FUJI HEA VY INDUSTRIES L TD. G2320GE5 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. CONTROL SYSTEMS CS AUTOMATIC T RANSMISSION 4A T AUTOMATIC TRANSMISSION (DIAGNOSTICS) 4AT(diag) AUTOMATIC TRANSMISSION 5AT AUTOMATIC TRANSMISSION (DIAGNOSTICS) 5AT(diag) MANUAL TRANSMISSION AND DIFFERENTIAL 5MT CLUTCH SYSTEM CL
C: CAUTION• Wear work clothing, including a cap, protectivegoggles and protective shoes during operation.• 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 facingupward until it is installed so as to prevent foreignmatter intrusion into valve body.• Before removal, installation or disassembly, besure to clarify the failure. Avoid unnecessary re-moval, installation, disassembly and replacement.• When disassembling the case and other light al-loy parts, use a plastic hammer to force it apart. Donot pry it apart with a screwdriver or other tool.• Be careful not to burn yourself, because eachpart on the vehicle is hot after running.• Use SUBARU genuine gear oil, grease etc. orthe equivalent. Do not mix gear oil, grease etc. withthat of another grade or from other manufacturers.• Be sure to tighten bolts and nuts to the specifiedtorque.• Place shop jacks or rigid racks at the specifiedpoints.• Apply gear oil or ATF onto sliding or revolutionsurfaces before installation in view of componentsusage.• Replace deformed or otherwise damaged snaprings 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 installO-rings, snap rings and other such parts.• Before securing a part on a vice, place cushion-ing material such as wood blocks, aluminum plateor cloth between the part and the vice.• Avoid damaging the mating surface of the case.• Before applying liquid gasket, completely re-move the old seal.
NOTE:The level of ATF varies with fluid temperature. Payattention to the ATF temperature when checkingATF level.
1) Raise the ATF temperature by driving a distanceof 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. <Ref. to4AT(diag)-17, READ CURRENT DATA, OPERA-TION, Subaru Select Monitor.>2) Park the vehicle on a level surface.3) After selecting all positions (P, R, N, D), set theselect lever in “P” range. Measure the ATF levelwith engine idling for one or two minutes.
4) Make sure that ATF level is above the center ofupper 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 centerbetween upper level and lower level.
CAUTION:• Use care not to exceed the upper limit level.• Be sure that the replenishment of ATF to theupper 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 distanceof 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. <Ref. to4AT(diag)-17, READ CURRENT DATA, OPERA-TION, Subaru Select Monitor.>7) Check the ATF for leaks.Make visual inspection for leaks from the inside oftransmission. If there are leaks, repair or replacethe gasket, oil seals, plugs or other parts.
B: REPLACEMENT1) Lift-up the vehicle.2) Remove the ATF drain plug to drain ATF.
CAUTION:Directly after the engine has been running, theATF is hot. Be careful not to burn yourself.
3) Check the condition of ATF. <Ref. to 4AT-32,CONDITION CHECK, Automatic TransmissionFluid.>4) Tighten the ATF drain plug.
NOTE:Use a new gasket.
Tightening torque: 25 N ⋅ m (2.5 kgf-m, 18.1 ft-lb)
5) Lower the vehicle.6) Pour ATF from the oil charge pipe.
NOTE:If the ATFs above are not available, use Dexron III.
Capacity: Fill the same amount of ATF drained.
Capacity when transmission is overhauled: 2.0 L model
8.4 — 8.72 (8.9 — 9.2 US qt, 7.4 — 7.7 Imp
qt) 2.5 L model
9.3
—
9.62 (9.8 —
10.1 US qt, 8.2 —
8.4 Impqt)
7) Bleed the air of control valve.<Ref. to 4AT-63, Air Bleeding of Control Valve.>8) Check the level and leaks of ATF.<Ref. to 4AT-31, INSPECTION, Automatic Trans-mission Fluid.>
A: INSPECTION1) 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 thatthe level gauge is correctly inserted and in the
proper orientation.4) Remove the level gauge again and note thereading. If the differential gear oil level is below the“L” line, add oil to bring the level up to the “F” line.
NOTE:To prevent overfilling the differential gear oil, do notadd oil above the “F” line.
B: REPLACEMENT1) Lift-up the vehicle.
2) Remove the differential gear oil drain plug usingTORX ® BIT T70, and drain the differential gear oilcompletely.
CAUTION:• Directly after the engine has been running,the differential gear oil is hot. Be careful not toburn yourself.• Be careful not to spill the differential gear oilon exhaust pipe to prevent it from emittingsmoke or fire. When the differential gear oil isspilled on exhaust pipe, wipe it away complete-ly.
3) Tighten the differential gear oil drain plug usingTORX ® BIT T70.
NOTE:Use a new gasket.
Tightening torque: 70 N ⋅ m (7.1 kgf-m, 51.6 ft-lb)
4) Lower the vehicle.5) Pour gear oil into the gauge hole.
Recommended gear oil:
<Ref. to 4AT-3, RECOMMENDED GEAR OIL,SPECIFICATION, General Description.>
Road tests should be conducted to properly diag-nose the condition of the automatic transmission.
