Legacy Transmission PDF

2004 LEGACY SERVICE MANUAL QUICK REFERENCE INDEX
TRANSMISSION SECTION
CONTROL SYSTEMS CS
AUTOMATIC TRANSMISSION 4AT
AUTOMATIC TRANSMISSION 4AT(diag)

(DIAGNOSTICS)

This service manual has been prepared
to provide SUBARU service personnel AUTOMATIC TRANSMISSION 5AT(diag)
with the necessary information and data (DIAGNOSTICS)
for the correct maintenance and repair
of SUBARU vehicles. MANUAL TRANSMISSION AND 5MT
This manual includes the procedures DIFFERENTIAL
for maintenance, disassembling, reas-
sembling, inspection and adjustment of CLUTCH SYSTEM CL
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.
FUJI HEAVY INDUSTRIES LTD. G2320GE5

CONTROL SYSTEMS
CS
Page
1. General Description ....................................................................................2
2. Select Lever ................................................................................................7
3. Select Cable..............................................................................................12
4. AT Steering Shift Switch ...........................................................................16
5. Shift Lock Solenoid ...................................................................................18
6. MT Gear Shift Lever..................................................................................21
7. MT Drive Select Lever...............................................................................28
8. Drive Select Cable ....................................................................................30
9. General Diagnostic Table..........................................................................32
General Description
CONTROL SYSTEMS
1. General Description
A: SPECIFICATION
Item Specification
Swing torque of rod against lever N (kgf, lb) 3.7 (0.38, 0.84) or less
B: COMPONENT
1. AT SELECT LEVER
(1)
(11) (2)
(12)
(9) (13)
(10)
(14)
(3)
(8)
(24)
(10)
(23)
(22)
P
(4)
R
N
(21)
D
T4
(5)
T2
(16) (20)
(28)
(7)
(15) (29)
(25)
T4
(31)
(30)
T1
(17) (32)
(6)
(34)
(19) (18)
T1
(26)
(27) T3
(33)
CS-00370
CS-2
General Description
CONTROL SYSTEMS
(1) Ring indicator (15) Shift lock solenoid UNIT (29) Connector pin
(2) Front cover (16) Plate (30) Snap pin
(3) Grip (17) Grommet (31) Washer
(4) Indicator cover ASSY (18) Plate nut (32) Select cable
(5) Blind (19) Detent spring (33) Nut A
(6) Guide plate (20) Detent plate (34) Clamp
(7) Pin (21) Bushing
(8) Clamp (22) Packing Tightening torque: N!m (kgf-m, ft-lb)
(9) Lever ASSY (23) Rod T1: 2.2 (0.22, 1.62)
(10) Bushing (24) Spring T2: 6 (0.61, 4.4)
(11) Rod (25) Bracket T3: 7.5 (0.76, 5.5)
(12) Spring (26) Packing T4: 18 (1.8, 13.3)
(13) Arm (27) Spacer
(14) Spring pin (28) Arm ASSY
CS-3
General Description
CONTROL SYSTEMS
2. 5MT GEAR SHIFT LEVER
(1)
(2)
(3)
T1
(16)
(26)
(4) (3)
(17) (7) T2
(19) (7)
(24) T1
(19) (26)
(18) (26) T2
(6)
(7)
(7)
(7) (19)
(7)
(8)
(5)
(9)
(12)
(10)
(11)
(13)
(14)
(20)
(15)
(25)
(21)
T2
T2 (23)
(22)
(26) T2
CS-00267
(1) Gear shift knob (11) O-ring (21) Washer

(2) Front cover ASSY (12) Spring pin (22) Stay
(3) Clamp (13) Bushing B (23) Cushion rubber
(4) Boot and insulator ASSY (14) O-ring (24) Boss
(5) Plate ASSY (15) Boot (25) Bushing
(6) Lever (16) Spring pin (26) Self-locking nut
(7) Bushing (17) Joint
(8) Lock wire (18) Rod Tightening torque: N!m (kgf-m, ft-lb)
(9) Snap ring (19) Spacer T1: 12 (1.2, 8.9)
(10) Bushing (20) Bracket T2: 18 (1.8, 13.3)
CS-4
General Description
CONTROL SYSTEMS
3. DRIVE SELECT LEVER
(8) (1)
T2
(7) T1
T1
(2)
(4)
(5) (4)
(3)
(10)
(9)
(6)
T3
T2
(11)
(12)
T2
CS-00371
(1) Cover (7) Plate ASSY Tightening torque: N!m (kgf-m, ft-lb)
(2) Knob (8) Bushing T1: 4.5 (0.46, 3.3)
(3) Lever ASSY (9) Clevis pin T2: 12 (1.2, 8.9)
(4) Bushing (10) Snap pin T3: 27.5 (2.80, 20.3)
(5) Spacer (11) Cable
(6) Spring (12) Clip
CS-5
General Description
CONTROL SYSTEMS
C: CAUTION
• Wear work clothing, including a cap, protective
goggles, 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.
• Before removal, installation or disassembly, be
sure to clarify the failure. Avoid unnecessary re-
moval, installation, disassembly and replacement.
• Use SUBARU genuine fluid, grease etc. or
equivalent. Do not mix fluid, grease etc. with that of
another grade or from other manufacturers.
• Be sure to tighten fasteners including bolts and
nuts to the specified torque.
• Place shop jacks or rigid racks at the specified
points.
• Apply grease onto sliding or revolution surfaces
before installation.
• Before installing O-rings or snap rings, apply suf-
ficient amount of fluid to avoid damage and defor-
mation.
• Before securing a part in a vice, place cushioning
material such as wood blocks, aluminum plate, or
cloth between the part and vice.
• Before disconnecting electrical connectors, be
sure to disconnect the negative terminal from bat-
tery.
CS-6
Select Lever
CONTROL SYSTEMS
2. Select Lever 8) Raise the pawl of clamp to remove cable.
A: REMOVAL
1) Set the vehicle on a lift.
2) Disconnect the ground cable from battery.
3) Shift the select lever to “N” range.
4) Lift-up the vehicle.
5) Remove the rear exhaust pipe and muffler.
• SOHC model
<Ref. to EX(H4SO 2.0)-11, REMOVAL, Rear Ex- (A)
haust Pipe.> <Ref. to EX(H4SO 2.0)-13, REMOV-

AL, Muffler.> CS-00279
• DOHC non-turbo model

(A) Claw
<Ref. to EX(H6DO)-8, REMOVAL, Rear Exhaust
Pipe.> <Ref. to EX(H6DO)-10, REMOVAL, Muf- 9) Lower the vehicle.
fler.> 10) Remove the console box. <Ref. to EI-53, RE-
• DOHC turbo model MOVAL, Console Box.>
<Ref. to EX(H4DOTC)-11, REMOVAL, Rear Ex- 11) Remove the harness clips from bracket.
haust Pipe.> <Ref. to EX(H4DOTC)-12, REMOV-
AL, Muffler.>
6) Remove the heat shield cover.
CS-00372
12) Disconnect the connectors, and then remove

the four bolts to take out the select lever assembly
AT-01331
from vehicle body.
7) Remove the cable from arm assembly.
C
B
(B)
D A
CS-00373
(A)
CS-00278
B: INSTALLATION
(A) Adjusting nut 1) Set the select lever to vehicle body.
(B) Arm ASSY 2) Tighten the four bolts to install the select lever to
vehicle body, and then connect the connector.
(1) Temporarily tighten the bolt A.
(2) Tighten the bolt B.
(3) Tighten the bolt A.
(4) Tighten the bolts C and D.
CS-7
Select Lever
CONTROL SYSTEMS
Tightening torque: NOTE:

18 N!m (1.8 kgf-m, 13.3 ft-lb) Inhibitor switch for 5AT model is not adjustable.
<Ref. to CS-15, ADJUSTMENT, Select Cable.>
<Ref. to 4AT-52, ADJUSTMENT, Inhibitor Switch.>
C
(1) Engine starts when the select lever is in “P”
B and “N” range, but not in other range.
(2) Back-up light illuminates when the select le-
ver is in “R” range, but not in other range.
(3) Select lever and indicator positions are
D A
matched.
C: DISASSEMBLY
CS-00373 1) Remove the packing and plate.
3) Install the harness clips to bracket.
CS-00281
CS-00372 2) Remove the grip.

4) Install the console box. <Ref. to EI-53, INSTAL-
LATION, Console Box.>
7) Shift the range select lever to “N” range.
8) Fix the cable to bracket. <Ref. to CS-13, IN-
STALLATION, Select Cable.>
9) Adjust the select cable position. <Ref. to CS-15,
ADJUSTMENT, Select Cable.>
10) After the completion of adjustment, confirm that CS-00374
the select lever operates properly at all range posi-
tions. 3) Insert a flat-tip screwdriver with thin tip under the
11) Install the heat shield cover. connector to disconnect each connector from plate
12) Install the rear exhaust pipe and muffler. assembly.
• SOHC model
<Ref. to EX(H4SO 2.0)-11, INSTALLATION, Rear
Exhaust Pipe.> <Ref. to EX(H4SO 2.0)-13, IN-
STALLATION, Muffler.>
<Ref. to EX(H6DO)-8, INSTALLATION, Rear Ex-
haust Pipe.> <Ref. to EX(H6DO)-10, INSTALLA-
TION, Muffler.>
• DOHC turbo model
<Ref. to EX(H4DOTC)-11, INSTALLATION, Rear CS-00375
Exhaust Pipe.> <Ref. to EX(H4DOTC)-12, IN-
13) Inspect the following items. When malfunctions
are found in the inspection, adjust the select cable
and inhibitor switch.
CS-8
Select Lever
CONTROL SYSTEMS
4) Remove the indicator cover. 8) Remove the bracket.
CS-00376 CS-00288
5) Remove the blind. 9) Remove the detent spring.
CS-00285 CS-00379
6) Remove the bolts, and then remove the guide 10) Remove the detent plate.
plate.
CS-00380
CS-00377
11) Remove the shift lock solenoid assembly.
7) Remove the clamp, spring, rod, packing and
bushing.
(E)
(D)
(C)
(B)
(A) CS-00381
CS-00378
(A) Clamp
(B) Spring
(C) Rod
(D) Bushing
(E) Plate
CS-9
Select Lever
CONTROL SYSTEMS
12) Raise the connector pawl. 16) Pull out the arm assembly, and then remove
the select lever assembly to remove the arm brack-
et and bushing.
(D)
(D)
(C)
(B)
(A)
CS-00292
13) Use a flat-tip screwdriver with thin tip to discon-

CS-00298
nect the connectors from terminals of SPORT
mode switch, shift lock solenoid assembly.
(A) Arm ASSY
(B) Select lever ASSY
(C) Arm bracket
(A) (D) Bushing
4 3 2 1
17) Remove the rod and spring from arm bracket.
10 9 8 7 6 5
(A)
(B)
(C)
CS-00382
(B)
(A) Shift lock solenoid terminal
(B) SPORT mode switch terminal
14) Remove the grommet.

CS-00383
(A) Rod
(B) Spring
(C) Arm bracket
D: ASSEMBLY
1) Clean all the parts before assembly.
2) Apply grease [SUNLIGHT 2 (Part No.
003602010) or equivalent] to each parts. <Ref. to
CS-00296 CS-2, AT SELECT LEVER, COMPONENT, Gener-
al Description.>
15) Remove the spring pin.
3) Assemble in the reverse order of disassembly.
NOTE:
• When installing the guide plate, shift the select
lever to “D” range (normal mode position), care
should be taken in the following points.
• Insert the protrusion (B) of guide plate into the
hole of shift lock solenoid assembly (A).
CS-00297
CS-10
Select Lever
CONTROL SYSTEMS
• Insert the link (D) of shift lock release into the

link (C) of shift lock solenoid assembly.
a (B)
(A)
b (D)
(C)
CS-00384
• Connect the switch and solenoid terminal to con-

nector.
(B) (A)
1 2 3 4
5 6 7 8 9 10
(C) (D)
CS-00385
(A) Shift lock solenoid (Color code: Blue and Red)

