2004 impreza service manual quick reference index transmission
Contents
1. 6 Take off the transmission jack 7 Tighten the nuts and bolts which hold the lower side of transmission to engine Tightening torque 50 N m 5 1 kgf m 36 9 ft Ib a 5 AT 00108 8 Tighten the bolt of clutch housing cover 9 Lower the vehicle 10 Connect the engine and transmission 1 Remove the ST from converter case NOTE Be careful not to drop the ST into converter case when removing ST ST 498277200 STOPPER SET 2 Install the starter lt Ref to SC H4SO 7 INSTALLATION Start er gt 3 Tighten the bolt which holds the upper side of transmission to engine Tightening torque 50 N m 5 1 kgf m 36 9 ft lb AT 00106 11 Install the torque converter clutch to drive plate 1 Tighten the bolts which hold the torque con verter clutch to drive plate 2 Tighten the other bolts while rotating the en gine by using ST 4AT 44 Automatic Transmission Assembl Tightening torque AUTOMATIC TRANSMISSION 25 N m 2 5 kgf m 18 1 ft Ib ST 28399SA010 OIL SEAL PROTECTOR 19 Align the spline of front differential shaft to that 3 Clog the plug onto service hole 4 Install the V belt cover of differential bevel gear for insertion and remove them using ST 12 Remove the ST ST 28399SA010 OIL SEAL PROTECTOR 20 Insert the front drive shaft into transmission se ST1 oe SA A A curely by pressing t2. 3 Remove the transmission jack 4 Install the heat shield cover If equipped 5 Install the front center rear exhaust pipes and the muffler Non turbo model lt Ref to EX H4SOw 00BD 7 INSTALLATION Front Exhaust Pipe gt lt Ref to EX H4SOw 00BD 10 INSTALLATION Rear Exhaust Pipe gt and lt Ref to EX H4SOw 00BD 11 INSTALLATION Muffler gt 6 Install center and rear exhaust pipes and muf fler Turbo model lt Ref to EX H4DOTC 10 INSTALLATION Center Exhaust Pipe gt lt Ref to EX H4DOTC 14 IN STALLATION Rear Exhaust Pipe gt and lt Ref to EX H4DOTC 15 INSTALLATION Muffler gt C INSPECTION Repair or replace parts if the results of the inspec tion below are not satisfactory 1 PITCHING STOPPER Make sure that the pitching stopper is not bent or damaged Make sure that the rubber is not stiff cracked or otherwise damaged 2 TRANSMISSION REAR CROSSMEMBER AND REAR CUSHION RUBBER Make sure that the crossmember is not bent or damaged Make sure that the cushion rubber is not stiff cracked or otherwise damaged 4AT 49 AUTOMATIC TRANSMISSION
3. Acceleration opening angle AWD mode Transfer clutch pressure kPa kg cm psi FWD mode Transfer clutch pressure kPa kg cm psi 95 100 Fully opens 910 1 070 9 3 10 9 132 155 Adjust ON Duty ratio to 60 Target 10 410 490 4 2 5 0 59 71 0 Fully closed 0 0 Fully closed 4AT 40 Automatic Transmission Assembly 9 Automatic Transmission As sembly A REMOVAL 1 Set the vehicle on a lift 2 Open the front hood fully and support it with stay 3 Disconnect the battery ground cable 4 Remove the air intake duct Non turbo model lt Ref to IN H4SO 6 REMOVAL Air Intake Duct gt 5 Remove the air cleaner case or air intake cham ber Non turbo model lt Ref to IN H4SO 5 REMOVAL Air Cleaner Case gt 6 Remove the intercooler Turbo model lt Ref to IN H4DOTC 10 REMOVAL Intercool er gt 7 Remove the air cleaner case stay Non turbo model AT 00101 8 Disconnect the following connectors 1 Transmission harness connector ae Par AT 00678 2 Transmission ground terminal 9 Remove the starter 2 0 L Non turbo and 2 5 L models lt Ref to SC H4SO 7 REMOVAL Starter gt 2 0 L Turbo model lt Ref to SC H4SO 7 REMOVAL Starter gt AUTOMATIC TRANSMISSION 10 Remove the pitching stopper AT 00679 11 Separate the
4. REMARKS ST 499267300 499267300 STOPPER PIN Used for installing inhibitor switch ST 499787700 499787700 WRENCH Used for removing and installing drive pinion lock nut ST 499787500 499787500 ADAPTER Used for removing and installing drive pinion lock nut ST 398643600 398643600 4AT 25 Used for measuring total end play extension end play and drive pinion height General Description AUTOMATIC TRANSMISSION ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 498627100 SEAT Used for holding low clutch piston retainer spring when installing snap ring ST 498627100 499577000 e Used for measuring the transmission case mating surface to the reduction gear end sur face e For MPT model ST 499577000 398744300 e Use for measuring contact face between multi plate clutch end and transmission For VTD model ST 398744300 499737000 PULLER Used for removing reduction driven gear assem bly ST 499737000 4AT 26 ILLUSTRATION General Description TOOL NUMBER DESCRIPTION AUTOMATIC TRANSMISSION REMARKS ST 499737100 499737100 PULLER SET Used for removing reduction drive gear assem bly B ST 498077600 498077600 REMOVER Used for removing ball bearing ST 498937110 498937110 HOLDER Used for removing and installing drive pinion lock nut 9 ST 498677100 498677100 COMPRESSOR
5. 19 Snap ring 6 D ring 13 Retaining plate High clutch 20 Thrust needle bearing 7 High clutch piston 14 Snap ring 21 High clutch hub 4AT 10 General Description AUTOMATIC TRANSMISSION 6 PLANETARY GEAR AND 2 4 BRAKE 24 A 23 25 22 AT 00007 1 Thrust needle bearing 10 Washer 19 Snap ring 2 Front sun gear 11 Thrust needle bearing 20 Spring retainer 3 Thrust needle bearing 12 Rear internal gear 21 2 4 brake piston 4 Snap ring 13 Washer 22 D ring 5 Front planetary carrier 14 Snap ring 23 D ring 6 Thrust needle bearing 15 Retaining plate 24 2 4 brake piston retainer 7 Rear sun gear 16 Drive plate 25 2 4 brake seal 8 Thrust needle bearing 17 Driven plate 26 Leaf spring 9 Rear planetary carrier 18 Pressure rear plate 4AT 11 General Description AUTOMATIC TRANSMISSION 7 LOW CLUTCH AND LOW amp REVERSE BRAKE i L gt gt LZ ur 30 29 AT 01278 1 Snap ring 12 Low clutch drum 23 Return spring 2 Retaining plate 13 Needle bearing 24 Snap ring 3 Drive plate 14 Snap ring 25 Retaining plate 4 Driven plate 15 One way clutch 26 Leaf spring 5 Dish plate 16 Snap ring 27 Drive plate 6 Snap ring 17 Thrust needle bearing 28 Driven plate 7 Cover 18 Seal ring 29 Dish plate 8 Spring retainer 19 Needle bearing 30 Low and reverse brake piston 9 D ring 20 One way cl
