Automatic Transmission 5AT: Diagnosis Subaru Outback BR

INSPECTION

Note. The level of ATF varies with fluid temperature. Pay attention to the ATF temperature when checking ATF level.

Scheme 1

1. Raise the ATF temperature by driving a distance of 5 to 10 km (3 to 6 miles). Otherwise, idle the engine to raise ATF temperature to 70 - 80°C (158 - 176°F) on Subaru Select Monitor. Ref. to «READ CURRENT DATA»(ref-371942-S06520178292010091900000) .
2. Park the vehicle on a level surface.
3. After selecting all positions (P, R, N, D), set the select lever in "P" range. Idle the engine for 1 to 2 minutes.
4. Remove the oil level gauge and wipe it clean.
5. Reinsert the level gauge all the way. Make sure the level gauge is inserted correctly and in the proper orientation.
6. Remove the oil level gauge again and make sure that the ATF level is between upper and lower marks of the HOT side.
7. If the ATF level is below the lower mark, add recommended ATF until the fluid level is between upper and lower marks. CAUTION: Be careful not to exceed the upper level. When the transmission is cold, be careful not to add ATF to the upper level on HOT side. Overfilling of ATF may cause oil splashing.
8. Check the ATF for leaks. Visually check for leaks in the transmission. If there are leaks, replace the gasket, oil seal, plug or other parts.

Scheme 2

1. Lift up the vehicle.
2. Remove the ATF drain plug to drain ATF. CAUTION: Directly after the vehicle has been running or the engine has been long idle running, the ATF is hot. Be careful not to burn yourself.
3. Check the ATF condition. Ref. to «CONDITION CHECK»(ref-371902-S03902822722010091900000) , Automatic Transmission Fluid.
4. Tighten the ATF drain plug. NOTE: Use a new gasket. Tightening torque: 20 N.m (2.0 kgf-m, 14.8 ft-lb)
5. Lower the vehicle.
6. Pour ATF from the oil charge pipe. Recommended fluid: Ref. to «HYDRAULIC CONTROL AND LUBRICATION»(ref-371902-S20141368272010091900000) , SPECIFICATION, General Description. CAUTION: Be sure to use the recommended or equivalent ATF. Using material except recommended one or substitute would cause trouble. Capacity: Fill with the same amount of ATF as drained. Capacity when transmission is overhauled: 9.6 - 10.0 l(10.1 - 10.6 US qt, 8.4 - 8.8 Imp qt)
7. Check the level and leaks of ATF. Ref. to «INSPECTION»(ref-371902-S33705940982010091900000) , Automatic Transmission Fluid.

Note. The stall test is extremely important in diagnosing the condition of an automatic transmission and engine. The test is necessary to measure the engine stall speeds in "2nd gear of manual mode". Purposes of the stall test: Operational check of the automatic transmission clutch Operational check of the torque converter clutch Engine performance check

1. Check that the throttle valve fully opens.
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 correct.
6. Raise the ATF temperature to 70 to 80°C (158 to 176°F) by driving a distance of 5 to 10 km (3 to 6 miles). Confirm the ATF temperature on Subaru Select Monitor. Ref. to «READ CURRENT DATA»(ref-371942-S06520178292010091900000) .
7. Place the wheel chocks at the front and rear of all wheels and apply the parking brake.
8. Move the select lever to ensure it operates properly, then set to "2nd gear of manual mode".
9. While stepping hard on the brake pedal, gradually step on the accelerator pedal.
10. When the engine speed is stabilized, quickly record the engine speed and release accelerator pedal.
11. Shift the select lever to "N" range, and cool down the engine by idling it for one minute or more. NOTE: Do not perform a stall test for over 5 seconds at a time. (Perform with the throttle from fully closed to fully open to end up reading the stall speed.) Doing so will make the engine oil and ATF deteriorate and the clutch and brake to be adversely affected. After performing the stall test, be sure to cool down the engine for at least one minute with the select lever set in "P" or "N" range, and at an idle speed of 1,200 RPM or less. 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. Perform the stall test in S mode. When depressing the accelerator pedal again after performing the stall test for 5 seconds or more, the electronic throttle control remains closed for approx. 60 seconds. When the stall test is performed for 15 seconds or more continuously, the test is completed forcibly to protect the transmission unit. When depressing the accelerator pedal again, the electronic throttle control remains closed for approx. 60 seconds. Stall speed (at sea level): 2,100 - 2,600 RPM STALL SPEED CHART Stall speed (at sea level) Range Possible faulty parts Over specified value 2nd gear of manual mode Line pressure too low Forward brake Direct clutch 3rd one-way clutch

Note. When the select lever is shifted while the engine is idling, there will be a certain time elapse or lag before shock is felt. Using this, check the condition of forward brake, reverse brake, 1st one-way clutch and 3rd one-way clutch.

1. Perform the test at normal operation fluid temperature of 70 - 80°C (158 - 176°F).
2. Be sure to allow one minute or more interval between tests.
3. 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-lag from shifting the lever until the shock is felt. Time-lag Standard: 1.2 seconds or less If "N" --> "D" time-lag is longer than specification: Line pressure too low Forward brake worn One-way clutch not operating properly
4. In the same manner, measure the time lag of "N" --> "R". Time-lag Standard: 1.5 seconds or less If "N" --> "R" time lag is longer than specification: Line pressure too low Reverse brake worn

Repair or replace parts if the results of the inspection below are not satisfied.

Inspect there is no ATF leakage from the joint of transmission and propeller shaft. If a leak is found, replace the oil seal. Ref. to REPLACEMENT , Extension Case Oil Seal.

