2004 LEGACY SERVICE MANUAL QUICK REFERENCE INDEX
Contents
1. AT 01981 4 Remove the retainer and return spring 5 Remove the front brake piston by blowing com pressed air 6 Remove the D ring from front brake piston SAT 86 Oil Pump Cover 2 OIL PUMP 1 Take out the oil pump housing AT 01982 2 Take out the oil pump body D ASSEMBLY 1 FRONT BRAKE 1 Apply ATF to D ring and then install it to the front brake piston 2 Install the front brake piston to oil pump cover NOTE Install by aligning the A mark on front brake pis ton surface with the oil pump cover rib 8 3 Install the retainer and return spring 4 Install the front brake piston assembly using ST1 ST2 and ST3 GI 18762AA000 COMPRESSOR SPECIAL TOOL ST2 18765AA000 COMPRESSOR SUPPORT AT 02350 AUTOMATIC TRANSMISSION ST3 18763AA000 COMPRESSOR SHAFT AT 01981 5 Install the genuine driven plate instead of retain er plate temporarily assemble the drive plate and driven plate ST 31536AA290 6 Install the snap ring DRIVEN PLATE AT 01980 7 Measure the clearance between retainer plate and snap ring and then select a suitable retainer plate from table Front brake clearance standard value 0 7 1 1 mm 0 028 0 043 in AT 01983 Front brake retainer plate Thickness mm in 3 4 0 134 Part Number 31567AB1302. A Outer race 4 Separate the front roller bearing from the shaft using press and ST SAT 89 Drive Pinion Shaft Assembly AUTOMATIC TRANSMISSION ST 498517000 REPLACER AT 00199 A Front roller bearing D ASSEMBLY 1 Measure the dimension A of drive pinion shaft ST 398643600 GAUGE A AT 00200 2 Using a press press fit the new roller bearing into specified position NOTE If excessive force is applied to roller bearing the roller bearing will not turn easily AT 00201 A Drive pinion shaft B Roller bearing 3 After fitting a new O ring to the shaft attach the drive pinion collar to shaft 4 Install the lock washer to drive pinion shaft in proper direction 5 Tighten new lock nuts using ST1 ST2 and ST3 Calculate the lock washer and lock nut specifica tions using following formula T2 L2 L1 L2 x T1 T1 116 N m 11 8 kgf m 85 3 ft lb Required torque setting T2 Tightening torque L1 ST2 length 0 072 m 2 83 in L2 Torque wrench length Example Torque wrench length Tighteningtorque m in N m kgf m ft lb 0 4 15 75 98 10 0 72 0 45 17 72 100 10 2 73 8 0 5 19 69 101 10 3 74 5 0 55 21 65 102 10 4 75 ST1 18667AA010 HOLDER ST2 499787700 WRENCH ST3 499787500 ADAPTER NOTE Install the ST2 to torque wrench as straight as pos sible
3. amp S ST3 3 ST2 AS L1 m in L2 m in ST1 Si AT 00202 6 Measure the starting torque of bearing Make sure the starting torque is within the specified range If the torque is not within specified range re place the roller bearing Starting torque 7 6 38 1 N 0 776 3 88 kgf 1 7 3 88 kg AT 00203 7 Stake the caulking of lock nut at two points 8 Measure the dimension B of drive pinion shaft SAT 90 Drive Pinion Shaft Assembly AUTOMATIC TRANSMISSION ST 398643600 GAUGE AT 00204 9 Calculate the thickness t mm of drive pinion shim t 6 5 0 0625 B A 10 Select three or less shims from following table Drive pinion shim Thickness mm in 0 150 0 0059 31451AA190 0 175 0 0069 31451AA200 0 200 0 0079 31451AA210 0 225 0 0089 Part Number 31451AA180 31451AA220 0 250 0 0098 0 275 0 0108 31451AA230 E INSPECTION e Make sure that all component parts are free of scratch hole and other faults e Adjust the teeth alignment lt Ref to 5AT 91 AD JUSTMENT Drive Pinion Shaft Assembly gt F ADJUSTMENT 1 Remove the liquid gasket completely from mat ing surfaces 2 Install the converter case to oil pump cover and secure them with tightening four bolts evenly NOTE Use an old gasket or aluminum washer so as not to damage the mating surface of housing Tig
4. 5 Remove the oil charge pipe lt Ref to 5AT 70 REMOVAL Oil Charge Pipe gt 6 Remove the ATF filter inlet and outlet pipes lt Ref to 5AT 60 REMOVAL ATF Filter gt 7 Remove the converter case aligning bolt 8 Lay along the transmission body and then re move the oil pan 9 Remove the three converter case aligning bolts TORX ST 18676AA020 TORX WRENCH 10 Separate the converter case by lightly tapping with plastic hammer 11 Remove the differential assembly lt Ref to 5AT 94 REMOVAL Front Differential gt 12 Remove the oil seal from converter case B INSTALLATION 1 Check the appearance of each component and clean them 2 Press fit the oil seal to converter case using ST ST 499587100 OIL SEAL INSTALLER An GEN AT 01979 3 Install the differential assembly to case lt Ref to 5AT 94 INSTALLATION Front Differential gt 4 Install the left and right side retainers lt Ref to 5AT 97 ADJUSTMENT Front Differential gt 5 Apply proper amount of liquid gasket to the en tire matching surface of converter case Liquid gasket THREE BOND 1215 Part No 004403007 AT 01975 6 Install the converter case assembly without damaging bushing and oil seal Tightening torque 41 N m 4 2 kgf m 30 4 ft lb 7 Install the three converter case aligning bolts TORX ST 18676AA020 TORX WRENCH Tightening torque 41 N m 4
5. 5 Tighten the securing bolts while pressing park ing support actuator with finger Tightening torque 10 2 N m 1 040 2 kgf m 7 4 1 5 ft lb CAUTION Press the reduction driven gear and parking pawl in bottom condition 6 Using the ST tighten the bolts which tightened in step 4 with specified angle Tightening angle 18 42 ST 18554AA000 ANGLE GAUGE SAT 82 Parking Pawl NOTE Do not use extension as much as possible AT 02072 7 Install the center differential carrier lt Ref to 5AT 80 INSTALLATION Center Differential Carri er gt 8 Install the extension case and intermediate case lt Ref to 5AT 72 INSTALLATION Extension Case amp Intermediate Case gt 9 Install the transmission assembly into vehicle lt Ref to 5AT 42 INSTALLATION Automatic Transmission Assembly gt C INSPECTION Make sure that the tab of parking pawl on reduction driven gear is not worn or otherwise damaged SAT 83 AUTOMATIC TRANSMISSION Converter Case AUTOMATIC TRANSMISSION 32 Converter Case A REMOVAL 1 Remove the transmission assembly from vehi cle lt Ref to 5AT 38 REMOVAL Automatic Trans mission Assembly gt 2 Remove the torque converter assembly lt Ref to 5AT 71 REMOVAL Torque Converter Assembly gt 3 Remove the transmission harness connector from stay 4 Remove the turbine speed sensor 1 lt Ref to 5AT 57 REMOVAL Turbine speed sensor 1 gt
6. _7 LU H AT 02372 2 If the clearance is out of specification select a suitable retainer plate from following table and assemble it Retainer plate Part Number Thickness mm in 31567AB100 4 2 0 165 31567AB170 0 173 31567AB180 31567AB190 0 189 31567AB200 10 Install the direct clutch assembly 4 4 0 173 4 6 0 181 4 8 0 189 5 0 0 197 SAT 102 AT 01997 AT Main Case AUTOMATIC TRANSMISSION 11 Install the high amp low reverse clutch assembly 14 Install the rear carrier assembly AT 01996 12 Install the thrust needle bearing of high amp low reverse clutch Sy ITI eeh AA et WII H Mid IS E A AT 01993 AROGE 15 Install the middle carrier assembly 13 Install the middle amp rear sun gear assembly AT 01992 AT 01994 5AT 103 AT Main Case AUTOMATIC TRANSMISSION 16 Install the thrust needle bearing of middle carri er assembly T S Oo AT 01991 17 Measure the total end play and select the bearing lt Ref to 5AT 106 ADJUSTMENT AT Main Case gt 18 Install the impact clutch pack assembly to oil pump cover AT 02006 A Impact clutch pack ASSY B Front sun gear ASSY 19 Turn the transmission sideways 20 Install the oil pump cover 1 Apply
