Subaru Legacy (2005 year). Service manual — part 638
5AT(diag)-143
AUTOMATIC TRANSMISSION (DIAGNOSTICS)
General Diagnostic Table
Engine skids when driving at 5th. Or slipping occurred.
• Fluid level and condition
• Line pressure
• Accelerator pedal position sensor
• Throttle position sensor
• CAN communication signal
• Oil pressure switch 1 and Front brake solenoid valve
Slip at lock up.
• Fluid level and condition
• Line pressure
• Engine speed signal
• Torque converter turbine speed sensor
• Lock up solenoid valve
• CAN communication signal
Maximum vehicle speed is low.
• Fluid level and condition
• Line pressure
• Accelerator pedal position sensor
• Throttle position sensor
• CAN communication signal
• Direct clutch solenoid valve
• Vehicle speed sensor 1 and 2
There is completely no creep.
• Fluid level and condition
• Engine speed signal
• CAN communication signal
• Oil pressure switch 4 and Direct clutch solenoid valve
• Line pressure
Excessive large creep.
• Engine speed signal
• CAN communication signal
• Oil pressure switch 4
Vehicle cannot be parking condition on “P” range. Parking con-
dition is not released though shifting to other ranges.
• Inhibitor switch
• Control cable adjustment
Vehicle can drive on “P” range.
• Inhibitor switch
• Fluid level and condition
• Control cable adjustment
• Line pressure
Vehicle can drive on “N” range.
• Inhibitor switch
• Fluid level and condition
• Control cable adjustment
• Line pressure
Vehicle cannot drive at any range.
• Fluid level and condition
• Line pressure
• Inhibitor switch
• Control cable adjustment
• Loosing or damaging of propeller shaft.
• Loosing or damaging of drive shaft.
Vehicle cannot drive on “D” range.
• Fluid level and condition
• Line pressure
• Inhibitor switch
• Control cable adjustment
• Loosing or damaging of propeller shaft.
• Loosing or damaging of drive shaft.
Vehicle cannot drive on “R” range.
• Fluid level and condition
• Line pressure
• Inhibitor switch
• Control cable adjustment
• Loosing or damaging of propeller shaft.
• Loosing or damaging of drive shaft.
Symptom
Problem parts
5AT(diag)-144
AUTOMATIC TRANSMISSION (DIAGNOSTICS)
General Diagnostic Table
Engine cannot start on “P” or “N” range
• Key switch and Starter
• Control cable adjustment
• Inhibitor switch
• CAN communication line
• TCM
Engine start other than “N” or “P” range
• Key switch and Starter
• Control cable adjustment
• Inhibitor switch
• TCM
Engine stalls.
• Fluid level and condition
• Engine speed signal
• Torque converter turbine speed sensor
• Lock up solenoid valve
• Line pressure
Engine stalls when shifting to “N”
→ “D” and “R” range.
• Fluid level and condition
• Engine speed signal
• Torque converter turbine speed sensor
• Lock up solenoid valve
• Line pressure
Symptom
Problem parts
MANUAL TRANSMISSION
AND DIFFERENTIAL
5MT
Page
General Description . . . . . . . . . . . . . . . . . . . . . 2
Transmission Gear Oil . . . . . . . . . . . . . . . . . . . ..29
Manual Transmission Assembly . . . . . . . . . . . . . . . ...30
Transmission Mounting System . . . . . . . . . . . . . . . . 36
Oil Seal. . . . . . . . . . . . . . . . . . . . . . . . . ..38
Differential Side Retainer Oil Seal. . . . . . . . . . . . . . . .39
Switches and Harness . . . . . . . . . . . . . . . . . . . ..40
Preparation for Overhaul. . . . . . . . . . . . . . . . . . ...42
Transfer Case and Extension Case Assembly. . . . . . . . . . ..43
Transfer Drive Gear . . . . . . . . . . . . . . . . . . . . ..47
Transfer Driven Gear . . . . . . . . . . . . . . . . . . . . 49
Center Differential . . . . . . . . . . . . . . . . . . . . . .51
Reverse Check Sleeve. . . . . . . . . . . . . . . . . . . ..52
Transmission Case . . . . . . . . . . . . . . . . . . . . ...55
Main Shaft Assembly for Single-Range . . . . . . . . . . . . . 61
Main Shaft Assembly for Dual-Range . . . . . . . . . . . . . ...66
Input Shaft Assembly . . . . . . . . . . . . . . . . . . . . 72
Drive Pinion Shaft Assembly. . . . . . . . . . . . . . . . . .76
Front Differential Assembly . . . . . . . . . . . . . . . . . ...84
Reverse Idler Gear. . . . . . . . . . . . . . . . . . . . . 91
Shifter Fork and Rod . . . . . . . . . . . . . . . . . . . . .93
Counter Gear . . . . . . . . . . . . . . . . . . . . . . . 96
General Diagnostic Table. . . . . . . . . . . . . . . . . . ..98
5MT-2
MANUAL TRANSMISSION AND DIFFERENTIAL
General Description
1. General Description
A: SPECIFICATION
1. MANUAL TRANSMISSION AND DIFFERENTIAL
★1
: For option code, refer to ID section. <Ref. to ID-5, MODEL NUMBER PLATE, IDENTIFICATION, Identification.>
★2
: Dual-range model only
Option code
★1
EC, K4, EK
KA
EC, K4, EK
KA, KS
Model
2.0 L
2.5 L
2.0 i
2.0 GT
Except for
OUTBACK
OUTBACK
Except for
OUTBACK
OUTBACK
Type
5-forward speeds and 1-reverse
(5
× 2-forward speeds and 1 × 2-reverse)
★2
Transmission gear ratio
1st
3.454
3.166
3.454
2nd
1.947
1.882
2.062
3rd
1.366
1.296
1.448
4th
0.972
1.088
5th
0.738
0.825
0.78
0.825
Reverse
3.333
Auxiliary transmission gear
ratio
★2
High
1.000
Low
1.447
1.196
Front reduction
gear
Final
Type of gear
Hypoid
Gear ratio
4.111
3.700
3.900
4.111
Rear reduction
gear
Transfer
Type of gear
Helical
Gear ratio
1.000
Final
Type of gear
Hypoid
Gear ratio
4.111
3.700
3.900
4.111
Front differential
Type and number of gear
Straight bevel gear (Bevel pinion: 2, Bevel gear: 2)
Center differential
Type and number of gear
Straight bevel gear (Bevel pinion: 2, Bevel gear: 2 and viscous coupling)
Transmission gear oil
GL-5
Transmission gear oil capacity
Single-range
model
3.5
2 (3.7 US qt, 3.1 Imp qt)
Dual-range
model
4.0
2 (4.2 US qt, 3.5 Imp qt)
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