3 (0.012)
sinking
I Limit for deflection mm (in) I 1.0 (0.039) at R = 107 (4.21) 1 0.8 (0.031) at R = 110 (4.33) I
13.: Inner diameter
O.D.: Outer diameter
cL-2
I
GENERAL DESCRIPTION
CLUTCH SYSTEM
B: COMPONENT
1. CLUTCH ASSEMBLY FOR NON-TURBO MODEL
TR0533
(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 T2: 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) TR0534
(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
I
CLUTCH SYSTEM
3. CLUTCH PIPE AND HOSE FOR NON-TURBO MODEL
(1)’ I
TR0535
(1) Operating cylinder (6) Pipe Tightening torque: N.m (kgf-m, ft-lb)
(2) Washer (7) Master cylinder ASSY T I : 8 (0.8, 5.8)
(3) Clutch hose (8) Clevis pin T2: 15 (1.5, 11)
(4) Bracket (9) Snap pin T3: 18 (1.8, 13.0)
(5) Clip (IO) Lever T4: 37 (3.8,27.5)
CL-5
CLUTCH SYSTEM
4. CLUTCH PIPE AND HOSE FOR TURBO MODEL
TR0536
(1) Operating cylinder (6) Pipe Tightening torque: N.m (kgf-m, ft-lb)
(2) Washer (7) Master cylinder ASSY T I : 8 (0.8, 5.8)
(3) Clutch hose (8) Clevis pin TZ: lS(1.5, 1 1 )
(4) Bracket (9) Snap pin T3: 18 (1.8, 13.0)
(5) Clip (10) Lever T4: 37 (3.8,27.5)
CL-6
I
GENERAL DESCRIPTION
CLUTCH SYSTEM
5. MASTER CYLINDER
NON-TURBO MODEL
TR0431
(1) Reservoir cap (7) Diaphragm spring Tightening torque: N-m (kgf-m, ft-lb)
(2) Reservoir tank (8) Gasket T I : 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
GENERAL DESCRIPTION
I
CLUTCH SYSTEM
TURBO MODEL
TR054!
(1) Reservoir cap (6) Seat Tightening torque: N.m (kgf-m, ft-lb)
(2) Reservoir tank (7) Return spring T: 10 (1.0, 7)
(3) Oil seal (8) Piston
(4) Straight pin (9) Push rod
(5) Master cylinder (10) Piston stop ring
CL-8
I I
GENERAL DESCRIPTION
6. CLUTCH PEDAL
TR0537
(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 cylinder bracket
(5) Brake pedal pad (16) Assist bushing (27) Lever
(6) Brake pedal (17) Assist rod B (28) Clutch switch (Starter interlock)
(7) Clevis pin (18) Spring S
(8) Brake pedal spring (19) Rods Tightening torque: N-m (kgf-m, ft-lb)
(9) Clutch pedal pad (20) Bushing S T1: 8 (0.8, 5.8)
(IO) Clutch pedal (21) O-ring T2: lS(1.8, 13.0)
(11) Bushing C (22) Clip T3: 30 (3.1,22.4)
cL-9
GENERAL DESCRIPTION
CLUTCH SYSTEM
C: CAUTION Be sure to tighten fasteners including bolts and

Wear working clothing, including a cap, protec- nuts to the specified torque.
tive goggles, and protective shoes during opera- Place shop jacks or safety stands at the specified
tion. points.
Remove contamination including dirt and corro- Apply grease onto sliding or revolution surfaces
sion before removal, installation or disassembly. before installation.
Keep the disassembled parts in order and pro- Before installing O-rings or snap rings, apply suf-
tect them from dust or dirt. ficient amount of fluid to avoid damage and defor-
Before removal, installation or disassembly, be mation.
sure to clarify the failure. Avoid unnecessary re- Before securing a part on a vice, place cushion-
moval, installation, disassembly, and replacement. ing material such as wood blocks, aluminum plate,
Be careful not to burn your hands, because each or shop cloth between the part and the vice.
part on the vehicle is hot after running. Keep fluid away from the vehicle body. If any flu-
Use SUBARU genuine fluid, grease etc. or the id contacts the vehicle body, immediately flush the
equivalent. Do not mix fluid, grease etc. with that of area with water.
another grade or from other manufacturers.
D: PREPARATION TOOL
1. SPECIAL TOOLS
TOOL NUMBER DESCRlPTtON REMARKS