NOTE:When performing the test, do not exceed postedspeed limit.
2. D RANGE SHIFT FUNCTION
Check shifting between 1st ←→ 2nd ←→ 3rd ←→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 thekick-down shock level.
5. ENGINE BRAKE OPERATION
• Check the 3rd gear engine brake when shiftingdown from 4th to 3rd range while driving in 4th gearof manual mode [50 — 60 km/h (31 — 37 MPH)].• Check the 2nd gear engine brake when shiftingdown from 3rd to 2nd range while driving in 3rdgear of manual mode [40 — 50 km/h (25 — 31MPH)].• Check the 1st gear engine brake when shifting
down from 2nd to 1st range while driving in 2ndgear of manual mode [20 — 30 km/h (12 — 19MPH)].
6. LOCK-UP FUNCTION
• Check that rpm does not change sharply whenthe axle pedal is lightly depressed while driving onflat roads at normal speed in “D” range.• 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 isdisplayed, perform the collective action with DTC
and check that any more DTC is displayed, andthen start the checking.1) Perform the check on flat and straight road orfree roller.
NOTE:• Slip lock-up does not operate when the vehicle islifted up, because of not occurring surface resis-tance.
• Also when checking on the free roller, check withdepressing the foot brake lightly to make the check-ing easier, because the surface resistance will bedeficient.
2) Connect the Subaru Select Monitor.3) Check the ATF temperature using Subaru SelectMonitor.
NOTE:• ATF temperature is between 50 — 100°C (122
— 212°F).• When the temperature is low, warm-up the ATFby running the vehicle or etc.
4) Start the engine, so that the lock-up duty can beread on data display of Subaru Select Monitor.5) Drive the vehicle at a constant speed of 35 — 40km/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.
• Slip lock-up control is not operating when thelock-up duty is less than 5%, or when the lock-upduty goes down immediately after starts rising. Onthese cases, improper ATF or deterioration of ATFmay 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 moreand shift to “P” range. Check that the vehicle doesnot 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
• Check that the gear remains in 3rd when goingup a grade.• Check that the gear remains in 3rd when apply-ing the brakes while going down a grade.
10.TRANSFER CLUTCH
Check tight corner braking when the vehicle startedwith steering fully turned.
NOTE:The stall test is of extreme importance in diagnos-ing the condition of the automatic transmission andthe 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 converterclutch.• 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 30minutes (with select lever set to “N” or “P”).7) Place the wheel chocks at the front and rear ofall wheels and engage the parking brake.8) Move the manual linkage to ensure it operatesproperly, and then set to the 2nd on manual mode.
9) While forcibly depressing the foot brake pedal,gradually depress the accelerator pedal until theengine operates at full throttle.
10) When the engine speed is stabilized, recordthat speed quickly and release the accelerator ped-al.11) Shift the select lever to “N” range, and cooldown the engine by idling it for more than oneminute.12) If the stall speed in the 2nd of manual mode is
higher than specifications, low clutch slipping and2-4 brake slipping may occur. To identify it, conductthe same test as above in “R” range.13) Perform the stall tests with the select lever in“D” range.
NOTE:• Do not continue the stall test for more than fiveseconds at a time (from closed throttle, fully openthrottle to stall speed reading). Failure to follow thisinstruction 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 oneminute after each stall test with the select lever setin “P” or “N” range and with the idle speed lowerthan 1,200 rpm.• If the stall speed is higher than the specifiedrange, attempt to finish the stall test in as short atime as possible, in order to prevent the automatictransmission from sustaining damage.
NOTE:If the select lever is shifted while the engine isidling, 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 &reverse brake and one-way clutch.• Perform the test at normal operation fluid tem-perature 70 — 80°C (158 — 176°F).• Be sure to allow a one minute interval betweentests.• Make three measurements and take the averagevalue.
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 fromshifting the lever until the shock is felt.Time lag: Less than 1.2 secondsIf “N” → “D” time lag is longer than specified:• Line pressure too low• Low clutch worn• One-way clutch not operating properly• D-ring worn4) In the same manner, measure the time lag for“N” → “R”.Time lag: Less than 1.5 secondsIf “N” → “R” time lag is longer than specified:• Line pressure too low• Reverse clutch worn• Low & reverse brake worn• D-ring worn
NOTE:If the clutch or the brake shows a sign of slippage orshifting sensation is not correct, the line pressureshould be checked.
• Excessive shocks during upshifting or shiftingtakes place at a higher point than under normal cir-cumstances, may be due to the line pressure beingtoo high.• Slippage or inability to operate the vehicle may,in most cases, be due to loss of oil pressure for theoperation of the clutch, brake or control valve.
