2004 LEGACY SERVICE MANUAL QUICK REFERENCE INDEX
Contents
1. AT 01326 A Brake pedal 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 the 2nd of manual mode 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 NOTE e Do not continue the stall test for more than five seconds at a time from closed throttle fully open throttle to stall soeed reading Failure to follow this instruction causes the engine oil and ATF to deteri orate and the clutch and brake to be adversely af fected Be sure to cool down the engine for at least one minute after each stall test with the select lever set in P or N range and with the idle speed lower than 1 200 rpm 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 4AT 35 Stall Test AUTOMATIC TRANSMISSION Stall speed at sea level 2 0 L model 2 300 2 700 rpm 2 5 L model 2 600 2 900 rpm Stall speed at sea level Range Cause Throttle valve not fully open Erroneous engine operation T2. 7 7 Imp qt 2 5 L model 9 3 9 6 2 9 8 10 1 US qt 8 2 8 4 Imp qt 7 Bleed the air of control valve lt Ref to 4AT 63 Air Bleeding of Control Valve gt 8 Check the level and leaks of ATF lt Ref to 4AT 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 Thick and varnish form fluid Burned clutch and etc S vehicle for faulty Replace ATF and check the water enter fluid ing point Clouded fluid or bubbles are found in Water mixed in fluid 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 all the way Be sure that the level gauge is correctly inserted and in the proper orientation 4 Remove the level gauge again and note the reading If the differential gear oil level is below the C line add oil to bring the level up to the F line NOTE To prevent overfilling the differential gear oil do not
3. 13 ATF COOLER WITH ATF WARMER FUNCTION 7 NX ai gt xN 5 AT 02162 1 ATF cooler outlet hose 5 Engine coolant inlet pipe Tightening torque N m kgf m ft lb 2 ATF cooler inlet hose 6 Engine coolant outlet pipe T 23 2 3 16 6 3 Hose clamp 7 ATF cooler bracket 4 ATF cooler ASSY 8 Clip 4AT 17 General Description AUTOMATIC TRANSMISSION 14 TRANSMISSION MOUNTING z AT 00014 1 Pitching stopper 3 Crossmember Tightening torque Nam kgf m ft lb 2 Rear cushion rubber 4 Stopper T1 35 3 6 26 T2 40 4 1 30 T3 50 5 1 37 T4 58 5 9 43 T5 70 7 1 51 4AT 18 General Description AUTOMATIC TRANSMISSION C CAUTION Wear work clothing including a cap protective goggles and protective shoes during operation e Remove contamination including dirt and corro sion before removal installation or disassembly Keep the disassembled parts in order and pro tect them from dust and dirt Do not place the oil pan with its inner side facing upward until it is installed so as to prevent foreign matter intrusion into valve body Before removal installation or disassembly be sure to clarify the failure Avoid unnecessary re moval installation disassembly and replacement e When disassembling the case and other light al
4. 499787700 WRENCH Used for removing and installing drive pinion lock nut Y ST 499787500 499787500 ADAPTER 4AT 25 Used for removing and installing drive pinion lock nut General Description AUTOMATIC TRANSMISSION ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 398643600 GAUGE Used for measuring total end play extension end play and drive pinion height ST 398643600 498627100 Used for holding low clutch piston retainer spring when installing snap ring ST 498627100 499577000 Used for measuring mating surface of transmis sion to end of reduction gear ST 499577000 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 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 49843710
5. Nomi nal diame ter mm in 236 9 29 249 9 69 Stall speed at sea level 2 300 2 700 2 500 2 900 rpm rpm One way clutch 2 OIL PUMP Type Sprague type one way clutch Pracoid constant displacement pump Driving method Driven by engine Number of teeth Inner rotor Outer rotor 10 3 TRANSMISSION CONTROL ELEMENT Type 4 forward 1 reverse double row planetary gears Multi plate clutch 3 sets Multi plate brake 2 sets One way clutch sprague type 1 sets 4 TRANSMISSION GEAR RATIO 5 PLANETARY GEAR AND PLATE Model Front sun gear number of teeth Front pinion num ber of teeth Front internal gear number of teeth Rear sun gear number of teeth Rear pinion num ber of teeth Rear internal gear number of teeth Drive plate num ber of high clutch Drive plate num ber of low clutch Drive plate num ber of reverse clutch Drive plate num ber of 2 4 brake Drive plate num ber of low amp reverse brake 6 SELECTOR POSITION P Park Transmission in neutral output mem ber immovable and engine start possi ble R Reverse Transmission in reverse for backing N Neutral Transmission in neutral and engine start possible D Drive 4 forward automatic gear change 1st _ 2nd lt _ 3rd lt _ 4th SPO
