Clutch Pedal Sticking
If you encounter a customer com-
(P/N 114130151) used on the connector
of the operating cylinder must be
plaint of the clutch pedal not returning replaced with new ones when replac-
completely after being engaged, or if ing the clutch hose. Tightening torque
there is a spongy or light pedal feel of the bolt is: 37 ±3 Nm (27 ±2 ft. lbs).
while shifting, the following repair • Add brake fluid.
method should be followed. This con- • Bleed the air from the system.
dition may affect certain manual trans- • Install the intercooler.
mission vehicles with a hydraulic • Insure there is no leakage from the
clutch system under certain weather line, check whether fluid leakage
conditions. The affected manual trans- occurs after the clutch pedal has been
mission Subaru models are as follows: fully depressed.
• Check whether the clutch performs
1995-2002 Legacy normally.
1997-2003 2.5L Impreza
To correct this condition you must
replace the parts in the chart that
match your vehicle using the following
For naturally-aspirated models
with hydraulic clutches:
• Remove the intake chamber from the
backside of the intake manifold.
• Remove the clutch hose and the
clutch operating cylinder. In this proce-
dure it is not necessary to remove the Clutch Operating Cylinder
master cylinder, the clutch pipe bracket.
• Replace the clutch hose and the
clutch operating cylinder with new 2002 WRX (5MT)
parts as listed below. Note that two
pieces of gasket (P/N 114130151) used Clutch Operating Cylinder: Do not replace
on the connector of the operating cylin- Clutch Hose: 37251AA003
der must be replaced with new ones Gaskets for Hose: 114130151 X 2
when replacing the clutch hose.
Tightening torque of the bolt is: 37 ±3 Legacy (5MT)
Nm (27 ±2 ft. lbs).
• Bolt the operating cylinder onto the Clutch Operating Cylinder: 30620AA042
transmission. Clutch Hose: 37251AC001
• Add brake fluid. Gaskets for Hose: 114130151 X 2
• Bleed the air from the system.
• Bleed the air from he system. Impreza (5MT)
• Install the intake chamber.
Clutch Operating Cylinder: 30620AA042
For turbo models: Clutch Hose: 37251AC001
• Remove the intercooler. Gaskets for Hose: 114130151 X 2
• Remove the clutch operating cylinder
hose. In this procedure, the clutch mas- Forester (5MT)
ter cylinder, clutch pipe and bracket
are unnecessary to be removed.
Clutch Operating Cylinder: 30620AA042
• Replace the clutch hose that was Clutch Hose: 37251AC001
removed with the new one listed Gaskets for Hose: 114130151 X 2
below. Note that two pieces of gasket
Power Steering can often see the wear marks in may be affected:
Pump Replacement the paint when removing the
When replacing the power brackets that hold the bushings. All 1999-2002 and some
steering pump on a Subaru vehi- The noise can be eliminated, in 2003 2.5L vehicles
cle, remember to replace the most cases, by applying Dow All 2002 and some
0-ring between the pump and the Corning Silicone Grease #111 to 2003 2.0L WRX vehicles
reservoir. The pump does not the bushing and the stabilizer bar
come with the O-ring and if not area where the bushings mount. Prior to replacing these parts,
installed, the pump will not oper- This grease has an operating confirm that the engine and trans-
ate. Also, make sure that the fluid range of -40°F to 400°F. It is also mission mounts are not broken,
level is at the proper level before waterproof and will not wash loose, or misaligned.
you start the engine. away with water. If you cannot
locate this grease, call Dow 2.5L Parts
Front Suspension Noise Chemical at 517.496.6000 and ask Use Clutch Kit: P/N
1995/96 Legacy for a distributor in your area. 32098AA020. This kit contains
A squeaking noise in the front the following parts (which can
suspension during extremely cold Cold Clutch Judder also be purchased separately):
weather (0°F or lower), may be If a customer complains of cold
caused by the front stabilizer bar clutch judder that goes away after Flywheel P/N 12342AA061
bushings. the first few applications, replace- Cover P/N 30210AA590
In extremely cold weather, the ment of some clutch parts will be Disc P/N 30100AA851
bushing material hardens and necessary to repair the vehicle. Bolts (8 pieces) P/N 800610740
rubs against the stabilizer bar. You The following Subaru vehicles Continued on page 20.