(B) Shift lock solenoid (Color code: Black)
(C) SPORT mode switch (Color code: White)
(D) SPORT mode switch (Color code: Black)
4) After completion of installation, shift the select

lever from “P” range to “D” range, then check
whether the indicator and select lever matches,
whether the pointer and position mark matches and
what the operating force is.
E: INSPECTION
1) Inspect the removed parts by comparing with
new ones for deformation, damage and wear. Re-
pair or replace if defective.
2) Confirm the select lever operating condition be-
fore assembly. Normal if it operates smoothly.
CS-11
Select Cable
CONTROL SYSTEMS
3. Select Cable • 4AT
A: REMOVAL
(A)
1) Set the vehicle on a lift. (D)
4) Lift-up the vehicle. (B)
5) Remove the front, center and rear exhaust pipes
and muffler. (SOHC and DOHC non-turbo model) (C) (E)
• SOHC model
<Ref. to EX(H4SO 2.0)-7, REMOVAL, Front Ex-
CS-00036
AL, Center Exhaust Pipe.> <Ref. to EX(H4SO 2.0)-
(A) Range select lever
11, REMOVAL, Rear Exhaust Pipe.> <Ref. to
(B) Snap pin
EX(H4SO 2.0)-13, REMOVAL, Muffler.>
• DOHC non-turbo model (C) Select cable
<Ref. to EX(H6DO)-5, REMOVAL, Front Exhaust (D) Bracket
Pipe.> <Ref. to EX(H6DO)-8, REMOVAL, Rear Ex- (E) Washer
haust Pipe.> <Ref. to EX(H6DO)-10, REMOVAL,
• 5AT
Muffler.>
6) Remove the center and rear exhaust pipe and (B) (E)
muffler. (DOHC turbo model)
<Ref. to EX(H4DOTC)-6, REMOVAL, Center Ex-
haust Pipe.> <Ref. to EX(H4DOTC)-11, REMOV- (D)
AL, Rear Exhaust Pipe.> <Ref. to EX(H4DOTC)- (A)
12, REMOVAL, Muffler.>
(C)
CS-00327

(B) Snap pin
(C) Select cable
(D) Bracket
(E) Washer
AT-01331 9) Remove the plate assembly from transmission
8) Remove the snap pin and washer from range se- case.
lect lever. • 4AT
(A)
(C)
(B)
CS-00037
(A) Select cable

(B) Plate ASSY
(C) Bracket
CS-12
Select Cable
CONTROL SYSTEMS
• 5AT • 4AT
(A)
(A)
(B) (B)
CS-00328 CS-00039
(A) Select cable (A) Select cable

(B) Plate ASSY (B) Plate ASSY
10) Disconnect the cable from arm assembly. • 5AT
(A)
(B)
(A) (B)
CS-00278 CS-00328
(A) Adjusting nut (A) Select cable

(B) Arm ASSY (B) Plate ASSY
11) Raise the pawl of clamp to remove the cable 4) Install the washer and snap pin to range select
from bracket. lever.
• 4AT
(A)
(D)
(B)
(A)
(C) (E)
CS-00279
CS-00036
(A) Pawl
12) Remove the select cable from plate assembly. (B) Snap pin
B: INSTALLATION (C) Select cable
1) Install the select cable to plate assembly. (D) Bracket
(E) Washer
Tightening torque:
18 N!m (1.8 kgf-m, 13.3 ft-lb)
2) Install the select cable to range select lever.
3) Install the plate assembly to transmission.
Tightening torque:
T: 24.5 N!m (2.5 kgf-m, 18.1 ft-lb)
CS-13
Select Cable
CONTROL SYSTEMS
• 5AT 8) Install the heat shield cover.
(B) (E)
(D)
(A)
(C)
CS-00327 AT-01331
9) Install the front, center and rear exhaust pipes

and muffler. (SOHC and DOHC non-turbo model)
(B) Snap pin
• SOHC model
(C) Select lever
<Ref. to EX(H4SO 2.0)-8, INSTALLATION, Front
(D) Bracket Exhaust Pipe.> <Ref. to EX(H4SO 2.0)-10, IN-
(E) Washer STALLATION, Center Exhaust Pipe.> <Ref. to
EX(H4SO 2.0)-11, INSTALLATION, Rear Exhaust
5) Install a new clump paying attention to the in-
Pipe.> <Ref. to EX(H4SO 2.0)-13, INSTALLA-
stalling direction.
TION, Muffler.>
<Ref. to EX(H6DO)-6, INSTALLATION, Front Ex-
TION, Rear Exhaust Pipe.> <Ref. to EX(H6DO)-10,
C
INSTALLATION, Muffler.>
10) Install the center and rear exhaust pipe and
(A)
C
muffler. (DOHC turbo model)
<Ref. to EX(H4DOTC)-7, INSTALLATION, Center
(B)
CS-00329 STALLATION, Rear Exhaust Pipe.> <Ref. to
EX(H4DOTC)-12, INSTALLATION, Muffler.>
(A) Clamp
C: INSPECTION
(B) Forward
Check the removed cable and replace or adjust if
6) Insert the tip of inner cable into connector hole of damaged, rusty or malfunctioning.
the select lever, and fix the cable to bracket. 1) Check for smooth operation of the cable.
2) Check the inner cable for damage and rust.
3) Check the outer cable for damage, bends and
cracks.
4) Check the boot for damage, cracks and deterio-
ration.
5) Move the select lever from “P” to “D” range.
Check the existence of feel to contact the detents in
each range. If the detents cannot be felt or the po-
sition pointer is improperly aligned, adjust the ca-
ble.
CS-00330 6) Check if the starter motor rotates when the se-
7) Shift the select lever to “N” range, and then ad- lect lever is set to “P” range.
just the select cable position. <Ref. to CS-15, AD- 7) Check the back-up light illumination when the
JUSTMENT, Select Cable.> select lever is in “R” range.
8) Check the parking lock operation when the se-
lect lever is in “P” range.
CS-14
Select Cable
CONTROL SYSTEMS
D: ADJUSTMENT 5) Turn the adjusting nut B until it lightly touches

1) Shift the select lever to “N” range. the connector.
(B)
• SOHC model
<Ref. to EX(H4SO 2.0)-11, REMOVAL, Rear Ex-
haust Pipe.> <Ref. to EX(H4SO 2.0)-13, REMOV- (A) (C)
AL, Muffler.>
Pipe.> <Ref. to EX(H6DO)-10, REMOVAL, Muf-
fler.> (D) (F)
• DOHC turbo model (E) CS-00041
<Ref. to EX(H4DOTC)-11, REMOVAL, Rear Ex-
haust Pipe.> <Ref. to EX(H4DOTC)-12, REMOV- (A) Forward side
AL, Muffler.> (B) Select lever
3) Remove the heat shield cover. (C) Connector
(D) Adjusting nut B
(E) Contact point
(F) Adjusting nut A
6) Set a spanner wrench to adjusting nut B so that

it does not rotate, and then tighten the adjusting nut
A.
Tightening torque:
7.5 N!m (0.76 kgf-m, 5.5 ft-lb)
AT-01331
4) Loosen the adjusting nuts on both sides.
(A)
(B)
CS-00042
(B) (A)
(A) Adjusting nut A
CS-00040
(B) Adjusting nut B
(A) Adjusting nut A
7) After the completion of adjustment, confirm that
(B) Adjusting nut B
the select lever operates normally at all ranges.
8) Install in the reverse order of removal.
CS-15
AT Steering Shift Switch
CONTROL SYSTEMS
4. AT Steering Shift Switch

A: REMOVAL
2) Set the tire to the straight-ahead position.
3) Remove the airbag module. <Ref. to AB-14, RE-
MOVAL, Driver’s Airbag Module.>
WARNING:
With the airbag module equipped, always refer
to “Airbag System” when performing the airbag
module repair service. <Ref. to AB-14, INSPEC-
TION, Driver’s Airbag Module.>
4) Remove the steering wheel. <Ref. to PS-20, RE-
MOVAL, Steering Wheel.>
5) Remove the cover from steering wheel.
6) Remove each one of AT steering shift switch
mounting screw from the LH and RH side.
CS-00331
7) Remove the steering shift switch.

B: INSTALLATION
1) Clean all parts before installation.
3) After completion of installation, set the select le-
ver to SPORT shift side and confirm that manual
mode “1” illuminates on the combination meter.
4) Operate the steering shift switch and confirm
that the “2” illuminates on combination meter.
CS-16
AT Steering Shift Switch
CONTROL SYSTEMS
C: INSPECTION
1 2 3 4 5
CS-00387
Step Check Yes No

1 SHIFT-UP SWITCH CONTINUITY CHECK. Is the resistance less than 10 Go to step 2. Replace the steer-
1) Press the shift-up switch. "? ing shift switch.
2) Measure the resistance between shift
switch connector terminals.
Terminals
No. 4 — No. 3:
2 SHIFT-DOWN SWITCH CONTINUITY Is the resistance less than 10 Go to step 3. Replace the steer-
CHECK. "? ing shift switch.
1) Press the shift-down switch.
Terminals
No. 3 — No. 2:
3 CHECK SHIFT SWITCH INSULATION. Is the resistance 1 M"? Steering shift Replace the steer-
1) Not to operate the shift switch. switch is normal. ing shift switch.
Terminals
No. 3 — No. 2:
No. 3 — No. 4:
CS-17
Shift Lock Solenoid
CONTROL SYSTEMS
5. Shift Lock Solenoid 9) Press the select lever backward while lifting up
the detent spring and remove the shift lock solenoid
A: REMOVAL assembly.
1) Remove the console box. <Ref. to EI-53, RE-
(A)
MOVAL, Console Box.>
(B)
2) Disconnect the connector.
4) Remove the grip.
5) Remove the indicator cover.
CS-00391
(A) Detent spring

(B) Shift lock solenoid ASSY
10) Raise the connector pawl.

CS-00388
6) Remove the blind.

7) Remove the bolts, and then remove the guide
plate.
CS-00292
11) Use a flat-tip screwdriver with thin tip to discon-

nect the connectors from terminals of “P” range
switch and shift lock solenoid assembly.
CS-00377
8) Remove the connector from the plate assembly

using a flat-tip screwdriver. (A)
4 3 2 1
10 9 8 7 6 5
CS-00392
(A) Shift lock solenoid terminal
CS-00390 B: INSTALLATION
Install in the reverse order of removal.
NOTE:
• Refer to COMPONENT for each tightening
torque. <Ref. to CS-2, COMPONENT, General De-
scription.>
• When installing the guide plate, shift the select
lever to “D” range (normal mode position), care
should be taken in the following points.
CS-18
Shift Lock Solenoid
CONTROL SYSTEMS
• Insert the protrusion (B) of guide plate into the

hole of shift lock solenoid assembly (A).
• Insert the link (D) of shift lock release into the
link (C) of shift lock solenoid assembly.
a (B)
(A)
b (D)
(C)
CS-00384
• Connect the switch and solenoid terminal to con-

nector.
(B) (A)
1 2 3 4
5 6 7 8 9 10
CS-00393
(A) Shift lock solenoid (Color code: Blue and Red)

(B) Shift lock solenoid (Color code: Black)
CS-19
Shift Lock Solenoid
CONTROL SYSTEMS
C: INSPECTION
Step Check Yes No
1 CHECK SHIFT LOCK SOLENOID. Is the resistance 7 — 18 "? Go to step 2. Replace the shift
Measure the resistance of shift lock solenoid lock solenoid.
connector terminals.
Terminals
No. 4 — No. 3:
2 CHECK SHIFT LOCK SOLENOID. Does the shift lock solenoid Normal operation Replace the shift
Connect the battery to shift lock solenoid con- operate normally? lock solenoid.
nector terminal, and then operate the solenoid.
Terminals
No. 3 (+) — No. 4 (#):
CS-20
MT Gear Shift Lever
CONTROL SYSTEMS
6. MT Gear Shift Lever 9) Lift-up the vehicle.

A: REMOVAL • SOHC model
1) Set the vehicle on a lift. <Ref. to EX(H4SO 2.0)-11, REMOVAL, Rear Ex-
2) Disconnect the ground cable from battery. haust Pipe.> <Ref. to EX(H4SO 2.0)-13, REMOV-
3) Remove the gear shift knob. AL, Muffler.>
4) Remove the console box. <Ref. to EI-53, RE- • DOHC non-turbo model
MOVAL, Console Box.> <Ref. to EX(H6DO)-8, REMOVAL, Rear Exhaust
5) Remove the clamp. Pipe.> <Ref. to EX(H6DO)-10, REMOVAL, Muf-
fler.>
<Ref. to EX(H4DOTC)-11, REMOVAL, Rear Ex-
haust Pipe.> <Ref. to EX(H4DOTC)-10, REMOV-
AL, Joint Pipe.>
CS-00311
6) Remove the boot and insulator assembly.
AT-01331
12) Remove the stay from transmission bracket.
CS-00312
(A)
7) Remove the harness clamp from plate.
(B)
CS-00050
(A) Stay
(B) Transmission bracket
13) Remove the rod from joint.

CS-00313
8) Remove the plate assembly from vehicle body.

(A)
(C) (B) (B)
(D) (A) CS-00051
(A) Stay
CS-00314 (B) Rod
CS-21
MT Gear Shift Lever
CONTROL SYSTEMS
14) Remove the cushion rubber from vehicle body. NOTE:

Insert the rod and the stay, and then temporarily set
them onto transmission mount.
(A)
(B)
CS-00052
(A) Stay CS-00315

(B) Cushion rubber
15) Extract the spring pin and remove the joint. 4) Mount the cushion rubber on the vehicle body.
Tightening torque:
(A) 18 N!m (1.8 kgf-m, 13.3 ft-lb)
(A)
(B)
CS-00053 (B)
(A) Joint
(B) Spring pin CS-00052
16) Lower the vehicle. (A) Stay

17) Remove the gear shift lever. (B) Cushion rubber
5) Using new self-locking nuts, connect the rod to

the joint.
Tightening torque:
18 N!m (1.8 kgf-m, 13.3 ft-lb)
(A)
CS-00315 (B)
B: INSTALLATION
1) Install the joint to transmission and secure with
spring pin.
2) Insert the gear shift lever from the room side.
CS-00051
(A) Stay
(B) Rod
6) Using new self-locking nuts, connect the stay to

transmission bracket.
CS-22
MT Gear Shift Lever
CONTROL SYSTEMS
Tightening torque: (5) Tighten the bolts (C) and (D).