6. 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 13 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 5 General Description AUTOMATIC TRANSMISSION 3 TRANSMISSION CASE AND CONTROL DEVICE 34 AT 02160 4AT 6 General Description AUTOMATIC TRANSMISSION a _ GRE lt iN oa wa O lt J lt lt Rei ot O ATF level gauge 19 Oil pan 37 Transmission case Oil charge pipe 20 Magnet 38 Plate ASSY O ring 21 Stud bolt Short 39 Washer Straight pin 22 Stud bolt Long 40 Inlet pipe Model with ATF cooler Return spring 23 Parking rod with warmer function Shaft 24 Manual plate 41 Outlet pipe Model with ATF Parking pawl 25 Spring pin cooler with warmer function Parking support 26 Detention spring Bushing 27 Ball Tightening torque N m kgf m ft lb Gasket 28 Spring T1 3 4 0 35 2 5 Inlet pipe Model without ATF 29 Gasket T2 5 0 5 3 6 cooler with warmer function 30 O
7. 200 line pressure lt Ref to 4AT 38 Line Pressure opened 10 2 12 2 Test gt 100 145 174 ST 498897700 OIL PRESSURE ADAPTER Manual Adjust 500 700 SET mode ON Duty 51 71 ST 498575400 OIL PRESSURE GAUGE 2nd ratio to 73 102 ASSY 60 Fully NOTE closed 0 e Before setting in FWD mode install the spare fuse on FWD mode switch MPT model e MTP model Fully closed 0 AT 00021 A Test plug e VTD model AT 00022 A Test plug e If no oil pressure is produced or if it does not change in AWD mode the control valve body may be malfunctioning If oil pressure is produced in FWD mode the same problem as AWD mode oc curs 4AT 39 Automatic Transmission Assembly AUTOMATIC TRANSMISSION 9 Automatic Transmission As sembly A REMOVAL 1 Set the vehicle on a lift 2 Fully open the front hood and support with hood stay 3 Disconnect the ground cable from battery 4 Remove the air intake duct lt Ref to IN H4SO 2 0 9 REMOVAL Air Intake Duct gt 5 Remove the air intake chamber lt Ref to IN H4SO 2 0 8 REMOVAL Air Intake Chamber gt 6 Remove the air cleaner case stay 7 Disconnect the following connectors 1 Transmission harness connectors 2 Transmission ground terminal 8 Remove the starter lt Ref to SC H4SO 2 0 6 REMOVAL Starter gt 9 Remove the pitching stopper 10
8. AT 02161 1 Seal ring 6 Snap ring 11 Lock nut 2 Ball bearing 7 Ball bearing 3 Reduction drive gear 8 Snap ring Tightening torque N m kgf m ft lb 4 Reduction drive shaft 9 Reduction driven gear T 100 10 2 73 8 5 Drive pinion shaft 10 Washer 4AT 12 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 Thicker 30 Lock nut 7 Planetary pinion shaft 19 Drive plate 31 Gasket 8 Snap ring 20 Driven plate Thinner 32 Extension case 9 Seal ring 21 Driven plate Thicker 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 13 General Description AUTOMATIC TRANSMISSION 10 DIFFERENTIAL GEAR AT 00011 1 Hypoid driven 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 1
9. Assembly usenesssssnnnnnnennnnnnnnnnnnnnnnnnnnn nennen 10 Transmission Mounting System Av 11 Gelee EE 12 Differential Side Retainer Oil Gesi T3 l Inhibitor SWOR EE EEN 14 Front Vehicle Speed Sensor EE 15 Rear Vehicle Speed Sensor nneue naeh 16 Torque Converter Turbine Speed Sensor 17 Qontrol Valve e E 18 Air Bleeding of Control Valve AAA 19 d EE ee ee Ree Need dete ase 20 Transmission Control Module TOM 21 Aral Gl SONS EE 22 ATF Cooler Pipe and RER 23 ATF Cooler with warmer function ENEE 24 en Tee EE 25 Air Breather HOSE r a teeetandeciadetsanecesnadadaneosdascasnaatssaneesaee 26 Oil Gharge te EE 27 Torque Converter Clutch Assembly AAA 28 Extension CASO EE 29 Transfer Tt EE nc 2 MulteplateCl teh nn ee hs Rea RE 32 Reduction Driven Gear 33 Reduction Drive EE 34 Center Differential Carter 35 Parking Pawl kericuhan E 36 Converter CaSe orn miis ear a E E E E a a aeaaeai 37 e AB P mp HOUSING EE 38 Drive Pinion Shaft Aesembhy AAA 39 Front Differential Assembly een coder nerieeeis eee AU Pd AUT AS EEN 41 Transmission Control Device unnannennnnnsnnnannnnnnennnnnnnnnn nennen nenn nennen General Description AUTOMATIC TRANSMISSION 1 General Description A SPECIFICATION 1 TORQUE CONVERTER CLUTCH Model 2 0L 2 5L Type Symmetric 3 element single stage 2 phase torque converter Stall torque ratio 2 0 2 2 2 1 2 3
10. Less than 1 5 seconds If N 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 line pressure jack up all the wheels 2 Maintain the temperature of ATF at approx 70 80 C 158 176 F during measurement ATF will reach the above mentioned tempera ture after idling the engine for approx 30 min utes with the select lever in N or P 2 Line pressure measurement under heavy load 1 Before measuring line pressure apply both the foot and parking brakes with all wheels chocked Same as for stall test conditions 2 Measure the line pressure when the select lever is in R or 2nd of manual mode with en gine under stall conditions 3 Measure the line pressure within 5 seconds after shi