7. B Inner rotor C Outer rotor Side clearance 0 02 0 045 mm 0 0008 0 0018 in B A Depth gauge B Inner rotor C Outer rotor AT 01978 3 If the depth and or side clearance are not within the specifications replace the rotor as sembly Oil pump rotor ASSY Thickness mm in 11 37 11 38 0 4476 0 4480 11 38 11 39 0 4480 0 4484 11 39 11 40 0 4484 0 4488 Part Number 15008AA130 15008AA140 15008AA150 Measure the total end play and adjust it within specifications lt Ref to 5AT 106 ADJUST MENT AT Main Case gt SAT 88 Drive Pinion Shaft Assembly AUTOMATIC TRANSMISSION 34 Drive Pinion Shaft Assembly A REMOVAL 1 Remove the transmission assembly from vehi cle lt Ref to 5AT 38 REMOVAL Automatic Trans mission Assembly gt 2 Pull out the torque converter assembly lt Ref to 5AT 71 REMOVAL Torque Converter Assembly gt 3 Remove the transmission harness connector from stay 4 Disconnect the air breather hose lt Ref to 5AT 69 REMOVAL Air Breather Hose gt 5 Remove the oil charge pipe lt Ref to 5AT 70 REMOVAL Oil Charge Pipe gt 6 Remove the ATF filter inlet and outlet pipes lt Ref to 5AT 60 REMOVAL ATF Filter gt 7 Separate the converter case and transmission case part lt Ref to 5AT 84 REMOVAL Converter Case gt 8 Remove the drive pinion shaft mounting bolt and then remove the driv
8. lt Ref to 5AT 60 IN STALLATION ATF Filter gt 28 Install the oil charge pipe with O ring lt Ref to 5AT 70 INSTALLATION Oil Charge Pipe gt 29 Install the torque converter assembly lt Ref to 5AT 71 INSTALLATION Torque Converter As sembly gt 30 Install the transmission assembly into vehicle lt Ref to 5AT 42 INSTALLATION Automatic Transmission Assembly gt C DISASSEMBLY 1 INPUT CLUTCH PACK ASSY 1 Remove the front sun gear AT 02007 2 Remove the snap ring and then remove the front carrier HDH Uton pn nooit AT 02008 3 Remove the input clutch assembly from rear in ternal gear AT 02009 D ASSEMBLY 1 INPUT CLUTCH PACK ASSY 1 Assemble the input clutch assembly to rear inter nal gear AT 02009 2 Install the front carrier and then install the snap ring l KOR AT 02008 3 Install the front sun gear sa SS V CES AT 02007 SAT 105 AT Main Case AUTOMATIC TRANSMISSION E INSPECTION 1 FRONT MIDDLE amp REAR PLANETARY CARRIER ASSY Inspect the followings e Visually inspect the tooth surface of planetary gear and replace with new one if damaged broken or excessively worn e Inspect the planetary carrier body for damage or brakeage 2 INPUT CLUTCH Check for damage of drive plate driven plate and snap ring and replace them as inpu
9. 31567AB140 3 6 0 142 31567AB150 3 8 0 150 4 0 31567AB160 0 157 8 Remove the snap ring replace the drive plate which used in measurement of clearance with re tainer plate and then reassemble SAT 87 Oil Pump Cover AUTOMATIC TRANSMISSION 2 OIL PUMP 1 Apply ATF to oil pump assembly and then install it to oil pump housing 2 Install the O ring to oil pump cover 3 Install the oil pump housing to oil pump housing cover Tightening torque 10 N m 1 0 kgf m 7 4 ft lb AT 01982 E INSPECTION 1 FRONT BRAKE Check the following items e Drive plate facing for wear and damage e Snap ring for wear return spring for damage and retainer for damage e Piston for damage e D ring for damage 2 OIL PUMP Check the following items e Oil pump cover and oil seal for breakage or dam age e Oil pump body for scratch or damage 1 Check seal ring and oil seal for breaks or dam ages 2 Check other parts for dents or abnormalities 3 Selection of oil pump rotor assembly 1 Tip clearance Install the inner rotor and outer rotor to oil pump housing With rotor gears facing each other measure the crest to crest clearance Tip clearance 0 02 0 15 mm 0 0008 0 0059 in A B C X Wi AT 01977 2 Side clearance Set a depth gauge to oil pump housing then measure the oil pump housing to rotor clear ance A Thickness gauge
10. Hose AUTOMATIC TRANSMISSION 21 ATF Cooler Pipe amp Hose A REMOVAL 1 EXCEPT FOR ATF COOLER MODEL WITH WARMER FUNCTION 1 Set the vehicle on a lift 2 Remove the battery 3 Lift up the vehicle 4 Remove the under cover 5 Remove the radiator under cover DO EH A ce A IOJ 2A e We S 1 ated Cer me a ae AT 01344 6 Disconnect the ATF cooler hose from radiator NOTE e Do not use a screwdriver or other pointed tools e When hard to remove the hose wrap the hose with cloth to prevent from damaging and then turn with pliers and pull out with hand straightly AT 01345 7 Disconnect the ATF cooler hoses from pipes NOTE e Do not use a screwdriver or other pointed tools e When hard to remove the hose wrap the hose with cloth to prevent from damaging and then turn with pliers and pull out with hand straightly we E 5AT 64 ATF Cooler Pipe amp Hose 9 Remove the oil cooler inlet and outlet pipes NOTE When disconnecting the outlet pipe be careful not to lose the ball and spring used with retaining screw A Outlet pipe B Inlet pipe 2 ATF COOLER MODEL WITH WARMER FUNCTION 1 Lift up the vehicle 2 Remove the front exhaust pipe lt Ref to EX H6DO 5 REMOVAL Front Exhaust Pipe gt 3 Disconnect the inlet and outlet hoses o
11. 01951 4 Install the rear vehicle speed sensor Tightening torque 7 N m 0 7 kgf m 5 1 ft lb AT 01950 5 Install the transmission assembly lt Ref to 5AT 42 INSTALLATION Automatic Transmission Assembly gt SAT 72 Extension Case amp Intermediate Case C DISASSEMBLY 1 Take out the transfer clutch and multi plate clutch hub assembly by lightly tapping the end of rear drive shaft NOTE Be careful not to damage the oil seal of extension 2 Remove snap ring using ST and press ST 18762AA000 COMPRESSOR SPECIAL TOOL ton AT 01961 4 Remove the dust cover from extension case 5 Remove the oil seal from extension case D ASSEMBLY 1 Press fit new oil seal using ST and press ST 498057300 INSTALLER 2 Press fit the dust cover 3 Insert the multi plate clutch drive plate driven plate and spring retainer AT 01962 gt Spring retainer Multi plate clutch LSD piston assembly E AUTOMATIC TRANSMISSION 4 Using the ST and compressor install the snap ring ST 18762AA000 COMPRESSOR SPECIAL TOOL AT 01960 5 Install the transfer clutch lt Ref to 5AT 74 IN STALLATION Transfer Clutch gt NOTE For 3 transfer clutch model make sure the press plate is included 6 Install the multi plate hub assembly E INSPECTION e Use compressed air to make sure the extensi
12. 2 kgf m 30 4 ft lb 8 Apply proper amount of liquid gasket to the en tire oil pan mating surface and then install it Liquid gasket THREE BOND 1217B Part No KO877YA020 SAT 84 Converter Case Tightening torque 5 N m 0 5 kgf m 3 7 ft lb AT 01955 9 Install the transmission harness connector to the stay 10 Install the air breather hose lt Ref to 5AT 69 INSTALLATION Air Breather Hose gt 11 Install the ATF filter pipe lt Ref to 5AT 60 IN STALLATION ATF Filter gt 12 Install the oil charge pipe with O ring lt Ref to 5AT 70 INSTALLATION Oil Charge Pipe gt 13 Install the torque converter assembly lt Ref to 5AT 71 INSTALLATION Torque Converter As sembly gt 14 Install the transmission assembly into vehicle lt Ref to 5AT 42 INSTALLATION Automatic Transmission Assembly gt C INSPECTION Measure the backlash and then adjust it within specification lt Ref to 5AT 91 ADJUSTMENT Drive Pinion Shaft Assembly gt SAT 85 AUTOMATIC TRANSMISSION Oil Pump Cover AUTOMATIC TRANSMISSION 33 Oil Pump Cover A REMOVAL 1 Remove the transmission assembly from vehi cle lt Ref to 5AT 38 REMOVAL Automatic Trans mission Assembly gt 2 Pull out the torque converter assembly lt Ref to 5AT 71 REMOVAL Torque Converter Assembly gt 3 Remove the transmission harness connector from stay 4 Remove the oil charge pipe lt