18 N!m (1.8 kgf-m, 13.3 ft-lb)
(C) (B)
(A)
(D) (A)
(B) CS-00314
CS-00050 10) Install the harness clamp to plate.
11) Install the boot and insulator assembly, and se-
(A) Stay cure them with clamp.
(B) Transmission bracket
7) Install the heat shield cover.
CS-00312
12) Install the console box. <Ref. to EI-53, INSTAL-

AT-01331 LATION, Console Box.>
8) Install the rear exhaust pipe and muffler. C: DISASSEMBLY
• SOHC model 1) Remove the lock wires.
<Ref. to EX(H6DO)-8, INSTALLATION, Rear Ex-
TION, Muffler.>
<Ref. to EX(H4DOTC)-11, INSTALLATION, Rear (A)
STALLATION, Muffler.> CS-00316
9) Install the plate assembly to vehicle body.
(A) Lock wire
Tightening torque:
18 N!m (1.8 kgf-m, 13.3 ft-lb)
(1) Set the plate assembly to vehicle.
(2) Temporarily tighten the bolt (A).
(3) Tighten the bolt (B).
(4) Tighten the bolt (A).
CS-23
MT Gear Shift Lever
CONTROL SYSTEMS
2) Remove the rod from lever. 6) Remove the boot, bushing and snap ring from
gear shift lever.
(B) (A) (B) (A) (C)

(A)
(C)
CS-00317
CS-00320
(A) Rod
(B) Lever (A) O-ring
(C) Stay (B) Bushing
(C) Snap ring
3) Separate the rod and inner boot.
4) Remove the snap ring from the stay. 7) Remove the spring pin, and then remove the
bushing and snap ring.
(A)
(B)
(A)
CS-00318
CS-00060
(A) Snap ring
(A) Spring pin
5) Separate the gear shift lever and the stay. (B) Bushing
8) Remove the boss from the joint.
CS-00319
CS-00322
CS-24
MT Gear Shift Lever
CONTROL SYSTEMS
9) Remove the bushing and spacer from boss. 2) Install the bushing and spacer to boss.
(A) (A)
(B) (B)
(A) CS-00238 (A) CS-00238
(A) Bushing (A) Bushing

(B) Spacer (B) Spacer
10) Remove the bushing and cushion rubber from 3) Using new self-locking nuts, install the boss to
the stay. the joint.
Tightening torque:
(A)
18 N!m (1.8 kgf-m, 13.3 ft-lb)
(B)
(C)
CS-00058
(A) Bushing B
(B) Stay CS-00322
(C) Cushion rubber 4) Install the snap ring to gear shift lever and install
the bushing.
D: ASSEMBLY NOTE:
NOTE: Apply grease to the bushing.
• Clean all the parts before assembly.
• Apply grease [SUNLIGHT 2 (Part No.
003602010) or equivalent] to each part.
1) Mount the bushing and cushion rubber on the
stay.
(A)
(B)
(A)
(B) CS-00060
(A) Spring pin

(B) Bushing
CS-00061
(A) Bushing
(B) Cushion rubber
CS-25
MT Gear Shift Lever
CONTROL SYSTEMS
5) Apply grease to the bushing and O-ring, and Tightening torque:

then install to the gear shift lever. 12 N!m (1.2 kgf-m, 8.9 ft-lb)
(A) (B) (A) (C)
(B)
(A)
CS-00320 (C)
CS-00317
(A) O-ring (A) Rod

(B) Bushing (B) Lever
(C) Snap ring (C) Stay
6) Apply sufficient grease into boss, and then install 10) Install a new lock wire.
the gear shift lever to the stay.
(A)
CS-00316
CS-00319
7) Install the washer and snap ring. (A) Lock wire
NOTE:
• Install the lock wire to the stay groove.
(A)
CS-00318
(A) Snap ring
8) Insert the gear shift lever and rod into boot hole.
9) Install the rod.
CS-26
MT Gear Shift Lever
CONTROL SYSTEMS
• Bend the extra wire to same direction of lock wire E: INSPECTION

winding. 1) Check the parts (bushing, cushion rubber, spac-
er, boot, stay and rod, etc.) for deformation, dam-
(A) (A) age and wear. If necessary, repair or replace faulty
parts. Compare the removed parts with new ones
B B
to judge if there are damages or not.
(B)
(B)
(C)
(A) (F)
(C)
(A) (C)
(A)
(C)
(D)
(B)
B-B
(B)
CS-00240
(A) Inner boot (E)

(B) Lock wire
(C) Stay CS-00323
(A) Bushing
(B) Cushion rubber
(C) Spacer
(D) Boot
(E) Stay
(F) Rod
2) Check the swing torque of rod linked with the

gear shift lever.
If the torque exceeds the specifications, replace the
bushing or retighten nuts.
Swing torque:
Less than 3.7 N (0.38 kgf, 0.84 lb)
(A)
(B)
CS-00116
(A) Pivot
(B) Swing torque
CS-27
MT Drive Select Lever
CONTROL SYSTEMS
7. MT Drive Select Lever B: INSTALLATION

1) Secure the drive select cable to the lever with
A: REMOVAL clip, and temporary tighten the flange nut.
1) Place the drive select lever in HI position.
2) Push the both sides of knob, and remove the
cover. (Rubber type)
(A)
(A)
(B)
(B) CS-00397
(A) Flange nut

CS-00395 (B) Clip
(A) Cover 2) Install the drive select lever to vehicle.

(B) Knob
Tightening torque:
3) Insert a screwdriver with thin tip into the both 18 N!m (1.8 kgf-m, 13.3 ft-lb)
sides of knob, and push to remove the cover.
(Leather type)
4) Remove the bolt, and then remove the knob.
6) Remove the drive select lever from vehicle body.
CS-00396
3) Adjust the drive select cable. <Ref. to CS-31,

ADJUSTMENT, Drive Select Cable.>
C: DISASSEMBLY
CS-00396 1) Remove the bolt and nut.
2) Remove the lever and spring.
7) Remove the flange nut and clip, and then re-
move the drive select cable.
(A)
(B)
(A)
(B)
CS-00398
CS-00397
(A) Lever
(B) Spring
(A) Flange nut
(B) Clip
CS-28
MT Drive Select Lever
CONTROL SYSTEMS
3) Remove the bushing and spacer from plate as-

sembly.
(B)
(A)
(A)
CS-00399
(A) Bushing
(B) Spacer
4) Remove the bushing from plate assembly.
CS-00400
D: ASSEMBLY
Tightening torque:
12 N!m (1.2 kgf-m, 8.9 ft-lb)
NOTE:
Refer to “COMPONENT” for greasing points. <Ref.
to CS-2, COMPONENT, General Description.>
2) Check the select lever for smooth operation.
E: INSPECTION
1) Check the select lever for smooth operation. If
not, check the transmission and drive select lever.
2) Transmission gear switches between HI and LO
positions normally. If not, adjust the drive select ca-
ble, and inspect the transmission.
3) Check that the drive select lever is not damaged.
Repair or replace if it is damaged.
CS-29
Drive Select Cable
CONTROL SYSTEMS
8. Drive Select Cable 8) Remove the clamp, and remove the drive select
cable from plate assembly.
A: REMOVAL
2) Place the drive select lever in HI position.
(A)
(B)
CS-00395
(A) Cover
(B) Knob
4) Insert a screwdriver with thin tip into the both

(Leather type) CS-00402
5) Remove the bolt, and then remove the knob. 9) Remove the boot and insulator assembly.
7) Loosen the flange nut.
CS-00312
10) Remove the air intake chamber and air intake

duct. <Ref. to IN(H4SO 2.0)-8, REMOVAL, Air In-
take Chamber.> <Ref. to IN(H4SO 2.0)-9, REMOV-
AL, Air Intake Duct.>
11) Remove the snap pin and clevis pin.
(B)
(A)
CS-00401
CS-00403
(A) Snap pin

(B) Clevis pin
CS-30
Drive Select Cable
CONTROL SYSTEMS
12) Loosen the nut, and remove the cable from ca- D: ADJUSTMENT
ble bracket. 1) Place the drive select lever in HI position.
(A)
(B)
CS-00404
13) Lift-up the vehicle, and then remove the cable

under vehicle. CS-00395
(A) Cover
(B) Knob
3) Insert a screwdriver with thin tip into the both

(Leather type)
4) Remove the bolt, and then remove the knob.
CS-00405 6) Loosen the flange nut.
B: INSTALLATION
NOTE:
• Adjust the drive select cable. <Ref. to CS-31,
ADJUSTMENT, Drive Select Cable.>
• Refer to “COMPONENT” for tightening torque.
<Ref. to CS-2, COMPONENT, General Descrip-
tion.>
• Correctly insert the cable end bolt to slit of lever
arm.
C: INSPECTION
1) Check the transmission is set in HI or LO posi-
tion according to the operation of drive select lever.
<Ref. to CS-31, ADJUSTMENT, Drive Select Ca-
ble.>
2) Check the cable for damage.
3) Check the cable for smooth operation. Replace
the cable if it does not operate smoothly.
CS-00401
7) Verify the transmission gear is set in HI position.

If not, pull the cable to set it in HI position.
8) Verify the select lever is set in HI position.
9) Tighten the flange nut with cable fixed.
Tightening torque:
18 N!m (1.8 kgf-m, 13.3 ft-lb)
CS-31
General Diagnostic Table
CONTROL SYSTEMS
9. General Diagnostic Table

A: INSPECTION
Symptom Possible cause Corrective action
Select lever Starter does not run. Adjust the select cable and inhibitor switch, or
inspect circuit.
Back-up light does not illuminate. Adjust the select cable and inhibitor switch, or
inspect circuit.
Shift lock control system does not operate nor- Inspect shift lock circuit.
mally.
Manual mode is not engaged. Adjust the mode switch and select lever, or inspect
circuit.
Up-shift is not engaged at manual mode. Check the shift-up switch and circuit.
Down-shift is not engaged at manual mode. Check the shift-down switch and circuit.
Drive select lever Does not shift to HI or LO. Adjust the drive select cable, or inspect transmis-
sion.
CS-32
CONTROL SYSTEMS CS

(DIAGNOSTICS)


approval.

AUTOMATIC TRANSMISSION
4AT
Page
2. Automatic Transmission Fluid ...................................................................31
3. Differential Gear Oil...................................................................................33
4. Road Test..................................................................................................34
5. Stall Test ...................................................................................................35
6. Time Lag Test ...........................................................................................37
7. Line Pressure Test ....................................................................................38
8. Transfer Clutch Pressure Test ..................................................................39
9. Automatic Transmission Assembly ...........................................................40
10. Transmission Mounting System ................................................................48
11. Extension Case Oil Seal ...........................................................................50
12. Differential Side Retainer Oil Seal.............................................................51
13. Inhibitor Switch..........................................................................................52
14. Front Vehicle Speed Sensor .....................................................................55
15. Rear Vehicle Speed Sensor......................................................................58
16. Torque Converter Turbine Speed Sensor .................................................59
17. Control Valve Body ...................................................................................60
18. Air Bleeding of Control Valve ....................................................................63
19. ATF Filter ..................................................................................................64
20. Transmission Control Module (TCM) ........................................................65
21. Lateral G Sensor .......................................................................................66
22. ATF Cooler Pipe and Hose .......................................................................67
23. ATF Cooler (with warmer function) ...........................................................72
24. Warmer Cock ............................................................................................76
25. Air Breather Hose......................................................................................78
26. Oil Charge Pipe.........................................................................................79
27. Torque Converter Clutch Assembly ..........................................................80
28. Extension Case .........................................................................................82
29. Transfer Clutch..........................................................................................86
30. Multi-plate Clutch ......................................................................................92
31. Rear Drive Shaft........................................................................................93
32. Reduction Driven Gear..............................................................................94
33. Reduction Drive Gear................................................................................96
34. Center Differential Carrier .........................................................................98
35. Parking Pawl ...........................................................................................100
36. Converter Case .......................................................................................101
37. Oil Pump Housing ...................................................................................103
38. Drive Pinion Shaft Assembly...................................................................108
39. Front Differential Assembly .....................................................................113
40. AT Main Case .........................................................................................119
41. Transmission Control Device ..................................................................140
General Description
1. General Description 5. PLANETARY GEAR AND PLATE