11. Separate the torque converter clutch from drive plate 1 Remove the V belt covers 2 Remove the service hole plug 3 Remove the bolts which hold torque con verter clutch to drive plate 4 Insert the wrench to crank pulley bolt and then remove all the bolts with slightly rotating crank pulley CAUTION Be careful not to drop bolts into torque convert er clutch housing 11 Install the ST to converter case ST 498277200 STOPPER SET AT 00804 12 Remove the ATF level gauge NOTE Plug the opening to prevent entry of foreign parti cles into transmission fluid AT 01330 13 Remove the throttle body lt Ref to FU H4SO 2 0 10 REMOVAL Throttle Body gt 4AT 40 Automatic Transmission Assembly 14 Drain the engine coolant by approx 2 Q 2 1 US qt 1 8 Imp qt Model with ATF cooler with warmer function 15 Disconnect the ATF cooler inlet and outlet hos es from ATF cooler pipes DE Vil sembly AT 02163 17 Remove the ATF cooler with warmer function from transmission body and then secure it to vehi cle body by wire etc Select the place not to pre vent transmission from being replaced Model with ATF cooler with warmer function AT 02164 AUTOMATIC TRANSMISSION 18 Remove the warmer cock assembly Model with ATF cooler with warmer function AT 02165 19 Rem
12. add oil above the F line PI 00183 A Oillevel gauge B Upper level C Lower level B REPLACEMENT 1 Lift up the vehicle 2 Remove the differential gear oil drain plug using TORX BIT T70 and 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 complete ly 3 Tighten the differential gear oil drain plug using TORX BIT T70 NOTE Use a new gasket AUTOMATIC TRANSMISSION Tightening torque 70 N m 7 1 kgf m 51 6 ft lb A Oil pan B Differential gear oil drain plug 4 Lower the vehicle 5 Pour gear oil into the gauge hole Recommended gear oil lt Ref to 4AT 3 RECOMMENDED GEAR OIL SPECIFICATION General Description gt Differential gear oil capacity 1 1 1 3 Q 1 2 1 4 US gt 1 0 1 1 Imp qt 6 Check the level of the 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 automatic transmission NOTE When performing th
13. ft lb AT 02164 18 Connect the ATF cooler inlet and outlet hoses to ATF cooler pipes Model with ATF cooler with warmer function AT 02171 19 Install the throttle body lt Ref to FU H4SO 2 0 10 INSTALLATION Throttle Body gt 20 Install the pitching stopper Tightening torque T1 50 N m 5 1 kgf m 37 ft lb T2 58 N m 5 9 kgf m 43 ft lb 2 A Ge NEZ Se 71 Ee WBE RS 4AT 45 Automatic Transmission Assembly AUTOMATIC TRANSMISSION 21 Lift up the vehicle 22 Replace the snap ring of front drive shaft with a new one 23 Apply grease to the oil seal lips 24 Install the ST to side retainer ST 28399SA010 OIL SEAL PROTECTOR A De KEENAN I 25 Align the spline of front differential shaft to that of differential bevel gear for insertion and remove them using ST ST 28399SA010 OIL SEAL PROTECTOR 26 Insert the front drive shaft into transmission se curely by pressing the front housing from outside D OC I BI L AT 00111 27 Install the ball joint into housing 28 Tighten the attachment bolts Tightening torque 50 N m 5 1 kgf m 36 9 ft lb SI ka QA AT 00809 29 Install the stabilizer to crossmember NOTE e Install the bushing on front crossmember side while aligning it with
14. loy parts use a plastic hammer to force it apart Do not pry it apart with a screwdriver or other tool Be careful not to burn yourself because each part on the vehicle is hot after running e Use SUBARU genuine gear oil grease etc or the equivalent Do not mix gear oil grease etc with that of another grade or from other manufacturers e Be sure to tighten bolts and nuts to the specified torque Place shop jacks or rigid racks at the specified points e Apply gear oil or ATF onto sliding or revolution surfaces before installation in view of components usage Replace deformed or otherwise damaged snap rings with new ones Before installing O rings or oil seals apply suffi cient amount of ATF to avoid damage and defor mation Be careful not to incorrectly install or fail to install O rings snap rings and other such parts Before securing a part on a vice place cushion ing material such as wood blocks aluminum plate or cloth between the part and the vice e Avoid damaging the mating surface of the case Before applying liquid gasket completely re move the old seal 4AT 19 General Description AUTOMATIC TRANSMISSION D PREPARATION TOOL 1 SPECIAL TOOL ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 498575400 OIL PRESSURE Used for measuring oil pressure GAUGE ASSY ST 498575400 498897200 ADAPTER Used for oil pump housing when measuring reverse clutch pressure and line pressur