498497100 CRANKSHAFT Used for stopping rotation of flywheel when Ioos.
STOPPER eninghightening bolt, etc.
I B2M3853
499747100 CLUTCH DISC Used when installing clutch disc to flywheel.
GUIDE
B2M4112
TOOL NAME REMARKS I

Dial Gauge Used for measuring clutch disk run-out.
CL-10
CLUTCH DISC AND COVER
1
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. <Ref. to MT-27, REMOVAL, Manual Trans- position the clutch cover so that there is a gap of
mission Assembly.> 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.)
Note the front and rear of the clutch disc when in-
stalling.
Temporarily tighten the bolts by hand. Each bolt
should be tightened to the specified torque in a
crisscross method.
Tightening torque:
15.7 N-m (1.6 kgf-m, 11.6 ft-lb)
I I1 1‘ 1
(A) Clutch cover
-. - .
3) Remove the clutch cover and clutch disc.

CAUTION:
Take care not to allow oil on the clutch disc
facing.
Do not disassemble either the clutch cover or
clutch disc.
B: 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
B2M 1I0118
- -
(A) “ 0marks
3) Remove the ST.

ST 499747100 CLUTCH DISC GUIDE
4) Install the transmission assembly. <Ref. to MT-
G2M0253 30, INSTALLATION, Manual Transmission Assem-
bly.>
CL-11
I CLUTCH DISC AND COVER
1
CLUTCH SYSTEM
C: INSPECTION 4) Deflection on facing:

If deflection exceeds the specified value at the out-
1. CLUTCH DISC er circumference of facing, repair or replace.
1) Facing wear: ST 499747100 CLUTCH DISC GUIDE
Measure the depth of rivet head from the surface of Limit for deflection:
facing. Replace if the facings are worn locally or Non-turbo model:
worn down to less than the specified value. 1.0 mm (0.039 in) at R = 107 mm (4.21 in)
Depth of rivet head: Turbo model:
Limit of sinking 0.8 mm (0.031 in) at R = 110 mm (4.33 in)
0.3 mm (0.012 in)
CAUTION:
Do not wash the clutch disc with any cleaning
fluid.
5) Worn spline, loose rivets and torsion spring fail-

ure:
Replace defective parts.
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) Spline
(B) Rivet
(C) Torsion spring
(A) Facing
CL-12
CLUTCH DISC AND COVER
I
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.
(Bf
(A) Thrust rivet

c.
(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
I FLYWHEEL
CLUTCH SYSTEM
3. Flywheel 2) Tighten the flywheel attaching bolts to the spec-

ified torque.
A: REMOVAL NOTE:
1) Remove the transmission assembly. <Ref. to Tighten the flywheel installing bolts gradually. Each
MT-27, REMOVAL, Manual Transmission Assem- bolt should be tightened to the specified torque in
bly.> a crisscross method.
2) Remove the clutch cover and clutch disc. <Ref.
to CL-11, REMOVAL, Clutch Disc and Cover.> Tightening torque:
72 N-m (7.3 kgf-m, 52.8 ft-lb)
CAUTION:
Take care not to allow oil on the clutch disc
facing.
Do not disassemble either the clutch cover or
clutch disc.
3) Using ST, remove the flywheel.
ST 498497100 CRANKSHAFT STOPPER
r.
3) Install the clutch disc and cover. <Ref. to CL-11,
INSTALLATION, INSTALLATION, Clutch Disc and
Cover.>
4) Install the transmission assembly. <Ref. to MT-
30, INSTALLATION, Manual Transmission Assem-
- .
' B2M0332B bly.>
C: INSPECTION
(A) Flywheel
CAUTION:
B: INSTALLATION Since this bearing is grease sealed and is of a
1) Install the flywheel and ST. non-lubrication type, do not wash with gaso-
line or any solvent.
ST 498497100 CRANKSHAFT STOPPER
1) Damage of facing and ring gear:
If defective, replace the flywheel.
(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
I
CLUTCH SYSTEM
4. Release Bearing and Lever 4) Remove the clutch release bearing from clutch
cover using a flat-type screwdriver.
A: REMOVAL
1. NON-TURBO MODEL
1) Remove the transmission assembly from vehicle
body.
<Ref. to MT-27, REMOVAL, Manual Transmission
Assembly.>
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. (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.)
(A) Clutch release lever
Contact surface of lever and operating cylin-
der
(B) Release lever seal
1) While pushing the release lever to pivot and
4) Remove the release lever retainer spring from twisting it to both sides, fit the retainer spring onto
release lever pivot with a screwdriver by accessing the constricted portion of pivot.
it through the clutch housing release lever hole. NOTE:
Then remove the release lever. 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.