6. 4AT 27 Used for installing 2 4 brake snap ring AUTOMATIC TRANSMISSION ILLUSTRATION General Description TOOL NUMBER DESCRIPTION REMARKS ST 498437000 498437000 HIGH CLUTCH PIS TON GUIDE Used for installing high clutch piston ST 498437100 498437100 LOW CLUTCH PIS TON GUIDE Used for installing low clutch piston ST 899580100 899580100 INSTALLER Used for press fitting the ball bearing for transfer clutch ST18675AA000 18675AA000 DIFFERENTIAL OIL SEAL INSTALLER 4AT 28 Used for installing differential side retainer oil seal ILLUSTRATION General Description TOOL NUMBER DESCRIPTION AUTOMATIC TRANSMISSION REMARKS ST28399SA010 28399SA010 OIL SEAL PROTEC TOR Used for installing front drive shaft ST 398497701 398497701 Used for installing needle bearing ST 899524100 899524100 PULLER SET e Using the bolt only 1 Bolt Used with PULLER SET 499737100 Used with PULLER 499737000 1 Puller 2 Cap ST24082AA230 24082AA230 CARTRIDGE Troubleshooting for electrical systems 4AT 29 General Description AUTOMATIC TRANSMISSION ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 22771AA030 SUBARU SELECT MONITOR KIT Troubleshooting for electrical system English 22771AA030 Without printer e German 22771AA070 Without printer French 22771AA0
7. E 4 12 10 EE E E ada 28 Transter OUO vacia lt ias Dental 29 Multi plate Clutch ccoccnonoccccnnncconononononnnnccnnnnnnronnnnnnncnanannnnnnnnnncnnnnnnnnnnnos 30 Rear Drive Shaft ieri e et o a a a a e ieaie 31 Reduction Driven Gear nnnesnnsnnensnnnnnannnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnen 32 Reduction Drive GEALF cocccconncccccnnocccnnnnnancnnnonancnnn nono cano nonaconononanananonananinans 33 Center Differential Carrier oo onnnnnoninnncnnnnnnocinnnnnancncnononannnononanccnnonaninnns 34 Parking PAW cionado bai oc 35 GCONVEHEM CASE oc tattoos dd 36 Oil Pump Housing en 37 Drive Pinion Shaft anaana conocio nono nana nono no nann nono nancc cnn nan 38 Eront Differential 42 2 42 a said 39 AT Transmission Main Case occccoonncnnccononenccocncnncnnoncnnonnnnnnranonnonronennnnnnnos 40 Transmission Control Device oooocccccnnnccnccnnncncnnnnanacano nana canon nnacanana ninas General Description AUTOMATIC TRANSMISSION 1 General Description 5 PLANETARY GEAR AND PLATE A SPECIFICATIONS 1 TORQUE CONVERTER CLUTCH Model Tooth num ber of front sun gear Tooth num ber of front pinion Tooth num ber of front internal gear Tooth num ber of rear 2 0L Model 1 6L Non 2 5L turbo Type Symmetric 3 element single stage 2 phase torque converter Stall torque 1 85 2 05 ratio Zei Wer 2 35 Nominal diameter 2 0L Turbo 23
8. 45 4 6 33 18 Test plug 37 Select lever 19 Oil filter Except for turbo model 38 Inhibitor switch ASSY AAT 8 General Description AUTOMATIC TRANSMISSION 4 CONTROL VALVE AND HARNESS ROUTING AT 01277 1 Stay 12 Accumulator spring 24 Line pressure duty solenoid 2 Transmission harness 13 Side plate 25 Low clutch timing solenoid 3 O ring 14 Separate plate 26 Lock up duty solenoid 4 O ring 15 Middle valve body 27 Oil strainer 5 Torque converter turbine speed 16 Separate plate 28 SPORT shift solenoid sensor 17 Fluid filter if equipped 6 O ring 18 Fluid filter 7 Front vehicle speed sensor 19 Lower valve body Tightening torque N m kgf m ft Ib 8 O ring 20 Shift solenoid 2 T1 7 0 7 5 1 9 Rear vehicle speed sensor 21 Shift solenoid 1 T2 8 0 8 5 8 10 Upper valve body 22 2 4 brake timing solenoid 11 Accumulator piston 23 2 4 brake duty solenoid 4AT 9 General Description AUTOMATIC TRANSMISSION 5 HIGH CLUTCH AND REVERSE CLUTCH 21 20 AT 00006 1 High clutch drum 8 Spring retainer 15 Dish plate 2 Lip seal 9 Cover 16 Driven plate Reverse clutch 3 D ring 10 Snap ring 17 Drive plate Reverse clutch 4 Reverse clutch piston 11 Driven plate High clutch 18 Retaining plate Reverse clutch 5 D ring 12 Drive plate High clutch
9. tral ble bution VTD Drive amp 4 forward Automatic gear change 1st _ 2nd D Drive _ u 9 q driven plate 3rd 4th number of 3 forward Automatic gear change 1st _ 2nd transfer 3 3rd gt clutch _ 3rd 4th Gontrol Electro hydraulic type 2 2nd 2 forward Automatic gear change 1st _ 2nd method y yp lt 3rd lt 4th Lubricant The same Automatic transmission fluid used 1st gear locked Deceleration possible 1st in automatic transmission 1 1st 2nd lt 3rd lt 4th Reduction h 1 000 53 53 Control E gear ratio Wire cable method 7 HYDRAULIC CONTROL AND LUBRICA TION Electro hydraulic control Four forward speed Type changes by electrical signals of vehicle speed and accel erator throttle opening Fluid Dexron Ill type 1 6L FWD 8 0 8 3 2 8 5 8 8 US model qt 7 0 7 3 Imp qt 1 6L AWD Fluid capac and 2 0L 8 4 8 7 2 8 9 9 2US ity Non turbo qt 7 4 7 7 Imp qt model Land 9 3 9 6 0 9 8 10 1 US 2 0 L Turbo Ae qt 8 2 8 4 Imp qt Forced feed lubrication with oil pump Automatic transmission fluid above mentioned 8 COOLING AND HARNESS Lubrication system Oil Liquid cooled cooler incorpo rated in radiator Inhibitor switch 12 poles Transmission harness 20 poles Cooling system 4AT 3 General Description AUTOMATIC TRANSMISSION 10 FINAL REDUCTION Model Except for 1 6 L 2 0 L Turbo 1 6L
10. 2 0 L Turbo Front final gear ratio 4 111 37 9 4 444 40 9 11 RECOMMENDED GEAR OIL C 30 26 15 5 0 15 25 30 F 22 15 5 23 32 59 77 86 Lubrication oil 1 Item API classification 2 Front differential gear oil SAE viscosity No and appli cable temperature Front differential oil capacity 1 1 1 3 Q 1 2 1 4 US qt 1 0 1 1 Imp qt 4AT 4 General Description AUTOMATIC TRANSMISSION B COMPONENT 1 TORQUE CONVERTER CLUTCH AND CASE AT 02375 1 Pitching stopper bracket Turbo 8 Oil drain pipe 16 Converter case model 9 Input shaft 17 Pitching stopper bracket Non 2 O ring 10 O ring turbo model 3 Differential oil level gauge 11 Torque converter clutch ASSY 4 Stay 12 Drain plug Tightening torque N m kgf m ft lb 5 Seal pipe 13 Gasket T1 18 1 8 13 0 6 Oil pump shaft 14 Oil seal T2 41 4 2 30 4 7 Clip 15 Clip Turbo model T3 70 7 1 51 6 4AT 5 General Description AUTOMATIC TRANSMISSION 2 OIL PUMP s y e RS i Pai 7 l ins AT 00003 1 Oil pump rotor 11 Gasket 21 Lock nut 2 Oil pump cover 12 O ring 3 Seal ring 13 Test plug Tightening torque N m kgf m ft lb 4 Thrust needle bearing 14 Stud bolt T1 7 0 7 5 1 5 Drive pinion shaft 15 O ring T2 13 1 3 9 4 6 Roller bearing 16 O ring T3 18 1 8 1