15. the paint mark on stabilizer e Ensure the bushing and stabilizer have the same identification colors when installing 2 FS 00050 1 Identification mark on stabilizer 2 Bushing identification color 30 Always tighten the rubber bushing location when wheels are in full contact with the ground and vehicle is curb weight Tightening torque 25 N m 2 5 kgf m 18 1 ft lb 31 Install the shift select cable onto select lever lt Ref to CS 13 INSTALLATION Select Cable gt 32 Install the oil charge pipe and connect the ATF cooler hoses to pipe Model without ATF cooler with warmer function AT 01333 33 Install the oil charge pipe Model with ATF cooler with warmer function 34 Install the propeller shaft lt Ref to DS 11 INSTALLATION Propeller Shaft gt 35 Install the heat shield cover AT 01331 36 Install the rear exhaust pipe and muffler as sembly 4AT 46 Automatic Transmission Assembly lt Ref to EX H4SO 2 0 11 INSTALLATION Rear Exhaust Pipe gt lt Ref to EX H4SO 2 0 13 IN STALLATION Muffler gt 37 Install the front and center exhaust pipe lt Ref to EX H4SO 2 0 8 INSTALLATION Front Exhaust Pipe gt 38 Install the under cover 39 Lower the lift 40 Install the ATF level gauge AT 01330 41 Connect the following connectors 1 Transmission harness connectors 2 Transmission ground termin
16. thickness of drive pinion Spring balance Used for measuring starting torque of drive pinion Circuit tester Used for measuring resistance and voltage TORX T70 Used for removing and installing differential gear oil drain plug Push pull gauge 4AT 30 Used for measuring clutch piston stroke 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 ATF 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 17 READ CURRENT DATA OPERA TION Subaru Select Monitor gt 2 Park the vehicle on a level surface 3 After selecting all positions P R N D set the select lever in P range Measure the ATF level with engine idling for one or two minutes AT 01323 A ATF level gauge B Upper level C Lower level 4 Make sure that ATF level is above the center of upper level and lower level at HOT side 5 If the ATF level is below the center between up per level and lower level replenish a recommend ed ATF until the fluid level exceeds the center between upper level and lower level CAUTION e Use care not to exceed the upper limit level e Be
17. 0 498437100 LOW CLUTCH PIS TON GUIDE Used for installing low clutch piston ST 899580100 899580100 INSTALLER Used for press fitting of ball bearing for transfer clutch ST28399SA010 28399SA010 OIL SEAL PROTEC TOR 4AT 28 Used for installing axle shaft ILLUSTRATION General Description TOOL NUMBER DESCRIPTION AUTOMATIC TRANSMISSION REMARKS ST18675AA000 18675AA000 DIFFERENTIAL OIL SEAL INSTALLER Used for installing differential side retainer oil seal ST 398497701 398497701 Used for installing needle bearing ST 899524100 899524100 PULLER SET Used for bolt only Used with PULLER SET 499737100 Used with PULLER 499737000 1 Puller 2 Cap ST24082AA230 24082AA230 CARTRIDGE 4AT 29 Troubleshooting for electrical system AUTOMATIC TRANSMISSION General Description ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 22771AA030 SUBARU SELECT _ Troubleshooting for electrical system MONITOR KIT English 22771 AA030 Without printer ST22771AA030 2 GENERAL TOOL TOOL NAME e German 22771AA070 Without printer e French 22771AA080 Without printer e Spanish 22771AA090 Without printer REMARKS Depth gauge Used for measuring transmission end play Thickness gauge Used for measuring clearance of clutch brake and oil pump Micro meter Used for measuring
18. 000 499787000 WRENCH ASSY 4AT 22 Used for removing and installing differential side retainer ILLUSTRATION General Description TOOL NUMBER DESCRIPTION AUTOMATIC TRANSMISSION REMARKS ST 398437700 398437700 DRIFT Used for installing converter case oil seal ST 398487700 398487700 INSTALLER Used for installing front differential taper roller bearing ST 398673600 398673600 COMPRESSOR Used for removing and installing clutch spring N ST 498255400 498255400 4AT 23 Used for measuring backlash of hypoid gear AUTOMATIC TRANSMISSION ILLUSTRATION General Description TOOL NUMBER DESCRIPTION REMARKS ST 399893600 399893600 PLIERS Used for removing and installing clutch spring ST 498247001 498247001 MAGNET BASE Used for measuring gear backlash Used with DIAL GAUGE 498247100 ST 498247100 498247100 DIAL GAUGE Used for measuring gear backlash Used with MAGNET BASE 498247001 ST 49851 7000 498517000 REPLACER 4AT 24 Used for removing front roller bearing ILLUSTRATION General Description TOOL NUMBER DESCRIPTION AUTOMATIC TRANSMISSION REMARKS ST 398623600 398623600 SEAT Used for removing spring of transfer clutch pis ton ST 499267300 499267300 STOPPER PIN Used for installing inhibitor switch ST 499787700