13. ATF to the O ring of input clutch shaft 2 Install the oil pump cover to AT main case while supporting the input clutch shaft and oil pump housing by hand AT 01990 3 Make sure the rear end of drive pinion shaft is engaged to the spline of reduction driven gear AT 02092 A Drive pinion shaft 4 Using a cloth protect the input clutch shaft and rotate to engage the spline of input clutch and rear carrier using pliers NOTE Work with pressing oil pump cover AT 02046 A Cloth 5 Combine the oil pump cover with transmis sion main case Tightening torque 41 N m 4 2 kgf m 30 4 ft lb AT 01976 21 Install the center differential carrier lt Ref to 5AT 80 INSTALLATION Center Differential Carri er gt 22 Install the reduction driven gear lt Ref to 5AT 78 INSTALLATION Reduction Driven Gear gt SAT 104 AT Main Case AUTOMATIC TRANSMISSION 23 Install the extension case and intermediate case lt Ref to 5AT 72 INSTALLATION Extension Case amp Intermediate Case gt 24 Install the control valve body lt Ref to 5AT 58 INSTALLATION Control Valve Body gt 25 Install the converter case assembly into trans mission case assembly lt Ref to 5AT 84 INSTAL LATION Converter Case gt 26 Install the air breather hose lt Ref to 5AT 69 INSTALLATION Air Breather Hose gt 27 Install the ATF filter pipe
14. DIAL GAUGE NOTE e Measure the backlash by applying a pinion tooth between two bevel gear teeth e Fix the bevel pinion gear in place with a screw driver or similar tool when measuring Standard value 0 13 0 18 mm 0 0051 0 0071 in BELA AT 00224 3 If the backlash is not within specifications select a washer from the table below Washer Part Number 803038021 803038022 803038023 Thickness mm in 0 95 0 037 1 00 0 039 1 05 0 041 5AT 96 Front Differential 6 Using the ST install the taper roller bearing ST 398487700 DRIFT 2 SIDE RETAINER NOTE Install the oil seal and O ring of side retainer after the adjustment of backlash and tooth contact 1 Install the bearing outer race to side retainer 2 Fit a new oil seal using ST ST 18675AA000 DIFFERENTIAL SIDE OIL SEAL INSTALLER NOTE Apply oil to the oil seal lips e 3 Install a new O ring AT 00226 AT 00219 E INSPECTION e Check each component for scratches damage and other faults e Measure the backlash and then adjust it within specification lt Ref to 5AT 97 ADJUSTMENT Front Differen tial gt F ADJUSTMENT 1 Using the ST screw in the retainer until light contact is felt NOTE Screw in the RH side slightly deeper than the LH side AUTOMATIC TRANSMISSION ST 18630AA010 WRENCH
15. INSTALLATION SE 1 Install the reverse brake piston NOTE Apply ATF onto the piston sliding surface GI 18762AA000 COMPRESSOR SPECIAL TOOL ST2 18765AA000 COMPRESSOR SUPPORT ST3 18763AA000 COMPRESSOR SHAFT 2 Install the return spring AT 02001 26 Remove the return spring AT 02002 3 Install the spring retainer and snap ring ST1 18762AA000 COMPRESSOR SPECIAL TOOL ST2 18765AA000 COMPRESSOR SUPPORT AT 02002 27 Remove the snap ring of reverse brake piston GI 18762AA000 COMPRESSOR SPECIAL TOOL ST2 18765AA000 COMPRESSOR SUPPORT ST3 18763AA000 COMPRESSOR SHAFT SAT 101 AUTOMATIC TRANSMISSION AT Main Case ST3 18763AA000 COMPRESSOR SHAFT ST3 ST2 AT 02000 4 Install the dish plate NOTE When installing make sure that the identification mark is facing the front side of transmission 5 Install the drive plate and driven plate 6 Install the leaf spring AT 01999 A Leaf spring 7 Install the retaining plate 8 Install the snap ring of reverse brake 9 Perform the clearance check of reverse brake 1 Measure the clearance between retainer plate and snap ring using thickness gauge Standard value 0 7 1 1 mm 0 028 0 043 in DI EE E M
16. Ref to 5AT 70 REMOVAL Oil Charge Pipe gt 5 Remove the ATF filter inlet and outlet pipes lt Ref to 5AT 60 REMOVAL ATF Filter gt 6 Separate the converter case and transmission case lt Ref to 5AT 84 REMOVAL Converter Case gt 7 Remove the differential side retainers using ST NOTE Hold the differential case assembly by hand to avoid damaging the retainer mounting hole of con verter case ST 18630AA010 WRENCH COMPL RETAIN ER 8 Remove the differential assembly without dam aging the installation part of retainer B INSTALLATION 1 When installing the differential assembly to case be careful not to damage the inside of case particularly the differential side retainer mating surface AT 01987 A Differential ASSY 2 Install the O ring to left and right side retainer 3 Install the side retainers using ST lt Ref to 5AT 94 REMOVAL Front Differential gt ST 18630AA010 WRENCH COMPL RETAIN ER 4 Adjust the front differential backlash lt Ref to 5AT 97 ADJUSTMENT Front Differential gt 5 Install the lock plate Tightening torque 25 N m 2 5 kgf m 18 1 ft lb AT 01988 A Lock plate 6 Install the converter case to transmission case lt Ref to 5AT 84 INSTALLATION Converter Case gt 7 Install the transmission harness connector to the stay 8 Install the ATF filter pipe lt Ref to 5AT 60 IN STALLATION ATF Filter gt
17. Ref to 5AT 70 REMOVAL Oil Charge Pipe gt 5 Remove the ATF filter inlet and outlet pipes lt Ref to 5AT 60 REMOVAL ATF Filter gt 6 Separate the converter case and transmission case part lt Ref to 5AT 84 REMOVAL Converter Case gt 7 Remove the oil pump cover aligning bolt and then separate it from the AT main case by lightly tapping with plastic hammer AT 01976 B INSTALLATION 1 Secure the oil pump cover Tightening torque 41 N m 4 2 kgf m 30 4 ft lb AT 01976 2 Install the converter case assembly into trans mission case assembly lt Ref to 5AT 71 INSTAL LATION Torque Converter Assembly gt 3 Install the transmission harness connector to the stay 4 Install the ATF filter pipe lt Ref to 5AT 60 IN STALLATION ATF Filter gt 5 Install the oil charge pipe with O ring lt Ref to 5AT 70 INSTALLATION Oil Charge Pipe gt 6 Install the torque converter assembly lt Ref to 5AT 71 INSTALLATION Torque Converter As sembly gt 7 Install the transmission assembly into vehicle lt Ref to 5AT 42 INSTALLATION Automatic Transmission Assembly gt C DISASSEMBLY 1 FRONT BRAKE 1 Remove the snap ring AT 01980 2 Remove the retainer plate drive plate and driven plate 3 Remove the snap ring using ST1 ST2 and ST3 GI 18762AA000 COMPRESSOR SPECIAL TOOL ST2 18765AA000 COMPRESSOR SUPPORT ST3 18763AA000 COMPRESSOR SHAFT
