1a. Subaru Service Helpline Updates
3. Motor Trend's REVIEW of the 1996 Outback
4. Edmund's COMPARISON of the 1996 Outback vs 1997 Explorer
5. 1996 MAINTENANCE SCHEDULE
These were taken from the ALLDATA system. Many of these must be taken with a grain of salt, since the issue dates are way before the advent of the 2.5l engine, and the 2.2l had none of these. I would only check out the 1995 and later bulletins. Listed below the Service Bulletin numbers are many notes from the Subaru Service Helpline Updates. Many of these pertain to the bulletins, but since no numbers are given in the updates I cannot correlate them with 100% accuracy. I will be adding more updates as I get them. NOTE - I am not responsible for any misdiagnosing you may do as a result of these bulletins. I provide them simply to let you know of potential problems and solutions.
182395 is the off-road-capable manual pages - call Subaru at 1-800-SUBARU3 if you haven't received yours by now (1996 owners only).
Bulletins for 1996 Subaru Legacy Outback 4-150 2.5L DOHC
Service Bulletins
TSB Number Issue Date TSB Title
1. 182395 SEP 95 Manual Update
2. 136795R SEP 95 Paint Codes
3. 136895 JUL 95 Paint Formula Information
4. 136795 JUL 95 136795 - 07/15/95
5. ATRATB078 NOV 91 How To Use A Pressure Gauge - Automatic Trans.
6. ATRATB028 OCT 90 Engine Testing With A Vacuum Gauge - Auto Trans.
7. ATRATB9002006 FEB 90 Automatic Transmission Fluid
8. ATRATB8930 OCT 89 Automatic Transmission Math Part 2
9. ATRATB8927 SEP 89 20 Steps To successful Auto Transmission Repair
10. ATRATB8923 AUG 89 Automatic Transmission Math Formulas
11. ATRATB8754 SEP 87 All Automatics - Front Bushing Wear
12. ATRATB8748 AUG 87 Metal Sealing Rings - Automatic Transmissions
NOTE: I've been shown information about other Outback-specific service bulletins regarding peeling paint on the rear bumper and a peeling bumper protector pad, but I have not been able to find them online anywhere. I'm still looking, though...
"CAUTION - VEHICLE SERVICING PERFORMED BY UNTRAINED PERSONS COULD RESULT IN SERIOUS INJURY TO THOSE PERSONS OR TO OTHERS.
Subaru Helpline Updates are intended for use by professional technicians ONLY. They are written to inform those technicians of conditions that may occur in some vehicles, or to provide information that could assist in the proper servicing of the vehicle. Properly trained technicians have the equipment, tools, safety instructions, and know-how to do the job correctly and safely. If a condition is described, DO NOT assume that this service helpline update applies to your vehicle, or that your vehicle will have that condition."
ABS-EQUIPPED SUBARU VEHICLES SYSTEM CHECK (8/96)
The Subaru Technical Helpline and our CDS department continue to receive calls about concerns that the customer's ABS system is not functioning correctly. When we question the technician/owner as to when this happens, quite often we are told that it is each time the vehicle is started, placed in gear, and the owner or technician is moving the vehicle.
The ABS Electronic Control Unit checks all components of the system each time the vehicle is started. This includes the Hydraulic Control Unit. When the Hydraulic Control Unit is operating during this checking period, the owner/technician may hear a noise/buzzing coming from the engine compartment. They may also feel the brake pedal pulsating slightly if their foot is on the brake pedal. This pulsating of the brake pedal may be more noticeable when backing down a slight grade (sloping driveway). It may also be felt when moving forward. The check is not performed until a speed sensor input is received by the ABS Electronic Control Unit.
THIS IS A NORMAL FUNCTION AND NO REPAIRS SHOULD BE ATTEMPTED!
97 LEGACY KEYLESS ENTRY (8/96)
Regarding the 1997 Legacy Keyless Entry Kit, please be advised of a functionality change. Due to the new door lock system, the remote functions differently from last year. To unlock only the driver's door, simply press the remote button once. Should the user wish to unlock all doors at the same time, hold the remote button down longer. This should unlock all of the doors.
LEGACY OUTBACK TRAILER HITCH HARNESS (8/96)
Regarding Legacy Outback Trailer Hitch Harness, be advised that SOA is currently "between suppliers". The new supplier needs a couple of months to meet our demand for a six-wire powered harness.