A: SPECIFICATION Model 2.0 L 2.5 L
Front sun gear
1. TORQUE CONVERTER CLUTCH number of teeth
33
Front pinion num-

Model 2.0 L 2.5 L 21
ber of teeth
Symmetric, 3 element, single stage,
Type Front internal gear
2 phase torque converter 75
number of teeth
Stall torque ratio 2.0 — 2.2 2.1 — 2.3
Rear sun gear
Nomi- 42
number of teeth
nal
mm (in) 236 (9.29) 249 (9.69) Rear pinion num-
diame- 17
ber of teeth
ter
Rear internal gear
Stall speed (at sea 2,300 — 2,700 2,500 — 2,900 75
number of teeth
level) rpm rpm
Drive plate num-
One-way clutch Sprague type one-way clutch 4
ber of high clutch
Drive plate num-
2. OIL PUMP 4 5
ber of low clutch
Type Pracoid constant-displacement pump Drive plate num-
ber of reverse 2
Driving method Driven by engine
clutch
Inner rotor 9
Number of teeth Drive plate num-
Outer rotor 10 2 3
ber of 2-4 brake
Drive plate num-
3. TRANSMISSION CONTROL ELEMENT ber of low & 4 5
reverse brake
4-forward, 1-reverse,
Type
double-row planetary gears 6. SELECTOR POSITION
Multi-plate clutch 3 sets
Multi-plate brake 2 sets Transmission in neutral, output mem-
One-way clutch P (Park) ber immovable, and engine start possi-
1 sets ble
(sprague type)
R (Reverse) Transmission in reverse for backing
4. TRANSMISSION GEAR RATIO Transmission in neutral and engine
N (Neutral)
start possible
1st 2.785 4-forward automatic gear change
D (Drive)
2nd 1.545 1st !" 2nd !" 3rd !" 4th
3rd 1.000
4-forward automatic gear change
4th 0.694 SPORT mode
1st !" 2nd !" 3rd !" 4th
Rev 2.272
4-forward manual gear change
Manual mode (+) (shift up)
1st " 2nd " 3rd " 4th
4-forward manual gear change
Manual mode (#) (shift down)
1st !2nd ! 3rd ! 4th
Control method Wire cable
4AT-2
General Description
7. HYDRAULIC CONTROL AND LUBRICA- 8. COOLING AND HARNESS

TION
Cooling System Liquid-cooled cooler
Electronic hydraulic control Inhibitor switch 12 poles
[Four forward speed Transmission harness 20 poles
Type changes by electrical signals
of vehicle speed and accel- 9. TRANSFER
erator (throttle) opening]
SUBARU ATF or Idemitsu 2.5 L with- 2.5 L with
“Apolloil ATF HP”, Castrol out vehicle vehicle
“Transmax J” Model 2.0 L dynamics dynamics
Fluid
NOTE: control control
If the ATFs above are not (VDC) (VDC)
available, use Dexron III.
Variable
2 (US qt, 8.4 — 8.7 Multi-plate transfer torque dis-
Fluid capacity Transfer type
Imp qt) (8.9 — 9.2, 7.4 — 7.7) (MPT) tribution
Forced feed lubrication with (VTD)
Lubrication system
oil pump Drive & driven
Automatic transmission fluid plate number of 4 5 3
Oil
(above mentioned) transfer clutch
Control method Electronic hydraulic type
The same Automatic transmission fluid
Lubricant
used in automatic transmission
Reduction gear
1.000 (53/53)
ratio
10.FINAL REDUCTION
Model Except for OUTBACK OUTBACK
Front final reduction gear ratio 4.111 (37/9) 4.444 (40/9)
11.RECOMMENDED GEAR OIL
(1)
(2)
(3)
GL-5
(4)
( C) -30 -26 -15 -5 0 15 25 30
( F) -22 -15 5 23 32 59 77 86
Lubrication oil 90
85W
80W
75W -90
MT-00001
(1) Item (3) API classification

(2) Front differential gear oil (4) SAE viscosity No. and applica-
ble temperature
Front differential oil capacity
1.1 — 1.3 (1.2 — 1.4, 1.0 — 1.1)
2 (US qt, Imp qt)
4AT-3
General Description
B: COMPONENT
1. TORQUE CONVERTER CLUTCH AND CASE
(2)
(1)
(4)
(19)
(3) T4
T3
(16)
T2
(18)
(17) T4
(5)
(15)
(6)
(7)
(14)
(8)
T4 T1
T4
(13)
T5
(12) (9)
(10)
(11)
AT-02159
(1) Pitching stopper bracket (10) O-ring (18) Bracket (if equipped)
(2) O-ring (11) Torque converter clutch ASSY (19) Clip (if equipped)
(3) Differential oil level gauge (12) Drain plug
(4) Stay (13) Gasket Tightening torque: N$m (kgf-m, ft-lb)
(5) Seal pipe (14) Oil seal T1: 18 (1.8, 13.0)
(6) Oil pump shaft (15) Converter case T2: 23 (2.3, 16.7)
(7) Clip (16) Harness stay T3: 33 (3.4, 24.3)
(8) Oil drain pipe (17) ATF cooler ASSY with warmer T4: 41 (4.2, 30.4)
(9) Input shaft function (if equipped) T5: 70 (7.1, 51.6)
4AT-4
General Description
2. OIL PUMP
AT-00003
(1) Oil pump rotor (11) Gasket (21) Lock nut

(2) Oil pump cover (12) O-ring
(3) Seal ring (13) Test plug Tightening torque: N$m (kgf-m, ft-lb)
(4) Thrust needle bearing (14) Stud bolt T1: 7 (0.7, 5.1)
(5) Drive pinion shaft (15) O-ring T2: 13 (1.3, 9.4)
(6) Roller bearing (16) O-ring T3: 18 (1.8, 13.0)
(7) Shim (17) Oil seal retainer T4: 25 (2.5, 18.1)
(8) Oil pump housing (18) Oil seal T5: 40 (4.1, 30)
(9) Nipple (19) O-ring T6: 42 (4.3, 31)
(10) Air breather hose (20) Drive pinion collar T7: 116 (11.8, 85)
4AT-5
General Description
3. TRANSMISSION CASE AND CONTROL DEVICE
(34)
(39)
T1
(1)
(33)
(32) (2)
T4 T9
(36)
T3 (3) (5)
(38) (6)
(35) (7)
(31)
T9 (37)
(4)
(41)
T9
T8 (29)
(8)
(40) (9)
(31) (27)
(28)
T10
(11)
(30)
(16) T9
(29)
(13) T9
(12)
(28) (14) T5
(28)
(10)
(26)
T9 T6
(21)
(25) (15)
(23) (19) T2
(20) (18)
(17) T9 (12) T9
(22)
(11)
(24)
T7
T3
AT-02160
4AT-6
General Description
(1) ATF level gauge (19) Oil pan (37) Transmission case
(2) Oil charge pipe (20) Magnet (38) Plate ASSY
(3) O-ring (21) Stud bolt (Short) (39) Washer
(4) Straight pin (22) Stud bolt (Long) (40) Inlet pipe (Model with ATF cooler
(5) Return spring (23) Parking rod with warmer function)
(6) Shaft (24) Manual plate (41) Outlet pipe (Model with ATF
(7) Parking pawl (25) Spring pin cooler with warmer function)
(8) Parking support (26) Detention spring
(9) Bushing (27) Ball Tightening torque: N$m (kgf-m, ft-lb)
(10) Gasket (28) Spring T1: 3.4 (0.35, 2.5)
(11) Inlet pipe (Model without ATF (29) Gasket T2: 5 (0.5, 3.6)
cooler with warmer function) (30) Outlet pipe (Model without ATF T3: 6 (0.6, 4)
(12) Union screw cooler with warmer function) T4: 12 (1.2, 8.7)
(13) O-ring (31) Union screw T5: 13 (1.3, 10)
(14) Test plug (32) Oil seal T6: 14 (1.4, 10)
(15) Oil filter (33) Select lever T7: 18 (1.8, 13)
(16) Oil filter stud bolt (34) Inhibitor switch ASSY T8: 21 (2.1, 15.5)
(17) Drain plug (35) Nipple T9: 25 (2.5, 18.1)
(18) Gasket (36) Air breather hose T10: 44 (4.5, 32.5)
4AT-7
General Description
4. CONTROL VALVE AND HARNESS ROUTING
(2)
(1)
(6) T1
(7)
(4) (8)
(5) (9)
(3) T1
T1
(10)
T2
AT-01322
(1) Stay (6) O-ring Tightening torque: N$m (kgf-m, ft-lb)

(2) Transmission harness (7) Front vehicle speed sensor T1: 7 (0.7, 5.1)
(3) O-ring (8) O-ring T2: 8 (0.8, 5.8)
(4) O-ring (9) Rear vehicle speed sensor
(5) Torque converter turbine speed (10) Control valve body
sensor
4AT-8
General Description
5. HIGH CLUTCH AND REVERSE CLUTCH
AT-00006
(1) High clutch drum (8) Spring retainer (15) Dish plate
(2) Lip seal (9) Cover (16) Driven plate (reverse clutch)
(3) D-ring (10) Snap ring (17) Drive plate (reverse clutch)
(4) Reverse clutch piston (11) Driven plate (high clutch) (18) Retaining plate (reverse clutch)
(5) D-ring (12) Drive plate (high clutch) (19) Snap ring
(6) D-ring (13) Retaining plate (high clutch) (20) Thrust needle bearing
(7) High clutch piston (14) Snap ring (21) High clutch hub
4AT-9
General Description
6. PLANETARY GEAR AND 2-4 BRAKE
(5)
(4)
(3)
(2)
(13)
(1) (12)
(11)
(10)
(9)
(8)
(7)
(6)
(19)
(18)
(16)
(17)
(16)
(17)
(16)
(15)
(14)
(24)
(26)
(25)
(23)
(22)
(21)
(20)
AT-00007
(1) Thrust needle bearing (10) Washer (19) Snap ring

(2) Front sun gear (11) Thrust needle bearing (20) Spring retainer
(3) Thrust needle bearing (12) Rear internal gear (21) 2-4 brake piston
(4) Snap ring (13) Washer (22) D-ring
(5) Front planetary carrier (14) Snap ring (23) D-ring
(6) Thrust needle bearing (15) Retaining plate (24) 2-4 brake piston retainer
(7) Rear sun gear (16) Drive plate (25) 2-4 brake seal
(8) Thrust needle bearing (17) Driven plate (26) Leaf spring
(9) Rear planetary carrier (18) Pressure rear plate
4AT-10
General Description
7. LOW CLUTCH AND LOW & REVERSE BRAKE
(10) (11)
(9)
(8)
(7)
(5) (6)
(4)
(3)
(4)
(3)
(2)
(1)
(16)
(15)
(14)
(13)
(12)
T (21)
(23)
(22)
(20)
(19)
(18)
(30)
(17)
(29)
(28)
(27)
(28)
(27)
(25) (26)
(24) AT-01278
(1) Snap ring (12) Low clutch dram (23) Return spring
(2) Retaining plate (13) Needle bearing (24) Snap ring
(3) Drive plate (14) Snap ring (25) Retaining plate
(4) Driven plate (15) One-way clutch (26) Leaf spring
(5) Dish plate (16) Snap ring (27) Drive plate
(6) Snap ring (17) Thrust needle bearing (28) Driven plate
(7) Cover (18) Seal ring (29) Dish plate
(8) Spring retainer (19) Needle bearing (30) Low & reverse brake piston
(9) D-ring (20) One-way clutch inner race
(10) Low clutch piston (21) Socket bolt Tightening torque: N$m (kgf-m, ft-lb)
(11) D-ring (22) Spring retainer T: 25 (2.5, 18.1)
4AT-11
General Description
8. REDUCTION GEAR
(4)
(3)
(2)
(8)
(1) (8) T
(11)
(9)
(10)
(8)
(7)
(6)
(5)
AT-02161
(1) Seal ring (6) Snap ring (11) Lock nut