19. 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 1 General Description EE 2 Automatic Transmission Fluid EE 3 Differential Gear CHL enren RAE d Road TeStisaiiieateestecansscnese Givers eeydavvhadeerii SEENEN Si SLL EE 6 Time Lag Teste ecke 7 Line Pressure Test 8 Transfer Clutch Pressure Leet acc nce ee 9 Automatic Transmission
20. 8 1 5 Differential case LH 11 Washer T2 62 6 3 45 6 6 Taper roller bearing 12 Differential bevel pinion 4AT 14 General Description AUTOMATIC TRANSMISSION 11 TRANSFER AND EXTENSION CASE AT 01784 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 6 Driven plate 15 Gasket Tightening torque N m kgf m ft lb 7 Retaining plate 16 Transfer clutch pipe T1 13 1 3 9 4 8 Snap ring 17 Extension case T2 25 2 5 18 1 9 Transfer piston seal 18 Transmission hanger 4AT 15 General Description AUTOMATIC TRANSMISSION 12 TRANSFER AND EXTENSION CASE WITH VTD T2 Vy AT 00013 1 Driven plate Thicker 10 Multi plate clutch LSD piston 18 Dust cover 2 Drive plate ASSY 19 O ring 3 Driven plate Thinner 11 D ring 20 Rear vehicle speed sensor 4 Driven plate Thicker 12 Gasket 5 Adjusting plate 13 Multi plate clutch LSD pipe Tightening torque N m kgf m ft lb 6 Snap ring 14 Extension case T1 7 0 7 5 1 7 Spring retainer 15 O ring T2 13 1 3 9 4 8 Plate 16 Test plug T3 25 2 5 18 1 9 O ring 17 Oil seal 4AT 16 General Description AUTOMATIC TRANSMISSION
21. RT mode 4 forward automatic gear change Ist lt _ 2nd lt _ 3rd 4th Manual mode 4 forward manual gear change shift up 1st gt 2nd gt 3rd gt 4th Manual mode 4 forward manual gear change shift down ist 2nd lt 3rd lt 4th Control method 4AT 2 Wire cable General Description AUTOMATIC TRANSMISSION 7 HYDRAULIC CONTROL AND LUBRICA 8 COOLING AND HARNESS TION Cooling System Liquid cooled cooler Electronic hydraulic control Inhibitor switch 12 poles Four forward speed Transmission harness 20 poles Type changes by electrical signals of vehicle speed and accel 9 TRANSFER erator throttle opening SUBARU ATF or Idemitsu 2 5 L with 2 5 L with Apolloil ATF HP Castrol out vehicle vehicle Fluid Transmax J dynamics dynamics NOTE control control If the ATFs above are not VDC VDC available use Dexron Ill D US qt 8 4 8 7 Wee qt 40 Multi plate transfer torque dis EIN capacity mp op 8 9 9 2 7 4 7 7 Transfer type MPT len Lubrication system ade feed lubrication with VTD on pump Drive amp driven Oil Automatic transmission fluid plate number of 4 3 above mentioned transfer clutch Control method Electronic hydraulic type The same Automatic transmission fluid used in automatic transmission Lubricant Reduction gear d 1 000 53 53 10 FINAL REDUCTION Model Exc
22. SMISSION 6 PLANETARY GEAR AND 2 4 BRAKE 24 La 23 25 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 10 General Description AUTOMATIC TRANSMISSION 7 LOW CLUTCH AND LOW amp REVERSE BRAKE AT 01278 1 Snap ring 12 Low clutch dram 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 amp reverse brake piston 9 D ring 20 One way clutch inner race 10 Low clutch piston 21 Socket bolt Tightening torque Nam kgf m ft Ib 11 D ring 22 Spring retainer T 25 2 5 18 1 4AT 11 General Description AUTOMATIC TRANSMISSION 8 REDUCTION GEAR
23. al 42 Install the air cleaner case stay Tightening torque 16 N m 1 6 kgf m 11 6 ft lb 43 Install the air intake chamber lt Ref to IN H4SO 2 0 8 INSTALLATION Air In take Chamber gt 44 Install the air intake duct lt Ref to IN H4SO 2 0 9 INSTALLATION Air In take Duct gt 45 Using a gauge hole add the ATF until the fluid level is found at the center between upper and low er levels of level gauge COLD side lt Ref to 4AT 31 Automatic Transmission Fluid gt 46 Take off the vehicle from a lift 47 Check the level of differential gear oil lt Ref to 4AT 33 Differential Gear Oil gt 48 Check the select lever operation lt Ref to 4AT 52 INSPECTION Inhibitor Switch gt 49 Bleed the air of control valve lt Ref to 4AT 63 Air Bleeding of Control Valve gt 50 Check the ATF level lt Ref to 4AT 31 Auto matic Transmission Fluid gt 51 Execute the learning control promotion lt Ref to 4AT diag 19 FACILITATION OF LEARNING CONTROL OPERATION Subaru Select Moni tor gt 52 Perform the road test lt Ref to 4AT 34 Road Test gt 4AT 47 AUTOMATIC TRANSMISSION