(B) Screwdriver
2. TURBO MODEL
1) Remove the transmission assembly from vehicle (A) Release lever
body. <Ref. to MT-27, REMOVAL, Manual Trans-
mission Assembly.> 2) Install the release bearing and fasten it with two
2) Remove the clutch release lever from transmis- clips.
sion.
3) Put the clutch release bearing in engine side.
CL-15
I RELEASE BEARING AND LEVER
CLUTCH SYSTEM
3) Install the release lever seal. 3) Apply grease to the specified points:
Spline FX2200
Shaft SUNLIGHT 2
(A) Release lever

(6) Release lever seal
4) Install the transmission assembly.
<Ref. to MT-30, INSTALLATION, Manual Tran
mission Assembly.>
2. TURBO MODEL
#) Install the release bearing on transmission.
2) Insert the release fork into release bearing tab.
S2M1938A
(A) Spline (FX2200)

(6) Shaft (SUNLIGHT 2)
4) Insert the release fork shaft into release fork.

CAUTION:
Make sure the cutout portion of the release fork
S2M1937A shaft contacts spring pin.
(A) Release fork

(6) Release bearing
1845A
(A) Release fork

(B) Release shaft
(C) Spring pin
5 ) Install the transmission assembly. <Ref. to MT-

30, INSTALLATION, Manual Transmission Assem-
bly.>
CL-16
RELEASE BEARING AND LEVER I
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 mm (0.055 in)
S2M1102E

(B) Pivot
(C) Clutch release bearing
(A) Bearing case
2) Check the bearing for smooth rotation by apply-

ing pressure in the thrust direction.
(A) Bearing case
3) Check wear and damage of bearing case sur-

face contacting with lever.
CL-17
I OPERATING CYLINDER I
CLUTCH SYSTEM
5. Operating Cylinder 4) Remove the operating cylinder from transmis-

sion.
A: REMOVAL Non-turbo model
1) Remove the air cleaner case and air intake duct
(Non-turbo model). <Ref. to IN(S0HC)-6, REMOV-
3) Remove the clutch hose from operating cylinder.
CAUTION:
Cover the hose joint to prevent clutch fluid from
flowing out.
Non-turbo model
Turbo model
-.
179J
-
(A) Clutch hose
(B) Operating cylinder
Turbo model
(A) Clutch hose

(6) Operating cylinder
CL-18
OPERATING CYLINDER I
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.
<Ref. to CL-24, Clutch Fluid Air Bleeding.>
NOTE:
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 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
c. .
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.
(A) Marking
(B) Clutch hose
(C) Operating cylinder
CL-19
I I
MASTER CYLINDER
CLUTCH SYSTEM
6. Master Cylinder B: INSTALLATION

1) Install the master cylinder to body, and install the
A: REMOVAL clutch pipe to master cylinder.
1) Thoroughly drain the brake fluid from reservoir CAUTION:
tank. Check that the pipe is routed properly.
2) Remove the snap pin, clevis pin and separate
the push rod of master cylinder from clutch pedal. Tightening torque:
T1: 15 N.m (1.5 kgf-m, 10.8 ff-lb)
T2: 18 N.m (1.8 kgf-m, 13.0 ff-lb)
B4M1189E
(A) Clevis pin