(2) Ball bearing (7) Ball bearing
(3) Reduction drive gear (8) Snap ring Tightening torque: N$m (kgf-m, ft-lb)
(4) Reduction drive shaft (9) Reduction driven gear T: 100 (10.2, 73.8)
(5) Drive pinion shaft (10) Washer
4AT-12
General Description
9. REDUCTION GEAR WITH VTD
(7)
(11)
(6)
(3) (2)
(4)
(5) (10)
(4) (9)
(3)
(8)
(23)
(1)
(22)
(21)
(19)
(20)
(19)
(17) (18)
(16)
(15)
(14)
(13)
(12) (32)
(31)
(29) T
(30)
(27)
(27)
(28)
(27)
(26)
(25)
(24)
AT-02203
(1) Ball bearing (13) Rear drive shaft (25) Snap ring
(2) Reduction drive gear (14) Ball bearing (26) Ball bearing
(3) Washer (15) Multi-plate clutch (LSD) hub (27) Snap ring
(4) Needle bearing (16) Ball bearing (28) Reduction driven gear
(5) Pinion gear (17) Revolution gear (29) Lock washer
(6) Carrier (18) Driven plate (Thicker) (30) Lock nut
(7) Planetary pinion shaft (19) Drive plate (31) Gasket
(8) Snap ring (20) Driven plate (Thinner) (32) Extension case
(9) Seal ring (21) Driven plate (Thicker)
(10) Thrust needle bearing (22) Pressure plate Tightening torque: N$m (kgf-m, ft-lb)
(11) Intermediate shaft (23) Rear drive shaft shim T: 100 (10.2, 73.8)
(12) Thrust washer (24) Drive pinion shaft
4AT-13
General Description
10.DIFFERENTIAL GEAR
(12)
(1) (13)
(2)
(11)
(3)
(4) (11) (12)
(13)
(5)
T2
(10)
T1
T1
(10) (6)
(9)
(7)
(8)
(7) (8)
(6) (9)
AT-00011
(1) Hypoid driven gear (7) Oil seal (13) Differential bevel gear
(2) Pinion shaft (8) O-ring
(3) Differential case (RH) (9) Differential side retainer Tightening torque: N$m (kgf-m, ft-lb)
(4) Straight pin (10) Lock plate T1: 25 (2.5, 18.1)
(5) Differential case (LH) (11) Washer T2: 62 (6.3, 45.6)
(6) Taper roller bearing (12) Differential bevel pinion
4AT-14
General Description
11.TRANSFER AND EXTENSION CASE
(7)
(6)
(5)
(6)
(5)
(14)
(4)
(3)
(1) (2)
(13)
(12)
(20)
T2 (19)
(11) (18)
(10)
(9)
(8)
(21) T1
(15) (22)
T2
(17)
(16)
AT-01784
(1) Thrust needle bearing (10) Return spring (19) Oil seal
(2) Needle bearing (11) Transfer clutch piston (20) Dust cover
(3) Snap ring (12) Rear drive shaft (21) Test plug
(4) Pressure plate (13) Ball bearing (22) O-ring
(5) Drive plate (14) Seal ring
(6) Driven plate (15) Gasket Tightening torque: N$m (kgf-m, ft-lb)
(7) Retaining plate (16) Transfer clutch pipe T1: 13 (1.3, 9.4)
(8) Snap ring (17) Extension case T2: 25 (2.5, 18.1)
(9) Transfer piston seal (18) Transmission hanger
4AT-15
General Description
12.TRANSFER AND EXTENSION CASE WITH VTD
(5)
(4)
(2)
(3)
(2)
(1)
T1
(20)
(19)
T3
(12)
(17) (18)
(9) (16) T2
(15)
(14)
(11)
(10) (13)
(8)
(7)
(6)
AT-00013
(1) Driven plate (Thicker) (10) Multi-plate clutch (LSD) piston (18) Dust cover
(2) Drive plate ASSY (19) O-ring
(3) Driven plate (Thinner) (11) D-ring (20) Rear vehicle speed sensor
(4) Driven plate (Thicker) (12) Gasket
(5) Adjusting plate (13) Multi-plate clutch (LSD) pipe Tightening torque: N$m (kgf-m, ft-lb)
(6) Snap ring (14) Extension case T1: 7 (0.7, 5.1)
(7) Spring retainer (15) O-ring T2: 13 (1.3, 9.4)
(8) Plate (16) Test plug T3: 25 (2.5, 18.1)
(9) O-ring (17) Oil seal
4AT-16
General Description
13.ATF COOLER WITH ATF WARMER FUNCTION
(2) (3)
(3)
(6)
(1)
(3)
(3)
(3)
(3)
(8)
T
(4) (7)
(3)
(5)
(3)
AT-02162
(1) ATF cooler outlet hose (5) Engine coolant inlet pipe Tightening torque: N$m (kgf-m, ft-lb)
(2) ATF cooler inlet hose (6) Engine coolant outlet pipe T: 23 (2.3, 16.6)
(3) Hose clamp (7) ATF cooler bracket
(4) ATF cooler ASSY (8) Clip
4AT-17
General Description
14.TRANSMISSION MOUNTING
T2 (2)
T2
T4
(1) (3)
T3
T5
(4)
T1
T5
AT-00014
(1) Pitching stopper (3) Crossmember Tightening torque: N$m (kgf-m, ft-lb)
(2) Rear cushion rubber (4) Stopper T1: 35 (3.6, 26)
T2: 40 (4.1, 30)
T3: 50 (5.1, 37)
T4: 58 (5.9, 43)
T5: 70 (7.1, 51)
4AT-18
General Description
C: CAUTION
goggles and protective shoes during operation.
• Do not place the oil pan with its inner side facing
upward until it is installed so as to prevent foreign
matter intrusion into valve body.
moval, installation, disassembly and replacement.
• When disassembling the case and other light al-
loy parts, use a plastic hammer to force it apart. Do
not pry it apart with a screwdriver or other tool.
• Be careful not to burn yourself, because each
part on the vehicle is hot after running.
• Use SUBARU genuine gear oil, grease etc. or
the equivalent. Do not mix gear oil, grease etc. with
that of another grade or from other manufacturers.
• Be sure to tighten bolts and nuts to the specified
torque.
points.
• Apply gear oil or ATF onto sliding or revolution
surfaces before installation in view of components
usage.
• Replace deformed or otherwise damaged snap
rings 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 install
O-rings, snap rings and other such parts.
• Before securing a part on a vice, place cushion-
ing material such as wood blocks, aluminum plate
or 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.
4AT-19
General Description
D: PREPARATION TOOL
1. SPECIAL TOOL
ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS
498575400 OIL PRESSURE Used for measuring oil pressure.
GAUGE ASSY
ST-498575400
498897200 ADAPTER Used for oil pump housing when measuring
reverse clutch pressure and line pressure.
ST-498897200
498897700 ADAPTER SET Used for measuring transfer clutch pressure.
ST-498897700
498545400 FILTER WRENCH Used for removing and installing ATF filter.
ST-498545400
4AT-20
General Description

498277200 STOPPER SET Used for removing and installing automatic
transmission assembly to engine.
ST-498277200
398527700 PULLER ASSY • Used for removing extension case roller bear-
ing.
• Used for removing extension oil seal.
• Used for removing front differential side
retainer bearing outer race.
retainer oil seal.
ST-398527700
498057300 INSTALLER Used for installing extension oil seal.
ST-498057300
41099AC000 ENGINE SUPPORT Used for supporting engine.
ASSY (1) ENGINE SUPPORT BRACKET
(41099AC010)
(1) (2) ENGINE SUPPORT (41099AC020)
(2)
ST41099AC000
4AT-21
General Description

498077000 REMOVER Used for removing differential taper roller bear-
ing.
ST-498077000
499247400 INSTALLER • Used for installing transfer outer snap ring.
• Used with GUIDE (499257300).
ST-499247400
499257300 SNAP RING • Used for installing transfer outer snap ring.
OUTER GUIDE • Used with INSTALLER (499247400).
ST-499257300
499787000 WRENCH ASSY Used for removing and installing differential side
retainer.
ST-499787000
4AT-22
General Description

398437700 DRIFT Used for installing converter case oil seal.
ST-398437700
398487700 INSTALLER Used for installing front differential taper roller
bearing.
ST-398487700
398673600 COMPRESSOR Used for removing and installing clutch spring.
ST-398673600
498255400 PLATE Used for measuring backlash of hypoid gear.
ST-498255400
4AT-23
General Description

399893600 PLIERS Used for removing and installing clutch spring.
ST-399893600
498247001 MAGNET BASE • Used for measuring gear backlash.
• Used with DIAL GAUGE (498247100).
ST-498247001
498247100 DIAL GAUGE • Used for measuring gear backlash.

• Used with MAGNET BASE (498247001).
ST-498247100
498517000 REPLACER Used for removing front roller bearing.
ST-498517000
4AT-24
General Description

398623600 SEAT Used for removing spring of transfer clutch pis-
ton.
ST-398623600
499267300 STOPPER PIN Used for installing inhibitor switch.
ST-499267300
499787700 WRENCH Used for removing and installing drive pinion lock
nut.
ST-499787700
499787500 ADAPTER Used for removing and installing drive pinion lock
nut.
ST-499787500
4AT-25
General Description

398643600 GAUGE Used for measuring total end play, extension end
play and drive pinion height.
ST-398643600
498627100 SEAT Used for holding low clutch piston retainer spring
when installing snap ring.
ST-498627100
499577000 GAUGE Used for measuring mating surface of transmis-
sion to end of reduction gear.
ST-499577000
499737000 PULLER Used for removing reduction driven gear assem-
bly.
ST-499737000
4AT-26
General Description

499737100 PULLER SET Used for removing reduction drive gear assem-
bly.
ST-499737100
498077600 REMOVER Used for removing ball bearing.
ST-498077600
498937110 HOLDER Used for removing and installing drive pinion lock
nut.
ST-498937110
498677100 COMPRESSOR Used for installing 2-4 brake snap ring.
ST-498677100
4AT-27
General Description

498437000 HIGH CLUTCH PIS- Used for installing high clutch piston.
TON GUIDE
ST-498437000
498437100 LOW CLUTCH PIS- Used for installing low clutch piston.
TON GUIDE
ST-498437100
899580100 INSTALLER Used for press-fitting of ball bearing for transfer
clutch.
ST-899580100
28399SA010 OIL SEAL PROTEC- Used for installing axle shaft.

TOR
ST28399SA010
4AT-28
General Description

18675AA000 DIFFERENTIAL OIL Used for installing differential side retainer oil
SEAL INSTALLER seal.
ST18675AA000
398497701 SEAT Used for installing needle bearing.
ST-398497701
899524100 PULLER SET Used for bolt only.

• Used with PULLER SET (499737100).
• Used with PULLER (499737000).
(1) Puller
(2) Cap
ST-899524100
24082AA230 CARTRIDGE Troubleshooting for electrical system.
ST24082AA230
4AT-29
General Description

22771AA030 SUBARU SELECT Troubleshooting for electrical system.
MONITOR KIT • English: 22771AA030 (Without printer)
• German: 22771AA070 (Without printer)
• French: 22771AA080 (Without printer)
• Spanish: 22771AA090 (Without printer)
ST22771AA030
2. GENERAL TOOL
TOOL NAME REMARKS
Depth gauge Used for measuring transmission end play.
Thickness gauge Used for measuring clearance of clutch, brake and oil pump.
Micro meter Used for measuring thickness of drive pinion.
Spring balance Used for measuring starting torque of drive pinion.
Circuit tester Used for measuring resistance and voltage.
TORX® T70 Used for removing and installing differential gear oil drain plug.
Push/pull gauge Used for measuring clutch piston stroke.
4AT-30
Automatic Transmission Fluid
2. Automatic Transmission Flu- B: REPLACEMENT

id 1) Lift-up the vehicle.
2) Remove the ATF drain plug to drain ATF.
A: INSPECTION CAUTION:
NOTE: Directly after the engine has been running, the
The level of ATF varies with fluid temperature. Pay ATF is hot. Be careful not to burn yourself.
attention to the ATF temperature when checking 3) Check the condition of ATF. <Ref. to 4AT-32,
ATF level. CONDITION CHECK, Automatic Transmission
1) Raise the ATF temperature by driving a distance Fluid.>
of 5 to 10 km (3 to 6 miles). Otherwise, idle the en- 4) Tighten the ATF drain plug.
gine to raise ATF temperature to 70 — 80%C (158 NOTE:
— 176%F) on Subaru Select Monitor. <Ref. to Use a new gasket.
4AT(diag)-17, READ CURRENT DATA, OPERA-
TION, Subaru Select Monitor.> Tightening torque:
2) Park the vehicle on a level surface. 25 N$m (2.5 kgf-m, 18.1 ft-lb)
3) After selecting all positions (P, R, N, D), set the
select lever in “P” range. Measure the ATF level (A)
with engine idling for one or two minutes.
(A)
F
(B)
HOT
(B)
L
(C)
AT-01332
F
(B)
COLD
L
(C) (A) Oil pan

AT-01323 (B) ATF drain plug
(A) ATF level gauge 5) Lower the vehicle.