24. e ST 498897200 498897700 ADAPTER SET Used for measuring transfer clutch pressure ST 498897700 498545400 FILTER WRENCH Used for removing and installing ATF filter A N ST 498545400 4AT 20 ILLUSTRATION General Description TOOL NUMBER DESCRIPTION AUTOMATIC TRANSMISSION REMARKS ST 498277200 498277200 STOPPER SET Used for removing and installing automatic transmission assembly to engine 398527700 PULLER ASSY Used for removing extension case roller bear ing Used for removing extension oil seal Used for removing front differential side retainer bearing outer race Used for removing front differential side retainer oil seal ST 498057300 498057300 INSTALLER Used for installing extension oil seal ST41099AC000 41099AC000 ENGINE SUPPORT ASSY 4AT 21 Used for supporting engine 1 ENGINE SUPPORT BRACKET 41099AC010 2 ENGINE SUPPORT 41099AC020 AUTOMATIC TRANSMISSION ILLUSTRATION General Description TOOL NUMBER DESCRIPTION REMARKS ST 498077000 498077000 REMOVER Used for removing differential taper roller bear ing ST 499247400 499247400 INSTALLER Used for installing transfer outer snap ring e Used with GUIDE 499257300 ST 499257300 499257300 SNAP RING OUTER GUIDE Used for installing transfer outer snap ring Used with INSTALLER 499247400 ST 499787
25. e 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 34 Remove the bolts which hold the clutch hous ing cover 35 Remove the bolts which hold lower side of transmission to engine Ze A k AT 00108 36 Place the transmission jack under transmis sion NOTE Make sure that the support plates of transmission jack don t touch the oil pan 4AT 42 Automatic Transmission Assembly 37 Remove the transmission rear crossmember from the vehicle 38 Fully contract the engine support while lower ing the transmission jack gradually and tilt the en gine backward NOTE Contract the support until the clearance between front crossmember and torque converter case be comes approx 10 mm 0 39 in 39 Remove the transmission CAUTION Remove the transmission and torque converter as a unit from engine AT 00109 40 Remove the rear cushion rubber from transmis sion assembly B INSTALLATION 1 Replace the differential side oil seal with a new one NOTE When a new oil seal
26. e test do not exceed posted speed limit 2 D RANGE SHIFT FUNCTION Check shifting between 1st lt gt 2nd gt 3rd lt gt 4th while driving on general 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 down from 4th to 3rd range while driving in 4th gear of manual mode 50 60 km h 31 37 MPH e Check the 2nd gear engine brake when shifting down from 3rd to 2nd range while driving in 3rd gear of manual mode 40 50 km h 25 31 MPH e Check the 1st gear engine brake when shifting down from 2nd to 1st range while driving in 2nd gear of manual mode 20 30 km h 12 19 MPH 6 LOCK UP FUNCTION e Check that rpm does not change sharply when the axle pedal is lightly depressed while driving on flat roads at normal speed in D range e Check slip lock up with following procedure Subaru Select Monitor is needed for checking Before start checking check that no DTC is dis played using Subaru Select Monitor When DTC is displayed perform the collective action with DTC and check that any more DTC is displayed and then start the checking 1 Perform the check on flat and straight road or free roller NOTE Slip lock up does not operate when the vehicle is lifted up becau
27. ept for OUTBACK OUTBACK Front final reduction 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 7786 Lubrication oil MT 00001 Item 3 API classification Front differential gear oil 4 SAE viscosity No and applica ble temperature Front differential oil capacity Q US qt Imp qt 1 1 1 3 1 2 1 4 1 0 1 1 4AT 3 General Description AUTOMATIC TRANSMISSION B COMPONENT 1 TORQUE CONVERTER CLUTCH AND CASE AT 02159 1 Pitching stopper bracket 10 O ring 18 Bracket if equipped 2 O ring 11 Torque converter clutch ASSY 19 Clip if equipped 3 Differential oil level gauge 12 Drain plug 4 Stay 13 Gasket Tightening torque N m kgf m ft Ib 5 Seal pipe 14 Oil seal T1 18 1 8 13 0 6 Oil pump shaft 15 Converter case T2 23 2 3 16 7 7 Clip 16 Harness stay T3 33 3 4 24 3 8 Oil drain pipe 17 ATF cooler ASSY with warmer T4 41 4 2 30 4 9 Input shaft function if equipped T5 70 7 1 51 6 4AT 4 General Description AUTOMATIC TRANSMISSION 2 OIL PUMP 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 Ib 4 Thrust needle bearing