18. differential as sembly 5 Install the snap ring 6 Using a press install a new ball bearing into the center differential assembly ST 498077000 REMOVER ST u i SE Zl A AT 00170 A Plate B Center differential carrier 7 Apply vaseline onto the seal ring outer surface and shaft grooves 8 Install a new seal rings E INSPECTION e Check each parts for holes damages or other foreign matters e Inspect the extension end play and adjust it to within specifications lt Ref to 5AT 74 ADJUST MENT Transfer Clutch gt SAT 81 Parking Pawl AUTOMATIC TRANSMISSION 31 Parking Pawl A REMOVAL 1 Remove the transmission assembly from vehi cle lt Ref to 5AT 38 REMOVAL Automatic Trans mission Assembly gt 2 Remove the extension case and intermediate case lt Ref to 5AT 72 REMOVAL Extension Case amp Intermediate Case gt 3 Remove the center differential carrier lt Ref to 5AT 80 REMOVAL Center Differential Carrier gt 4 Remove the parking support actuator 5 Remove the parking pawl parking pawl shaft and return spring B INSTALLATION 1 Set the transmission to N range 2 Install the parking pawl parking pawl shaft and return spring 3 Temporarily secure the parking support actua tor 4 Set the ST between parking pawl and parking support actuator ST 18679AA000 ADJUSTER
19. press remove the revolution gear AT 00149 A Revolution gear 2 Using a press remove the front and rear side ball bearings and clutch hub AT 00151 A Rear ball bearing B Rear drive shaft C Clutch hub D ASSEMBLY Assemble in the reverse order of disassembly NOTE e Use new ball bearings and revolution gear e Make sure the clutch hub is oriented in the cor rect direction A C D AT 00152 A Front side B Clutch hub C Rear side D Revolution gear E INSPECTION e Check each parts for holes damages or other foreign matters e Inspect the extension end play and adjust it to within specifications lt Ref to 5AT 74 ADJUST MENT Transfer Clutch gt SAT 77 Reduction Driven Gear AUTOMATIC TRANSMISSION 29 Reduction Driven Gear A REMOVAL 1 Remove the transmission assembly from vehi cle lt Ref to 5AT 38 REMOVAL Automatic Trans mission Assembly gt 2 Remove the rear vehicle speed sensor and then separate the extension case and intermediate case from transmission case lt Ref to 5AT 72 REMOV AL Extension Case amp Intermediate Case gt 3 Remove the center differential carrier lt Ref to 5AT 80 REMOVAL Center Differential Carrier gt 4 Set the select lever to P range 5 Using the ST1 and ST2 extract the reduction driven gear ST1 499737100 PULLER SET ST2 18680AA000 GE
20. to side retainer ST 398527700 PULLER ASSY AT 00222 5 Restore the removed claws to original position and install the pin and split pin 6 Hold the shaft of ST to avoid removing from side retainer and then remove the bearing outer race ST 398527700 PULLER ASSY SAT 95 Front Differential AUTOMATIC TRANSMISSION NOTE Replace the bearing inner and outer races as a sin gle unit AT 00223 A Shaft B Side retainer D ASSEMBLY 1 DIFFERENTIAL CASE ASSEMBLY 1 Install the washer differential bevel gear and dif ferential bevel pinion in the differential case RH Insert the pinion shaft 2 Install the straight pin in reverse direction AT 00218 A Differential case RH 3 Install the washer and differential bevel gear to differential case LH Put the differential case RH on the case and then combine the both cases 4 Install the hypoid driven gear and secure by tightening the bolt Tightening torque 62 N m 6 3 kgf m 45 6 ft lb AT 00217 A Hypoid driven gear B Differential case RH C Differential case LH 5 Measurement of backlash Selection of washer 1 Install the SUBARU genuine axle shaft to differential case Parts No 38415AA070 AXLE SHAFT 2 Measure the gear backlash using ST1 and ST2 and then insert the ST2 from the access window of case ST1 498247001 MAGNET BASE ST2 498247100
21. 2004 LEGACY 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 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 CONTROL SYSTEMS AUTOMATIC TRANSMISSION 4AT AUTOMATIC TRANSMISSION AAT diag DIAGNOSTICS AUTOMATIC TRANSMISSION 5AT AUTOMATIC TRANSMISSION DIAGNOSTICS Ets LETS MANUAL TRANSMISSION AND DIFFERENTIAL 5MT CLUTCH SYSTEM CL G2320GE5 AUTOMATIC TRANSMISSION Page 1 General Eet ieee satire ege GER 2 2 Automatic Transmission Flug 27 3 Differential Gear OU 29 dk Poad Teslan ana eee 30 GC H KEE 31 6 Time Lag TeSt geeiert iehisdetinenidncos tone a A aE A ance Aner 33 7 Line Press re Test iini tians fee hag decane oct einai ARA L
22. 30 0 27 3 33 T in 1 059 0 917 0 012 0 131 According to the calculation the value T would be 3 33 3 63 mm 0 131 0 143 in therefore se lect the thrust bearing with the thickness of 3 4 mm 0 134 in or 3 6 mm 0 142 in thrust bearing from the table NOTE Calculation formula for T is applied when measur ing using ST 499575400 GAUGE In the calcula tion without using ST insert the thickness of collar to calculate value E on step 5 SAT 107 Transmission Control Device AUTOMATIC TRANSMISSION 37 Transmission Control Device A REMOVAL 1 Remove the transmission assembly from vehi cle lt Ref to 5AT 38 REMOVAL Automatic Trans mission Assembly gt 2 Pull out the torque converter assembly lt Ref to 5AT 71 REMOVAL Torque Converter Assembly gt 3 Lift up the lever on rear side of transmission har ness connector and then disconnect it from stay 4 Disconnect the air breather hose lt Ref to 5AT 69 REMOVAL Air Breather Hose gt 5 Wrap vinyl tape around the nipple attached to the air breather hose 6 Remove the pitching stopper bracket 7 Remove the control valve body assembly lt Ref to 5AT 58 REMOVAL Control Valve Body gt 8 Pull out the straight pin of manual plate AT 00305 9 Remove the bolts securing select lever and then remove the select lever manual plate and parking rod NOTE Be careful not to damage the lips of press
23. 9 Install the oil charge pipe with a O ring lt Ref to 5AT 70 INSTALLATION Oil Charge Pipe gt 10 Install the torque converter assembly lt Ref to 5AT 71 INSTALLATION Torque Converter As sembly gt 11 Install the transmission assembly into vehicle lt Ref to 5AT 42 INSTALLATION Automatic Transmission Assembly gt C DISASSEMBLY 1 DIFFERENTIAL CASE ASSEMBLY 1 Remove the taper roller bearing using ST and press ST 498077000 REMOVER AT 00216 SAT 94 Front Differential AUTOMATIC TRANSMISSION 2 Secure the case in a vise and remove the hypoid driven gear tightening bolts then separate the hy poid driven gear case RH and case LH AT 00217 A Hypoid driven gear B Differential case RH C Differential case LH 3 Pull out the straight pin and shaft and then re move the differential bevel gear washer and differ ential bevel pinion AT 00218 A Differential case RH 2 SIDE RETAINER NOTE After adjusting the drive pinion backlash and tooth contact remove and install the oil seal and O ring 1 Remove the O ring AT 00219 2 Remove the oil seal e AT 00220 3 Remove the split pin and then remove the claw ST 398527700 PULLER ASSY AT 00221 A Claw B Split pin C Pin 4 Attach two claws to the outer race and set the ST
24. ANAI NAANA TRENAS SANAS RAUTAA ANNA stad 34 8 Transfer Clutch Pressure Tei 36 9 Automatic Transmission Assembly cee eeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeenaaees 38 10 Transmission Mounting System Av 47 11 Extension Case Oil Seal n ronan A a d 49 12 Differential Side Retainer Oil Gezai 50 13 gt MADIO r SWitC Hire n a A a A eaaa uaea ieee 51 14 Front Vehicle Speed Sensor EE 52 15 Rear Vehicle Speed SSNSOM ic cece scacds eae w ceases Geeta oacceen scien dare antes echae 54 16 Turbine speed sensor 1 cee ccceeeeeeeeseeeeeeeeeeeeeeseeeaeeeeeeeeesenseeeseeeeeeeeeeeees 57 ifs Gontrol Valve Body basctet st duet EE 58 REN OR GIE 60 19 Transmission Control Module TOM 61 20 Lateral G Gensor enrian a iia a a aaa aaa ana raaa Eonia daadaa 63 21 ATF Cooler Pipe amp HOSE narn e e e eine eA 64 22 Ar Breather Hos Seega a ENEE AA 69 GC Heu eiee Ce 70 24 Torque Converter Assembly ae ccc secces vets scteuesaeetdedacseedeedinieeeeticaeatier aliens 71 25 Extension Case amp Intermediate Case 72 en d et ET e EE 74 27 Multi Plate Chutch a rE e Aa A 76 28 Rear Drive hatt 77 29 Reduction Driven Gear 78 30 Center Differential Carter 80 Si Ee ee EE 82 32 EIER eege tected eege 84 33 Oil ie ee EE 86 34 Drive Pinion Shaft Assembly AAA 89 35 gt Pront BC UC EE 94 36 AT Main e 99 37 Transmission Control Device 0 cee ceeeeeceeeeceeececeeeceneeeceeeceteeeseeeeneaess 108 ATF Cooler Pipe amp