(B) Upper level 6) Pour ATF from the oil charge pipe.
(C) Lower level Recommended fluid:
SUBARU ATF (Part No. K0410Y0700) or Ide-
4) Make sure that ATF level is above the center of
mitsu “Apolloil ATF HP”, Castrol “Transmax
upper level and lower level at HOT side.
J”.
5) If the ATF level is below the center between up-
per level and lower level, replenish a recommend- NOTE:
ed ATF until the fluid level exceeds the center If the ATFs above are not available, use Dexron III.
between upper level and lower level. Capacity:
CAUTION: Fill the same amount of ATF drained.
• Use care not to exceed the upper limit level.
Capacity when transmission is overhauled:
• Be sure that the replenishment of ATF to the
2.0 L model
upper level with the transmission cold will
8.4 — 8.7 2 (8.9 — 9.2 US qt, 7.4 — 7.7 Imp
cause overfilling of ATF and result in a trans-
qt)
mission failure.
2.5 L model
6) Raise the ATF temperature by driving a distance 9.3 — 9.6 2 (9.8 — 10.1 US qt, 8.2 — 8.4 Imp
of 5 to 10 km (3 to 6 miles). Otherwise, idle the en- qt)
gine to raise ATF temperature to 70 — 80%C (158
— 176%F) on Subaru Select Monitor. <Ref. to 7) Bleed the air of control valve.
4AT(diag)-17, READ CURRENT DATA, OPERA- <Ref. to 4AT-63, Air Bleeding of Control Valve.>
TION, Subaru Select Monitor.> 8) Check the level and leaks of ATF.
7) Check the ATF for leaks. <Ref. to 4AT-31, INSPECTION, Automatic Trans-
Make visual inspection for leaks from the inside of mission Fluid.>
transmission. If there are leaks, repair or replace
the gasket, oil seals, plugs or other parts.
4AT-31
C: CONDITION CHECK
NOTE:
When replacing ATF, check the inside condition of the transmission body by inspecting the drained ATF.
Fluid condition Trouble and possible cause Corrective action
Large amount of metallic pieces are Excessive wear of the internal of the trans- Replace ATF and check if AT operates
found. mission body. correctly.
Replace ATF and check AT itself and
Thick and varnish-form fluid. Burned clutch and etc.
vehicle for faulty.
Clouded fluid or bubbles are found in Replace ATF and check the water enter-
Water mixed in fluid.
fluid. ing point.
4AT-32
Differential Gear Oil
3. Differential Gear Oil Tightening torque:

70 N$m (7.1 kgf-m, 51.6 ft-lb)
A: INSPECTION
1) Park the vehicle on a level surface. (A)
2) Remove the oil level gauge and wipe it clean.
3) Reinsert the level gauge all the way. Be sure that
the level gauge is correctly inserted and in the
proper orientation.
4) Remove the level gauge again and note the
reading. If the differential gear oil level is below the
“L” line, add oil to bring the level up to the “F” line.
NOTE: (B)
AT-02204
To prevent overfilling the differential gear oil, do not
add oil above the “F” line.
(A) Oil pan
(B) Differential gear oil drain plug
(A)
4) Lower the vehicle.
(B) (A) 5) Pour gear oil into the gauge hole.
(C) Recommended gear oil:
<Ref. to 4AT-3, RECOMMENDED GEAR OIL,
SPECIFICATION, General Description.>
Differential gear oil capacity:
1.1 — 1.3 2 (1.2 — 1.4 US qt, 1.0 — 1.1 Imp qt)
PI-00183
6) Check the level of the differential gear oil.
(A) Oil level gauge <Ref. to 4AT-33, INSPECTION, Differential Gear
(B) Upper level
Oil.>
(C) Lower level
B: REPLACEMENT
2) Remove the differential gear oil drain plug using
TORX® BIT T70, and drain the differential gear oil
completely.
CAUTION:
• Directly after the engine has been running,
the differential gear oil is 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. When the differential gear oil is
spilled on exhaust pipe, wipe it away complete-
ly.
3) Tighten the differential gear oil drain plug using
TORX® BIT T70.
NOTE:
Use a new gasket.
4AT-33
Road Test
4. Road Test • Also when checking on the free roller, check with
depressing the foot brake lightly to make the check-
A: INSPECTION ing easier, because the surface resistance will be
deficient.
1. GENERAL PRECAUTION
2) Connect the Subaru Select Monitor.
Road tests should be conducted to properly diag- 3) Check the ATF temperature using Subaru Select
nose the condition of the automatic transmission. Monitor.
NOTE: NOTE:
When performing the test, do not exceed posted • ATF temperature is between 50 — 100%C (122
speed limit. — 212%F).
2. D RANGE SHIFT FUNCTION • When the temperature is low, warm-up the ATF
by running the vehicle or etc.
Check shifting between 1st !" 2nd !" 3rd !" 4) Start the engine, so that the lock-up duty can be
4th while driving on general city streets. read on data display of Subaru Select Monitor.
3. D RANGE SHIFT SHOCK 5) Drive the vehicle at a constant speed of 35 — 40
km/h (22 — 25 MPH).
Check the shock level when shifting up during nor- 6) Read the lock-up duty while vehicle is running.
mal driving.
Standard value:
4. KICK-DOWN FUNCTION 25 — 45%
Check kick-down for each gear. Also check the NOTE:
kick-down shock level. The value may be lower on the free roller.
5. ENGINE BRAKE OPERATION • Slip lock-up control is not operating when the
lock-up duty is less than 5%, or when the lock-up
• Check the 3rd gear engine brake when shifting
duty goes down immediately after starts rising. On
down from 4th to 3rd range while driving in 4th gear
these cases, improper ATF or deterioration of ATF
of manual mode [50 — 60 km/h (31 — 37 MPH)].
may be the cause. Check the amount of ATF or re-
• Check the 2nd gear engine brake when shifting
place them, and then recheck it.
down from 3rd to 2nd range while driving in 3rd
gear of manual mode [40 — 50 km/h (25 — 31 7. P RANGE OPERATION
MPH)].
Stop the vehicle on an uphill grade of 5% or more
• Check the 1st gear engine brake when shifting
and shift to “P” range. Check that the vehicle does
down from 2nd to 1st range while driving in 2nd
not move when the parking brake is released.
gear of manual mode [20 — 30 km/h (12 — 19
MPH)]. 8. NOISE AND VIBRATION
6. LOCK-UP FUNCTION Check for noise and vibration while driving and dur-
ing shifting.
• Check that rpm does not change sharply when
the axle pedal is lightly depressed while driving on 9. CLIMBING CONTROL FUNCTION
flat roads at normal speed in “D” range.
• Check that the gear remains in 3rd when going
• Check slip lock-up with following procedure.
up a grade.
Subaru Select Monitor is needed for checking.
• Check that the gear remains in 3rd when apply-
Before start checking, check that no DTC is dis-
ing the brakes while going down a grade.
played using Subaru Select Monitor. When DTC is
displayed, perform the collective action with DTC 10.TRANSFER CLUTCH
and check that any more DTC is displayed, and
Check tight corner braking when the vehicle started
then start the checking.
with steering fully turned.
1) Perform the check on flat and straight road or
free roller. 11.OIL LEAKS
NOTE: After the driving test, inspect for oil leaks.
• Slip lock-up does not operate when the vehicle is
lifted up, because of not occurring surface resis-
tance.
4AT-34
Stall Test
5. Stall Test 10) When the engine speed is stabilized, record

that speed quickly and release the accelerator ped-
A: INSPECTION al.
NOTE: 11) Shift the select lever to “N” range, and cool
The stall test is of extreme importance in diagnos- down the engine by idling it for more than one
ing the condition of the automatic transmission and minute.
the engine. It should be conducted to measure the 12) If the stall speed in the 2nd of manual mode is
engine stall speeds in “R” and 2nd of manual mode. higher than specifications, low clutch slipping and
Purposes of the stall test: 2-4 brake slipping may occur. To identify it, conduct
• To check the operation of the automatic trans- the same test as above in “R” range.
mission clutch. 13) Perform the stall tests with the select lever in
• To check the operation of the torque converter “D” range.
clutch. NOTE:
• To check engine performance. • Do not continue the stall test for more than five
1) Check that the throttle valve opens fully. seconds at a time (from closed throttle, fully open
2) Check that the engine oil level is correct. throttle to stall speed reading). Failure to follow this
3) Check that the coolant level is correct. instruction causes the engine oil and ATF to deteri-
4) Check that the ATF level is correct. orate and the clutch and brake to be adversely af-
5) Check that the differential gear oil level is cor- fected.
rect. • Be sure to cool down the engine for at least one
6) Increase ATF temperature to 70 — 80%C (158 — minute after each stall test with the select lever set
176%F) by idling the engine for approximately 30 in “P” or “N” range and with the idle speed lower
minutes (with select lever set to “N” or “P”). than 1,200 rpm.
7) Place the wheel chocks at the front and rear of • If the stall speed is higher than the specified
all wheels and engage the parking brake. range, attempt to finish the stall test in as short a
time as possible, in order to prevent the automatic
8) Move the manual linkage to ensure it operates
transmission from sustaining damage.
properly, and then set to the 2nd on manual mode.
AT-02205
9) While forcibly depressing the foot brake pedal,

gradually depress the accelerator pedal until the
engine operates at full throttle.
(A) (B)
AT-01326
(A) Brake pedal

(B) Accelerator pedal
4AT-35
Stall Test
Stall speed (at sea level):

2.0 L model:
2,300 — 2,700 rpm
2.5 L model:
2,600 — 2,900 rpm
Stall speed (at sea level) Range Cause
• Throttle valve not fully open
2nd on manual
Less than standard • Erroneous engine operation
mode, R
• Torque converter clutch’s one-way clutch slipping
• Line pressure is too low
D • Low clutch slipping
• One-way clutch malfunctioning
More than standard R • Reverse clutch slipping
• Low & reverse brake slipping
2nd on manual
• Low clutch slipping
mode
• 2-4 brake slipping
4AT-36
Time Lag Test
6. Time Lag Test

A: INSPECTION
NOTE:
If the select lever is shifted while the engine is
idling, 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 between
tests.
• 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 it takes from
shifting the lever until the shock is felt.
Time lag: Less than 1.2 seconds
If “N” " “D” time lag is longer than specified:
• Line pressure too low
• Low clutch worn
• One-way clutch not operating properly
• D-ring worn
4) In the same manner, measure the time lag for
“N” " “R”.
Time lag: Less than 1.5 seconds
If “N” " “R” time lag is longer than specified:
• Reverse clutch worn
• Low & reverse brake worn
• D-ring worn
4AT-37
Line Pressure Test
7. Line Pressure Test 4) Connect the ST1 with ST2.

ST1 498897200 OIL PRESSURE GAUGE
A: MEASUREMENT ADAPTER
NOTE: ST2 498575400 OIL PRESSURE GAUGE
If the clutch or the brake shows a sign of slippage or ASSY
shifting sensation is not correct, the line pressure 5) Check for duty ratio changes by adjusting the ac-
should be checked. celeration pedal position using Subaru Select Mon-
• Excessive shocks during upshifting or shifting itor.
takes place at a higher point than under normal cir- Standard line pressure
cumstances, may be due to the line pressure being Line pres-
too high. Range posi- Throttle Line pressure
sure duty
• Slippage or inability to operate the vehicle may, tion valve angle kPa (kg/cm2, psi)
ratio (%)
in most cases, be due to loss of oil pressure for the 1,000 — 1,300
operation of the clutch, brake or control valve. Manual
25 — 35 Full open (10.2 — 13.3,
mode (2nd)
1) Line pressure measurement (under no load): 145 — 189)
(1) Before measuring line pressure, jack-up all 1,500 — 1,850
the wheels. R 15 — 25 Full open (15.3 — 18.9,
(2) Maintain the temperature of ATF at approx. 217 — 268)
70 — 80%C (158 — 176%F) during measurement. 500 — 800
(ATF will reach the above-mentioned tempera- D 35 — 43 Full closed (5.1 — 8.2,
73 — 116)
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 both
the foot and parking brakes with all wheels
chocked (Same as for “stall” test conditions).
(2) Measure the line pressure when the select
lever is in “R” or 2nd of manual mode with en-
gine under stall conditions.
(3) Measure the line pressure within 5 seconds
after shifting the select lever to each position. (If
the line pressure needs to be measured again,
allow the engine to idle and cool it down more
than 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
(A)
AT-00020
(A) Test plug
4AT-38
Transfer Clutch Pressure Test
8. Transfer Clutch Pressure Standard transfer clutch

ON Accelera-
Test Range Duty tion pedal
pressure
kPa (kg/cm2, psi)
A: INSPECTION position ratio position
(%) (%) FWD
AWD mode
Check the transfer clutch pressure in accordance mode
with the following chart in the same manner as with Fully 1,000 — 1,200
line pressure. <Ref. to 4AT-38, Line Pressure 95 opened: (10.2 — 12.2, —
Test.> 100 145 — 174)
ST 498897700 OIL PRESSURE ADAPTER Manual Adjust
500 — 700
SET mode
60
ON Duty
(5.1 — 7.1, —
ST 498575400 OIL PRESSURE GAUGE (2nd) ratio to
73 — 102)
ASSY 60%.
Fully
NOTE: —
closed: 0
— 0 (0, 0)
• Before setting in FWD mode, install the spare
Fully
fuse on FWD mode switch. (MPT model) N or P 5
closed: 0
0 —
• MTP model
(A)
AT-00021
(A) Test plug
• VTD model
(A)
AT-00022
(A) Test plug
• If no oil pressure is produced or if it does not

change in AWD mode, the control valve body may
be malfunctioning. If oil pressure is produced in
FWD mode, the same problem as AWD mode oc-
curs.
4AT-39
Automatic Transmission Assembly
9. Automatic Transmission As- 10) Separate the torque converter clutch from drive
plate.
sembly (1) Remove the V-belt covers.
A: REMOVAL (2) Remove the service hole plug.
1) Set the vehicle on a lift. (3) Remove the bolts which hold torque con-
2) Fully open the front hood and support with hood verter clutch to drive plate.
stay. (4) Insert the wrench to crank pulley bolt, and
3) Disconnect the ground cable from battery. then remove all the bolts with slightly rotating
4) Remove the air intake duct. crank pulley.
<Ref. to IN(H4SO 2.0)-9, REMOVAL, Air Intake CAUTION:
Duct.> Be careful not to drop bolts into torque convert-
5) Remove the air intake chamber. er clutch housing.
<Ref. to IN(H4SO 2.0)-8, REMOVAL, Air Intake
Chamber.>
6) Remove the air cleaner case stay.
AT-00102
11) Install the ST to converter case.