28. fting the select lever to each position If the line pressure needs to be measured again allow the engine to idle and cool it down more than 1 minute 4 Maintain the ATF temperature at approx 70 80 C 158 176 F during measurement ATF will reach the above mentioned tempera ture after idling the engine for approx 30 min utes with the select lever in N or P 3 Remove the test plug and install the ST instead ST 498897200 OIL PRESSURE GAUGE ADAPTER AT 00020 A Test plug 4 Connect the ST1 with ST2 ST1 498897200 OIL PRESSURE GAUGE ADAPTER ST2 498575400 OIL PRESSURE GAUGE ASSY 5 Check for duty ratio changes by adjusting the ac celeration pedal position using Subaru Select Mon itor Standard line pressure Line pres sure duty ratio Range posi Throttle Line pressure tion valve angle kPa kg cm psi 1 000 1 300 102 133 145 189 1 500 1 850 15 3 18 9 217 268 500 800 5 1 8 2 73 116 Manual mode 2nd a Full open Full open Full closed 4AT 38 Transfer Clutch Pressure Test AUTOMATIC TRANSMISSION 8 Transfer Clutch Pressu re X Standard transfer clutch ccelera Test Range tion pedal kP ee i A INSPECTION position position a kg cmf psi Check the transfer clutch pressure in accordance AND mode with the following chart in the same manner as with Fully 1 000 1
29. has been installed the re placement is not required 2 Install the rear cushion rubber to transmission assembly Tightening torque 39 N m 4 0 kgf m 29 ft lb 3 Install the ST to converter case AUTOMATIC TRANSMISSION ST 498277200 STOPPER SET 4 Install the transmission onto engine 1 Lift up the transmission gradually using a transmission jack AT 00109 2 Engage them at splines 3 Turn the screws of engine support while raising the transmission jack gradually and tilt the engine forward 5 Install the transmission rear crossmember Tightening torque T1 35 N m 3 6 kgf m 26 ft lb T2 70 N m 7 1 kgf m 51 ft lb 6 Take off the transmission jack 7 Tighten the bolts which hold the lower side of transmission to engine 4AT 43 Automatic Transmission Assembly AUTOMATIC TRANSMISSION Tightening torque 50 N m 5 1 kgf m 36 9 ft lb AT 00108 8 Screw the bolts for the clutch housing cover 9 Lower the lift 10 Connect the engine and transmission 1 Remove the ST from converter case NOTE When removing the ST be careful not to drop it into converter case ST 498277200 STOPPER SET 2 Install the starter lt Ref to SC H4SO 2 0 6 INSTALLATION Starter gt 3 Tighten the bolts which hold the upper side of transmission to engine Tightening torque 50 N m 5 1 kgf m 36 9 f
30. orque converter clutch s one way clutch slipping Line pressure is too low Low clutch slipping 2nd on manual Less than standard mode R One way clutch malfunctioning Line pressure is too low More than standard Reverse clutch slipping Low amp reverse brake slipping Line pressure is too low Low clutch slipping 2 4 brake slipping 2nd on manual mode 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 Perform the test at normal operation fluid tem perature 70 80 C 158 176 F e Be sure to allow a one 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 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 for N gt R Time lag
31. ove the bracket for warmer cock assem bly Model with ATF cooler with warmer function AT 02166 20 Remove the pitching stopper bracket 21 Set the ST ST 41099AC000 ENGINE SUPPORT ASSEM BLY 22 Remove the bolts which hold upper side of transmission to engine AT 00106 23 Lift up the vehicle 24 Remove the under cover 4AT 41 Automatic Transmission Assembly AUTOMATIC TRANSMISSION 25 Remove the front center and rear exhaust pipes and muffler lt Ref to EX H4SO 2 0 7 REMOVAL Front Ex haust Pipe gt lt Ref to EX H4SO 2 0 11 REMOV AL Rear Exhaust Pipe gt lt Ref to EX H4SO 2 0 13 REMOVAL Muffler gt 26 Remove the heat shield cover AT 01331 27 Remove the ATF drain plug to drain ATF A Oil pan B ATF drain plug 28 Disconnect the ATF cooler hoses from pipes of transmission side and remove the oil charge pipe Model without ATF cooler with warmer function AT 01333 29 Remove the propeller shaft lt Ref to DS 10 REMOVAL Propeller Shaft gt 30 Remove the shift select cable lt Ref to CS 12 REMOVAL Select Cable gt 31 Remove the brackets two which hold front stabilizer 32 Remove the bolt securing ball joint of front arm to housing AT 00809 33 Pull out the front drive shaft from transmission 1 Using a tir
32. ply ing the brakes while going down a grade 10 TRANSFER CLUTCH Check tight corner braking when the vehicle started with steering fully turned 11 0IL LEAKS After the driving test inspect for oil leaks 4AT 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 2nd of manual mode Purposes of the stall test To check the operation of the automatic trans mission clutch To check the operation of the torque converter clutch To check engine performance 1 Check that the throttle valve opens fully 2 Check that the engine oil level is correct 3 Check that the coolant level is correct 4 Check that the ATF level is correct 5 Check that the differential gear oil level is cor rect 6 Increase ATF temperature to 70 80 C 158 176 F by idling the engine for approximately 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 then set to the 2nd on manual mode O AT 02205 9 While forcibly depressing the foot brake pedal gradually depress the accelerator pedal until the engine operates at full throttle