11. Multi plate clutch LSD pipe 22 Harness bracket 5 Retaining plate 14 Extension case 6 Snap ring 15 O ring Tightening torque N m kgf m ft lb 7 Spring retainer 16 Test plug T1 7 0 7 5 1 8 Plate 17 Oil seal T2 13 1 3 9 4 9 O ring 18 Dust cover T3 25 2 5 18 1 4AT 17 General Description AUTOMATIC TRANSMISSION 13 TRANSMISSION MOUNTING A AT 01276 1 Pitching stopper 4 Rear cushion rubber AWD model Tightening torque N m kgf m ft Ib 2 Rear bracket FWD model 5 Crossmember T1 35 3 6 26 3 Rear cushion rubber FWD model 6 Stopper T2 39 4 0 29 T3 50 5 1 37 T4 58 5 9 43 T5 70 7 1 51 T6 123 12 5 90 4AT 18 General Description AUTOMATIC TRANSMISSION C CAUTION e Wear working clothing including a cap protec tive goggles and protective shoes during operation e Remove contamination including dirt and corro sion before removal installation and disassembly Keep the disassembled parts in order and pro tect them from dust or dirt e Until the oil pan is removed do not place with the oil pan inner side facing up to prevent foreign mat ter from entering the valve body e Before removal installation or disassembly be sure to clarify the failure Avoid unnecessary re moval installation disassembly and replacement e When disassembling the case
12. TRANSMISSION 10 DIFFERENTIAL GEAR AT 00011 1 Crown gear 7 Oil seal 13 Differential bevel gear 2 Pinion shaft 8 O ring 3 Differential case RH 9 Differential side retainer Tightening torque N m kgf m ft lb 4 Straight pin 10 Lock plate T1 25 2 5 18 1 5 Differential case LH 11 Washer T2 62 6 3 45 6 6 Taper roller bearing 12 Differential bevel pinion 4AT 15 General Description AUTOMATIC TRANSMISSION 11 TRANSFER AND EXTENSION CASE WITH MPT AT 00012 1 Thrust needle bearing 10 Return spring 19 Oil seal 2 Needle bearing 11 Transfer clutch piston 20 Dust cover 3 Snap ring 12 Rear drive shaft 21 Test plug 4 Pressure plate 13 Ball bearing 22 O ring 5 Drive plate 14 Seal ring 23 Clip 6 Driven plate 15 Gasket 7 Retaining plate 16 Transfer clutch pipe Tightening torque N m kgf m ft lb 8 Snap ring 17 Extension case T1 13 1 3 9 4 9 Transfer piston seal 18 Transmission hanger T2 25 2 5 18 1 4AT 16 General Description AUTOMATIC TRANSMISSION 12 TRANSFER AND EXTENSION CASE WITH VTD AT 02377 1 Driven plate Thick 10 Multi plate clutch LSD piston 19 O ring 2 Driven plate 11 D ring 20 Rear wheel sensor 3 Driven plate Thin 12 Gasket 21 Transmission hanger 4 Driven plate Thick 13
13. and other light al loy parts use a plastic hammer to open Do not pry it apart with a screwdriver or other tool Be careful not to burn your hands because each part on the vehicle is hot after running e Do not mix gear oil grease etc with that of an other grade or from other manufacturers D PREPARATION TOOL 1 SPECIAL TOOLS ILLUSTRATION TOOL NUMBER DESCRIPTION e Be sure to tighten fasteners including bolts and nuts to the specified torque e Place shop jacks or rigid racks at the specified points e Apply ATF or gear oil onto sliding or revolution surfaces before installation e Replace deformed or otherwise damaged snap rings with new ones e Before installing O rings or oil seals apply suffi cient amount of ATF to avoid damage and defor mation e Be careful not to incorrectly install or fail to install O rings snap rings and other such parts Before securing a part on a vise place cushion ing material such as wood blocks aluminum plate or shop cloth between the part and the vise e Avoid damaging the mating surface of the case Before applying sealant completely remove the old seal REMARKS 498575400 ST 498575400 OIL PRESSURE GAUGE ASSY Used for measuring oil pressure 498897200 ST 498897200 ADAPTER Used oil pump housing when measuring reverse clutch pressure and line pressure 4AT 19 General Description AUTOMATIC TRANSMISSION ILLUSTRATION TOOL
14. valve not fully open Less than specifications 2 HOLD switch ON R Erroneous engine operation Torque converter clutch s one way clutch slipping Line pressure too low Low clutch slipping One way clutch malfunction Line pressure too low Greater than specifications Reverse clutch slipping Low amp reverse brake slipping Line pressure too low 2 HOLD switch ON Low clutch slipping 2 4 brake slipping 4AT 36 Time Lag Test AUTOMATIC TRANSMISSION 6 Time Lag Test A INSPECTION NOTE If the select lever is shifted while the engine is idling there will be a certain time elapse or lag be fore the shock can be felt This is used for checking the condition of the low clutch reverse clutch low amp reverse brake and one way clutch e Perform the test at normal operating fluid tem perature 70 to 80 C 158 to 176 F Be sure to allow a 1 minute interval between tests e Make three measurements and take the average value 1 Fully apply the parking brake 2 Start the engine Check the idling speed A C OFF 3 Shift the select lever from N to D range Using a stop watch measure the time it takes from shifting the lever until the shock is felt Time lag Less than 1 2 seconds If N gt D time lag is longer than specified e Line pressure too low e Low clutch worn e One way clutch not operating properly e D ring worn 4 In the same manner measure the time lag f