25. AR HOLDER 3 A Reduction driven gear AT 01968 B INSTALLATION 1 Set the select lever to P range 2 Use a plastic hammer to install reduction driven gear assembly 3 Select the reduction gear shim lt Ref to 5AT 79 ADJUSTMENT Reduction Driven Gear gt 4 Connect the transmission case extension case and intermediate case and install the rear wheel speed sensor lt Ref to 5AT 72 INSTALLATION Extension Case amp Intermediate Case gt 5 Install the transmission assembly into vehicle lt Ref to 5AT 42 INSTALLATION Automatic Transmission Assembly gt C DISASSEMBLY 1 Remove the ball bearing from reduction driven gear using ST ST 498077310 REMOVER AT 00157 A Ball bearing 2 Remove the ball bearing on reverse side with the same procedure in step 1 3 Remove the snap ring from reduction driven gear D ASSEMBLY 1 Install the snap ring to reduction driven gear 2 Install the new ball bearing to reduction driven gear using press AT 01970 A Ball bearing SAT 78 Reduction Driven Gear 3 Install the ball bearing on reverse side with the same procedure in step 2 AT 01971 E INSPECTION Make sure the ball bearing and gear are not de formed or damaged F ADJUSTMENT 1 Using depth gauge measure depth A from mating surface of extension case to ball bearing on re
26. ASSY AT 00227 2 Remove the oil pump cover 3 Remove the liquid gasket from the mating sur face completely 4 Install the oil pump cover to converter case and secure them with tightening four bolts evenly NOTE Use an old gasket or aluminum washer so as not to damage the mating surface of housing Tightening torque 41 N m 4 2 kgf m 30 4 ft lb 5 Rotate the drive pinion ten times or more using ST1 and ST2 ST1 18667AA010 HOLDER ST2 499787700 WRENCH ST1 AT 01985 6 Tighten the retainer LH until contact is felt while rotating the shaft Then loosen the retainer RH Keep tightening the retainer LH and loosening the retainer RH until the pinion shaft cannot be turned This is the zero state AT 01986 A Retainer SAT 97 Front Differential AUTOMATIC TRANSMISSION 7 After the zero state is established back off the retainer LH 3 notches and secure it with the lock plate Then back off the retainer RH and retighten until it stops Rotate the drive pinion few times Tighten the retainer RH 1 3 4 notches further This sets the preload Finally secure the retainer with its lock plate AT 01988 A Lock plate NOTE Turning the retainer by one tooth changes the backlash about 0 05 mm 0 0020 in AT 01989 A 0 05 mm 0 0020 in 8 Turn the drive pinion several times with ST1 a
27. Less than 8 mm 0 31 in AT 01641 A Dimension A AUTOMATIC TRANSMISSION 6 Install the transmission assembly into the vehi cle lt Ref to 5AT 42 INSTALLATION Automatic Transmission Assembly gt C INSPECTION Make sure the ring gear and protrusion of torque converter end are not deformed or damaged SAT 71 Extension Case amp Intermediate Case AUTOMATIC TRANSMISSION 25 Extension Case amp Intermedi ate Case A REMOVAL 1 Remove the transmission assembly lt Ref to 5AT 38 REMOVAL Automatic Transmis sion Assembly gt 2 Remove the rear vehicle speed sensor AT 01950 3 Separate the extension case and intermediate case AT 01951 4 Separate the intermediate case and transmis sion main case r M fi i Si al AT 01952 B INSTALLATION 1 Secure the intermediate case to transmission main case Tightening torque 25 N m 2 5 kgf m 18 4 ft lb NOTE Use a new gasket jl I i i dp Uu D Di ll AT 01952 2 Attach the selected reduction driven gear shim to end surface of reduction driven gear with vase line lt Ref to 5AT 79 ADJUSTMENT Reduction Driven Gear gt 3 Install the extension case to intermediate case NOTE Use a new gasket Tightening torque 25 N m 2 5 kgf m 18 4 ft lb AT
28. MATIC TRANSMISSION T Shim thickness A Depth from end of extension case to ball bearing outer ring contact surface B Height from end of intermediate case to ball bearing outer ring contact surface a Collar thickness used when measuring A B Collar thickness used when measuring B 0 28 0 011 Gasket thickness Unit mm in Adjustment shim Part Number Thickness mm in 33281 AA040 0 2 0 008 33281 AA050 0 5 0 020 33281 AA060 0 3 0 012 SAT 75 Multi Plate Clutch AUTOMATIC TRANSMISSION 27 Multi Plate Clutch A REMOVAL Remove the multi plate clutch following the same instructions as for the extension case lt Ref to 5AT 72 REMOVAL Extension Case amp Intermedi ate Case gt B INSTALLATION Install the multi plate clutch following the same in structions as for the extension case lt Ref to 5AT 72 INSTALLATION Extension Case amp Intermedi ate Case gt C INSPECTION e Inspect the drive plate facing for wear and dam age e Inspect the snap ring for wear return spring for permanent distortion breakage and deformation e Inspect the damage for D ring e Measure the multi plate clutch clearance and ad just it within specification lt Ref to 5AT 76 AD JUSTMENT Multi Plate Clutch gt D ADJUSTMENT 1 Remove drive plate and driven plate from center differential carrier 2 Measure the depth A from mating surface of extension case to multi pla
29. ar end of reduction driven gear AT 02090 2 Using a depth gauge measure the height B from mating surface of extension case to ball bear ing inside low part of extension case AT 02091 3 Calculation formula Select the ball bearing from the table to adjust clearances within 0 05 0 25 mm 0 0020 0 098 in When clearances are 0 05 mm 0 0020 in T mm A B 0 23 T in A B 0 0091 When clearances are 0 25 mm 0 0098 in T mm A B 0 03 T in A B 0 0011 AUTOMATIC TRANSMISSION T Shim clearance A Depth from mating surface of extension case to ball bearing outer ring end surface B Height from mating surface of extension case to ball bearing inside low part Reduction gear shim Part Number 31288AA030 Thickness mm in 0 2 0 008 0 5 0 020 0 3 0 012 31288AA050 31288AA060 5AT 79 Center Differential Carrier AUTOMATIC TRANSMISSION 30 Center Differential Carrier A REMOVAL 1 Remove the transmission assembly from vehi cle lt Ref to 5AT 38 REMOVAL Automatic Trans mission Assembly gt 2 Remove the rear wheel speed sensor and sep arate the extension case and intermediate case from transmission case lt Ref to 5AT 72 REMOV AL Extension Case amp Intermediate Case gt 3 Pull out the rear drive shaft lt Ref to 5AT 77 REMOVAL Rear Drive Shaft gt 4 Pull out the center differential ca