Note: If the OE flywheel and cover have
more then 30,000 miles on them and are
bump in the road such as when turning
into a driveway. Please keep in mind
in good condition, they can be reused. that while the noise sounds the same,
After 30,000 miles of driving, the surface the cause (and ultimately the repair per-
finish is equivalent to the replacement formed) is different between 1995-99
flywheel and cover. Legacy and 2000 Legacy models.
The power steering assist is created
2.0L Parts using hydraulic pressure. This pressure
Flywheel P/N 12342AA071 is generated by the pump and then dis-
Cover P/N 30210AA570 tributed through valving on the steering
Disc P/N 30100AA840 rack, to the appropriate side of the rack.
Bolts (8pieces) P/N 800610740 There is always pressure on both sides
of the rack, in order to provide quick
Note: 2002 WRX vehicles with an engine steering reaction and a positive feel.
number of E/G #331738 and later can When the steering input is negative,
also reuse the OE flywheel and cover if that is, straight driving, the fluid is cir-
they are in good condition and have culated for lubrication, while maintain-
more then 30,000 miles on them. ing equal pressure. When the steering
Vehicles produced prior to E/G #331738
will need to install all four parts.
These countermeasure parts were
installed into production beginning with
the following VINs:
2.5L Legacy Baja 36103910
2.5L Legacy Sedan 36206712
2.5L Legacy Wagon 36305452
2.5L Legacy Outback 36622108
2.5L Impreza Sedan 3G506077
2.5L Impreza Wagon 3G805549
2.0L Impreza Sedan 3G500127
2.0L Impreza Wagon 3G800014
Power Steering Hoses
2.5L Forester 3G732771
wheel is turned, hydraulic pressure is
Vehicles after the listed countermea- greater on the input side, while some
sure, or repairs to vehicles after the residual pressure is maintained on the
clutch set has been installed, can be free side of the rack.
repaired using individual parts as need- When turning the steering wheel, even
ed. Repair history should be checked to slightly, on rough roads, or especially
determine what parts are currently in when entering a driveway over a curb,
the vehicle. The parts system should be the tires will input a reactive force
checked for any future information through the rack, caused by the impact.
regarding these parts. This causes the hydraulic pressure in
the input lines to force back against the
Steering Knocking/Rattle Noise residual pressure in the free side lines.
When Turning When the higher pressure hits the lower
If you should encounter a knocking or pressure, knocking noise is generated.
rattle noise from the vehicle steering sys- While some customers may object to
tem on a 1995-2000 Legacy, use the pro- this noise, it does not harm the steering
cedures below to diagnose and reduce or system or any of its components. This
eliminate the noise. The noise is usually noise can be reduced or eliminated by
heard when turning and going over a following the procedures below.
1995-1999 Model Years ice manual, it will be necessary to Outback Gear Ratios
If you should encounter the con- drive the vehicle to confirm the When performing repairs on
dition on a 1995-99 Subaru vehi- correction. automatic or manual transmission
cle, it will be necessary to install a Outback vehicles, be certain to
steering universal joint with 2000 Model Year check appropriate Service materi-
damper. The steering universal If you should encounter the con- als to determine whether or not
joint with damper are available in dition on a 2000 Subaru vehicle, it the vehicle you are working on has
two lengths. will be necessary to install a set of a different final drive ratio than a
modified power steering lines. non-Outback version of the same
Legacy Models: P/N 34160AC030 vehicle. If a different ratio is indi-
(shorter length) Modified Power Steering Lines: cated, be certain to obtain the cor-
P/N 34190AE120 rect matching parts while perform-
Outback Models: P/N 34160AC090 ing your repairs.