15. 2 ft Ib 25 Install the shift select cable onto select lever lt Ref to CS 14 INSTALLATION Select Cable gt 26 Install the oil charge pipe and connect the ATF cooler hoses to pipe AT 00683 27 Install the propeller shaft lt Ref to DS 17 INSTALLATION Propeller Shaft gt 28 Install the heat shield cover If equipped AT 00682 29 Install the rear exhaust pipe and muffler as sembly Non turbo model lt Ref to EX H4SO 10 INSTALLATION Rear Ex haust Pipe gt and lt Ref to EX H4SO 12 INSTAL LATION Muffler gt 2 0 L Turbo model lt Ref to EX H4DOTC 14 INSTALLATION Rear Exhaust Pipe gt and lt Ref to EX H4DOTC 15 IN STALLATION Muffler gt 30 Install the front and center exhaust pipe Non turbo model lt Ref to EX H4SO 7 INSTALLATION Front Ex haust Pipe gt 31 Install the center exhaust pipe Turbo model lt Ref to EX H4DOTC 10 INSTALLATION Center Exhaust Pipe gt 32 Install the under cover 33 Lower the vehicle 34 Install the ATF level gauge AT 00693 35 Connect the following connectors 1 Transmission harness connectors 2 Transmission ground terminal 36 Install the air cleaner case stay Tightening torque 16 N m 1 6 kgf m 11 6 ft lb 37 Install the air cleaner case or air intake cham ber Non turbo model lt Ref to IN H4SO 5 INSTALLATION Air Cleaner Case gt 4AT 46 Aut
16. 2004 IMPREZA SERVICE MANUAL QUICK REFERENCE INDEX TRANSMISSION SECTION CONTROL SYSTEMS cs AUTOMATIC TRANSMISSION 4AT AUTOMATIC TRANSMISSION 4AT diag DIAGNOSTICS MANUAL TRANSMISSION AND 5MT DIFFERENTIAL This service manual has been prepared to provide SUBARU service personnel MANUAL TRANSMISSION AND 6MT with the necessary information and data DIFFERENTIAL for the correct maintenance and repair of SUBARU vehicles MANUAL TRANSMISSION AND CIA This manual includes the procedures DIFFERENTIAL DIAGNOSTICS for maintenance disassembling reas sembling inspection and adjustment of CLUTCH SYSTEM CL 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 G1870GE4 ii AUTOMATIC TRANSMISSION 1 General Description nennen seckaslatentetdieneiess 2 Automatic Transmission Fluid ooccccnnncccnccnnnnnnnonccinana naco ncnnnnn caco nenn nenne 3 Differential Gear Oll onnninnnnininnonononinanonananano nana conocio naco na nono na nana no nana canina
17. 3 0 7 Shim 17 Oil seal retainer T4 25 2 5 18 1 8 Oil pump housing 18 Oil seal T5 40 4 1 30 9 Nipple 19 O ring T6 42 4 3 31 10 Air breather hose 20 Drive pinion collar T7 116 11 8 85 AAT 6 General Description AUTOMATIC TRANSMISSION 3 TRANSMISSION CASE AND CONTROL DEVICE T4 AT 00854 4AT 7 General Description AUTOMATIC TRANSMISSION 1 ATF level gauge 20 Oil filter stud bolt 39 Nipple 2 Oil charge pipe 21 Drain plug 40 Air breather hose 3 O ring 22 Gasket 41 Transmission case 4 Transfer valve plate 23 Oil pan 42 Plate ASSY 5 Transfer valve ASSY 24 Magnet 43 Washer 6 Transfer clutch seal 25 Stud bolt Short 7 Transfer duty solenoid 26 Stud bolt Long Tightening torque N m kgf m ft lb 8 Straight pin 27 Parking rod T1 3 5 0 36 2 6 9 Return spring 28 Manual plate T2 5 0 5 3 6 10 Shaft 29 Spring pin T3 6 0 6 4 11 Parking pawl 30 Detention spring T4 8 0 8 6 12 Parking support 31 Ball T5 12 1 2 8 7 13 Inlet filter 32 Spring T6 13 1 3 10 14 Gasket 33 Gasket TZ 14 1 4 10 15 Inlet pipe 34 Outlet pipe T8 18 1 8 13 16 Union screw 35 Union screw T9 25 2 6 18 17 O ring 36 Oil seal T10
18. 4SO 6 REMOVAL Front Exhaust Pipe gt lt Ref to EX H4SO 10 REMOVAL Rear Exhaust Pipe gt and lt Ref to EX H4SO 12 RE MOVAL Muffler gt 4 Remove the center and rear exhaust pipes and muffler Turbo model lt Ref to EX H4DOTC 9 REMOVAL Center Ex haust Pipe gt lt Ref to EX H4DOTC 14 REMOV AL Rear Exhaust Pipe gt and lt Ref to EX H4DOTC 15 REMOVAL Muffler gt 5 Remove the heat shield cover If equipped 6 Set the transmission jack under the transmis sion Make sure that the support plates of transmis sion jack don t touch the oil pan 7 Remove the transmission rear crossmember 8 Remove the rear cushion rubber B INSTALLATION 1 PITCHING STOPPER 1 Install the pitching stopper Tightening torque T1 50 N m 5 1 kgf m 37 ft Ib T2 58 N m 5 9 kgf m 43 ft Ib AT 00691 2 Install the air cleaner case Non turbo model lt Ref to IN H4SO 5 INSTALLATION Air Cleaner Case gt 3 Remove the intercooler Turbo model lt Ref to IN H4DOTC 10 INSTALLATION Inter cooler gt 4AT 48 Transmission Mounting System 2 TRANSMISSION REAR CROSSMEMBER AND REAR CUSHION RUBBER 1 Install the rear cushion rubber Tightening torque 39 N m 4 0 kgf m 29 ft Ib 2 Install the crossmember Tightening torque T1 35 N m 3 6 kgf m 26 ft Ib T2 70 N m 7 1 kgf m 51 ft Ib
19. 57300 SNAP RING OUTER GUIDE e Used for installing transfer outer snap ring e Used with INSTALLER 499247400 ST 499787000 499787000 WRENCH ASSY Used for removing and installing differential side retainer ST 398437700 398437700 4AT 22 Used for installing converter case oil seal ILLUSTRATION General Description TOOL NUMBER DESCRIPTION AUTOMATIC TRANSMISSION REMARKS ST 398487700 398487700 INSTALLER Used for installing taper roller bearing of front dif ferential ST 398673600 398673600 COMPRESSOR Used for removing and installing clutch spring ST 498255400 498255400 Used for measuring backlash of hypoid gear ST 399893600 399893600 PLIERS 4AT 23 Used for removing and installing clutch spring AUTOMATIC TRANSMISSION ILLUSTRATION General Description TOOL NUMBER DESCRIPTION REMARKS ST 498247001 498247001 MAGNET BASE e Used for measuring gear backlash e Used with DIAL GAUGE 498247100 ST 498247100 498247100 DIAL GAUGE Used for measuring gear backlash e Used with MAGNET BASE 498247001 ST 498517000 498517000 REPLACER Used for removing front roller bearing ST 398623600 398623600 4AT 24 Used for removing spring of transfer clutch pis ton ILLUSTRATION General Description TOOL NUMBER DESCRIPTION AUTOMATIC TRANSMISSION
20. 6 mm 9 29 in 246 mm 9 69 in 2 400 2 200 2 100 2 900 Stall speed at sea level 000 2 700 2 600 3 500 sun gear pm rpm rpm rpm Tooth num One way y ber of rear clutch Sprague type one way clutch inion Tooth num 2 OIL PUMP ber of rear internal gear Type Pracoid constant displacement pump Drive amp Driving method Driven by engine driven plate Number of teeth Inner rotor number of PS Outer rotor 10 high clutch Drive amp 3 TRANSMISSION CONTROL ELEMENT driven plate number of low clutch 4 forward 1 reverse double row planetary gears Multi plate clutch 3 sets Multi plate brake 2 sets One way clutch sprague type 4 TRANSMISSION GEAR RATIO Type Drive amp driven plate number of reverse clutch Drive amp driven plate number of 2 4 brake Drive driven plate number of low reverse brake 1 sets Gear ratio 2 785 1 545 1 000 0 694 2 272 4AT 2 General Description AUTOMATIC TRANSMISSION 6 SELECTOR POSITION 9 TRANSFER P Park Transmission in neutral output member immov able and engine start possible Model 2 2 0 L Turbo R Transmission in reverse for backing a Reverse Variable Transfer tha N Neu Transmission in neutral and engine start possi type Multi plate transfer MPT torque distri