Scheme 3

1. Lift up the vehicle.
2. Clean the transmission exterior.
3. Remove the ATF drain plug to drain ATF. CAUTION: Immediately after the vehicle has been running or the engine has been long idle running, the ATF is hot. Be careful not to burn yourself.
4. Tighten the ATF drain plug. NOTE: Use a new gasket. Tightening torque: 20 N.m (2.0 kgf-m, 14.8 ft-lb)
5. Remove the rear exhaust pipe. Ref. to «REMOVAL»(ref-371938-S08736757402010091900000) , Rear Exhaust Pipe.
6. Remove the heat shield cover.
7. Remove the propeller shaft. Ref. to «REMOVAL»(ref-371909-S33653701722010091900000) , Propeller Shaft.
8. Using the ST, remove the oil seal. ST 398527700 PULLER ASSY
9. Using the ST, install the oil seal. ST 498057300 INSTALLER
10. Install the propeller shaft. Ref. to «INSTALLATION»(ref-371909-S25688249532010091900000) , Propeller Shaft.
11. Install the heat shield cover. Ref. to «INSTALLATION»(ref-371913-S24263252922010091900000) , Heat Shield Cover.
12. Install the rear exhaust pipe. Ref. to «INSTALLATION»(ref-371938-S01176927902010091900000) , Rear Exhaust Pipe.
13. Lower the vehicle.
14. Pour ATF from the oil charge pipe. Ref. to «AUTOMATIC TRANSMISSION FLUID»(ref-371902-S14762472072010091900000) .
15. Check the level and leaks of the ATF. Ref. to «INSPECTION»(ref-371902-S33705940982010091900000) , Automatic Transmission Fluid.

Check for leakage of gear oil from differential side retainer oil seal part. If there is an oil leak, replace the oil seal.

Scheme 4

1. Disconnect the ground cable from battery.
2. Remove the collector cover. NOTE: Follow the steps below when removing the collector cover. Pull up the two points at the rear (A). Pull up the two points at the front (B) while moving them forward.
3. Lift up the vehicle.
4. Remove the under cover. Ref. to «REMOVAL»(ref-371913-S09538241932010091900000) , Front Under Cover.
5. Remove the front exhaust pipe. Ref. to «REMOVAL»(ref-371938-S37097172362010091900000) , Front Exhaust Pipe.
6. Remove the differential gear oil drain plug using TORX® bit T70, and then drain differential gear oil. CAUTION: Immediately after the vehicle has been running or after idling for a long time, the differential gear oil will be hot. Be careful not to burn yourself. Be careful not to spill the differential gear oil on exhaust pipe to prevent it from emitting smoke or fire. If differential gear oil is spilled on the exhaust pipe, wipe it off completely.
7. Tighten the differential gear oil drain plug. NOTE: Use a new gasket. Tightening torque: 70 N.m (7.1 kgf-m, 51.6 ft-lb)
8. Separate the front drive shaft from the transmission. Ref. to «REMOVAL»(ref-371909-S27229056122010091900000) , Front Drive Shaft.
9. Remove the differential side retainer oil seal using driver wrapped with vinyl tape etc.
10. Using the ST, install the differential side retainer oil seal by lightly tapping with a plastic hammer. NOTE: Use a new oil seal. Apply differential gear oil to the oil seal lips. Check the identification marks (L, R) during installation not to mix up the oil seal RH and LH. ST 18675AA000 DIFFERENTIAL SIDE OIL SEAL INSTALLER
11. Install the front drive shaft. Ref. to «INSTALLATION»(ref-371909-S19257939972010091900000) , Front Drive Shaft.
12. Install the front exhaust pipe. Ref. to «INSTALLATION»(ref-371938-S05858096482010091900000) , Front Exhaust Pipe.
13. Install the undercover. Ref. to «INSTALLATION»(ref-371913-S15712020302010091900000) , Front Under Cover.
14. Lower the vehicle.
15. Connect the ground cable to battery.
16. Pour differential gear oil into the level gauge hole. Ref. to «DIFFERENTIAL GEAR OIL»(ref-371902-S18986870782010091900000) .
17. Check the level of differential gear oil. Ref. to «INSPECTION»(ref-371902-S42188848372010091900000) , Differential Gear Oil.
18. Install the collector cover.

Inhibitor switch cannot be checked, because the inhibitor switch is installed on control valve assembly. When a malfunction occurs, refer to 5AT (diag) article. Ref. to DTC P0705 TRANSMISSION RANGE SENSOR CIRCUIT (PRNDL INPUT) , Diagnostic Procedure with Diagnostic Trouble Code (DTC).

Scheme 5

Scheme 6

Scheme 7

Scheme 8

1. Remove the transmission assembly from the vehicle. Ref. to «REMOVAL»(ref-371902-S37686204272010091900000) , Automatic Transmission Assembly.
2. Disconnect the rear vehicle speed sensor connector. NOTE: Secure the transmission harness to the transmission body using wire etc.
3. Remove the extension case.
4. Remove the center differential carrier. Ref. to «REMOVAL»(ref-371902-S30595591252010091900000) , Center Differential Carrier.
5. Lay along the transmission case, and then remove the oil pan.
6. Remove the old gasket on the oil pan and transmission case completely.
7. Disconnect the front vehicle speed sensor connector.
8. Remove the front vehicle speed sensor securing bolt.
9. Remove the front vehicle speed sensor through the hole of AT transmission main case.

Scheme 9

1. Install the front vehicle speed sensor. Tightening torque: 7 N.m (0.7 kgf-m, 5.2 ft-lb)
2. Connect the front vehicle speed sensor connector.
3. Apply proper amount of liquid gasket to the entire oil pan mating surface. Liquid gasket: THREE BOND 1217B (Part No. K0877YA020) or equivalent
4. Install the oil pan by equally tightening the bolts. Tightening torque: 5 N.m (0.5 kgf-m, 3.7 ft-lb)
5. Install the center differential carrier. Ref. to «INSTALLATION»(ref-371902-S13407400132010091900000) , Center Differential Carrier.
6. Install the extension case. Tightening torque: 25 N.m (2.5 kgf-m, 18.4 ft-lb)
7. Connect the rear vehicle speed sensor connector.
8. Install the transmission assembly to the vehicle. Ref. to «INSTALLATION»(ref-371902-S14197603732010091900000) , Automatic Transmission Assembly.
9. Pour ATF from the oil charge pipe. Ref. to «AUTOMATIC TRANSMISSION FLUID»(ref-371902-S14762472072010091900000) .
10. Check the level and leaks of ATF. Ref. to «INSPECTION»(ref-371902-S33705940982010091900000) , Automatic Transmission Fluid.