(B) Snap pin 2) Connect the push rod of master cylinder to clutch
-* (C) Push rod pedal, and install the clevis pin and snap pin.
(D) Locknut
NOTE:
3) Remove the air cleaner case and air intake duct Apply grease to the clevis pin.
(Non-turbo model). <Ref. to IN(S0HC)-6, RE-
MOVAL, Air Cleaner Case.> and <Ref. to IN(S0-
HC)-7, REMOVAL, Air Intake Duct.>
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 / B4M1189C
the paint surface; wipe it off quickly if spilt.
(A) Clevis pin
(B) Snap pin
(C) Push rod
3) After bleeding air from the system, ensure that

the clutch operates properly.
<Ref. to CL-24, Clutch Fluid Air Bleeding.>
4) Install the air cleaner case and air intake duct
(Non-turbo model). <Ref. to IN(S0HC)-6, INSTAL-
LATION, Air Cleaner Case.> and <Ref. to IN(S0-
HC)-7, INSTALLATION, Air Intake Duct.>
5) Install the intercooler (Turbo model). <Ref. to
(A) Master cylinder IN(D0HC TURBO)-11, INSTALLATION, Intercool-
(B) Clutch pipe er.>
CL-20
MASTER CYLINDER I
CLUTCH SYSTEM
1) Remove the straight pin and reservoir tank. 1) Install the clutch damper. (Non-turbo model)
Tightening torque:
46.6 N.m (4.75 kgf-m, 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)
(A) Reservoir tank

(B) Straight pin
2) Remove the oil seal.
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
(A) Oil seal rod, fluid reservoir, return spring, gasket, clutch
(B) Master cylinder damper and hose replace the faulty part.
3) Move the cylinder boot backward.
TR0475
(A) Master cylinder body

(B) Return spring
(A) Cylinder boot
(C) Piston
(B) Master cylinder
(D) Stop ring
4) Remove the stop ring. (E) Rod ASSY
CAUTION: (F) Clutch damper (Non-turbo model)
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)
CL-21
I CLUTCH PIPE AND HOSE
CLUTCH SYSTEM
7. Clutch Pipe and Hose B: INSTALLATION

Install in the reverse order of removal.
A: REMOVAL NOTE:
1) Remove the air cleaner case. (Non-turbo model) Bleed the clutch fluid. <Ref. to CL-24, Clutch Fluid
<Ref. to IN(S0HC)-6, REMOVAL, Air Cleaner Air Bleeding.>
Case.>
2) Remove the intercooler. (Turbo model) <Ref. to Tightening torque:
IN(D0HC TURBO)-IO, REMOVAL, Intercooler.> T1: 15 N.m (1.5 kgf-m, 10.8 ft-lb)
3) Drain the clutch fluid. <Ref. to CL-23, Clutch Flu- T2: 18 N-m (1.8 kgf-m, 13.0 ft-16)
id.> T3: 25 N-m (2.5 kgf-m, 18.1 ft-16)
4) Remove the clutch pipe from the clutch hose and
master cylinder.
5) Pull out the clamp, then remove the clutch hose
from bracket I
'\
'\
(A) Clamp
(B) Clutch hose
6) Remove the hose from operating cylinder.
7) Remove the bracket.
(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 I
CLUTCH SYSTEM
8. Clutch Fluid B: REPLACEMENT

CAUTION:
A: INSPECTION The FMVSS No. 116, fresh DOT3 or 4 brake
1) Park the vehicle on a level surface. fluid must be used.
2) Inspect the fluid level using the scale on the out- Cover the bleeder with waste cloth, when
side of the reservoir tank. If the level is below “MIN”, loosening it, to prevent brake fluid from being
add fluid to bring it up to “MAX, and also inspect for splashed over surrounding parts.
leakage. 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.
For convenience and safety, it is advisable to
e have two men working.
The amount of brake fluid required is approxi-
(A) Max. level mately 70 m f2 (2.4 US fl 02, 2.5 Imp fl 02) for total
c.
(B) Min. level clutch system.
(C) Reservoir tank 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:
FM VSS No. 1 16, 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
I CLUTCH FLUID AIR BLEEDING I
CLUTCH SYSTEM
9. Clutch Fluid Air Bleeding 4) Slowly depress the clutch pedal and keep it de-
pressed. Then open the air bleeder to discharge air
A: PROCEDURE together with the fluid.
Release the air bleeder for 1 or 2 seconds. Next,
NOTE:
with the bleeder closed, slowly release the clutch
Bleed air from the oil line with the help of a co-work-
pedal,
er.
1) Remove the air cleaner case and air intake duct.
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.
(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.
(A) Clutch hose
(B) Air bleeder
(C) Operating cylinder
CL-24
CLUTCH FLUID AIR BLEEDING I
CLUTCH SYSTEM
6) Tighten the air bleeder.