30. ce between measurement value and T Standard value 0 2 0 6 mm 0 008 0 024 in If outside the standard value replace the plate set drive and driven plate and select the driven plate No 3 to bring clearance within the standard value Driven plate No 3 Thickness mm in 1 6 0 063 Part Number 31589AA041 31589AA050 2 0 0 079 31589AA060 2 4 0 094 31589AA070 2 8 0 110 SAT 76 Rear Drive Shaft AUTOMATIC TRANSMISSION 28 Rear Drive Shaft A REMOVAL 1 Remove the transmission assembly from vehi cle lt Ref to 5AT 38 REMOVAL Automatic Trans mission Assembly gt 2 Remove the rear vehicle speed sensor and then remove the extension case lt Ref to 5AT 72 RE MOVAL Extension Case amp Intermediate Case gt 3 Pull out the rear drive shaft from center differen tial assembly AT 01963 4 Remove the drive plate and driven plate B INSTALLATION 1 Select the appropriate shim lt Ref to 5AT 74 ADJUSTMENT Transfer Clutch gt 2 Install drive plate and driven plate 3 Insert the rear drive shaft into the center differen tial assembly 4 Combine the extension case and then install the rear vehicle speed sensor lt Ref to 5AT 72 IN STALLATION Extension Case amp Intermediate Case gt 5 Install the transmission assembly into vehicle lt Ref to 5AT 42 INSTALLATION Automatic Transmission Assembly gt C DISASSEMBLY 1 Using a
31. d then set the calculated value as C Calculation formula C A B 5AT 106 AT Main Case AUTOMATIC TRANSMISSION 4 Using the ST measure the depth D from AT main case mating surface to thrust bearing trans ferring surface of front sun gear GAUGE ST 499575400 AT 02014 5 Set the value as E which subtract the thickness of ST GAUGE from measured value on step 4 Calculation formula E mm D 15 E in D 0 59 6 Calculation formula Select a thrust bearing from the table to adjust clearance within 0 25 0 55 mm 0 0098 0 022 in When clearances are 0 25 mm 0 0098 in T mm E C 0 03 T in E C 0 0012 When clearances are 0 55 mm 0 022 in T mm E C 0 27 T in E C 0 012 T Thrust bearing clearance C Distance from oil pump cover mating surface to rear end of oil pump cover E Depth from mating surface of AT main case to bearing surface of front sun gear Example When the A is 39 50 mm 1 56 in B is going to be 16 20 mm 0 64 in so the C would be 23 30 mm 0 92 in by calculation When the D is 41 90 mm 1 65 in subtract the thickness of ST GAUGE from D and then the value E would be 26 90 mm 1 06 in Calculation when clearance is 0 25 mm 0 0098 in T mm 26 90 23 30 0 03 3 63 T in 1 059 0 917 0 0012 0 143 Calculation formula when clearances are 0 55 mm 0 022 in T mm 26 90 23
32. e shaft assembly from oil pump cover AT 01984 9 Remove the oil pump cover from AT main case lt Ref to 5AT 86 Oil Pump Cover gt B INSTALLATION 1 Assemble the drive pinion assembly to oil pump cover NOTE Be careful not to bend the shim Tightening torque 70 N m 7 1 kgf m 51 6 ft lb AT 01984 2 Adjust the tooth contact between drive pinion shaft assembly and front differential side gear lt Ref to 5AT 91 ADJUSTMENT Drive Pinion Shaft Assembly gt 3 Combine the converter case with transmission case lt Ref to 5AT 84 INSTALLATION Converter Case gt 4 Install the transmission harness connector to the stay 5 Install the ATF filter pipe lt Ref to 5AT 60 IN STALLATION ATF Filter gt 6 Install the oil charge pipe with O ring 7 Install the torque converter assembly lt Ref to 5AT 71 INSTALLATION Torque Converter As sembly gt 8 Install the transmission assembly into vehicle lt Ref to 5AT 42 INSTALLATION Automatic Transmission Assembly gt C DISASSEMBLY 1 Remove the caulking part of lock nut and then remove the lock nut with holding rear spline part of the shaft using ST1 and ST2 Pull out the drive pin ion collar ST1 18667AA010 HOLDER ST2 499787700 WRENCH ST3 499787500 ADAPTER AT 00197 2 Remove the O ring 3 Separate the rear roller bearing and outer race from the shaft using press AT 00198
33. e tip of the hose 6 Check the ATF cooler for cracks or deformation ATF cooler model with warmer function SAT 68 Air Breather Hose 22 Air Breather Hose A REMOVAL 1 Remove the intercooler Turbo model lt Ref to IN H4DOTC 12 REMOVAL Intercooler gt 2 Remove the air intake chamber Non turbo model Pet to IN H6DO 7 REMOVAL Air Intake Chamber gt 3 Disconnect the air breather hose A Air breather hose Transmission case B Air breather hose Oil pump cover B INSTALLATION 1 Connect the air breather hose A Air breather hose Transmission case B Air breather hose Oil pump cover 2 Install the intercooler Turbo model lt Ref to IN H4DOTC 12 INSTALLATION Intercooler gt 3 Install the air intake chamber Non turbo model lt Ref to IN H6DO 7 INSTALLATION Air Intake Chamber gt C INSPECTION Make sure the hose is not cracked or clogged SAT 69 AUTOMATIC TRANSMISSION Oil Charge Pipe AUTOMATIC TRANSMISSION 23 Oil Charge Pipe A REMOVAL 1 Remove the intercooler Turbo model lt Ref to IN H4DOTC 12 REMOVAL Intercool er gt 2 Remove the air intake chamber Non turbo model Pet to IN H6DO 7 REMOVAL Air Intake Chamber gt 3 Remove the oil charge pipe and then remove the O ring from flange side A Oil level gauge B Oil charge pipe B INSTALLATION 1 Install the oil charge pipe with a new O ri
34. emove the control valve body lt Ref to 5AT 58 REMOVAL Control Valve Body gt 12 Remove the oil pump cover lt Ref to 5AT 86 REMOVAL Oil Pump Cover gt NOTE The input clutch pack assembly and front sun gear assembly are also removed together 15 Remove the rear carrier assembly gt SEH INN Oe Kreesser once y i EUW 0 Os EE AT 01990 13 Remove the needle bearing of the mid carrier assembly AT 01993 SAT 99 AT Main Case AUTOMATIC TRANSMISSION 16 Remove the mid amp rear sun gear assembly 19 Remove the direct clutch assembly AT 01994 17 Remove the thrust needle bearing of high amp low e reverse clutch 21 Remove the retaining plate 22 Remove the leaf spring AT 01995 18 Remove the high amp low reverse clutch assem bly AT 01999 AT 01996 A Leaf spring 23 Take out the drive plate driven plate and dish plate 24 Remove the snap ring of the spring retainer of reverse brake SAT 100 AT Main Case AUTOMATIC TRANSMISSION GI 18762AA000 COMPRESSOR SPECIAL 28 Apply compressed air TOOL ST2 18765AA000 COMPRESSOR SUPPORT ST3 18763AA000 COMPRESSOR SHAFT AT 02004 29 Remove the reverse brake piston ST3 AT 02005 B
35. f the ATF cooler pipe from oil cooler pipe AT 02027 4 Remove the union screw of oil cooler inlet and outlet pipes AUTOMATIC TRANSMISSION 5 Remove the pipe securing bolts on the side of transmission 6 Lower the vehicle 7 Remove the air intake chamber lt Ref to IN H6DO 7 REMOVAL Air Intake Cham ber gt 8 Remove the resonator chamber lt Ref to IN H6DO 9 REMOVAL Resonator Chamber gt 9 Remove the oil charge pipe lt Ref to 5AT 70 REMOVAL Oil Charge Pipe gt 10 Disconnect the ATF cooler hoses and pipes 11 Remove the pitching stopper bracket securing bolt and bolt on the side of transmission and then remove ATF cooler pipe AT 02033 SAT 65 ATF Cooler Pipe amp Hose AUTOMATIC TRANSMISSION 12 Remove the ATF cooler from the installation bracket as necessary AT 02031 13 Remove the ATF cooler bracket from transmis sion body as necessary AT 02032 B INSTALLATION 1 EXCEPT FOR ATF COOLER MODEL WITH WARMER FUNCTION 1 Install the oil cooler inlet and outlet pipes with new washer Tightening torque T1 25 N m 2 5 kgf m 18 1 ft lb T2 44 N m 4 5 kgf m 32 5 ft lb AT 01384 2 Install the ATF cooler pipe to frame SWAT E A A d ia ry 3 Connect the ATF cooler hose to pipe on the transmission side NOTE e Ins