Scheme 10

1. Set the vehicle on a lift.
2. Disconnect the ground cable from battery.
3. Lift up the vehicle.
4. Clean the transmission exterior.
5. Remove the bolts which connect the front exhaust pipe and rear exhaust pipe.
6. Remove the bolts holding the heat shield cover, and move the heat shield cover to the rear.
7. Disconnect the rear vehicle speed sensor connector.
8. Remove the rear vehicle speed sensor.

Check each parts for holes, damages or other foreign matters.

Scheme 11

1. Disconnect the ground cable from battery.
2. Remove the instrument panel lower cover. Ref. to «REMOVAL»(ref-371913-S16002500292010091900000) , Instrument Panel Lower Cover.
3. Disconnect the connector from TCM.
4. Remove the TCM. NOTE: Replace the TCM and bracket as a set.

Scheme 12

1. Install the TCM to the bracket. CAUTION: Do not remove the TCM after installed to the bracket, or the bracket and TCM may be damaged. If installed by mistake, the part must be replaced with a new part.
2. Install the TCM. Tightening torque: 7.5 N.m (0.8 kgf-m, 5.5 ft-lb)
3. Connect the connector to TCM.
4. Install the instrument panel lower cover. Ref. to «INSTALLATION»(ref-371913-S19395593592010091900000) , Instrument Panel Lower Cover.
5. Perform Clear Memory 2 operation. Ref. to «CLEAR MEMORY MODE»(ref-371942-S04843487322010091900000) .
6. Perform learning operation. Ref. to «LEARNING CONTROL»(ref-371942-S05358684462010091900000) .

Scheme 13

Scheme 14

Scheme 15

Scheme 16

Scheme 17

1. Remove the collector cover. NOTE: Follow the steps below when removing the collector cover. Pull up the two points at the rear (A). Pull up the two points at the front (B) while moving them forward.
2. Remove the battery.
3. Lift up the vehicle.
4. Remove the under cover. Ref. to «REMOVAL»(ref-371913-S09538241932010091900000) , Front Under Cover.
5. Remove the front exhaust pipe. Ref. to «REMOVAL»(ref-371938-S37097172362010091900000) , Front Exhaust Pipe.
6. Disconnect the ATF cooler hose from the radiator. NOTE: Do not use a screwdriver or other pointed tools. If it is hard to remove the ATF cooler hose, wrap the hose with cloth to prevent from damaging it, and while turning with pliers, pull straight out by hand.
7. Disconnect the ATF cooler hoses from ATF cooler pipes. NOTE: Do not use a screwdriver or other pointed tools. If it is hard to remove the ATF cooler hose, wrap the hose with cloth to prevent from damaging it, and while turning with pliers, pull straight out by hand.
8. Remove the oil charge pipe. Ref. to «REMOVAL»(ref-371902-S04229620982010091900000) , Oil Charge Pipe.
9. Remove the ATF cooler inlet pipe and outlet pipe from the transmission. NOTE: When disconnecting the ATF cooler outlet pipe, be careful not to lose the ball and spring used together with the retaining screw.
10. Lower the vehicle.
11. Remove the ATF cooler pipe assembly mounting bolt.
12. Detach the A/C pipe from clip.
13. Remove the ATF cooler pipe from frame.

Scheme 18

1. Install the ATF cooler pipe to frame. CAUTION: Be careful not to bend the A/C pipe, when installing the ATF cooler pipe. Tightening torque: 7.5 N.m (0.08 kgf-m, 5.5 ft-lb)
2. Install the A/C pipe to clip.
3. Lift up the vehicle.
4. install the ATF cooler inlet and outlet pipes with new gaskets. NOTE: Use a new bolt for the converter case joint. Tightening torque: T1: 38 N.m (3.9 kgf-m, 28.0 ft-lb) T2: 40 N.m (4.1 kgf-m, 29.5 ft-lb) T3:45 N.m (4.6 kgf-m, 33.2 ft-lb)
5. Install the oil charge pipe. Ref. to «INSTALLATION»(ref-371902-S25503852982010091900000) , Oil Charge Pipe.
6. Connect the ATF cooler hose to the ATF cooler pipe on the transmission side. NOTE: Use a new ATF cooler hose. Install so that the ATF cooler hose is not folded over, excessively bent or twisted. Insert the ATF cooler hose to the specified position.
7. Connect the ATF cooler hose to the ATF cooler pipe on the radiator side. NOTE: Use a new ATF cooler hose. Install so that the ATF cooler hose is not folded over, excessively bent or twisted. Insert the ATF cooler hose to the specified position.
8. Install the front exhaust pipe. Ref. to «INSTALLATION»(ref-371938-S05858096482010091900000) , Front Exhaust Pipe.
9. Install the under cover. Ref. to «INSTALLATION»(ref-371913-S15712020302010091900000) , Front Under Cover.
10. Lower the vehicle.
11. Install the battery.
12. Fill ATF. Ref. to «AUTOMATIC TRANSMISSION FLUID»(ref-371902-S14762472072010091900000) . NOTE: Make sure there are no ATF leaks in joints between the transmission, radiator, ATF cooler pipes, and ATF cooler hoses.
13. Install the collector cover.

Repair or replace any faulty ATF cooler hoses, ATF cooler pipes, clamps, and washers found in the inspection below.

1. Check for ATF leaks in joints between the transmission, radiator, ATF cooler pipes, and ATF cooler hoses.
2. Check the clamp for deformation.
3. Lightly bend the ATF cooler hose and check for cracks in the surface or other damages.
4. Pinch the ATF cooler hose with your fingers and check for poor elasticity.
5. Check for peeling, cracks, and deformation at the tip of the ATF cooler hose.