21. 80 Without printer e Spanish 22771AA090 Without printer ST22771AA030 2 GENERAL PURPOSE TOOLS REMARKS Used for measuring transmission end play Used for measuring clearances of clutch brake and oil pump Used for measuring thickness of drive pinion Used for measuring starting torque of drive pinion Used for measuring resistance and voltage Used for removing and installing differential gear oil drain plug TOOL NAME Depth gauge Thickness gauge Micro meter Spring balance Circuit tester TORX T70 Push pull gauge Used for measuring low amp reverse and high clutch piston stroke 4AT 30 Automatic Transmission Fluid AUTOMATIC TRANSMISSION 2 Automatic Transmission Flu id A INSPECTION NOTE The level of ATF varies with fluid temperature Pay attention to the fluid temperature when checking ATF level 1 Raise the ATF temperature by driving a distance of 5 to 10 km 3 to 6 miles Otherwise idle the en gine to raise ATF temperature to 70 80 C 158 176 F on SUBARU Select Monitor lt Ref to 4AT diag 21 READ CURRENT DATA OPERA TION Subaru Select Monitor gt 2 Make sure the vehicle is level 3 After selecting all positions P R N D 3 2 1 set the select lever in P range Measure the ATF level with the engine idling for one or two minutes AT 00674 A ATF level gauge B Upper level C Lower level 4 Make su
22. Clutch Pressure Test 8 Transfer Clutch Pressure Test A INSPECTION e MPT MODEL Check the transfer clutch pressure in accordance with the following chart in the same manner as with line pressure lt Ref to 4AT 38 Line Pressure Test gt ST 498897700 OIL PRESSURE ADAPTER SET OIL PRESSURE GAUGE ASSY AWD mode D range FWD mode P range engine speed 2 000 rpm If oil pressure is not produced or if it does not change in the AWD mode the transfer duty sole noid or transfer valve assembly may be malfunc tioning If oil pressure is produced in the FWD mode the problem is similar to that in the AWD mode NOTE Before setting in FWD mode install the spare fuse on FWD mode switch ST 498575400 AT 00021 A Test plug NOTE If the oil pressure is not produced or if it does not change in the AWD mode the transfer duty sole noid or transfer valve assembly may be malfunc tioning If the oil pressure is produced in the FWD mode the problem is similar to that in the AWD mode e VTD MODEL Check transfer clutch pressure using the following chart lt Ref to 4AT 38 Line Pressure Test gt ST 498897700 OIL PRESSURE ADAPTER SET AUTOMATIC TRANSMISSION OIL PRESSURE GAUGE ASSY ST 498575400 AT 00676 A Test plug 4AT 39 Transfer Clutch Pressure Test AUTOMATIC TRANSMISSION STANDARD TRANSFER CLUTCH PRESSURE Range posi tion ON Duty ratio
23. NUMBER DESCRIPTION REMARKS 498897700 ADAPTER SET Used for measuring transfer clutch pressure Pa ST 498897700 498545400 FILTER WRENCH Used for removing and installing ATF filter ST 498545400 498277200 STOPPER SET Used for removing and installing automatic trans mission assembly to engine ST 498277200 41099AA010 ENGINE SUPPORT Used for supporting engine BRACKET e Used with ENGINE SUPPORT 41099AA020 ST41099AA010 4AT 20 ILLUSTRATION General Description TOOL NUMBER DESCRIPTION AUTOMATIC TRANSMISSION REMARKS ST41099AA020 41099AA020 ENGINE SUPPORT e Used for supporting engine Used with ENGINE SUPPORT BRACKET 41099AA010 ST 398527700 398527700 PULLER ASSY e Used for removing extension case roller bear ing e Used for removing extension oil seal e Used for removing front differential side retainer bearing outer race e Used for removing front differential side retainer bearing outer ball race ST 498057300 498057300 INSTALLER Used for installing extension oil seal ST 498077000 498077000 REMOVER Used for removing differential taper roller bear ing 4AT 21 AUTOMATIC TRANSMISSION ILLUSTRATION General Description TOOL NUMBER DESCRIPTION REMARKS ST 499247400 499247400 INSTALLER e Used for installing transfer outer snap ring e Used with GUIDE 499257300 ST 499257300 4992
24. brakes while going down a grade 10 TRANSFER CLUTCH Check if the tight corner braking occurs when the vehicle is started with steering wheel held at fully turned position MPT model 11 0IL LEAKS After the driving test inspect for oil leaks AAT 34 Stall Test AUTOMATIC TRANSMISSION 5 Stall Test A INSPECTION NOTE The stall test is of extreme importance in diagnos ing the condition of the automatic transmission and the engine It should be conducted to measure the engine stall speeds in R and 2 ranges Purposes of the stall test To check the operation of the automatic trans mission clutch e To check the operation of the torque converter clutch e To check engine performance 2 Check that engine oil level is correct 3 Check that coolant level is correct 4 Check that ATF level is correct 5 Check that differential gear oil level is correct 6 Increase ATF temperature to 70 to 80 C 158 to 176 F by idling the engine for approx 30 minutes with select lever set to N or P 7 Place the wheel chocks at the front and rear of all wheels and engage the parking brake 8 Move the manual linkage to ensure it operates properly and shift the select lever to the 2 range Turn hold switch ON 9 While forcibly depressing the foot brake pedal gradually depress the accelerator pedal until the engine operates at full throttle AT 00449 A Brake p