33. se of not occurring surface resis tance Also when checking on the free roller check with depressing the foot brake lightly to make the check ing easier because the surface resistance will be deficient 2 Connect the Subaru Select Monitor 3 Check the ATF temperature using Subaru Select Monitor NOTE e ATF temperature is between 50 100 C 122 212 F When the temperature is low warm up the ATF by running the vehicle or etc 4 Start the engine so that the lock up duty can be read on data display of Subaru Select Monitor 5 Drive the vehicle at a constant speed of 35 40 km h 22 25 MPH 6 Read the lock up duty while vehicle is running Standard value 25 45 NOTE The value may be lower on the free roller e Slip lock up control is not operating when the lock up duty is less than 5 or when the lock up duty goes down immediately after starts rising On these cases improper ATF or deterioration of ATF may be the cause Check the amount of ATF or re place them and then recheck it 7 P RANGE OPERATION Stop the vehicle on an uphill grade of 5 or more and shift to P range Check that the vehicle does not move when the parking brake is released 8 NOISE AND VIBRATION Check for noise and vibration while driving and dur ing 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 ap
34. sure that the replenishment of ATF to the upper level with the transmission cold will cause overfilling of ATF and result in a trans mission failure 6 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 17 READ CURRENT DATA OPERA TION Subaru Select Monitor gt 7 Check the ATF for leaks Make visual inspection for leaks from the inside of transmission If there are leaks repair or replace the gasket oil seals plugs or other parts B REPLACEMENT 1 Lift up the vehicle 2 Remove the ATF drain plug to drain ATF CAUTION Directly after the engine has been running the ATF is hot Be careful not to burn yourself 3 Check the condition of ATF lt Ref to 4AT 32 CONDITION CHECK Automatic Transmission Fluid gt 4 Tighten the ATF drain plug NOTE Use a new gasket Tightening torque 25 N m 2 5 kgf m 18 1 ft lb A Oil pan B ATF drain plug 5 Lower the vehicle 6 Pour ATF from the oil charge pipe Recommended fluid SUBARU ATF Part No K0410Y0700 or Ide mitsu Apolloil ATF HP Castrol Transmax J NOTE lf the ATFs above are not available use Dexron Ill Capacity Fill the same amount of ATF drained Capacity when transmission is overhauled 2 0 L model 8 4 8 7 2 8 9 9 2 US qt 7 4
35. t lb AT 00106 11 Install the torque converter clutch to drive plate 1 Tighten the bolts which hold torque convert er clutch to drive plate 2 Insert the wrench to crank pulley bolt and then tighten all bolts while slightly rotating the crank pulley Tightening torque 25 N m 2 5 kgf m 18 1 ft lb 3 Fit the plug to service hole 4 Install the V belt cover 12 Remove the ST 13 Install the warmer cock assembly bracket Model with ATF cooler with warmer function Tightening torque 16 N m 1 6 kgf m 11 6 ft lb AT 02166 14 Install the warmer cock assembly Model with ATF cooler with warmer function 4AT 44 Automatic Transmission Assembly Tightening torque T1 6 4 N m 0 65 kgf m 4 7 ft lb T2 15 N m 1 5 kgf m 10 8 ft Ib 15 Connect each hose to warmer cock assembly Model with ATF cooler with warmer function AT 02163 16 Install the pitching stopper bracket and bracket Model with ATF cooler with warmer function Tightening torque 41 N m 4 2 kgf m 30 4 ft lb AT 02169 A Pitching stopper bracket B Bracket Model with ATF cooler with warmer function 17 Install the ATF cooler with warmer function to transmission body Model with ATF cooler with warmer function AUTOMATIC TRANSMISSION Tightening torque 23 N m 2 3 kgf m 16 6
36. utlet pipe Model without ATF T3 6 0 6 4 Union screw cooler with warmer function T4 12 1 2 8 7 O ring 31 Union screw T5 13 1 3 10 Test plug 32 Oil seal T6 14 1 4 10 Oil filter 33 Select lever T7 18 1 8 13 Oil filter stud bolt 34 Inhibitor switch ASSY T8 21 2 1 15 5 Drain plug 35 Nipple T9 25 2 5 18 1 Gasket 36 Air breather hose T10 44 4 5 32 5 4AT 7 General Description AUTOMATIC TRANSMISSION 4 CONTROL VALVE AND HARNESS ROUTING T1 AT 01322 1 Stay 6 O ring Tightening torque N m kgf m ft Ib 2 Transmission harness 7 Front vehicle speed sensor T1 7 0 7 5 1 3 O ring 8 O ring T2 8 0 8 5 8 4 O ring 9 Rear vehicle speed sensor 5 Torque converter turbine speed 10 Control valve body sensor 4AT 8 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 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 9 General Description AUTOMATIC TRAN
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