What this means to you is that the trailer hitches being ordered will no longer come with a harness. The price of the hitch has been adjusted accordingly, therefore, no warranty or transportation claims will be entertained for lack of a harness.
Instead a six-pin connector kit will be provided. Accompanying port-installed hitches will be this kit (probably found in the cargo area). This connector kit will enable an after market six-wire, powered harness to be adapted to fit the Legacy body harness connector. A six-wire harness should be easily found in any area of the country at appropriate retail outlet stores.
4EAT TRANSMISSIONS BINDING IN TURNS (8/96)
A different kind of binding concern has arisen regarding the full-time AWD 4EAT. This type of binding is characterized by a bucking, clunking type of behavior mostly occurring while backing off the gas in turns. This is contrary to the more familiar binding that occurred when accelerating or maintaining speed through a turn.
If you encounter this new type of binding, remove the transfer case housing from the rear of the transmission and inspect the rear of the housing where the transfer clutch sealing rings ride. If the transfer clutch sealing rings have worn grooves in the case this could be responsible for the binding since erratic amounts of pressure may be delivered to the transfer clutch, producing the bucking sensations. If the transfer case has been grooved, it should be replaced along with the transfer seals. The new part number for the seals is 31377AA180. Please note that the roller bearings in this case does not come with the case. Kindly refer to the July Tech Helpline Update for information regarding changing this bearing and the puller required. Since this new kind of bearing is quite similar to the old, it is up to your expertise to determine which situation you are confronted with. For your own sake, don't base your diagnosis on anyone else's description of the behavior. Drive the car yourself to make the determination.
If the binding is determined not to be of this new type, then diagnose and repair in the traditional fashion. Check for mismatched tires, throttle position sensor misadjustment, sticking duty solenoid "C" valve bodies, etc. If pressures are good and plate replacement is required, be sure to break in the new plates with multiple turns in both directions at low speeds under load.
97 LEGACY - INFORMATION FOR YOU (9/96)
1. Engine pistons are coated with molybdenum to reduce friction. This coating allows for smoother travel through the cylinder and also reduces cylinder wall scuffing. The piston skirt will have a black appearance to it. This coating should NOT be removed if replacing pistons.
2. The piston skirt has been reshaped (shorter) and the overall weight reduced. Piston to cylinder wall clearance has been reduced by increasing the piston diameter.
3. Compression ratio has been increased to 9.7 to 1 by reshaping the crown of the piston.
4. Piston pin offset has been changed by 0.5mm.
5. There is an identification dot (indentation) on the piston crown and it MUST face the front of the engine when the piston is installed. Piston size is also stamped into the piston crown.
6. Both the 2.2l and 2.5l engines will use solid lifters. Both are adjustable but have DIFFERENT means of adjustment. Valve adjustment is scheduled to be checked/reset at 100,000 miles.
7. The 2.5l engine uses a metal head gasket which your parts department should have in stock. Numbers on the gasket should face up/outward when the gasket is properly installed.
8. ALL SUBARU ENGINES will use a new dry coil type injector. Servicing and diagnosing of these injectors remains the same as in the past.
9. The charcoal canister now operates with manifold vacuum instead of ported vacuum as in the past. A purge control VALVE instead of a solenoid is employed and it receives a duty signal from the ECU.
10. All '97 Legacy vehicles will employ a new central door locking system. NOTE: Unlike the previous system, when you lock the doors using the central door lock switch and close the door, THE DOORS WILL LOCK! The door handle is NOT required to be held in the "up" position to lock the doors.
11. A new resin-type door checker is used on '97 Legacy models. DO NOT LUBRICATE this checker. Improper door operation could result.
12. The two guide pins for the front brake calipers are different sizes and colors. The lower guide pin is GOLD in color and is 9.7mm in diameter. The upper guide pin is GRAY in color and is 10mm in diameter. These bolts MUST be installed in their proper locations.
13. 2.5l Legacy vehicles equipped with the 4EAT will use a different input shaft and converter with 23 teeth compared to 22 teeth of the current input shaft. Therefore, other models and parts are NOT interchangeable.
1997MY ENGINE NOISE (9/96)
'97MY engines have been fitted with solid valve lifters. These lifters help increase the power of the engines.
The 2.5l engine in '97 uses a lifter setup that requires the use of a shim to adjust the clearace.
A characteristic of this type of setup is a slight tapping noise, heard especially at idle, under the hood. The intensity of the noise may vary with engine temperature. Typically, this noise is not apparent in the passenger compartment. It is imperative that you discuss this operating characteristic with all dealer service personell to prevent unnecessary and unsuccessful attempts to totally eliminate this noise.