25. conds after shifting the select lever to each position If line pressure needs to be measured again allow the engine to idle and then stop it to cool down for at least one minute 4 Maintain the temperature of ATF at approx 70 80 C 158 176 F during measurement ATF will reach the above temperature after idling the engine for approx 30 minutes with the select lever in N or P 3 Temporarily attach the ST to a suitable place in the drivers compartment remove the blind plug lo cated in front of the toe board and pass the hose of the ST to engine compartment OIL PRESSURE GAUGE ASSY ST 498575400 AT 00019 A Pressure gauge hose B Hole in toe board blank cap hole C Brake pedal 4 Remove the test plug and install the ST instead ST 498897200 OIL PRESSURE GAUGE ADAPTER AT 02379 A Test plug 5 Connect the ST1 with ST2 ST1 498897200 OIL PRESSURE GAUGE ADAPTER OIL PRESSURE GAUGE ASSY 6 Check for duty ratio changes by opening and closing the throttle valve using SUBARU Select Monitor ST2 498575400 Standard line pressure Range seta Throttle Line pressure position tio position kPa kg cm psi 2 1 130 1 275 HOLD 5 Full open 11 5 13 0 Switeh 164 185 ON 1 520 1 716 R 5 Full open 15 5 17 5 220 249 300 410 D 95 Full closed 3 1 4 2 44 60 4AT 38 Transfer
26. edal B Accelerator pedal 10 When the engine speed is stabilized record that speed quickly and release the accelerator ped al 11 Shift the select lever to N range and cool down the engine by idling it for more than one minute 12 If the stall speed in 2 range is higher than specifications low clutch slipping and 2 4 brake slipping may occur To identify it conduct the same test as above in R range 13 Perform the stall tests with the select lever in D range Turn hold switch OFF NOTE e Do not continue the stall test for MORE THAN 5 SECONDS at a time from closed throttle fully open throttle to stall speed reading Failure to fol low this instruction causes the engine oil and ATF to deteriorate and the clutch and brake to be ad versely affected e Be sure to cool down the engine for at least 1 minute after each stall test with the select lever set in the P or N range and with the idle speed lower than 1 200 rpm e If the stall speed is higher than the specified range attempt to finish the stall test in as short a time as possible in order to prevent the automatic transmission from sustaining damage Stall speed at sea level 1 6 L model 2 400 3 000 rpm 2 0 L Non turbo model 2 200 2 700 rpm 2 0 L Turbo model 2 900 3 500 rpm 2 5 L model 2 100 2 600 rpm 4AT 35 Stall Test AUTOMATIC TRANSMISSION Stall speed at sea level Position Cause Throttle
27. er side of transmission to engine a 5 AT 00108 31 Place the transmission jack under transmis sion NOTE Make sure that the support plates of transmission jack don t touch the oil pan 32 Remove the transmission rear crossmember from vehicle 33 While gradually lowering the transmission jack fully contract the engine support and tilt the engine rearward 34 Remove the transmission CAUTION Remove the transmission and torque converter as a unit away from engine AT 00109 35 Separate the transmission assembly and rear cushion rubber B INSTALLATION 1 Replace the differential side oil seal with new one NOTE Replacement is not necessary when new oil seal has been installed 2 Install the rear cushion rubber to transmission assembly Tightening torque 39 N m 4 0 kgf m 29 ft Ib 4AT 43 Automatic Transmission Assembly AUTOMATIC TRANSMISSION 3 Install the ST to converter case ST 498277200 STOPPER SET 4 Install the transmission onto engine 1 Gradually raise the transmission with trans mission jack AT 00109 2 Engage them at splines 3 While gradually lifting the transmission jack turn the screw of engine support and then tilt the engine forward 5 Install the transmission rear crossmember Tightening torque T1 35 N m 3 6 kgf m 26 ft Ib T2 70 N m 7 1 kgf m 51 ft Ib
28. hauled 1 6 L FWD model 8 0 8 3 2 8 5 8 8 US gt 7 0 7 3 Imp qt 1 6 L AWD and 2 0 L Non turbo model 8 4 8 7 2 8 9 9 2 US gt 7 4 7 7 Imp qt 2 5 L and 2 0 L Turbo model 9 3 9 6 0 9 8 10 1 US gt 8 2 8 4 Imp qt 7 Check the level and leaks of ATF lt Ref to AAT 31 INSPECTION Automatic Trans mission Fluid gt 4AT 31 Automatic Transmission Fluid AUTOMATIC TRANSMISSION C CONDITION CHECK NOTE When replacing ATF check the inside condition of the transmission body by inspecting the drained ATF Fluid condition Trouble and possible cause Corrective action Large amount of metallic pieces are Excessive wear of the internal of the trans Replace ATF and check if AT operates found mission body correctly Replace ATF and check AT itself and vehicle for faulty Clouded fluid or bubbles are found in Water mixed in fluid Replace ATF and check the water enter fluid ing point Thick and varnish form fluid Burned clutch and etc 4AT 32 Differential Gear Oil 3 Differential Gear Oil A INSPECTION 1 Park the vehicle on a level surface 2 Remove the oil level gauge and wipe it clean 3 Reinsert the level gauge allthe way Be sure that the level gauge is correctly inserted and in the proper orientation 4 Remove it again and note the reading If the dif ferential gear oil level is below the L line fill oil to bring the level up to the P li
29. he front housing from outside SY SCN__ ST2 N CAN MI S Ee DEE J S E A Y D 5 SS Dy 3 i gt lt lt gt 8 AT 02380 13 Install the pitching stopper bracket Fr a AT 00111 Tightening torque 21 Install the ball joint into housing 41 N m 4 1 kgf m 30 0 ft Ib 22 Connect the stabilizer link to transverse link 14 Install the pitching stopper and tighten the bolts Wagon model Tightening torque NOTE T1 50 N m 5 1 kgf m 37 ft Ib T2 58 N m 5 9 kgf m 43 ft Ib Discard the loosened self locking nut and replace with a new one Tightening torque T1 30 N m 3 1 kgf m 22 4 ft Ib T2 50 N m 5 1 kgf m 37 ft Ib o O 15 Lift up the vehicle 16 Replace the snap ring of front drive shaft with a new one m QA m AT 0069 17 Apply grease to the oil seal lips 18 Install the ST to side retainer Sal IT 4AT 45 Automatic Transmission Assembly AUTOMATIC TRANSMISSION 23 Tighten the installing bolts Sedan model Tightening torque 50 N m 5 1 kgf m 36 9 ft Ib AT 00809 24 Install the stabilizer link to transverse link Se dan model Tightening torque 45 N m 4 6 kgf m 33