Scheme 19

1. Remove the collector cover. NOTE: Follow the steps below when removing the collector cover. Pull up the two points at the rear (A). Pull up the two points at the front (B) while moving them forward.
2. Remove the air intake boot. Ref. to «REMOVAL»(ref-371896-S05520593882010091900000) , Air Intake Boot.
3. Disconnect the air breather hose.

Make sure the air breather hose is not cracked or clogged.

Scheme 20

1. Disconnect the ground cable from battery.
2. Lift up the vehicle.
3. Remove the under cover. Ref. to «REMOVAL»(ref-371913-S09538241932010091900000) , Front Under Cover.
4. Remove the front exhaust pipe. Ref. to «REMOVAL»(ref-371938-S37097172362010091900000) , Front Exhaust Pipe.
5. Disconnect the connector from turbine speed sensor 1.
6. Remove the oil charge pipe, and then remove the O-ring from flange side.

Scheme 21

1. Install the oil charge pipe. NOTE: Use new gaskets and O-rings. Tightening torque: 38 N.m (3.9 kgf-m, 28.0 It-lb)
2. Connect the connector to the turbine speed sensor 1.
3. Install the front exhaust pipe. Ref. to «INSTALLATION»(ref-371938-S05858096482010091900000) , Front Exhaust Pipe.
4. Install the under cover. Ref. to «INSTALLATION»(ref-371913-S15712020302010091900000) , Front Under Cover.
5. Lower the vehicle.
6. Connect the ground cable to battery.

1. Make sure the oil charge pipe is not deformed or damaged.
2. Check that there are no ATF leaks from the O-ring.

Scheme 22

1. Remove the transmission assembly from vehicle body. Ref. to «REMOVAL»(ref-371902-S37686204272010091900000) , Automatic Transmission Assembly.
2. Pull out the torque converter and oil pump shaft horizontally. NOTE: Be sure not to scratch the inside of bushing in oil pump shaft. Be careful that the oil pump shaft may drawn out simultaneously.
3. Remove the oil pump shaft from torque converter as necessary.

Scheme 23

1. When the oil pump shaft is removed, install the shaft to torque converter. NOTE: Use a new circlip. Make sure the circlip is firmly inserted.
2. Install the oil pump shaft to torque converter, and then make sure that the clip is secured on groove.
3. Apply ATF to the revolving and sliding surface of the oil pump shaft.
4. Holding the torque converter assembly by hand, lightly rotate it to engage with the oil pump rotor.
5. Check the protruding dimension of the torque converter assembly. Dimension A: 8 mm (0.31 in) or less
6. Install the transmission assembly to the vehicle. Ref. to «INSTALLATION»(ref-371902-S14197603732010091900000) , Automatic Transmission Assembly.

Make sure the ring gear and protrusion of torque converter end are not deformed or damaged.

Scheme 24

1. Remove the transmission assembly from the vehicle. Ref. to «REMOVAL»(ref-371902-S37686204272010091900000) , Automatic Transmission Assembly.
2. Use the ST to lock the crankshaft, and remove the drive plate. ST 498497100 CRANKSHAFT STOPPER

Scheme 25

1. Temporarily tighten the drive plate.
2. Using the ST, lock the crankshaft. ST 498497100 CRANKSHAFT STOPPER
3. Tighten the drive plate mounting bolt. NOTE: Tighten the drive plate mounting bolts gradually. Each bolt should be tightened in a crisscross order. Tightening torque: 90 N.m (9.2 kgf-m, 66.4 ft-lb)
4. Install the transmission assembly to the vehicle. Ref. to «INSTALLATION»(ref-371902-S14197603732010091900000) , Automatic Transmission Assembly.

1. Use compressed air to make sure the extension case routes are not clogged or leaking.
2. Inspect the extension end play, and adjust it to within the standard value. Ref. to «ADJUSTMENT»(ref-371902-S39559671762010091900000) , Transfer Clutch.

1. Inspect the drive plate facing for wear and damage.
2. Make sure the snap ring is not worn and the return spring has no permanent distortion, damage, or deformation.
3. Check that the D-ring is not damaged.
4. Inspect the extension end play, and adjust it to within the standard value. Ref. to «ADJUSTMENT»(ref-371902-S39559671762010091900000) , Transfer Clutch.

Scheme 26

Scheme 27

Scheme 28

1. Insert the rear drive shaft into the reduction drive gear and center differential assembly.
2. Using the ST, measure the depth "A", which is from mating surface of extension case to ball bearing outer ring contact surface. ST 398643600 GAUGE
3. Using the ST, measure the height "B" from the AT main case mating surface to ball bearing outer ring contact surface. ST 398643600 GAUGE
4. Calculation formula: When clearances are 0.05 mm (0.0020 in): T (mm) = A - B + 0.23 [T (in) = A-B + 0.0091] When clearances are 0.25 mm (0.0098 in): T (mm) = A - B + 0.03 [T (in) = A-B + 0.0012] A: Depth from end of extension case to ball bearing outer ring contact surface B: Height from end of AT main case contact surface to the ball bearing outer ring contact surface T: Shim thickness Standard: 0.05 - 0.25 mm (0.0020 - 0.0098 in) NOTE: Calculation formula for "T" above is applied when measuring with the ST (398643600 GAUGE). When not using the ST, When clearances are 0.05 mm (0.0020 in): T (mm) = (A - a) - ((B - p) - 0.28) - 0.05 [T (in) = (A - a) - ((B - p) - 0.011) - 0.0020] When clearances are 0.25 mm (0.0098 in): T (mm) = (A - α) - ((B - β) - 0.28) - 0.25 [T (in) = (A - α) - ((B - β) - 0.011) - 0.0098] is applied. T: Shim thickness A: Depth from end of extension case to ball bearing outer ring contact surface B: Height from end of AT main case contact surface to the ball bearing outer ring contact surface α: Thickness of collar used when measuring "A" β: Thickness of collar used when measuring "B" 0.28 (0.011): Gasket thickness (Unit mm (in)) ADJUSTMENT SHIM SPECIFICATIONS Adjustment shim Part No. Thickness mm (in) 33281AA040 0.2 (0.008) 33281AA050 0.5 (0.020) 33281AA060 0.3 (0.012)