Every engine is being closely screened for noise level at the production line. We are confident that each engine meets our standards for operating noise at the time of production.
1996 and 1997 2.2l MANUAL TRANSMISSION EQUIPPED VEHICLES (9/96)
We have been advised of a running production change concerning the pressure plate for the above application [applies to 1996 Outbacks only]. The part number in question is 30210AA300. According to our information, double stamping of the diaphragm spring has been adopted to minimize variation of the spring. This will improve the parallel movement of the pressure plate during engagement and decrease the potential for clutch chatter.
1997 LEGACY warranty CLAIMS FOR LOOSE FUEL CAPS (9/96)
In the July Service Helpline Update reference was made to certain vehicles that will illuminate the MIL if the fuel cap is not properly tightened. It was also implied that this would not be covered under warranty.
This policy has been revised to allow no more than ONE claim per VIN under the "Customer Concern with no Repair Made" Policy, as described in section 8.4.17.1 of the CDS Policies, Guidelines and Procedures Manual.
FUEL GUAGES ON "E" (10/96)
Which would you rather have happen. Finding out that your car has more gas in the tank than you thought or getting stranded, out of gas, on the side of the road? Hopefully you're among the thinking people and chose the first alternative. This is Subaru's perspective also. That's why you will find that Subaru has provided a generous "E" on their fuel guages giving the customer an extra margin for error in their driving should they overlook monitoring their fuel supply for too long a time period. This prompts drivers to obtain fuel before they are in danger of running out and getting stranded.
...
Our Owner's Manuals state that the low fuel warning lights come on when there are about 2.3 US gallons left in the tank. Those are 2.3 usable gallons when the light is on steady . There is always some fuel (approx 1 US gallon) intentionally left unusable at the bottom of fuel tanks to help prevent contaminants received during fueling (water, sand, etc) from being drawn into the injection system. This means that between the usable 2.3 gallons left and the unusable 1 gallon left, that there are at least 3.3 gallons left in the tank when the guage reads "E" and the low fuel light is not on steady yet.
On a Legacy with a 15.9 gallon tank, this means that if you fuel your car when the guage reads "E" and the low fuel light is not on steady yet, you will be putting in approximately 12 gallons. This is normal. It also means that if you fuel your vehicle this way you will never get yourself stranded by finding yourself unexpectedly out of gas.
4EAT COLD WEATHER OPERATION (11/96)
Now that the colder weather is returning to many parts of the country, we though thtis would be a good time to remind you of this information.
The 4EAT has an automatic transmission fluid (ATF) temperature sensor. When the ATF temperature is below a certain temperature, the transmission control unit (TCU) will not lock up the torque converter. If it's even colder, it will not allow an upshift to 4th gear. This is a normal occurence and should not be diagnosed as an operational problem. This condition is usually noticed by the owner first thing in the morning or any time the vehicle has been sitting for several hours exposed to cold temperatures. Once the ATF temperature rises sufficiently, the transmission will operate with all its functions.
These normal events may appear abnormal to the customer. They may not remember last winter or may have only had their car since it's been warm. It's important for you to remember these normal operations. Also, remember that it is ATF temperature that determines whether or not the transmission gives you 4th gear or locks up the converter, not ENGINE temperature. Therefore, the temperature guage indicator on the dash has no bearing on the transmission actions. Under the right combination of temperature and driving conditions, it could take 10 miles or more to achieve full transmission operating temperatures.
***STATE I/M 240 EMISSION TESTING AND SUBARU AWD VEHICLES*** (4/97)
We would like to remind you that the United States E.P.A. has exempted Subaru Full-Time AWD (AWD) vehicles from the following performance warranty tests:
Loaded Test
Idle Test with Loaded Preconditioning
We have received reports of vehicles being damaged due to the above testing.
Resultant vehicle damage due to improper testing is NOT covered under the Subaru limited vehicle warranty and is the responsibility of the State I/M Program or its contractors or licensees.
Please refer to Subaru Technical Service Bulletin 11-45-95 for more information. It might be a good idea to give a copy of the Bulletin to your local IM stations [service bulletin is forthcoming - I just need to get it - Rich]
[** Subaru's official postion is that under no conditions may an AWD vehicle be tested on a 2-wheel dyno. 4-wheel dynos are supposed to be OK. States that only have 2-wheel dynos are to administer the tailpipe test ONLY.]