ST 498277200 STOPPER SET
AT-01327
7) Disconnect the following connectors.

(1) Transmission harness connectors
ST
AT-00804
12) Remove the ATF level gauge.

AT-01328 NOTE:
Plug the opening to prevent entry of foreign parti-
(2) Transmission ground terminal cles into transmission fluid.
8) Remove the starter.
<Ref. to SC(H4SO 2.0)-6, REMOVAL, Starter.>
9) Remove the pitching stopper.
AT-01330
13) Remove the throttle body. <Ref. to FU(H4SO

AT-01329 2.0)-10, REMOVAL, Throttle Body.>
4AT-40
14) Drain the engine coolant by approx. 2 2 (2.1 18) Remove the warmer cock assembly. (Model
US qt, 1.8 Imp qt). (Model with ATF cooler with with ATF cooler with warmer function)
warmer function)
15) Disconnect the ATF cooler inlet and outlet hos-
es from ATF cooler pipes.
AT-02165
19) Remove the bracket for warmer cock assem-

bly. (Model with ATF cooler with warmer function)
AT-02171
16) Disconnect each hose from warmer cock as-

sembly.
AT-02166
20) Remove the pitching stopper bracket.

21) Set the ST.
AT-02163
ST 41099AC000 ENGINE SUPPORT ASSEM-
17) Remove the ATF cooler with warmer function BLY
from transmission body, and then secure it to vehi-
cle body by wire, etc.. Select the place not to pre-
vent transmission from being replaced. (Model with
ATF cooler with warmer function)
ST
AT-02167
22) Remove the bolts which hold upper side of

transmission to engine.
AT-00106

AT-02164 24) Remove the under cover.
4AT-41
25) Remove the front, center and rear exhaust 32) Remove the bolt securing ball joint of front arm
pipes and muffler. to housing.
AL, Rear Exhaust Pipe.> <Ref. to EX(H4SO 2.0)-
13, REMOVAL, Muffler.>
AT-00809
33) Pull out the front drive shaft from transmission.

(1) Using a tire lever or a pinch bar, etc., pull out
the front drive shaft until its joint facing to trans-
mission can move smoothly.
AT-01331
NOTE:
27) Remove the ATF drain plug to drain ATF. Place cloth between tire lever or pinch bar and
transmission in order to avoid damaging the side
(A)
retainer of transmission.
(2) Hold the transmission side joint portion of
front drive shaft by hand and extract the housing
from the transmission by pressing it outside so
as not to stretch the boot.
(B) 34) Remove the bolts which hold the clutch hous-
ing cover.
35) Remove the bolts which hold lower side of
AT-01332
(A) Oil pan

(B) ATF drain plug
28) Disconnect the ATF cooler hoses from pipes of

transmission side, and remove the oil charge pipe.
(Model without ATF cooler with warmer function)
AT-00108
36) Place the transmission jack under transmis-

sion.
NOTE:
Make sure that the support plates of transmission
jack don’t touch the oil pan.
AT-01333
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 front
stabilizer.
4AT-42
37) Remove the transmission rear crossmember ST 498277200 STOPPER SET

from the vehicle.
ST
AT-00103
AT-01334
4) Install the transmission onto engine.
38) Fully contract the engine support while lower- (1) Lift up the transmission gradually using a
ing the transmission jack gradually, and tilt the en- transmission jack.
gine backward.
NOTE:
Contract the support until the clearance between
front crossmember and torque converter case be-
comes approx. 10 mm (0.39 in).
39) Remove the transmission.
CAUTION:
Remove the transmission and torque converter
as a unit from engine.
AT-00109
(2) Engage them at splines.

(3) Turn the screws of engine support while
raising the transmission jack gradually, and tilt
the engine forward.
5) Install the transmission rear crossmember.
Tightening torque:
T1: 35 N$m (3.6 kgf-m, 26 ft-lb)
T2: 70 N$m (7.1 kgf-m, 51 ft-lb)
AT-00109
40) Remove the rear cushion rubber from transmis-

T2 T1 T2
sion assembly.
B: INSTALLATION
1) Replace the differential side oil seal with a new
one.
NOTE:
When a new oil seal has been installed, the re-
placement is not required.
AT-01335
2) Install the rear cushion rubber to transmission
assembly. 6) Take off the transmission jack.
7) Tighten the bolts which hold the lower side of
Tightening torque: transmission to engine.
39 N$m (4.0 kgf-m, 29 ft-lb)
4AT-43
Tightening torque: Tightening torque:

50 N$m (5.1 kgf-m, 36.9 ft-lb) 25 N$m (2.5 kgf-m, 18.1 ft-lb)
AT-00108 AT-00102
8) Screw the bolts for the clutch housing cover. (3) Fit the plug to service hole.
9) Lower the lift. (4) Install the V-belt cover.
10) Connect the engine and transmission. 12) Remove the ST.
(1) Remove the ST from converter case.
NOTE:
When removing the ST, be careful not to drop it into
converter case.
(2) Install the starter.
<Ref. to SC(H4SO 2.0)-6, INSTALLATION, ST
Starter.>
(3) Tighten the bolts which hold the upper side
of transmission to engine. AT-02167
Tightening torque: 13) Install the warmer cock assembly bracket.

50 N$m (5.1 kgf-m, 36.9 ft-lb) (Model with ATF cooler with warmer function)
Tightening torque:
16 N$m (1.6 kgf-m, 11.6 ft-lb)
AT-00106
11) Install the torque converter clutch to drive plate.

(1) Tighten the bolts which hold torque convert- AT-02166
er clutch to drive plate.
14) Install the warmer cock assembly. (Model with
(2) Insert the wrench to crank pulley bolt, and
ATF cooler with warmer function)
then tighten all bolts while slightly rotating the
crank pulley.
4AT-44

T1: 6.4 N$m (0.65 kgf-m, 4.7 ft-lb) 23 N$m (2.3 kgf-m, 16.6 ft-lb)
T2: 15 N$m (1.5 kgf-m, 10.8 ft-lb)
T2
T1
AT-02168
15) Connect each hose to warmer cock assembly.

(Model with ATF cooler with warmer function)
AT-02164
18) Connect the ATF cooler inlet and outlet hoses

to ATF cooler pipes. (Model with ATF cooler with
AT-02163
warmer function)
16) Install the pitching stopper bracket and bracket
(Model with ATF cooler with warmer function).
Tightening torque:
41 N$m (4.2 kgf-m, 30.4 ft-lb)
(A)
(B)
AT-02171
19) Install the throttle body. <Ref. to FU(H4SO

2.0)-10, INSTALLATION, Throttle Body.>
20) Install the pitching stopper.
AT-02169
Tightening torque:
(A) Pitching stopper bracket
T1: 50 N$m (5.1 kgf-m, 37 ft-lb)
T2: 58 N$m (5.9 kgf-m, 43 ft-lb)
(B) Bracket (Model with ATF cooler with warmer
function)
17) Install the ATF cooler with warmer function to

transmission body. (Model with ATF cooler with
warmer function)
T1
T2
AT-01346
4AT-45
21) Lift-up the vehicle. • Ensure the bushing and stabilizer have the same
22) Replace the snap ring of front drive shaft with a identification colors when installing.
new one.
23) Apply grease to the oil seal lips.
24) Install the ST to side retainer.
ST 28399SA010 OIL SEAL PROTECTOR
FS-00050
(1) Identification mark on stabilizer

(2) Bushing identification color
ST
AT-00110
30) Always tighten the rubber bushing location
25) Align the spline of front differential shaft to that when wheels are in full contact with the ground and
of differential bevel gear for insertion, and remove vehicle is curb weight.
them using ST.
ST 28399SA010 OIL SEAL PROTECTOR Tightening torque:
26) Insert the front drive shaft into transmission se- 25 N$m (2.5 kgf-m, 18.1 ft-lb)
curely by pressing the front housing from outside. 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 ATF
cooler hoses to pipe. (Model without ATF cooler
with warmer function)
AT-00111
27) Install the ball joint into housing.

28) Tighten the attachment bolts.
Tightening torque: AT-01333
50 N$m (5.1 kgf-m, 36.9 ft-lb) 33) Install the oil charge pipe. (Model with ATF
cooler with warmer function)
34) Install the propeller shaft.
<Ref. to DS-11, INSTALLATION, Propeller Shaft.>
AT-00809
29) Install the stabilizer to crossmember.

NOTE:
• Install the bushing (on front crossmember side)
AT-01331
while aligning it with the paint mark on stabilizer.
36) Install the rear exhaust pipe and muffler as-
sembly.
4AT-46

37) Install the front and center exhaust pipe.
Exhaust Pipe.>
38) Install the under cover.
39) Lower the lift.
40) Install the ATF level gauge.
AT-01330
41) Connect the following connectors.

(2) Transmission ground terminal
42) Install the air cleaner case stay.
Tightening torque:
16 N$m (1.6 kgf-m, 11.6 ft-lb)
43) Install the air intake chamber.
<Ref. to IN(H4SO 2.0)-8, INSTALLATION, Air In-
take Chamber.>
44) Install the air intake duct.
take Duct.>
45) Using a gauge hole, add the ATF until the fluid
level is found at the center between upper and low-
er levels of level gauge “COLD” side. <Ref. to 4AT-
31, Automatic Transmission Fluid.>
46) Take off the vehicle from a lift.
47) Check the level of differential gear oil. <Ref. to
4AT-33, Differential Gear Oil.>
48) Check the select lever operation.
<Ref. to 4AT-52, INSPECTION, Inhibitor Switch.>
49) Bleed the air of control valve. <Ref. to 4AT-63,
Air Bleeding of Control Valve.>
50) Check the ATF level. <Ref. to 4AT-31, Auto-
matic Transmission Fluid.>
51) Execute the learning control promotion. <Ref.
to 4AT(diag)-19, FACILITATION OF LEARNING
CONTROL, OPERATION, Subaru Select Moni-
tor.>
52) Perform the road test.
<Ref. to 4AT-34, Road Test.>
4AT-47
CONTROL SYSTEMS CS

(DIAGNOSTICS)


approval.

4AT
Page
4. Road Test..................................................................................................34
5. Stall Test ...................................................................................................35
6. Time Lag Test ...........................................................................................37
19. ATF Filter ..................................................................................................64
21. Lateral G Sensor .......................................................................................66
24. Warmer Cock ............................................................................................76
26. Oil Charge Pipe.........................................................................................79
28. Extension Case .........................................................................................82
29. Transfer Clutch..........................................................................................86
31. Rear Drive Shaft........................................................................................93
35. Parking Pawl ...........................................................................................100
36. Converter Case .......................................................................................101
37. Oil Pump Housing ...................................................................................103
40. AT Main Case .........................................................................................119
Transmission Mounting System
10.Transmission Mounting Sys- B: INSTALLATION

tem 1. PITCHING STOPPER
A: REMOVAL 1) Install the pitching stopper.
1. PITCHING STOPPER Tightening torque:
T1: 50 N!m (5.1 kgf-m, 37 ft-lb)
1) Remove the air intake chamber. T2: 58 N!m (5.9 kgf-m, 43 ft-lb)
Chamber.>
T1
T2
AT-01346

AT-01329 <Ref. to IN(H4SO 2.0)-8, INSTALLATION, Air In-
take Chamber.>
2. TRANSMISSION REAR CROSSMEMBER
& REAR CUSHION RUBBER 2. TRANSMISSION REAR CROSSMEMBER
& REAR CUSHION RUBBER
2) Jack-up the vehicle and support it with study 1) Install the rear cushion rubber.
racks. Tightening torque:
3) Remove the front, center, rear, exhaust pipes 40 N!m (4.1 kgf-m, 29.5 ft-lb)
and muffler.
2) Install the crossmember.
haust Pipe.> <Ref. to EX(H4SO 2.0)-11, REMOV- Tightening torque:
AL, Rear Exhaust Pipe.> <Ref. to EX(H4SO 2.0)- T1: 35 N!m (3.6 kgf-m, 26 ft-lb)
13, INSTALLATION, Muffler.> T2: 70 N!m (7.1 kgf-m, 51 ft-lb)
5) Set the transmission jack under the transmis-
sion. Make sure that the support plate of transmis- T2 T1 T2
sion jack does not touch the oil pan.
6) Remove the transmission rear crossmember.
AT-01335
3) Remove the transmission jack.