Scheme 29

Scheme 30

1. Install the drive plate and driven plate to the center differential carrier.
2. Measure the depth "A" from the mating surface of the extension case to the transfer clutch piston.
3. Using the ST, measure the height "B" from the AT main case mating surface to end of ST, and then subtract the thickness of ST (PISTON GUIDE) (50 mm (1.97 in)) from measured value. ST 398744300 PISTON GUIDE
4. Calculation formula: When clearances are 0.2 mm (0.008 in): T (mm) = A - B + 0.08 [T (in) = A - B + 0.0031] When clearances are 0.6 mm (0.024 in): T (mm) = A - B - 0.32 [T (in) = A - B - 0.0126] T: Thickness of driven plate No. 3 A: Depth from mating surface of the extension case to the transfer clutch piston. B: Height from AT main case mating surface to end of ST Standard: 0.2 - 0.6 mm (0.008 - 0.024 in) NOTE: Calculation formula for "T" is applied when measuring using ST (398643600 GAUGE, 398744300 PISTON GUIDE). When not using the ST, When clearances are 0.2 mm (0.008 in): T (mm) = A - (B - α - 0.28) - 0.2 [T (in) = A - (B - α - 0.011) - 0.008] When clearances are 0.6 mm (0.024 in): T (mm) = A - (B - α - 0.28) - 0.6 [T (in) = A - (B - α - 0.011) - 0.024] is applied. T: Thickness of driven plate No. 3 A: Depth from mating surface of the extension case to the transfer clutch piston. B: Height from the AT main case mating surface to the contact face of the tool that was used as the substitute of the ST. α: Thickness of tool used when measuring "B" 0.28 (0.011): Gasket thickness (Unit mm (in)) If it is out of specification, select the driven plate No. 3 to adjust within the specification. DRIVEN PLATE NO. 3 SPECIFICATIONS Driven plate No. 3. Part No. Thickness mm (in) 31589AA041 1.6 (0.063) 31589AA050 2.0 (0.079) 31589AA060 2.4 (0.094) 31589AA070 2.8 (0.110)

1. Check each parts for holes, damages or other foreign matters.
2. Inspect the extension end play, and adjust it to within the standard value. Ref. to «ADJUSTMENT»(ref-371902-S39559671762010091900000) , Transfer Clutch.

Scheme 31

1. Remove the transmission assembly from vehicle body. Ref. to «REMOVAL»(ref-371902-S37686204272010091900000) , Automatic Transmission Assembly.
2. Remove the rear vehicle speed sensor, and separate the extension case from transmission case. Ref. to «REMOVAL»(ref-371902-S41849151192010091900000) , Extension Case.
3. Remove the center differential carrier. Ref. to «REMOVAL»(ref-371902-S30595591252010091900000) , Center Differential Carrier.
4. Set the range select lever to the "P" range.
5. Using ST1, ST2 and ST3, pull out the reduction driven gear. ST1 499737100 PULLER SET ST2 18680AA010 GEAR HOLDER ST3 18766AA000 SUPPORT PULLER

Check the ball bearing and gear for break or damage.

Scheme 32

Scheme 33

1. Using the ST, measure the height "A" from the AT main case mating surface to ball bearing outer ring contact surface. ST 499575400 GAUGE
2. Using the ST, measure the depth "B", which is from mating surface of extension case to ball bearing outer ring contact surface. ST 499575400 GAUGE
3. Calculation formula: Select the ball bearing shim from the table to adjust clearances within 0.05 - 0.25 mm (0.0020 - 0.0098 in). When clearances are 0.05 mm (0.0020 in): T (mm) = B - A + 0.23 [T (in) = B - A + 0.0091] When clearances are 0.25 mm (0.0098 in): T (mm) = B - A + 0.03 [T (in) = B-A +0.0012] T: Shim clearance A: Height from the mating surface of the AT main case to the ball bearing outer ring end surface B: Depth from mating surface of extension case to ball bearing outer ring contact surface REDUCTION GEAR SHIM SPECIFICATIONS Reduction gear shim Part No. Thickness mm (in) 31288AA030 0.2 (0.008) 31288AA050 0.5 (0.020) 31288AA060 0.3 (0.012)

Scheme 34

1. Remove the transmission assembly from the vehicle. Ref. to «REMOVAL»(ref-371902-S37686204272010091900000) , Automatic Transmission Assembly.
2. Remove the rear vehicle speed sensor, and separate the extension case from transmission case. Ref. to «REMOVAL»(ref-371902-S41849151192010091900000) , Extension Case.
3. Extract the rear drive shaft. Ref. to «REMOVAL»(ref-371902-S06160333622010091900000) , Rear Drive Shaft.
4. Pull out the center differential carrier assembly.
5. Pull out the shim (s) from transmission case.

1. Check each parts for holes, damages or other foreign matters.
2. Inspect the extension end play, and adjust it to within the standard value. Ref. to «ADJUSTMENT»(ref-371902-S39559671762010091900000) , Transfer Clutch.

Scheme 35

Scheme 36

1. Remove the transmission assembly from vehicle body. Ref. to «REMOVAL»(ref-371902-S37686204272010091900000) , Automatic Transmission Assembly.
2. Remove the extension case. Ref. to «REMOVAL»(ref-371902-S41849151192010091900000) , Extension Case.
3. Remove the center differential carrier. Ref. to «REMOVAL»(ref-371902-S30595591252010091900000) , Center Differential Carrier.
4. Remove the front vehicle speed sensor. Ref. to «REMOVAL»(ref-371902-S13401770802010091900000) , Front Vehicle Speed Sensor.
5. Remove the parking support actuator.
6. Remove the parking pawl, parking pawl shaft and return spring.

