Subaru Legacy (2005 year). Service manual — part 535
4AT-121
AUTOMATIC TRANSMISSION
AT Main Case
41.AT Main Case
A: REMOVAL
1) Remove the transmission assembly from vehi-
cle. <Ref. to 4AT-39, REMOVAL, Automatic Trans-
mission Assembly.>
2) Pull out the torque converter clutch assembly.
<Ref. to 4AT-81, REMOVAL, Torque Converter
Clutch Assembly.>
3) Remove the input shaft.
4) Lift up the lever on rear side of transmission har-
ness connector, and then disconnect it from the
stay.
5) Disconnect the inhibitor switch connector from
stay.
6) Disconnect the air breather hose.
7) Remove the oil charge pipe. <Ref. to 4AT-80,
REMOVAL, Oil Charge Pipe.>
8) Remove the oil cooler inlet and outlet pipes.
<Ref. to 4AT-68, REMOVAL, ATF Cooler Pipe and
Hose.>
9) Separate the converter case and transmission
case. <Ref. to 4AT-102, REMOVAL, Converter
Case.>
10) Remove the oil pump housing.
<Ref. to 4AT-104, REMOVAL, Oil Pump Housing.>
11) Take out the high clutch, thrust needle bearing
and reverse clutch assembly.
12) Take out the high clutch hub and thrust bear-
ing.
13) Take out the front sun gear and thrust needle
bearing.
14) Pull out the leaf spring without folding.
NOTE:
Remove it while pressing down lower leaf spring.
(A) High clutch and reverse clutch ASSY
(B) Thrust needle bearing
AT-00114
AT-00232
(B)
(A)
(A) High clutch hub
(B) Thrust needle bearing
(A) Front sun gear
(B) Thrust needle bearing
(A) Leaf spring
(B) Retaining plate
AT-00233
(A)
(B)
AT-00251
(A)
(B)
AT-00252
(A)
(B)
4AT-122
AUTOMATIC TRANSMISSION
AT Main Case
15) Remove the snap ring and thrust needle bear-
ing.
16) Take out the retaining plate, drive plate and
driven plate of 2-4 brake.
17) Take out the thrust needle bearing, planetary
gear assembly and low clutch assembly.
18) Remove the 2-4 brake seal.
19) Remove the snap ring.
20) Take out the 2-4 brake return spring.
21) Remove the 2-4 brake piston and piston retain-
er without damaging.
(A) Snap ring
(B) Thrust needle bearing
AT-00253
(A)
(B)
AT-00254
AT-00255
AT-02215
(A) Snap ring
(B) 2-4 brake piston
(A) 2-4 brake piston
(B) 2-4 brake piston retainer
AT-00285
(B)
(A)
AT-00286
AT-00287
(A)
(B)
4AT-123
AUTOMATIC TRANSMISSION
AT Main Case
22) Pull out the leaf spring without folding.
23) Remove the snap ring.
24) Take out the retaining plate, drive plate, driven
plate and dish plate.
25) Turn the transmission case upside down, and
then take out the socket bolts while holding the
one-way clutch inner race with hand.
26) Remove the spring retainer.
27) Take out the return spring.
28) Apply compressed air.
29) Take out the low & reverse piston.
(A) Leaf spring
(A) Snap ring
AT-00293
(A)
AT-00294
( A )
AT-00295
AT-00296
AT-00302
AT-00301
AT-00297
AT-00300
4AT-124
AUTOMATIC TRANSMISSION
AT Main Case
B: INSTALLATION
1) Install the low & reverse brake piston.
NOTE:
• Be careful not to damage the lip seal.
• Apply ATF to lips.
2) Install the return spring.
3) Install the spring retainer.
4) Install the one-way clutch inner race, spring re-
tainer and return spring.
5) Tighten the socket bolts evenly from the rear
side of transmission case.
Tightening torque:
25 N
⋅
m (2.5 kgf-m, 18.4 ft-lb)
6) Place the front side of transmission body up.
7) Install the thrust needle bearing.
8) Place the dish plate, driven plate, drive plate and
retaining plate neatly in this order on surface table.
9) Set the dial gauge to clutch, and read its scale.
NOTE:
The value, which is read in the gauge at this time, is
zero point.
10) Scale and record the weight “Z” of a flat board
which will be put on retaining plate.
NOTE:
• Use a stiff board which does not bend against
load as a flat board to be put on retaining plate.
• Use a flat board of its weight less than 8.5 kg
(18.7 lb).
11) Put the flat board weighed on retaining plate.
12) Using the following formula, calculate “N” indi-
cated on the push/pull gauge.
N = 83 N (8.5 kgf, 18.7 lbf)
− Z
N: Value indicated on push/pull gauge
83 N (8.5 kgf, 18.7 lbf): Load applied to clutch plate
Z: Flat board weight
AT-00300
AT-00301
AT-00302
AT-00296
AT-01720
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