HESITATION ON ACCELERATION - 11-53-98 (2/99)
Applicability: 97-98 Legacy, Impreza, and Forester Manual Transmission Vehicles with 2.5l and 2.2l engines.
In the event you encounter a customer complaint of a slight engine hesitation between 1500-2500 rpm's when the engine is cold or hot, perform the following
Eliminate all external influences, such as an incorrect or dirty air filter, loose or tracked intake duct, dirty fuel filter, low fuel pressure, PVC system, or low engine vacuum that would indicate an external leak or an internal engine component.
If all external components are confirmed to be operating within vehicle specifications, the hesitation may be caused by the ignition control logic in the ECM. Under certain low rpm driving patterns, the ignition control system can pick up engine vibrations through the knock sensor and may retard the ignition timing. This ignition timing is learned by the ECM and placed in memory. NOTE: This area of memory can not be viewed by using the Select Monitor. When the vehicle is driven uinder these conditions, the timing may be retarded and could cause the engine to hesitate on acceleration. To confirm this condition, road test the vehicle while viewing the Knock Sensor Signal on the Select Monitor. If you duplicate the hesitation, and the reading on the monitor is around -10 degrees, you will need to change the ECM to correct the concern. [my note: this is an enhanced ECM, not a replacement with the same component]
PISTON SLAP IN 98 2.5L ENGINES
I don't have official wording on this, but the problem and solution are as follows:
A redesign of the piston "skirt" (the metal ring that sits above the piston head and surrounds the piston shaft) to lighten weight and improve performance has left the skirt too short and the piston may travel excessively from side to side, especially when cold. The symptoms include a ringing/tapping sound that doesn't go away completely when the engine is warmed up, and gets worse with age. The solution is to replace the entire short block (most of the engine) and pistons with redesigned ones. If you can convince the dealer that this is your problem, they're usually pretty easy about doing the work.
Current Recalls Regarding Outbacks
1. Throttle Valve Recall. A missing part in the throttle system may not allow a complete return of the throttle valve, resulting in a high idling condition (about 2,200 rpm). That high idle condition would cause faster vehicle movement and acceleration when your car is engaged in a drive or in reverse gear increasing the risk of a vehicle crash. You should contact your Subaru dealer and schedule a service appointment to inspect your vehicle. If you are driving your vehicle and you notice one of the above conditions, you should take your vehicle to a Subaru dealer immediately.
Affects 1997 and 1998 Legacys, VINs (last 6 digits) 202504-214589 and 607818-645477.
2. Transmission lever weld. Details to follow.
3. Too-thin CV-joint grease. This is *NOT* a recall, but enough complaints have occured that I thought I'd mention it. Symptoms are smoke and a burning smell from under the hood on some 1998 Outbacks and Foresters. The cause is improper DOJ (CV joint...) grease, which is too thin and melts at lower-than-desired temperatures, leaking onto the exhaust and vaporizing. Subaru will fix this under warranty, and it is not a safety issue, though driving your CV joints dry will destroy them.
4. 29,442 Legacys, including the Outback and SUS, manufactured in 1996 and 1997, may have a bad weld on a front transverse link assembly (one per side). If the weld begins to fail, the driver will hear loud and unusual noises; if the weld fails completely, a tire may fold under the vehicle, causing loss of control. This is apparently another part-supplier problem... Subaru has sent letters to registered potentially-affected owners; one must schedule an appointment with a dealer to have the welds inspected and replaced if a fault is found.
5. 21,000 1998-99 Legaycs. The oil filter can crack and spray oil on hot surfaces. This basically involved one particular lot number of the OEM oil filter (Purolator, I think). If you've had your first oil change, you have no concern. If you have stockpiled a number of filters for home use, and you bought them around August, take one to your dealer to check the affected lot numbers.
6. There is a new recall regarding unwanted airbag deployment in '95 and '96 Legacys and Imprezas. The official recall notice hasn't been sent out yet, but it has to do with hitting the tiedown loops underneat the car against a hard surface and deploying the airbag. More details forthcoming.
7. *NEW* 221,000 1998-1999 Legacys and Foresters with 2.5l engines are being recalled due to a malfunctioning valve in the brake master cylinder. This valve can stick and cause loss of braking in extreme cold weather (-22f and below). Braking can be restored by quickly releasing and re-applying the pedal. This is a voluntary recall (meaning that Subaru wasn't forced by the Gov't to do it) and letters will be sent to those affected. No accidents or injuries have been reported as a result of this.