Subaru Legacy (2005 year). Service manual — part 505
AUTOMATIC TRANSMISSION
4AT
Page
General Description . . . . . . . . . . . . . . . . . . . . . 2
Automatic Transmission Fluid . . . . . . . . . . . . . . . . ...31
Differential Gear Oil. . . . . . . . . . . . . . . . . . . . ...33
Road Test. . . . . . . . . . . . . . . . . . . . . . . . ..34
Stall Test . . . . . . . . . . . . . . . . . . . . . . . . ...35
Time Lag Test . . . . . . . . . . . . . . . . . . . . . . ...36
Line Pressure Test . . . . . . . . . . . . . . . . . . . . . 37
Transfer Clutch Pressure Test . . . . . . . . . . . . . . . . ..38
Automatic Transmission Assembly . . . . . . . . . . . . . . ...39
Transmission Mounting System . . . . . . . . . . . . . . . . 47
Extension Case Oil Seal . . . . . . . . . . . . . . . . . . ...49
Differential Side Retainer Oil Seal. . . . . . . . . . . . . . . .50
Inhibitor Switch. . . . . . . . . . . . . . . . . . . . . . ..51
Front Vehicle Speed Sensor . . . . . . . . . . . . . . . . . .55
Rear Vehicle Speed Sensor. . . . . . . . . . . . . . . . . ..58
Torque Converter Turbine Speed Sensor . . . . . . . . . . . . .59
Control Valve Strainer . . . . . . . . . . . . . . . . . . . ...60
Control Valve Body . . . . . . . . . . . . . . . . . . . . ...62
Air Bleeding of Control Valve . . . . . . . . . . . . . . . . . 64
ATF Filter . . . . . . . . . . . . . . . . . . . . . . . . ..65
Transmission Control Module (TCM) . . . . . . . . . . . . . . 66
Lateral G Sensor . . . . . . . . . . . . . . . . . . . . . ...67
ATF Cooler Pipe and Hose . . . . . . . . . . . . . . . . . ...68
ATF Cooler (with Warmer Function) . . . . . . . . . . . . . . .73
Warmer Cock . . . . . . . . . . . . . . . . . . . . . . . 77
Air Breather Hose. . . . . . . . . . . . . . . . . . . . . ..79
Oil Charge Pipe. . . . . . . . . . . . . . . . . . . . . . .80
Torque Converter Clutch Assembly . . . . . . . . . . . . . . ..81
Extension Case . . . . . . . . . . . . . . . . . . . . . . .83
Transfer Clutch. . . . . . . . . . . . . . . . . . . . . . ..87
Multi-plate Clutch . . . . . . . . . . . . . . . . . . . . . ..93
Rear Drive Shaft. . . . . . . . . . . . . . . . . . . . . . 94
Reduction Driven Gear. . . . . . . . . . . . . . . . . . . ..95
Reduction Drive Gear. . . . . . . . . . . . . . . . . . . . 97
Center Differential Carrier . . . . . . . . . . . . . . . . . . .99
Parking Pawl . . . . . . . . . . . . . . . . . . . . . . ...101
Converter Case . . . . . . . . . . . . . . . . . . . . . ...102
Oil Pump Housing . . . . . . . . . . . . . . . . . . . . ...104
Drive Pinion Shaft Assembly. . . . . . . . . . . . . . . . ...109
Front Differential Assembly . . . . . . . . . . . . . . . . . .115
AT Main Case . . . . . . . . . . . . . . . . . . . . . . .121
Transmission Control Device . . . . . . . . . . . . . . . . ..142
4AT-2
AUTOMATIC TRANSMISSION
General Description
1. General Description
A: SPECIFICATION
1. TORQUE CONVERTER CLUTCH
2. OIL PUMP
3. TRANSMISSION CONTROL ELEMENT
4. TRANSMISSION GEAR RATIO
5. PLANETARY GEAR AND PLATE
6. SELECTOR POSITION
Model
2.0 L
2.5 L
Type
Symmetric, 3 element, single stage,
2 phase torque converter
Stall torque ratio
2.0 — 2.2
1.8 — 2.15
Nomi-
nal
diame-
ter
mm (in)
236 (9.29)
246 (9.69)
Stall speed (at sea
level)
2,000 — 2,500
rpm
2,300 — 2,800
rpm
One-way clutch
Sprague type one-way clutch