36. fitted oil seal in the case Ox Bolt Range select lever Manual plate Parking rod 10 Remove the detention spring B INSTALLATION 1 Install the detention spring to transmission case Tightening torque 6 N m 0 6 kgf m 4 3 ft ib 2 Insert the select lever and then tighten the bolt Tightening torque 6 N m 0 6 kgf m 4 3 ft Ib SAT 108 Transmission Control Device 3 Insert the manual plate and parking rod Bolt Range select lever Manual plate Parking rod AT 00305 5 Install the oil pan and control valve assembly lt Ref to 5AT 58 INSTALLATION Control Valve Body gt 6 Install the pitching stopper bracket Tightening torque 41 N m 4 2 kgf m 30 4 ft lb 7 Insert the transmission connector to the stay 8 Install the air breather hose lt Ref to 5AT 69 IN STALLATION Air Breather Hose gt 9 Install the torque converter assembly lt Ref to 5AT 71 INSTALLATION Torque Converter As sembly gt 10 Install the transmission assembly into vehicle lt Ref to 5AT 42 INSTALLATION Automatic Transmission Assembly gt C INSPECTION Make sure the manual lever and detention spring are not worn or otherwise damaged SAT 109 AUTOMATIC TRANSMISSION Transmission Control Device AUTOMATIC TRANSMISSION SAT 110
37. htening torque 41 N m 4 2 kgf m 30 4 ft lb 3 Rotate the drive pinion several times using ST1 and ST2 GI 18667AA010 HOLDER ST2 499787700 WRENCH AT 01985 4 Adjust the backlash between drive pinion and hypoid driven gear lt Ref to 5AT 97 ADJUST MENT Front Differential gt 5 Apply red lead evenly to the surfaces of three or four teeth on hypoid driven gear Rotate the drive pinion in the leftward and rightward for several times Remove the oil pump cover and check the tooth contact pattern If the tooth contact is improper readjust the back lash or shim thickness lt Ref to 5AT 97 ADJUST MENT Front Differential gt Correct tooth contact Checking item Tooth contact pattern is slightly shifted toward to toe side under no load rotation When loaded contact pattern moves toward heel AT 00207 A Toe side B Heel side e Face contact Checking item Backlash is too large Contact pattern AT 00208 SAT 91 Drive Pinion Shaft Assembly AUTOMATIC TRANSMISSION Corrective action Increase thickness of drive pin ion height adjusting shim in order to bring drive pin ion close to hypoid driven gear gt AT 00212 e Flank contact Checking item Backlash is too small Contact pattern fame EE AT 00209 Corrective action Reduce thickness of drive pinion height adjusting shim in order to bring drive pinion away from
38. hypoid driven gear e AT 00213 e Toe contact inside end contact Checking item Contact areas are too small Contact pattern AT 00210 Corrective action Reduce thickness of drive pinion height adjusting shim in order to bring drive pinion away from hypoid driven gear dai cn ww AT 00213 e Heel contact outside end contact Checking item Contact areas are too small Contact pattern Pe AT 00211 Corrective action Increase thickness of drive pin ion height adjusting shim in order to bring drive pin ion close to hypoid driven gear gt EE D AT 00212 6 If tooth contact is correct mark the retainer posi tion and loosen it After fitting a new O ring and oil seal screw in the retainer to the marked position Tighten the lock plate with specified torque 5AT 92 Drive Pinion Shaft Assembly AUTOMATIC TRANSMISSION Tightening torque 25 N m 2 5 kgf m 18 1 ft lb AT 01986 A Lock plate SAT 93 Front Differential AUTOMATIC TRANSMISSION 35 Front Differential A REMOVAL 1 Remove the transmission assembly from vehi cle lt Ref to 5AT 38 REMOVAL Automatic Trans mission Assembly gt 2 Pull out the torque converter assembly lt Ref to 5AT 71 REMOVAL Torque Converter Assembly gt 3 Remove the transmission harness connector from stay 4 Remove the oil charge pipe lt
39. nd check to see if the backlash is within the specified value with ST2 ST3 ST4 and ST5 ST1 499787700 WRENCH ST2 498247001 MAGNET BASE ST3 498247100 DIAL GAUGE ST4 499787500 ADAPTER ST5 498255400 PLATE Backlash 0 13 0 18 mm 0 0051 0 0071 in 9 Adjust the tooth contact between front differen tial and drive shaft lt Ref to 5AT 91 ADJUST MENT Drive Pinion Shaft Assembly gt SAT 98 AT Main Case AUTOMATIC TRANSMISSION 36 AT Main Case 14 Remove the mid carrier assembly A REMOVAL 1 Remove the transmission assembly from vehi cle lt Ref to 5AT 38 REMOVAL Automatic Trans mission Assembly gt 2 Pull out the torque converter assembly lt Ref to 5AT 71 REMOVAL Torque Converter Assembly gt 3 Remove the transmission harness connector from stay 4 Disconnect the air breather hose 5 Remove the oil charge pipe lt Ref to 5AT 70 REMOVAL Oil Charge Pipe gt 6 Remove the ATF filter inlet and outlet pipes lt Ref to 5AT 60 REMOVAL ATF Filter gt 7 Remove the extension case and intermediate case lt Ref to 5AT 72 REMOVAL Extension Case amp Intermediate Case gt 8 Remove the center differential carrier lt Ref to 5AT 80 REMOVAL Center Differential Carrier gt 9 Remove the reduction driven gear lt Ref to 5AT 78 REMOVAL Reduction Driven Gear gt 10 Separate the converter case and transmission AT 01992 case lt Ref to 5AT 84 REMOVAL Converter Case gt 11 R
40. nd pipes AT 02030 5 Connect the engine harness connectors and then install the engine hanger rear 6 Install the oil charge pipe lt Ref to 5AT 70 IN STALLATION Oil Charge Pipe gt 7 Install the resonator chamber lt Ref to IN H6DO 9 INSTALLATION Resonator Chamber gt 8 Install the air intake chamber lt Ref to IN H6DO 7 INSTALLATION Air Intake Chamber gt 9 Lift up the vehicle 10 Install the pipe securing bolts on the side of transmission AT 02028 11 Install the union screw of oil cooler inlet and outlet pipes Tightening torque T1 25 N m 2 5 kgf m 18 1 ft lb T2 44 N m 4 5 kgf m 32 5 ft lb 12 Install the inlet and outlet pipes of the ATF oil cooler hose to oil cooler pipe AT 02027 13 Install the front exhaust pipe lt Ref to EX H6DO 6 INSTALLATION Front Ex haust Pipe gt C INSPECTION Repair or replace any defective hoses pipes clamps and washers found from the inspection be low 1 Check for ATF leaks in joints between the trans mission radiator pipes and hoses 2 Check for deformed clamps 3 Lightly bend the hose and check for cracks in the surface and other damages 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 th
41. ng Tightening torque 41 N m 4 2 kgf m 30 2 ft lb e P l 01986 A Oil level gauge B Oil charge pipe 2 Install the intercooler Turbo model lt Ref to IN H4DOTC 12 INSTALLATION Intercooler gt 3 Install the air intake chamber Non turbo model lt Ref to IN H6DO 7 INSTALLATION Air Intake Chamber gt C INSPECTION Make sure the oil charge pipe is not deformed or damaged SAT 70 Torque Converter Assembly 24 Torque Converter Assembly A REMOVAL 1 Remove the transmission assembly from vehi cle lt Ref to 5AT 38 REMOVAL Automatic Trans mission Assembly gt 2 Pull out the torque converter and oil pump shaft horizontally NOTE e Be sure not to scratch the inside of bush in oil pump shaft e Be careful that the oil pump shaft may drawn out simultaneously AT 00113 3 Remove the oil pump shaft from torque convert er as necessary B INSTALLATION 1 When the oil pump shaft is removed install the shaft to torque converter NOTE Make sure the clip is firmly inserted 2 Install the oil pump shaft to torque converter and then make sure that the clip is secured on groove 3 Apply ATF to the revolution and sliding surface oil pump shaft 4 Holding the torque converter assembly by hand lightly rotate the torque converter assembly to en gage the oil pump rotor 5 Check the protruding dimension of the torque converter assembly Dimension A