30. ne 5 To prevent overfilling the differential gear oil do not add oil above the F line A Oil level gauge B Upper level C Lower level B REPLACEMENT 1 Lift up the vehicle 2 Remove the differential gear oil drain plug using TORX T70 and then drain the differential gear oil completely CAUTION e Directly after the engine has been running the differential gear oil is hot Be careful not to burn yourself e Be careful not to spill the differential gear oil on exhaust pipe to prevent it from emitting smoke or fire When the differential gear oil is spilled on exhaust pipe wipe it away camplete ly 3 Replace the gasket with a new one and then tighten_the differential gear oil drain plug using TORX T70 AUTOMATIC TRANSMISSION Tightening torque 70 N m 7 1 kgf m 51 6 ft lb dlh AT 02378 A Oil pan B Differential oil drain plug 4 Lower the vehicle 5 Pour gear oil into the gauge hole Recommended fluid lt Ref to RM 3 LUBRICANTS RECOMMEND ED MATERIALS Recommended Materials gt Gear oil capacity 1 1 1 30 1 2 1 4 US qt 1 0 1 1 Imp qt 6 Check the level of differential gear oil lt Ref to 4AT 33 INSPECTION Differential Gear Oil gt 4AT 33 Road Test AUTOMATIC TRANSMISSION 4 Road Test A INSPECTION 1 GENERAL PRECAUTION Road tests should be conducted to properly diag nose the condition of the automa
31. omatic Transmission Assembly AUTOMATIC TRANSMISSION 38 Install the air intake duct Non turbo model lt Ref to IN H4SO 6 INSTALLATION Air Intake Duct gt 39 Install the intercooler Turbo model lt Ref to IN H4DOTC 10 INSTALLATION Inter cooler gt 40 Connect the battery ground cable 41 Fill ATF up to the middle of the COLD side on level gauge by using the oil charge pipe lt Ref to 4AT 31 Automatic Transmission Fluid gt 42 Take off the vehicle from lift arms 43 Check select lever operation lt Ref to 4AT 52 INSPECTION Inhibitor Switch gt 44 Check the ATF level lt Ref to 4AT 31 Auto matic Transmission Fluid gt 45 Check the road test lt Ref to 4AT 34 Road Test gt 4AT 47 Transmission Mounting System AUTOMATIC TRANSMISSION 10 Transmission Mounting Sys tem A REMOVAL 1 PITCHING STOPPER 1 Disconnect the ground cable from battery 2 Remove the air cleaner case 2 0 L Non turbo model lt Ref to IN H4SO 5 REMOVAL Air Cleaner Case gt 3 Remove the intercooler 2 0 L Turbo model lt Ref to IN H4DOTC 10 REMOVAL Intercool er gt 4 Remove the pitching stopper AT 00679 2 TRANSMISSION REAR CROSSMEMBER AND REAR CUSHION RUBBER 1 Disconnect the ground cable from battery 2 Jack up the vehicle and support it with sturdy racks 3 Remove the front center rear exhaust pipes and muffler Non turbo model lt Ref to EX H
32. or N gt R Time lag Less than 1 5 seconds If N gt R time lag is longer than specified e Line pressure too low e Reverse clutch worn e Low amp reverse brake worn e D ring worn 4AT 37 Line Pressure Test AUTOMATIC TRANSMISSION 7 Line Pressure Test A MEASUREMENT NOTE If the clutch or the brake shows a sign of slippage or shifting sensation is not correct the line pressure should be checked e Excessive shocks during upshifting or shifting takes place at a higher point than under normal cir cumstances may be due to the line pressure being too high e Slippage or inability to operate the vehicle may in most cases be due to loss of oil pressure for the operation of the clutch brake or control valve 1 Line pressure measurement under no load 1 Before measuring the line pressure jack up all wheels 2 Maintain the temperature of ATF at approx 70 80 C 158 176 F during measurement ATF will reach the above temperature after idling the engine for approx 30 minutes with se lect lever in N or P 2 Line pressure measurement under heavy load 1 Before measuring the line pressure apply both foot and parking brakes with all wheels chocked Same as for stall test conditions 2 Measure the line pressure when select lever is in R 2 HOLD switch ON with engine un der stall conditions 3 Measure the line pressure within 5 se
33. re that ATF level is between the upper level and lower level at HOT side If the level is below the lower level check for leaks in the transmission If there are leaks it is neces sary to repair or replace gasket oil seals plugs or other parts 5 Ifthe ATF level is below the center between up per and lower marks fill the recommended ATF un til the ATF level is found above the center between upper and lower marks CAUTION e Use care not to exceed the upper level e Filling of ATF to the upper level when the transmission is cold will result in overfilling of ATF causing a transmission failure 6 Check ATF level after raising ATF temperature to 70 80 C 158 176 F by during the distance of5to 10 km 3 to 6 miles or by idling the engine again B REPLACEMENT 1 Lift up the vehicle 2 Drain the ATF completely CAUTION Directly after the engine has been running the ATF is hot Be careful not to burn yourself 3 Check the ATF condition lt Ref to 4AT 32 CONDITION CHECK Automatic Transmission Fluid gt 4 Replace with a new gasket and then tighten the ATF drain plug Tightening torque 25 N m 2 5 kgf m 18 1 ft Ib A Oil pan B ATF drain plug 5 Lower the vehicle 6 Pour ATF into the oil charge pipe Recommended fluid Dexron Ill type automatic transmission fluid Capacity Fill the same amount of ATF drained from drain plug hole Capacity when transmission is over