(longer length) Always check the part number
suppression for any changes. After Noise From Rear Axle Oil Seal
Always check the part number installing the Modified Power — Legacy Models
suppression for any changes. After Steering Lines using the proce- If you encounter a high pitched
installing the new steering univer- dures in the appropriate service noise coming from the rear of
sal joint with damper using the manual, drive the vehicle to con- Legacy vehicles, the cause may be
procedures in the appropriate serv- firm the correction. Continued on page 22.
rear axle oil seal number 2 coming
loose from its mounting. This noise can
reports a good speed sensor 2 reading,
then you’re likely to have a concern
often be duplicated by placing the vehi- with the signal from speed sensor 1 to
cle on a lift and rotating the tire on the the transmission control computer.
side suspected of causing the noise. Speed sensor 1 is the speed sensor in
Too much pressure applied during the the back of the transmission by the
seal installation process may be respon- transfer clutch on an AWD vehicle and
sible for the seals becoming loose. inside the transmission back cover of a
A modified installation procedure has two-wheel drive vehicle. Diagnose with
been instituted and applies to the fol- resistance readings, direct signal moni-
lowing VIN range: toring, and physical examination, if
Sedan: V7209190 If speed sensor 1 checks out, and it
Wagon: V7312934 has been determined that speed sensor
Outback: V7624830 2 itself is okay (since the engine control
computer can read it), check the con-
If you encounter this noise, inspect nections from speed sensor 2 to the
the above mentioned seal for proper transmission computer.
installation. If you need to install a
new seal, do not apply too much pres- Identifying 1997 Subaru Legacy
sure when installing it. Otherwise, the Propeller Shafts
seal may be deformed and work loose There is a paint mark located on the
at a future date. end of the universal joint that fastens to
the rear differential. It is necessary to
4EAT Speed Sensors unbolt the propeller shaft from the rear
If you are in the process of diagnos- differential to locate the paint mark.
ing delayed or erratic shifting on a
4EAT transmission, pay close attention Sedan & Wagon 5MT
to the comparison of readings between Paint Color: Blue
speed sensor 1 and speed sensor 2 as P/N 27031AC080
displayed on the Select Monitor. If Outback 5MT
these sensors are working properly, the Paint Color: White
two readings should be close, but are P/N 27031AC060
rarely absolutely identical. If, however, Outback 4EAT
in the vehicle that you are driving, you Paint Color: Pink
notice that the speed sensor 1 signal P/N 27031AC070
and the speed sensor 2 signal are Sedan & Wagon 4EAT
always precisely identical, there may No Paint
be a malfunction in the signal or circuit P/N 27031AC010
from one of the sensors. When the
transmission computer senses a failure
in one of the speed sensor circuits, it
may substitute the other sensor’s read-
ing in the display of the Select Monitor.
This is why the two readings would be
identical. Check the computer’s memo-
ry for fail codes corresponding to either
or both of the sensors.
If you have codes for both, identify
which sensor is the one that is not
sending a proper signal by looking at
the speed sensor display in the engine
computer side of the Select Monitor.
The engine computer only monitors
speed sensor 2. If the engine computer Driveshaft Removal
Rear Axle Binding On Turns same” if they are all the same size, tion can be repaired by doing the
If a customer complains of a rear the same manufacturer, and the following:
axle that is binding on turns, phys- measurements mentioned above • Remove and disassemble both
ically measure the outer circumfer- are within the 1/4-inch limit. inner axle joints.
ence of the tires before making any If the vehicle has lots of miles on • Clean the grease from the joints.
repairs. This means that you must it, determine whether the tires • Inspect the “freeze out” plug that
actually measure the tires using a have been rotated on a regular covers the splined shaft area in the
piece of string or a flexible meas- basis. Most have not and this caus- base of the inner joints to be sure
uring device. Differences as small es them to wear differently. that the plug has not fallen out.
as a 1/4-inch can cause a binding It’s a whole lot easier to take the • If the plug has fallen out, it may
situation. time to measure the tires than it is be possible to reinstall it. Make
It doesn’t matter what the num- to rebuild an AWD clutch pack certain you do not block the air
bers are on the sidewall of the tire. along with its assorted subsystems, bleed hole. This air bleed hole is
Even new tires can be different then find out that the tires were located at a point around the outer
sizes due to variations in the causing the problem all along. circumference of the seal plug. If
molds they come from. Different the air bleed hole is blocked, then
tire brands can be and, in most Grease Leaking From Inner there is a possibility that the axle
cases, are different sizes even Axle Joints boots may be damaged.
though they may have the same If you encounter a 1998 Subaru • Install new grease P/N
numbers on the tire sidewall. This that has grease leaking out of the 28093TA000. (This grease is used
is why you must measure the tires. inner axle joint along the transmis- on 1997 model year vehicles).