Tightening torque:
T: 8 N.m (0.8 kgf-m, 5.8 ff-lb)
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 ff-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
I CLUTCH PEDAL I
CLUTCH SYSTEM
1O.Clutch Pedal B: INSTALLATION

A: REMOVAL
CAUTION:
1) Remove the steering column. <Ref. to PS-23,
REMOVAL, Tilt Steering Column.>
If the cable clamp is damaged, replace it with
a new one.
2) Disconnect the connectors from stop light and Never fail to cover outer cable end with boot.
clutch switches. Be careful not to kink the accelerator cable.
3) Remove the snap pins which secure lever to
push rod and operating rod. Always use a new clevis pins.
4) Remove the clevis pins which secure lever to 2) Adjust the clutch pedal after installation.<Ref. to
push rod and operating rod. CL-27, ADJUSTMENT, Clutch Pedal.>
C: DISASSEMBLY
1) Remove the clutch switches.
2) Remove the clips, assist spring, rod and bush-
ing.
(A) Operating rod

(B) Push rod
(C) Snap pin
02M4115A
(D) Clevis pin
(A) Clip
5 ) Remove the air cleaner case and intake duct.
(Non-turbo model) <Ref. to IN(S0HC)-6, REMOV- (B) Assist spring
AL, Air Cleaner Case.> and <Ref. to IN(S0HC)-7, (C) Assist rod
REMOVAL, Air Intake Duct.> (D) Bushing
6) Remove intercooler. (Turbo model) <Ref. to (E) Clevis pin
7) Remove the nut which secures clutch master 3) Remove the spring pin and lever.
cylinder.
(A) Pin
8) Remove the bolts and nuts which secure brake (B) Lever
and clutch pedals, and remove pedal assembly.
CL-26
CLUTCH PEDAL I
CLUTCH SYSTEM
4) Remove the clutch pedal and bushings. 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
B2M4117A
(A) Clutch pedal

(B) Bushing
5 ) Remove the stopper, clip, O-ring, rod S, and

then remove the spring and bushing S.
(A) Clutch pedal

(B) Brake pedal
F: ADJUSTMENT
1) Turn the lock nuts until clutch pedal full stroke
length is within specifications.
(A) Clip CAUTION:
(B) O-ring Do not attempt to turn the clutch switch to ad-
(C) Bushings just clutch pedal full stroke length.
(D) Spring S NOTE:
(E) Rod S If the lock nuts cannot adjust the clutch pedal full
(F) Stopper stroke length to specifications, turn the master cyl-
inder push rod to adjust it.
6) Remove the stoppers from clutch pedal.
7) Remove the clutch pedal pad. (Non-turbo model) Specified clutch pedal full stroke: A
130 - 135 mm (5.12 - 5.31 in)
D: ASSEMBLY Tightening torque (Clutch switch lock nut):
1) Attach the clutch switch, etc. to pedal bracket T: 8 N.m (0.8 kgf-m, 5.8 ft-16)
temporarily.
2) Clean the inside of bores of clutch pedal and
brake pedal, apply grease, and set bushings into
bores.
3) 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.
CL-27
CLUTCH PEDAL
CLUTCH SYSTEM
2) Turn the master cylinder push rod so that the cle- 6) Push the release lever until operating cylinder
vis pin moves to the left and then to the right. Clevis push rod retracts. Ensure that the clutch fluid level
pin must move without resistance while it is rattling. in reservoir tank increases. If the clutch fluid level
increases, hydraulic clutch is properly adjusted; if
Tightening torque (Push rod lock nut):
fluid level does not increase or push rod does not
T: 10 N.m (1.0 kgf-m, 7 fWb) retract, replace the master cylinder with a new
one.<Ref. to CL-20, Master Cylinder.>
B4M1189G
1918
(A) Clevis pin
(B) Snap pin (1) Push rod
(C) Push rod (2) Release lever
*. (D) Locknut (3) Operating cylinder
3) Depress and release the clutch pedal 2 to 3 7) Push the release lever until operating cylinder
times to ensure that the clutch pedal and release push rod retracts. Check that the clutch fluid level in
fork operates smoothly. If the clutch pedal and re- reservoir tank increases.
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 mm (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 1918
rattling. If resistance is felt, repeat adjustment pro-