42. on case routes are not clogged and not leaks e Measure the extension end play and adjust it to within specifications lt Ref to 5AT 74 ADJUSTMENT Transfer Clutch gt SAT 73 Transfer Clutch AUTOMATIC TRANSMISSION 26 Transfer Clutch A REMOVAL 1 Remove the transmission assembly from vehi cle lt Ref to 5AT 38 REMOVAL Automatic Trans mission Assembly gt 2 Remove the extension case and then remove the transfer clutch lt Ref to 5AT 72 REMOVAL Extension Case amp Intermediate Case gt lt Ref to 5AT 73 DISASSEMBLY Extension Case amp Inter mediate Case gt B INSTALLATION 1 Select the rear drive shaft shim lt Ref to 5AT 74 ADJUSTMENT Transfer Clutch gt 2 Select the driven plate No 3 lt Ref to 5AT 74 ADJUSTMENT Transfer Clutch gt 3 Install the extension case and intermediate case lt Ref to 5AT 72 INSTALLATION Extension Case amp Intermediate Case gt 4 Install the transmission assembly into vehicle lt Ref to 5AT 42 INSTALLATION Automatic Transmission Assembly gt C INSPECTION e Inspect the drive plate facing for wear and dam age e Inspect the snap ring for wear return spring for permanent distortion breakage and deformation e Check that the D ring is not damaged e Inspect the extension end play and adjust it to within specifications lt Ref to 5AT 74 ADJUST MENT Transfer Clutch gt D ADJUSTMENT 1 Insert the rear drive shaft in
43. rrier assembly AT 01972 5 Pull out the shim s from transmission case B INSTALLATION 1 Install the center differential assembly with the shim s NOTE Press fit it to the bottom of bearing shoulder com pletely AT 01972 2 Insert the rear drive shaft lt Ref to 5AT 77 IN STALLATION Rear Drive Shaft gt 3 Connect the transmission case extension case and intermediate case and install the rear wheel speed sensor lt Ref to 5AT 72 INSTALLATION Extension Case amp Intermediate Case gt 4 Install the transmission assembly into vehicle lt Ref to 5AT 42 INSTALLATION Automatic Transmission Assembly gt C DISASSEMBLY 1 Remove the seal ring AT 02015 A Seal ring 2 Using a press and ST remove the ball bearing ST 498077600 REMOVER AT 00167 3 Remove the snap ring and pull out the shaft from center differential assembly AT 01973 A Snap ring B Shaft SAT 80 Center Differential Carrier AUTOMATIC TRANSMISSION 4 Remove the thrust washers pinion gears and washers from center differential assembly AT 00169 A Pinion gear 5 Pull out the intermediate shaft and thrust bear ing D ASSEMBLY 1 Install the thrust washer onto intermediate shaft 2 Install the thrust bearing onto intermediate shaft 3 Install the pinion gears and washers 4 Insert the shaft into the center
44. t clutch assem bly if damaged 3 HIGH amp LOW REVERSE CLUTCH AS SEMBLY Check the clearance of high amp low reverse clutch Measure the clearance L between snap ring and retaining plate using thickness gauge If the mea sured value is out of specification replace them as high amp low reverse clutch assembly Standard value 1 8 2 2 mm 0 070 0 087 in AT 02010 4 DIRECT CLUTCH ASSEMBLY Check the clearance of direct clutch Measure the clearance L between snap ring and retaining plate using thickness gauge If the mea sured value is out of specification replace them as direct clutch assembly Standard value 0 6 0 8 mm 0 024 0 031 in AT 02011 5 REVERSE BRAKE Check the following items e Drive plate facing for wear and damage e Snap ring for wear return spring for breakage and spring retainer for deformation e Lip seal and D ring for damage e Piston operation F ADJUSTMENT 1 Using the ST measure the height A from AT main case mating surface to convex surface of oil pump cover ST 499575400 GAUGE AT 02012 2 Using the ST measure the depth B from the convex surface of oil pump cover to thrust bearing transferring surface ST 499575400 GAUGE AT 02013 3 Calculate the measured value on step 1 and 2 an
45. tall so that the hose is not folded over exces sively bent or twisted e Be careful to insert the hose to the specified po sition E Q AT 01388 5AT 66 ATF Cooler Pipe amp Hose 4 Connect the ATF cooler hose to pipe on radiator side NOTE e Install so that the hose is not folded over exces sively bent or twisted e Be careful to insert the hose to the specified po sition AT 01345 5 Install the radiator under cover Tightening torque 4 9 N m 0 5 kgf m 3 6 ft lb AT 01344 6 Install the under cover 7 Install the battery 8 Fill ATF lt Ref to 5AT 27 Automatic Transmis sion Fluid gt NOTE Make sure there are no ATF leaks in joints between the transmission radiator pipes and hoses AUTOMATIC TRANSMISSION 2 ATF COOLER MODEL WITH WARMER FUNCTION 1 Install the ATF cooler bracket if it is removed from transmission body Tightening torque 25 N m 2 5 kgf m 18 1 ft lb AT 02032 2 Install the ATF cooler if it is removed from instal lation bracket Tightening torque 25 N m 2 5 kgf m 18 1 ft lb AT 02031 3 Install the pitching stopper securing bracket and bolt on the side of transmission AT 02033 SAT 67 ATF Cooler Pipe amp Hose AUTOMATIC TRANSMISSION 4 Install the ATF cooler hoses a
46. te clutch LSD piston AT 01966 A Measured value 3 Using the ST measure the height B from inter mediate case mating surface to end of center differ ential clutch drum and then subtract the thickness of ST gauge 50 mm 1 97 in from measured val ue ST 378744300 GAUGE NOTE Measure with driven plate No 3 removed AT 01967 B Measured value 4 Calculation formula When clearances are 0 2 mm 0 008 in T mm A B 0 28 0 2 T in A B 0 011 0 008 When clearances are 0 6 mm 0 024 in T mm A B 0 28 0 6 T in A B 0 011 0 024 NOTE e Calculation formula for T is applied when mea suring using ST 398643600 GAUGE 398744300 GAUGE When not using ST apply following When clearances are 0 2 mm 0 008 in T mm A B a 0 28 0 2 T in A B a 0 011 0 008 When clearances are 0 6 mm 0 024 in T mm A B a 0 28 0 6 T in A B a 0 011 0 024 T Thickness of driven plate No 3 A Measure the depth from mating surface of exten sion case to multi plate clutch LSD piston B Height from end of intermediate case to center differential clutch drum a Collar thickness used when measuring B 0 28 0 011 Gasket thickness Unit mm in e Measure multi plate clutch LSD driven and drive plate thickness to find the clearan
47. to the reduction drive gear and center differential assembly AT 01963 2 Using the ST measure the depth A which is from mating surface of extension case to ball bear ing outer ring contact surface ST 398643600 GAUGE AT 01964 A Measured value 3 Using the ST measure the height B from the intermediate case mating surface to ball bearing outer ring contact surface ST 398643600 GAUGE AT 01965 B Measured value 4 Calculation formula When clearances are 0 05 mm 0 0020 in T mm A B 0 28 0 05 T in A B 0 011 0 0020 When clearances are 0 25 mm 0 0098 in T mm A B 0 28 0 25 T in A B 0 011 0 0098 A Depth from end of extension case to ball bearing outer ring contact surface B Height from end of intermediate case to ball bearing outer ring contact surface T Shim thickness 0 05 0 25 mm 0 0020 0 0098 in NOTE Calculation formula for T is applied when measur ing using ST 898643600 GAUGE When not us ing ST apply following When clearances are 0 05 mm 0 0020 in T mm A a B p 0 28 0 05 T in A a B B 0 011 0 0020 When clearances are 0 25 mm 0 0098 in T mm A a B B 0 28 0 25 T in A a B B 0 011 0 0098 SAT 74 Transfer Clutch AUTO
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