Type
Parachoid constant-discharge pump
Driving method
Driven by engine
Number of teeth
Inner rotor
9
Outer rotor
10
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
1st
2.785
2nd
1.545
3rd
1.000
4th
0.694
Rev
2.272
Model
2.0 L
2.5 L
Front sun gear
number of teeth
33
Front pinion num-
ber of teeth
21
Front internal gear
number of teeth
75
Rear sun gear
number of teeth
42
Rear pinion num-
ber of teeth
17
Rear internal gear
number of teeth
75
Drive plate num-
ber of high clutch
4
Drive plate num-
ber of low clutch
4
5
Drive plate num-
ber of reverse
clutch
2
Drive plate num-
ber of 2-4 brake
2
3
Drive plate num-
ber of low &
reverse brake
4
5
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
←
→
3rd
←
→
4th
SPORT mode
4-forward automatic gear change
1st
←
→
2nd
←
→
3rd
←
→
4th
Manual mode (+)
4-forward manual gear change
(shift up)
1st
→ 2nd → 3rd → 4th
Manual mode (
−)
4-forward manual gear change
(shift down)
1st
← 2nd ← 3rd ← 4th
Control method
Wire cable type
4AT-3
AUTOMATIC TRANSMISSION
General Description
7. HYDRAULIC CONTROL AND LUBRICA-
TION
8. COOLING AND HARNESS
9. TRANSFER
10.FINAL REDUCTION
11.RECOMMENDED GEAR OIL
Type
Electronic hydraulic control
[Four forward speed
changes by electrical signals
of vehicle speed and accel-
erator (throttle) opening]
Fluid
SUBARU ATF or IDEMITSU
“Apolloil ATF HP”, Castrol
“Transmax J”
NOTE:
If the ATF above are not
available, use Dexron III.
Fluid
capacity
2 (US
qt, Imp
qt)
2.0 L
8.4 — 8.7
(8.9 — 9.2, 7.4 — 7.7)
2.5 L
9.3 — 9.6
(9.8 — 10.1, 8.2 — 8.4)
Lubrication system
Forced feed lubrication with
oil pump
Oil
Automatic transmission fluid
(above mentioned)
Cooling system
Liquid-cooled cooler
Inhibitor switch
12 poles
Transmission harness
20 poles
Model
2.0 L
2.5 L
except for
VTD model
2.5 L VTD
model
Transfer type
Multi-plate transfer
(MP-T)
Variable
torque dis-
tribution
(VTD)
Drive & driven
plate number of
transfer clutch
4
5
3
Control method
Electronic hydraulic type
Lubricant
The same Automatic transmission fluid
used in automatic transmission
Reduction gear
ratio
1.000 (53/53)
Model
Except for OUTBACK
OUTBACK
Front final reduction gear ratio
4.111 (37/9)
4.444 (40/9)
Lubrication oil
(1) Item
(3) API standard
(2) Front differential gear oil
(4) SAE viscosity No. and applica-
ble temperature
Front differential oil
capacity
2 (US qt,
Imp qt)
1.1 — 1.3 (1.2 — 1.4, 1.0 — 1.1)
MT-00001
(1)
(4)
GL-5
(3)
(2)
( C)
( F)
-30 -26 -15
15
90
85W
80W
75W -90
25
30
-5 0
-22 -15
23 32
86
59
77
5
4AT-4
AUTOMATIC TRANSMISSION
General Description
B: COMPONENT
1. TORQUE CONVERTER CLUTCH AND CASE
(1)
Pitching stopper bracket
(11)
Torque converter clutch ASSY
Tightening torque: N
⋅
m (kgf-m, ft-lb)
(2)
O-ring
(12)
Drain plug
T1: 18 (1.8, 13.3)
(3)
Differential oil level gauge
(13)
Gasket
T2: 23 (2.3, 17)
(4)
Stay
(14)
Oil seal
T3: 33 (3.4, 24.3)
(5)
Seal pipe
(15)
Converter case
T4: 41 (4.2, 30.4)
(6)
Oil pump shaft
(16)
Harness stay
T5: 44 (4.5, 32.5) (Aluminum gasket)
70 (7.1, 51.6) (Copper gasket)
(7)
Clip
(17)
ATF cooler ASSY with warmer
function (if equipped)
(8)
Oil drain pipe
(9)
Input shaft
(18)
Bracket (if equipped)
(10)
O-ring
(19)
Clip (if equipped)
AT-02159
T4
T4
T4
T4
T5
T1
(8)
(11)
(1)
(2)
(16)
(18)
(17)
(19)
(3)
(4)
(7)
(5)
(6)
(10)
(9)
(14)
(15)
(12)
(13)
T3
T2
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