cedures again from the beginning. (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 level does not increase or push
rod does not retract, clutch pedal must be readjust-
ed.
CL-28
CLUTCH PEDAL
I
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
c. ~ (C) Reservoir tank
CL-29
I CLUTCH SWITCH
CLUTCH SYSTEM
11.Clutch Switch 2) Check the clutch switch continuity. If continuity is

not as specified, replace the switch.
A: REMOVAL (1) Disconnect the clutch switch connector.
1) Disconnect the ground terminal from battery. (2) Measure the resistance between 1 and 2 of
2) Disconnect the connector from clutch switch. clutch switch terminal.
3) Remove the clutch switch. Terminals/Specified resistance
B: INSTALLATION When clutch pedal depressed:
1) Move the clevis pin of the push rod right and left 1 - ZLess than 1 0
and hold where it moves smoothly, then measure TerminaWSpecified resistance
stroke of clutch pedal. When clutch pedal not depressed:
Specified clutch pedal full stroke:A 1 - ZMore than lMSZ
130 -135 mm (5.12 - 5.31 in) Clutch switch (Starter interlock)
Tightening torque:
T: 8 N-m (0.8 kgf-m, 5.8 ft-lb)
Clutch switch (With cruise control)

04M 119OC
2) If the clutch pedal stroke is out of specification,

adjust the stroke. <Ref. to CL-27, ADJUSTMENT,
Clutch Pedal.>
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.
TR0541
Specified position: L
(3) If not as specified, replace the clutch switch.
P'.5/omm(0.079+0.059/0
in)
I L
G4M0327
CL-30
GENERAL DIAGNOSTIC TABLE
I
CLUTCH SYSTEM
12.General Diagnostic Table

A: INSPECTION
1. CLUTCH
I Symptom Possible cause Corrective

1. Clutch slippage. (a) Clutch facing smeared by oil Replace.
It is hard to perceive clutch slippage in (bl Worn clutch facina Replace.
the early stage, but pay attention to the (c) Deteriorated diaphragm spring Replace.
following symptoms
(d) Distorted pressure plate or flywheel Sorrect or replace.
Engine speeds up when shifting.
High speeds driving is impossible; (e) Defective release bearing holder Sorrect 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. (a) Worn or rusty clutch disc hub spline ReDlaCe clutch disc.
As a symptom of this trouble, a harsh (b) Excessive deflection of clutch disc Correct or replace.
scratching noise develops and control facina
becomes quite difficult when shifting (c) Seized crankshaft pilot needle bear- Replace.
gears. The symptom becomes more inn
apparent when shifting into the first gear.
(d) Cracked clutch disc facing ReDlace.
However, because much trouble of this
sort is due to defective synchronization (e) Sticked clutch disc (smeared by oil or Replace.
mechanism, carry out the test as water)
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. (a) Adhesion of oil on the facing Replace clutch disc.
Clutch chattering is an unpleasant vibra- (bl Weak or broken torsion spring Replace clutch disc.
tion to the whole body when the vehicle is (c) Defective facing contact or excessive Replace clutch disc defection.
just started with clutch partially engaged. disc
(d) Warped pressure plate or flywheel Correct or replace.
(e) Loose disc rivets Replace clutch disc.
(fl Loose enaine mountina Retiahten or replace mounting.
(9) Improper adjustment of pitching stop- Adjustment.
per
CL-31
GENERAL DIAGNOSTIC TABLE
I
CLUTCH SYSTEM
Symptom Possible cause Corrective

4. Noisy clutch (a) Broken, worn or unlubricated release Replace release bearing.
Examine whether the noise is generated bearing
when the clutch is disengaged, engaged, (b) Insufficient lubrication of pilot bearing Apply grease.
or partially engaged. (c) Loose clutch disc hub Replace clutch disc.
I (d) Loose torsion spring retainer I Replace clutch disc.
(e) Deteriorated or broken torsion spring Replace clutch disc.
5. Clutch grabs. (a) Grease or oil on facing Replace clutch disc.
When starting the vehicle with the clutch (b) Deteriorated cushioning spring Replace clutch disc.
partially the clutch engages (c) Worn or rusted spline of clutch disc or Take off rust, apply grease or replace
suddenly and the vehicle jumps instead main shaft clutch disc or main shaft.
of making a smooth start.
(d) Deteriorated or broken torsion spring Replace clutch disc.
(e) Loose engine mounting Retighten or replace mounting.
(f) Deteriorated diaphragm spring Replace.
2. CLUTCH PEDAL
Trouble Corrective action