Scheme 37

Scheme 38

Scheme 39

1. Set the transmission to the N range.
2. Install the parking pawl, parking pawl shaft and return spring.
3. Install the parking support actuator. Tightening torque: 10 N.m (1.0 kgf-m, 7.4 ft-lb)
4. Using the ST, tighten the bolts which tightened in step 3 ) with specified angle. NOTE: Do not use extension as much as possible. Tightening angle: 17°±2° ST 18854AA000 ANGLE GAUGE
5. Make sure that the return spring is sticking out of the parking pole hole.
6. Install the front vehicle speed sensor. Ref. to «INSTALLATION»(ref-371902-S42872775172010091900000) , Front Vehicle Speed Sensor.
7. Install the center differential carrier. Ref. to «INSTALLATION»(ref-371902-S13407400132010091900000) , Center Differential Carrier.
8. Install the extension case. Ref. to «INSTALLATION»(ref-371902-S13329184862010091900000) , Extension Case.
9. Install the transmission assembly to the vehicle. Ref. to «INSTALLATION»(ref-371902-S14197603732010091900000) , Automatic Transmission Assembly.

Make sure that the tab of parking pawl on reduction driven gear is not worn or otherwise damaged.

Scheme 40

1. Remove the transmission assembly from the vehicle. Ref. to «REMOVAL»(ref-371902-S37686204272010091900000) , Automatic Transmission Assembly.
2. Remove the torque converter assembly. Ref. to «REMOVAL»(ref-371902-S04595510652010091900000) , Torque Converter Assembly.
3. Remove the transmission harness connector from stay.
4. Remove the turbine speed sensor 1. Ref. to «REMOVAL»(ref-371902-S24019999302010091900000) , Turbine Speed Sensor 1.
5. Remove the ATF inlet and outlet pipes. Ref. to «REMOVAL»(ref-371902-S13421677622010091900000) , ATF Cooler Pipe and Hose.
6. Remove the converter case attachment bolts.
7. Lay along the transmission body, and then remove the oil pan.
8. Remove the three converter case mounting bolts (TORX®). ST 18676AA020 TORX® WRENCH
9. Separate the converter case by lightly tapping with plastic hammer.
10. Remove the front differential assembly. Ref. to «REMOVAL»(ref-371902-S07180175952010091900000) , Front Differential Assembly.
11. Remove the oil seal from converter case.

Scheme 41

Scheme 42

1. Check the appearance of each component and clean them.
2. Press-fit the oil seal to converter case using ST. NOTE: Use a new oil seal. ST 499587100 OIL SEAL INSTALLER
3. Install the front differential assembly to the case. Ref. to «INSTALLATION»(ref-371902-S20741698522010091900000) , Front Differential Assembly.
4. Install the right and left side retainers. Ref. to «ADJUSTMENT»(ref-371902-S18432784062010091900000) , Front Differential Assembly.
5. Apply proper amount of liquid gasket to the entire matching surface of converter case. Liquid gasket: THREE BOND 1215 (Part No. 004403007) or equivalent
6. Install the converter case assembly without damaging bushing and oil seal. NOTE: Use a new bolt for the oil charge pipe and ATF cooler pipe portions Tightening torque: Oil charge pipe and ATF cooler pipe portions 38 N.m (3.9 kgf-m, 28.0 ft-lb) Other than the above 41 N.m (4.2 kgf-m, 30.2 ft-lb)
7. Install the three converter case mounting bolts (TORX®). Tightening torque: 41 N.m (4.2 kgf-m, 30.2 ft-lb) ST 18676AA020 TORX® WRENCH
8. Apply proper amount of liquid gasket to the entire oil pan mating surface, and then install it. Liquid gasket: THREE BOND 1217B (Part No. K0877YA020) or equivalent Tightening torque: 5 N.m (0.5 kgf-m, 3.7 ft-lb)
9. Install the transmission harness connector to the stay.
10. Install the ATF cooler pipe. Ref. to «INSTALLATION»(ref-371902-S42933691982010091900000) , ATF Cooler Pipe and Hose.
11. Install the torque converter assembly. Ref. to «INSTALLATION»(ref-371902-S01601256022010091900000) , Torque Converter Assembly.
12. Install the transmission assembly to the vehicle. Ref. to «INSTALLATION»(ref-371902-S14197603732010091900000) , Automatic Transmission Assembly.

Measure the backlash, and then adjust it to be within specification. Ref. to ADJUSTMENT , Drive Pinion Shaft Assembly.

Scheme 43

1. Remove the transmission assembly from the vehicle. Ref. to «REMOVAL»(ref-371902-S37686204272010091900000) , Automatic Transmission Assembly.
2. Pull out the torque converter assembly. Ref. to «REMOVAL»(ref-371902-S04595510652010091900000) , Torque Converter Assembly.
3. Remove the transmission harness connector from stay.
4. Remove the ATF inlet and outlet pipes. Ref. to «REMOVAL»(ref-371902-S13421677622010091900000) , ATF Cooler Pipe and Hose.
5. Separate the converter case and transmission case. Ref. to «REMOVAL»(ref-371902-S41955636532010091900000) , Converter Case.
6. Remove the oil pump cover mounting bolt, and then separate the oil pump cover from the AT main case by lightly tapping with plastic hammer.

1. Make sure that all component parts are free of scratches, holes and other faults.
2. Adjust the tooth alignment. Ref. to «ADJUSTMENT»(ref-371902-S21489317092010091900000) , Drive Pinion Shaft Assembly.