1) Line pressure measurement (under no load):(1) Before measuring line pressure, jack-up allthe 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 boththe foot and parking brakes with all wheelschocked (Same as for “stall” test conditions).(2) Measure the line pressure when the selectlever is in “R” or 2nd of manual mode with en-gine under stall conditions.(3) Measure the line pressure within 5 secondsafter shifting the select lever to each position. (Ifthe line pressure needs to be measured again,
allow the engine to idle and cool it down morethan 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
4) Connect the ST1 with ST2.ST1 498897200 OIL PRESSURE GAUGE
ADAPTERST2 498575400 OIL PRESSURE GAUGE
ASSY5) Check for duty ratio changes by adjusting the ac-celeration pedal position using Subaru Select Mon-
AUTOMATIC TRANSMISSIONTransfer Clutch Pressure Test
8. Transfer Clutch PressureTest
A: INSPECTIONCheck the transfer clutch pressure in accordancewith the following chart in the same manner as withline pressure. <Ref. to 4AT-38, Line Pressure
Test.>ST 498897700 OIL PRESSURE ADAPTER
SETST 498575400 OIL PRESSURE GAUGE
ASSY
NOTE:• Before setting in FWD mode, install the sparefuse on FWD mode switch. (MPT model)
• MTP model
• VTD model
• If no oil pressure is produced or if it does notchange in AWD mode, the control valve body maybe malfunctioning. If oil pressure is produced inFWD mode, the same problem as AWD mode oc-curs.
A: REMOVAL1) Set the vehicle on a lift.2) Fully open the front hood and support with hoodstay.
3) Disconnect the ground cable from battery.4) Remove the air intake duct.<Ref. to IN(H4SO 2.0)-9, REMOVAL, Air IntakeDuct.>5) Remove the air intake chamber.<Ref. to IN(H4SO 2.0)-8, REMOVAL, Air IntakeChamber.>6) Remove the air cleaner case stay.
7) Disconnect the following connectors.(1) Transmission harness connectors
(2) Transmission ground terminal8) Remove the starter.<Ref. to SC(H4SO 2.0)-6, REMOVAL, Starter.>9) Remove the pitching stopper.
10) Separate the torque converter clutch from driveplate.
(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 rotatingcrank 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
12) Remove the ATF level gauge.
NOTE:Plug the opening to prevent entry of foreign parti-cles into transmission fluid.
13) Remove the throttle body. <Ref. to FU(H4SO2.0)-10, REMOVAL, Throttle Body.>
25) Remove the front, center and rear exhaustpipes and muffler.<Ref. to EX(H4SO 2.0)-7, REMOVAL, Front Ex-haust Pipe.> <Ref. to EX(H4SO 2.0)-11, REMOV-AL, Rear Exhaust Pipe.> <Ref. to EX(H4SO 2.0)-13, REMOVAL, Muffler.>26) Remove the heat shield cover.
27) Remove the ATF drain plug to drain ATF.
28) Disconnect the ATF cooler hoses from pipes oftransmission side, and remove the oil charge pipe.(Model without ATF cooler with warmer function)
29) Remove the propeller shaft.<Ref. to DS-10, REMOVAL, Propeller Shaft.>30) Remove the shift select cable.<Ref. to CS-12, REMOVAL, Select Cable.>31) Remove the brackets (two) which hold frontstabilizer.
32) Remove the bolt securing ball joint of front armto housing.
33) Pull out the front drive shaft from transmission.(1) Using a tire lever or a pinch bar, etc., pull outthe 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 sideretainer of transmission.
(2) Hold the transmission side joint portion offront drive shaft by hand and extract the housingfrom the transmission by pressing it outside soas not to stretch the boot.
34) Remove the bolts which hold the clutch hous-ing cover.35) Remove the bolts which hold lower side oftransmission to engine.
36) Place the transmission jack under transmis-sion.
NOTE:Make sure that the support plates of transmission
Tightening torque: 50 N ⋅ m (5.1 kgf-m, 36.9 ft-lb)
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.<Ref. to SC(H4SO 2.0)-6, INSTALLATION,Starter.>(3) Tighten the bolts which hold the upper sideof transmission to engine.
Tightening torque: 50 N ⋅ m (5.1 kgf-m, 36.9 ft-lb)
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 thecrank 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)
14) Install the warmer cock assembly. (Model withATF cooler with warmer function)
21) Lift-up the vehicle.22) Replace the snap ring of front drive shaft with anew one.23) Apply grease to the oil seal lips.24) Install the ST to side retainer.ST 28399SA010 OIL SEAL PROTECTOR
25) Align the spline of front differential shaft to thatof differential bevel gear for insertion, and removethem using ST.ST 28399SA010 OIL SEAL PROTECTOR26) Insert the front drive shaft into transmission se-curely by pressing the front housing from outside.
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)
29) Install the stabilizer to crossmember.
NOTE:• Install the bushing (on front crossmember side)while aligning it with the paint mark on stabilizer.
• Ensure the bushing and stabilizer have the sameidentification colors when installing.
30) Always tighten the rubber bushing locationwhen wheels are in full contact with the ground andvehicle 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.<Ref. to CS-13, INSTALLATION, Select Cable.>32) Install the oil charge pipe, and connect the ATFcooler hoses to pipe. (Model without ATF coolerwith warmer function)
33) Install the oil charge pipe. (Model with ATFcooler with warmer function)34) Install the propeller shaft.<Ref. to DS-11, INSTALLATION, Propeller Shaft.>35) Install the heat shield cover.
36) Install the rear exhaust pipe and muffler as-sembly.
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