Tires can only be considered the sion splined stub shaft, the situa- • Reassemble.
Continued on page 24.
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• Perform like new parts • Ensure long term reliability
• Provide exact replacement and fit • Backed by same warranty as new parts
Remanufactured for Subaru by
Available only through your local SUBARU dealer
Rear Differential Vent Oil Leakage
If you should encounter a rear differ-
This is done to keep the transmission
from upshifting/downshifting in and out
ential leaking oil from the vent, please of 4th gear needlessly. On the uphill
perform the following procedures: control, the slope angle is estimated
• Check to see if the rear differential has from the throttle opening angle and
been over-filled with oil. If not, proceed vehicle speed change. When the TCU
to the next step. detects that the vehicle is moving
• Drain the rear differential. uphill, upshifting is restrained by select-
• Remove the rear differential from the ing a special shift map, which prevent
vehicle. needless upshifting/downshifting.
• Remove the vent from the rear cover. When driving downhill, under coast-
• Turn the differential over and drain ing conditions, if the driver touches the
the vent chamber. brake pedal, the TCM will downshift the
• Reinstall the vent and rear differential transmission into 3rd gear to provide
assembly back into the vehicle. engine braking. This downhill control is
• Fill the rear differential with new canceled when the TCU detects the
fluid to the proper level. vehicle acceleration by the driver’s
• Road test the vehicle and reinspect for depressing of the accelerator pedal and
leaks. input from the Throttle Position Sensor.
Both of these conditions are part of
Note: If leakage is going to occur, it will the slope control logic and are a charac-
usually happen on low mileage vehicles. teristic of the vehicle TCM logic.
If mileage is high, then check for other If a customer comes to you with a
causes like improper gear ratio, improp- transmission shift concern, question the
er tire match, wrong type of fluid, etc. customer thoroughly on how and when
this condition occurs. If possible, road
1999 4EAT Transmission Operation test the vehicle with the customer. If it
There are seven different shift sched- is something you’re not sure about,
ules/maps in the TCM logic control of drive a similar vehicle to determine if
the 1999 Second Generation 4EAT. They there is a problem with the customer’s
are Normal, Power, Slope, Hold 2nd, vehicle.
Cruise, Hot ATF, Cold ATF. The shift
schedule/map will determine how and Noise From Rear Axle Oil Seal —
when the transmission shifts. For exam- Legacy Models
ple, in the slope mode, when driving up If you encounter a high pitched noise
a hill under certain engine load condi- coming from the rear of Legacy vehicles,
tions, the TCM will shift the transmis- the cause may be rear axle oil seal num-
sion back down to 3rd gear. ber 2 coming loose from its mounting.
In most cases, the transmission will This noise can often be duplicated by
stay in 3rd gear until the vehicle reaches placing the vehicle on a lift and rotating
the top of the hill, then it will upshift. the tire on the side suspected of causing
It has been determined that too much
pressure during the seal installation
process might be responsible for the
seals becoming loose.
A modified installation procedure
applies to the following VIN range:
If you encounter this noise, inspect
Phase II 4EAT Transmission the above-mentioned seal for proper
installation. If you need to install a that pilot bearing noise will be fied by part numbers starting with
new seal, be certain you do not unaffected by installing the front 27011AA***. Physically, the dif-
apply too much pressure when wheel drive fuse, whereas the ring ferentials can be identified by the
installing it. Otherwise, the seal and pinion noise will effectively fact that the side covers for setting
may be deformed and work loose disappear with the fuse installed. case preload are bolted on as
in the future. The slight ring and pinion noise opposed to the Fuji-produced dif-
occurs in the 40-60 mph range and ferential (38300AA***), which
Rear Differential is considered a normal characteris- have side covers that screw in sim-
Modifications tic of the rear differential. ilar to the side covers on Subaru
Rear differentials with an updat- However, the pilot bearing noise front differentials.