34. s A A O 2 rare A O A a E ran eae 6 Time Lag Testurteil q WEiNne Pressure lest 2 1 2 2 ne een dee ai 8 Transfer Clutch Pressure Test cccccccccccececceeseseeceeeeeeeeeeaeaeaeseseeeeeeeeeeees 9 Automatic Transmission Assembly uuessessssnnnnnnennnnnnnnnnnnnnnnnnnnn ernennen 10 Transmission Mounting System ussrssnsnnnnennnnnnnnnnnnnnnnnnnnnnnnnnnnnnn nenn 11 Extension Case Oil Seal uunuueenennnnunnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnn namen 12 Differential Side Retainer Oil Seal o onnnnnnnnnnconinininnnincnnanananananinana canino 13 x Inhibitor OM E a a en es ea 14 Front Vehicle Speed Sensor cooooccccccccnnoooooccononcnononnnnncnononccnnnnnnnnnnnnncccinnnnos 15 Rear Vehicle Speed Sensor 2u2s4ssnnnnennennnnnnnnnnnnnnnnnnnnnnnnnnnnnennennnen 16 Torque Converter Turbine Speed Sensor ccccccnonococcccnncccccnonannnonnnnncnnnnnnos 17 2 GOntrol Valve Body ar ra a a ad 18 Shift Solenoids Duty Solenoids and ATF Temperature Sensor 19 Transfer Duty Solenoid and Valve Body ocoooocccccnncccccccconcccconancccnnananccnnnnno 20 ATE Filter 2 2 22 id cido 21 Transmission Control Module TOM cceeeccceeeeeeeseeeeeeeeeeeesseesaaees 22 ATF Cooler Pipe and Hose iio ie 23 Air Breather Hos turis idos 24 OilCharg PP a hah rteo a 25 Torque Converter Clutch Assembly oooooccccicncccccccnonoccccnonnccnnnnancnonnnnnnncnnnnns 26 TRANSMISSION GOVER iii ande aus tates 27
35. st Pipe gt and lt Ref to EX H4DOTC 15 REMOVAL Muffler gt 21 Remove the heat shield cover If equipped AT 00682 22 Drain ATF to remove the ATF drain plug dTh AT 02389 A Oil pan B Drain plug 23 Disconnect the ATF cooler hoses from pipes of transmission side and remove the oil charge pipe AT 00683 24 Remove the propeller shaft lt Ref to DS 16 REMOVAL Propeller Shaft gt 25 Remove the shift select cable lt Ref to CS 13 REMOVAL Select Cable gt 26 Disconnect the stabilizer link from transverse link 27 Remove the bolt securing ball joint of trans verse link to housing 4AT 42 Automatic Transmission Assembly AUTOMATIC TRANSMISSION e WAGON MODEL e SEDAN MODEL MT 00076 28 Pull out the front drive shaft from transmission 1 Using a tire lever or a pinch bar etc pull out the front drive shaft until its joint facing to trans mission can move smoothly NOTE Place cloth between tire lever or pinch bar and transmission in order to avoid damaging the side retainer of transmission 2 Hold the transmission side joint portion of front drive shaft by hand and extract the housing from the transmission by pressing it outside so as not to stretch the boot 29 Remove the bolts which hold the clutch hous ing cover 30 Remove the nuts which hold the low
36. tic transmission NOTE When performing the test do not exceed posted speed limit 2 DRANGE SHIFT FUNCTION Check shifting between ist gt 2nd gt 3rd gt 4th while driving on normal city streets 3 D RANGE SHIFT SHOCK Check the shock level when shifting up during nor mal driving 4 KICK DOWN FUNCTION Check kick down for each gear Also check the kick down shock level 5 ENGINE BRAKE OPERATION e Check the 3rd gear engine brake when shifting between D gt 3rd range while driving in 4th gear of D range 50 to 60 km h 31 to 37 MPH e Check the 2nd gear engine brake when shifting between 3 gt 2 range while driving in the 3 range 3rd gear 40 to 50 km h 25 to 31 MPH e Check the 1st gear engine brake when shifting between 2 gt 1 range while driving in the 2 range 2nd gear 20 to 30 km h 12 to 19 MPH 6 LOCK UP FUNCTION Check that engine speed does not change sharply when the acclelerator pedal is lightly depressed when driving on flat roads at normal speed in D range 7 PRANGE OPERATION Stop the vehicle on an uphill grade of 5 or more and shift to P range Check that the vehicle does not move when the parking brake is released 8 UNUSUAL SOUNDS AND VIBRATION Check for unusual sounds and vibration while driv ing and during shifting 9 CLIMBING CONTROL FUNCTION e Check that the gear remains in 3rd when going up a grade e Check that the gear remains in 3rd when apply ing the
37. torque converter clutch from drive plate 1 Remove the service hole plug 2 Remove the bolts which hold torque con verter clutch to drive plate 3 While rotating the engine remove the other bolts using ST CAUTION Be careful not to drop the bolts into torque con verter clutch housing 12 Install the ST to converter case ST 498277200 STOPPER SET AT 00804 13 Remove the ATF level gauge 4AT 41 Automatic Transmission Assembly AUTOMATIC TRANSMISSION NOTE Plug the opening to prevent an entry of foreign par ticles into transmission fluid AT 00680 14 Remove the pitching stopper bracket 15 Setthe ST ST1 41099AA010 ENGINE SUPPORT BRACK ET ST2 41099AA020 ENGINE SUPPORT CH ES SE Sa ES 7 E 16 Remove the bolt which holds the right upper side of transmission to engine ST1 q AT 00106 17 Lift up the vehicle 18 Remove the under cover 19 Remove the front center and rear exhaust pipe and muffler Non turbo model lt Ref to EX H4SO 6 REMOVAL Front Exhaust Pipe gt lt Ref to EX H4SO 10 REMOVAL Rear Exhaust Pipe gt and lt Ref to EX H4SO 12 RE MOVAL Muffler gt 20 Remove the center and rear exhaust pipes and muffler Turbo model lt Ref to EX H4DOTC 9 REMOVAL Center Ex haust Pipe gt lt Ref to EX H4DOTC 14 REMOV AL Rear Exhau
38. utch inner race 10 Low clutch piston 21 Socket bolt Tightening torque N m kgf m ft lb 11 D ring 22 Spring retainer T 25 2 5 18 1 4AT 12 General Description AUTOMATIC TRANSMISSION 8 REDUCTION GEAR WITH MPT AT 02376 A AWD B FWD 1 Seal ring 7 Ball bearing 13 Ball bearing 2 Ball bearing 8 Snap ring 3 Reduction drive gear 9 Reduction driven gear Tightening torque N m kgf m ft lb 4 Reduction drive shaft 10 Washer T 100 10 2 73 8 5 Drive pinion shaft 11 Lock nut 6 Snap ring 12 Reduction drive shaft 4AT 13 General Description AUTOMATIC TRANSMISSION 9 REDUCTION GEAR WITH VTD AT 02203 1 Ball bearing 13 Rear drive shaft 25 Snap ring 2 Reduction drive gear 14 Ball bearing 26 Ball bearing 3 Washer 15 Multi plate clutch LSD hub 27 Snap ring 4 Needle bearing 16 Ball bearing 28 Reduction driven gear 5 Pinion gear 17 Revolution gear 29 Lock washer 6 Carrier 18 Driven plate Thick 30 Lock nut 7 Planetary pinion shaft 19 Driven plate 31 Gasket 8 Snap ring 20 Driven plate Thin 32 Extension case 9 Seal ring 21 Driven plate Thick 10 Thrust needle bearing 22 Pressure plate Tightening torque N m kgf m ft lb 11 Intermediate shaft 23 Rear drive shaft shim T 100 10 2 73 8 12 Thrust washer 24 Drive pinion shaft 4AT 14 General Description AUTOMATIC
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