Scheme 44

Scheme 45

Scheme 46

Scheme 47

Scheme 48

Scheme 49

Scheme 50

Scheme 51

Scheme 52

1. Assemble the drive pinion shaft assembly to oil pump cover.
2. Remove the liquid gasket from the mating surface completely.
3. Install the converter case to oil pump cover, and secure them with tightening four bolts evenly. NOTE: Use an old gasket or aluminum washer to prevent damaging the mating surface of the housing. Tightening torque: 41 N.m (4.2 kgf-m, 30.2 ft-lb)
4. Rotate the drive pinion a few times using ST1 and ST2. ST1 18667AA010 HOLDER ST2 499787700 WRENCH
5. Adjust the drive pinion and hypoid driven gear backlash. Ref. to «ADJUSTMENT»(ref-371902-S18432784062010091900000) , Front Differential Assembly.
6. Apply lead-free red dye evenly on the surface of three to four teeth of the hypoid driven gear. Rotate the drive pinion in the leftward and rightward for several times. Remove the oil pump cover, and check the tooth contact pattern. If the teeth contact is inappropriate, adjust the backlash or thickness of the shim. Ref. to «ADJUSTMENT»(ref-371902-S18432784062010091900000) , Front Differential Assembly. Correct tooth contact Check item: Tooth contact surface is slightly shifted toward the toe side under a no-load condition. (When driving, it moves towards the heel side. Face contact Check item: Backlash is too large. Contact pattern Adjustment: Increase the thickness of the shim according to the procedures for moving the drive pinion closer to the driven gear. Flank contact Check item: Backlash is too small. Contact pattern Adjustment: Reduce the thickness of the shim according to the procedure for moving the drive pinion away from the driven gear. Toe contact (inside contact) Check item: Teeth contact area is too small. Contact pattern Adjustment: Reduce the thickness of the shim according to the procedure for moving the drive pinion away from the driven gear. Heel contact (outside end contact) Check item: Teeth contact area is too small. Contact pattern Adjustment: Increase the thickness of the shim according to the procedures for moving the drive pinion closer to the driven gear.
7. If tooth contact is correct, mark the retainer position and loosen it. After fitting a new O-ring and oil seal, screw in the retainer to the marked position. Tighten the lock plate with specified torque. Tightening torque: 25 N.m (2.5 kgf-m, 18.4 ft-lb)

1. Check each component for scratches, damage or other faults.
2. Measure the backlash, and then adjust it to be within specification. Ref. to «ADJUSTMENT»(ref-371902-S18432784062010091900000) , Front Differential Assembly.

Scheme 53

Scheme 54

Scheme 55

Scheme 56

1. Using the ST, screw-in the retainer until resistance is felt. NOTE: Screw-in the retainer RH side slightly deeper than the retainer LH. ST 18658AA020 WRENCH COMPL RETAINER
2. Remove the oil pump cover.
3. Remove the liquid gasket from the mating surface completely.
4. Install the oil pump cover to converter case, and secure them with tightening four bolts evenly. NOTE: Use an old gasket or aluminum washer to prevent damaging the mating surface of the housing. Tightening torque: 41 N.m (4.2 kgf-m, 30.2 ft-lb)
5. Rotate the drive pinion ten times or more using ST1 and ST2. ST1 18667AA010 HOLDER ST2 499787700 WRENCH
6. Tighten the LH retainer by rotating the shaft until resistance is felt. Then loosen the retainer RH. Keep tightening the retainer LH, and loosening the retainer RH until the pinion shaft no longer be turned. This is the "zero" state.
7. After the "zero" state is established, loosen the retainer LH by 3 notches and secure it with the lock plate. Then loosen the retainer RH and retighten until it stops. Rotate the drive pinion 2 or 3 times. Tighten the retainer RH further 1-3/4 notches. This sets the preload. Finally, secure the retainer with its lock plate. NOTE: Turning the retainer by one tooth changes the backlash approx. 0.05 mm (0.0020 in).
8. Install the SUBARU genuine axle shaft to the left and right sides of the front differential.
9. Turn the drive pinion a few times with ST1 and check to see if the backlash is within the specified value, using ST2, ST3, ST4 and ST5. NOTE: Secure the ST1 and stator shaft with the tie-wrap. Backlash: 0.13 - 0.18 mm (0.0051 - 0.0071 in) ST1 499787700 WRENCH ST2 498247001 MAGNET BASE ST3 498247100 DIAL GAUGE ST4 499787500 ADAPTER ST5 498255400 PLATE
10. Adjust the teeth contact of the front differential and drive shaft. Ref. to «ADJUSTMENT»(ref-371902-S21489317092010091900000) , Drive Pinion Shaft Assembly.

Scheme 57

Scheme 58

Scheme 59

Scheme 60

Scheme 61

Scheme 62

Scheme 63

Scheme 64

Scheme 65

Scheme 66

Scheme 67

Scheme 68

Scheme 69

Scheme 70

Scheme 71

Scheme 72

1. Remove the transmission assembly from the vehicle. Ref. to «REMOVAL»(ref-371902-S37686204272010091900000) , Automatic Transmission Assembly.
2. Pull out the torque converter assembly. Ref. to «REMOVAL»(ref-371902-S04595510652010091900000) , Torque Converter Assembly.
3. Remove the transmission harness connector from stay.
4. Remove the ATF inlet and outlet pipes. Ref. to «REMOVAL»(ref-371902-S13421677622010091900000) , ATF Cooler Pipe and Hose.
5. Remove the extension case. Ref. to «REMOVAL»(ref-371902-S41849151192010091900000) , Extension Case.
6. Remove the center differential carrier. Ref. to «REMOVAL»(ref-371902-S30595591252010091900000) , Center Differential Carrier.
7. Remove the reduction driven gear. Ref. to «REMOVAL»(ref-371902-S37612231512010091900000) , Reduction Driven Gear.
8. Separate the converter case from the transmission case. Ref. to «REMOVAL»(ref-371902-S41955636532010091900000) , Converter Case.
9. Remove the control valve body. Ref. to «REMOVAL»(ref-371902-S36943346192010091900000) , Control Valve Body.
10. Remove the oil pump cover. Ref. to «REMOVAL»(ref-371902-S38107393652010091900000) , Oil Pump Cover. NOTE: The input clutch pack assembly and front sun gear assembly are also removed together.
11. Remove the needle bearing of the middle carrier assembly.
12. Remove the middle carrier assembly.
13. Remove the rear carrier assembly.
14. Remove the middle & rear sun gear assembly.
15. Remove the thrust needle bearing of high & low reverse clutch.
16. Remove the high & low reverse clutch assembly.
17. Remove the direct clutch assembly.
18. Remove the snap ring of reverse brake.
19. Remove the retaining plate.
20. Remove the leaf spring.
21. Take out the drive plate, driven plate and dish plate.
22. Remove the snap ring of the reverse brake spring retainer. ST1 18762AA000 COMPRESSOR SPECIAL TOOL ST2 18765AA000 COMPRESSOR SUPPORT ST3 18763AA000 COMPRESSOR SHAFT
23. Remove the spring retainer.
24. Remove the return spring.
25. Apply compressed air.
26. Remove the reverse brake piston.
27. Remove the thrust bearing and seal ring.