ed style pilot bearing and AKA can be corrected.
pinion bearing are available. This Order the updated assembly by Shifter Rattle
is a countermeasure for a high looking up the appropriate part If you encounter a shifter rattle
pitched whine noise (sometimes number and changing the last digit complaint on a 1996/97 Legacy
described as a turbine jet engine to a 2. If you have a question Outback or on a 1998 Forester, the
winding up) from the rear differen- regarding the part number or its necessary parts are available to
tial that can start at a relatively availability, please consult your correct this symptom. For the 1996
slow speed (25 mph) and rises in Subaru parts department. Legacy Outback, order a modified
pitch and volume to about 50 Please note that these modifica- spacer, P/N 35045AC040. For the
mph. This can be distinguished tions and part number changes 1998 Forester or 1997 Legacy,
from the characteristic differential only pertain to Nissan-produced order a modified bolt, P/N
ring and pinion noise by the fact differentials. These can be identi- 35045FC000.
Continued on page 30.
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Case Boss Wear
Continued from page 25.
8. If both axle ratios are the same, the
marks on the tire should be in the same
Some shops are replacing the trans- positions as each other. If not, the axle
mission case because of wear found on ratios are different.
the case boss. This has been a judgment
call because the Service Manual does Note: This procedure must not be
not provide specifications. Fuji Heavy attepted on 1991 Legacy Turbo or SVX
Industries has provided information vehicles. These vehicles are equipped
regarding the wear limit of this case with a limited slip rear axle.
area. It is not necessary for the case to
be replaced if this area is not worn Caution should be used whenever
under 32.8 mm. Always measure this you are working on manual or automat-
boss prior to ordering a new case. ic transmission vehicles. Leave the
parking brake off, but make sure the
Correct Axle Ratios wheels that are on the ground are
You’ve just changed a 4EAT/AWD blocked. On automatic transmission
transmission or rear differential and vehicles, be sure that the shift lever is
now the rear axle is binding during the not placed into any Drive ranges. If you
road test. suspect that the differential may be
Or, the customer has brought the locked due to internal damage, do not
vehicle in complaining about a shud- perform this test. Make sure nobody is
der when turning (rear axle binding). around the vehicle while conducting
They inform you that the problem has this test, other than the person perform-
occurred since the transmission or rear ing it. Never leave the vehicle running
differential was changed at another and unattended.
The possible cause may be an Popping Out Of Fifth Gear
improper front to rear axle ratio match. Some 1999 and 2000 Legacy and
Driving a vehicle with different front to Forester vehicles may intermittently
rear gear ratios, even for a short time, pop out of fifth gear when coasting.
may cause permanent damage to the The cause may be a loose main shaft
transfer clutches. nut. In some cases, all that maybe nec-
To determine if the front and rear essary to repair the transmission is to
axle ratios are the same or different replace the nut, torque to specifications
without removing the transmission, use and stake the nut. In other cases, dam-
the following procedure: age to the hub and syncro assembly
1. Position vehicle on the ground. may be found.
2. Lift one side of the vehicle so that
the tires are off the ground. Block the 4EAT Remanufactured Transaxles
wheels on the other side of the vehicle Subaru of America, Inc. offers reman-
as a safety precaution. If lifting the ufactured automatic transmissions for
vehicle with a floor jack, place jack most Subaru models, starting from
stands under the vehicle. 1990 vehicles. Please check applica-
3. With a marking crayon, place a mark tions and availability through normal
on the two raised tires at the 6 o’clock parts channels prior to making vehicle
4. Open the hood and disconnect the Never attempt to repair a remanufac-
main wiring harness for the transmis- tured transmission. These units are
sion or unplug the TCU. This will put warranted by the remanufacturer for 2
the transmission in its Fail-Safe mode. years or 24,000 miles. If you attempt to
5. Place the transmission gear selector repair the unit, it will void the warran-
in Neutral. ty. This will result in the remanufactur-
6. Start the engine. er rejecting your claim.
7. Manually rotate one of the raised Remanufactured units can be identified
tires through at least five rotations. easily because they are painted gray.
What Performance Looks Like
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