Insufficient pedal play Adjust pedal play.
Clutch pedal free play insufficient Adjust pedal free play.
Excessively worn and damaged pedal shaft and/or bushing Replace bushing and/or shaft with new one.
3. DIAGNOSTIC DIAGRAM OF CLUTCH DRAG
Step No
CHECK GEAR NOISE. Clutch is normal.
1)Start the engine. rom the transmission gear?
2)Disengage the clutch and shift quickly from
neutral to reverse in idling condition.
! CHECK GEAR NOISE. Defective trans-
Disengage the clutch at idle and shift from neu- rom the transmission gear? mission or exces-
tral to reverse within 0.5 - 1.O seconds. sive clutch drag
torque.
Inspect Pilot bear-
ing, clutch disc,
transmission and
clutch disc hub
spline.
I CHECK GEAR NOISE. Clutch and fly-
1)Disengage the clutch at idle and shift from wheel seizure.
neutral to reverse within 0.5 - 1.O seconds. Inspect clutch disc, Inspect clutch disc,
2)With the clutch disengaged, shift from N to clutch cover, clutch spline of clutch
R. R to N several times. release, and clutch disc hub.
pedal free play.
CL-32

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I

2002 IMPREZA SERVICE MANUAL QUICK REFERENCE INDEX

This service manual has been prepared

All information, illustration and specifi-

FUJI HEAVY INDUSTRIES LTD. G1830BE4

Indicator light bulb Cushion (25) Slider

2. MT GEAR SHIFT LEVER

(1) Gear shift knob (IO) O-ring A (19) Stay

\ \o\ ' B2M2246E TR0548

3. AT Shift Lock System

Stop light switch I B280 I 9

I “P” position switch I B280

9 - 16 V when key is inserted.

1. INTEGRATED MODULE POWER SUPPLY AND GROUND LINE

Step Check Yes No

2. SELECT LEVER CANNOT BE SHIFT LOCKED

Step Check Yes No

3. SELECT LEVER SHIFT LOCK CANNOT BE RELEASED

INHIBITOR STOP LIGHT

Step Check Yes No

Step Check Yes No

4. KEY INTERLOCK DOES NOT LOCK OR RELEASE

Step Check Yes No

Step Check Yes No

4. Select Lever B: INSTALLATION

3) Install the console box. <Ref. to El-39, INSTAL-

C: DISASSEMBLY 6) Remove the lock plate.

7) Remove the pattern plate.

3) Remove the slider. TR0557

10)Remove the select lever lower then take away

(A) Select lever lower

1 1 ) Remove the spring and remove the detent arm.

(A) Detent arm

12)Remove the cushion.

(A) Range select lever

(A) Select cable

4) Install the snap pin to range select lever

(A) Adjusting nut A

5) Move the select lever to the “N” position, then ad-

8) Turn the adjusting nut B until it lightly touches the

(A) Front side

S).While preventing the adjusting nut B from mov-

(A) Adjusting nut A

10) After completion of fitting, make sure that the

6. AT Shift Lock Solenoid and 6 : INSTALLATION

6) Remove the slider.

9) Remove the clamp and remove the shift lock so-

7. Integrated Module B: INSTALLATION

2 ) Remove the lower cover.

3) Remove the knee bolster.

4) Disconnect the connector from integrated mod-

@.Lift-up the vehicle.

13) Lower the vehicle.

B: INSTALLATION 7) Connect the rod to the joint.

8) Connect the stay to transmission bracket.

C: DISASSEMBLY 5) Remove the bush and cushion rubber from stay.

' ' B3M0617C

(A) Rod (A) O-ring B

(A) Snap ring (A) Spring pin

4) Remove the boot from gear shift lever.

7) Insert the rod into the boot hole.

9) Check the swing torque of the rod in relation to E: INSPECTION

(A) Center of rotation