Scheme 73

Scheme 74

Scheme 75

Scheme 76

Scheme 77

Scheme 78

Scheme 79

Scheme 80

1. Apply ATF to the new seal ring.
2. Install the thrust bearing and new seal ring to the drum support.
3. Install the reverse brake piston. NOTE: Apply ATF onto the piston sliding surface. ST1 18762AA000 COMPRESSOR SPECIAL TOOL ST2 18765AA000 COMPRESSOR SUPPORT ST3 18763AA000 COMPRESSOR SHAFT
4. Install the return spring.
5. Install the spring retainer and snap ring. ST1 18762AA000 COMPRESSOR SPECIAL TOOL ST2 18765AA000 COMPRESSOR SUPPORT ST3 18763AA000 COMPRESSOR SHAFT
6. Install the dish plate. NOTE: When installing, make sure that the identification mark is facing the rear side of transmission.
7. Install the drive plate and driven plate. NOTE: When the reverse brake is disassembled, use a new drive plate and driven plate set.
8. Install the leaf spring.
9. Install the retaining plate.
10. Install the snap ring of the reverse brake.
11. Apply compressed air intermittently to check for operation.
12. Check the piston stroke. Check the amount of drive plate compression "A" described in the wave clutch set of repair parts. Measure the clearance "B" between the retaining plate and snap ring using a thickness gauge. NOTE: Set shims of the same thickness on both sides so that the retaining plate will not tilt. Do not push the shim down with force to a point where the waves on the drive plate will become crushed. Select and install a retaining plate so that the value calculated from the dimension A and B is within the standard. T = A + B T: Piston stroke A: Amount of drive plate compression B: Clearance between retaining plate and snap ring Initial standard: 2.0 - 2.4 mm (0.08 - 0.09 in) RETAINING PLATE SPECIFICATIONS Retaining plate Part No. Thickness mm (in) 31567AB100 4.2 (0.165) 31567AB170 4.4 (0.173) 31567AB180 4.6 (0.181) 31567AB190 4.8 (0.189) 31567AB200 5.0 (0.197)
13. Install the direct clutch assembly.
14. Install the high & low reverse clutch assembly.
15. Install the thrust needle bearing of the high & low reverse clutch.
16. Install the middle & rear sun gear assembly.
17. Install the rear carrier assembly.
18. Install the middle carrier assembly.
19. Install the thrust needle bearing of middle carrier assembly.
20. Measure the total end play, and select the bearing. Ref. to «ADJUSTMENT»(ref-371902-S27804520132010091900000) , AT Main Case.
21. Install the input clutch pack assembly to oil pump cover.
22. Turn the transmission sideways.
23. Install the oil pump cover. Apply ATF to the O-ring of input clutch shaft. Install the oil pump cover to AT main case while supporting the input clutch shaft and oil pump housing with your hand. Make sure the rear end of drive pinion shaft is engaged to the spline of reduction driven gear. Protect the input clutch shaft with a cloth, and rotate to engage the spline of the input clutch and rear carrier using pliers. NOTE: Work with pressing the oil pump cover. Combine the oil pump cover with transmission main case. Tightening torque: 41 N.m (4.2 kgf-m, 30.2 ft-lb)
24. Install the center differential carrier. Ref. to «INSTALLATION»(ref-371902-S13407400132010091900000) , Center Differential Carrier.
25. Install the reduction driven gear. Ref. to «INSTALLATION»(ref-371902-S35786950552010091900000) , Reduction Driven Gear.
26. Install the extension case. Ref. to «INSTALLATION»(ref-371902-S13329184862010091900000) , Extension Case.
27. Install the control valve body. Ref. to «INSTALLATION»(ref-371902-S20954234102010091900000) , Control Valve Body.
28. Install the converter case assembly to the transmission case assembly. Ref. to «INSTALLATION»(ref-371902-S36953341792010091900000) , Converter Case.
29. Install the ATF cooler pipe. Ref. to «INSTALLATION»(ref-371902-S42933691982010091900000) , ATF Cooler Pipe and Hose.
30. Install the torque converter assembly. Ref. to «INSTALLATION»(ref-371902-S01601256022010091900000) , Torque Converter Assembly.
31. Install the transmission assembly to the vehicle. Ref. to «INSTALLATION»(ref-371902-S14197603732010091900000) , Automatic Transmission Assembly.
32. Perform Clear Memory 2 operation. Ref. to «CLEAR MEMORY MODE»(ref-371942-S04843487322010091900000) .
33. Perform learning operation. Ref. to «LEARNING CONTROL»(ref-371942-S05358684462010091900000) .
34. Perform the inspection at the end of repair work, and make sure there is no faulty as below; Excessive shift shock Oil leakage from the transmission body, etc. Occurrence of noise caused by interference etc.

Scheme 81

Scheme 82

Scheme 83

1. Remove the front sun gear.
2. Remove the thrust bearing.
3. Remove the snap ring, and then remove the front carrier.
4. Remove the input clutch assembly from rear internal gear.

Make sure the manual lever and detent spring are not worn or otherwise damaged.

SYMPTOMS CHART