AT-01334
and muffler.
7) Remove the rear cushion rubber. Exhaust Pipe.> <Ref. to EX(H4SO 2.0)-11, IN-
STALLATION, Rear Exhaust Pipe.> <Ref. to
EX(H4SO 2.0)-13, INSTALLATION, Muffler.>
4AT-48
C: INSPECTION
Repair or replace parts if the results of the inspec-
tion below are not satisfied.
1. PITCHING STOPPER
Make sure that the pitching stopper is not bent or
damaged. Ensure there are no cracks, hardening,
or damage on rubbers.
Make sure that the crossmember is not bent or
damaged. Ensure there are no cracks, hardening,
or damage on cushion rubbers.
4AT-49
Extension Case Oil Seal
11.Extension Case Oil Seal 13) Pour ATF into the oil charge pipe.
A: INSPECTION Recommended fluid:

Make sure that the ATF does not leak from the joint
of transmission and propeller shaft. If so, replace
J”.
the oil seal. <Ref. to 4AT-50, REPLACEMENT, Ex-
tension Case Oil Seal.> NOTE:
If the ATFs above are not available, use Dexron III.
B: REPLACEMENT
1) Lift-up the vehicle. Capacity:
2) Clean the transmission exterior. Fill the same amount of ATF drained.
3) Remove the ATF drain plug to drain ATF. 14) Bleed the air of control valve.
CAUTION: <Ref. to 4AT-63, Air Bleeding of Control Valve.>
Directly after the engine has been running, the 15) Check the level and leaks of ATF. <Ref. to 4AT-
ATF is hot. Be careful not to burn yourself. 31, Automatic Transmission Fluid.>
4) Tighten the ATF drain plug.
NOTE:
Use a new gasket.
Tightening torque:
25 N!m (2.5 kgf-m, 18.1 ft-lb)
(A)
(B)
AT-01332
(A) Oil pan

(B) ATF drain plug

AL, Muffler.>
7) Remove the propeller shaft. <Ref. to DS-10, RE-
MOVAL, 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 DS-11, IN-
STALLATION, Propeller Shaft.>
12) Install the rear exhaust pipe and muffler.
4AT-50
Differential Side Retainer Oil Seal
12.Differential Side Retainer Oil 7) Using the ST, install the differential side retainer
by slightly tapping with hammer.
Seal ST 18675AA000 DIFFERENTIAL SIDE OIL
A: INSPECTION SEAL INSTALLER
Check the leakage of gear oil from differential side
retainer oil seal part. If there is oil leakage, replace ST
the oil seal.
B: REPLACEMENT
2) Remove the front and center exhaust pipe. <Ref.
to EX(H4SO 2.0)-7, REMOVAL, Front Exhaust
Pipe.>
TORX® BIT T70, and drain the differential gear oil. AT-00029
CAUTION: 8) Apply gear oil to the oil seal lips.

• Directly after the engine has been running, 9) Install the front drive shaft. <Ref. to DS-22, IN-
the differential gear oil is hot. Be careful not to STALLATION, Front Drive Shaft.>
burn yourself. 10) Install the front and center exhaust pipe. <Ref.
• Be careful not to spill the differential gear oil to EX(H4SO 2.0)-8, INSTALLATION, Front Ex-
on exhaust pipe to prevent it from emitting haust Pipe.>
smoke or fire. When the differential gear oil is 11) Lower the vehicle.
spilled on exhaust pipe, wipe it away complete- 12) Pour the gear oil into the gauge hole.
ly. Recommended gear oil:
(A)
Differential gear oil capacity:
1.1 — 1.3 2 (1.3 — 1.4 US qt, 1.0 — 1.1 Imp qt)
4AT-33, INSPECTION, Differential Gear Oil.>
(B)
AT-02204
(A) Oil pan

4) 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)
5) Separate the front drive shaft from transmission.
<Ref. to DS-22, REMOVAL, Front Drive Shaft.>
6) Remove the differential side retainer oil seal us-
ing a driver wrapped with vinyl tape or etc.
4AT-51
Inhibitor Switch
13.Inhibitor Switch 3) Check there is continuity at equal points when

the select lever is turned 1.5" in both directions
A: INSPECTION from “N” range.
When the driving condition or starter motor opera- If there is continuity in one direction or in other
tion is erroneous, first check the shift linkage for im- points, adjust the inhibitor switch. <Ref. to 4AT-52,
proper operation. If the shift linkage is functioning ADJUSTMENT, Inhibitor Switch.>
properly, check the inhibitor switch.
1) Disconnect the inhibitor switch connector.
2) Check continuity in inhibitor switch circuits with
the select lever moved to each position.
(C)
NOTE:
(A)
• Also check that continuity in ignition circuit does (B)
not exist when the select lever is in “R” and “D” (A)
ranges.
• If the inhibitor switch is inoperative, check for
poor contact of connector on transmission side. AT-02206
Range Pin No.

(A) Continuity does not exist.
P 4—3
(B) Continuity exists.
Signal sent to TCM R 4—2
(C) 1.5"
N 4—1
D 4—8 4) Repeat the above checks. If there are abnormal-
Ignition circuit P/N 12 — 11 ities, adjust the select cable. <Ref. to CS-15, AD-
Back-up light circuit R 10 — 9 JUSTMENT, Select Cable.>
B: ADJUSTMENT
1) Set the select lever to “N” range.
(A) 2) Loosen the three inhibitor switch securing bolts.
3) Insert the ST as vertical as possible into the
holes in the inhibitor switch lever and switch body.
(4) (3) (2) (1)
ST 499267300 STOPPER PIN
(8) (7) (6) (5)
(12) (11) (10) (9) ST
AT-00030
(A) Inhibitor switch connector
AT-00032
4) Tighten the three inhibitor switch securing bolts.

Tightening torque:
3.4 N!m (0.35 kgf-m, 2.5 ft-lb)
5) Repeat the above checks. If the inhibitor switch
is determined to be “faulty”, replace it.
C: REMOVAL
2) Set the select lever to “N” range.
3) Remove the air intake chamber.
Chamber.>
4AT-52
Inhibitor Switch
4) Disconnect the inhibitor switch connector. 10) Remove the three bolts which secure inhibitor
switch.
(A)
(A)
AT-01350
AT-00036
(A) Inhibitor switch connector
(A) Inhibitor switch
5) Remove the inhibitor switch connector from stay.
6) Lift-up the vehicle. 11) Shift the range select lever to parking position
7) Remove the front and center exhaust pipe. (left side).
(A)
haust Pipe.>
8) Remove the snap pin and washers from range
select lever.
(A)
(B) AT-00037
(C) (D) (A) Range select lever
12) Remove the inhibitor switch from transmission.

AT-00034
(A) Range select lever (A)

(B) Snap pin
(C) Select cable
(D) Washer
9) Remove the plate assembly from transmission

case.
AT-00038
(A)
13) Disconnect the inhibitor switch harness con-

nector from inhibitor switch.
D: INSTALLATION
1) Connect the inhibitor switch harness connector
(B)
AT-00035 to inhibitor switch.
(A) Select cable

(B) Plate ASSY
4AT-53
Inhibitor Switch
2) Install the inhibitor switch to transmission case. 7) Install the snap pin washers to range select le-
ver.
(A)
(A)
(B)
(C) (D)
AT-00038
AT-00034
3) Move the range select lever to neutral position. (B) Snap ring
4) Tighten the three inhibitor switch securing bolts (C) Select cable
using ST.
(D) Washer
ST 499267300 STOPPER PIN
Tightening torque: 8) Install the front and center exhaust pipe.
3.5 N!m (0.36 kgf-m, 2.6 ft-lb) <Ref. to EX(H4SO 2.0)-8, INSTALLATION, Front
Exhaust Pipe.>
ST
10) Install the inhibitor switch connector to the stay.
(A) 11) Connect the inhibitor switch connector.
(A)
(B)
AT-00039

(B) Range select lever
AT-01350
5) Install the select cable to range select lever.
6) Install the plate assembly to transmission. (A) Inhibitor switch connector
Tightening torque: 12) Install the air intake chamber.

T: 25 N!m (2.5 kgf-m, 18.1 ft-lb) <Ref. to IN(H4SO 2.0)-8, INSTALLATION, Air In-
take Chamber.>
13) Inspect the inhibitor switch. <Ref. to 4AT-52,
(A)
INSPECTION, Inhibitor Switch.>
(B)
AT-00040
(A) Select cable

(B) Plate ASSY
4AT-54
Front Vehicle Speed Sensor
14.Front Vehicle Speed Sensor 11) Remove the front and center exhaust pipe.
A: REMOVAL haust Pipe.> <Ref. to EX(H4SO 2.0)-11, REMOV-
1) Set the vehicle on a lift. AL, Rear Exhaust Pipe.> <Ref. to EX(H4SO 2.0)-
2) Disconnect the ground cable from battery. 13, REMOVAL, Muffler.>
3) Remove the air intake chamber. 12) Remove the shield cover.
<Ref. to IN(H4SO 2.0)-8, REMOVAL, Air Intake 13) Remove the propeller shaft. <Ref. to DS-10,
Chamber.> REMOVAL, Propeller Shaft.>
4) Disconnect the transmission connector. 14) Place the transmission jack under transmis-
sion.
NOTE:
(A)
Make sure that the support plates of transmission
jack does not touch the oil pan.
15) Remove the transmission rear crossmember
bolt.
AT-01337
(A) Transmission connector
5) Remove the pitching stopper. <Ref. to 4AT-48,

REMOVAL, Transmission Mounting System.>
6) Remove the transmission connector from the
stay. AT-00043
7) Lift-up the vehicle. 16) Lower the transmission jack.
8) Clean the transmission exterior.
9) Remove the ATF drain plug to drain ATF. NOTE:
Do not separate the transmission jack and trans-
CAUTION: mission.
Directly after the engine has been running, the 17) Remove the oil cooler inlet and outlet pipes.
ATF is hot. Be careful not to burn yourself.
10) Tighten the ATF drain plug. NOTE:
When removing the outlet pipe, be careful not to
NOTE: lose the ball and spring used with retaining screw.
Use a new gasket. 18) Remove the front vehicle speed sensor and
Tightening torque: torque converter turbine speed sensor.
25 N!m (2.5 kgf-m, 18.1 ft-lb)
(A)
(A)
(B)
(B)
AT-00044
AT-01332
(A) Front vehicle speed sensor
(A) Oil pan (B) Torque converter turbine speed sensor
(B) ATF drain plug
4AT-55
19) Disconnect the connector from rear vehicle B: INSTALLATION

speed sensor. 1) Pass the harness assembly through the hole in
• MPT model transmission case.
(A)
AT-02207 AT-00048
(A) Rear vehicle speed sensor 2) Connect the harness connector and transmis-
sion ground.
• VTD model
Tightening torque:
8 N!m (0.8 kgf-m, 5.8 ft-lb)
(A)
(B)
(A)
AT-00117
(A) Rear vehicle speed sensor AT-00050
20) Remove the oil pan. (A) Transmission ground

21) Disconnect the harness connector and trans- (B) Harness connector
mission ground terminal.
3) Apply proper amount of liquid gasket to the en-
(A) tire oil pan mating surface.
(B) Liquid gasket:
THREE BOND 1217B (Part No. K0877YA020)
AT-00050
(A) Transmission ground

(B) Harness connector
22) Remove the harness assembly. AT-00051
4) Apply liquid gasket fully to the three holes other

than screw holes on the transmission case
4AT-56
Liquid gasket: 15) Install the pitching stopper. <Ref. to 4AT-48,

THREE BOND 1217B (Part No. K0877YA020) INSTALLATION, Transmission Mounting System.>
take Chamber.>
17) Fill the same amount of ATF drained.
18) Bleed the air of control valve.
<Ref. to 4AT-63, Air Bleeding of Control Valve.>
19) Check the level of ATF. <Ref. to 4AT-31, Auto-
AT-01339 CONTROL, OPERATION, Subaru Select Moni-
5) Install the oil pan. tor.>
Tightening torque:
5 N!m (0.5 kgf-m, 3.6 ft-lb)
6) Install the front vehicle speed sensor and torque
converter turbine speed sensor.
Tightening torque:
7 N!m (0.7 kgf-m, 5.1 ft-lb)
7) Connect the connector to rear vehicle speed
sensor.
8) Install the oil cooler pipe.
NOTE:
Use a copper washer.
Tightening torque:
T1: 25 N!m (2.5 kgf-m, 18.1 ft-lb)
T2: 44 N!m (4.5 kgf-m, 32.5 ft-lb)
T1
T2
T1
AT-01340
9) Install the transmission rear crossmember bolt.

Tightening torque:
70 N!m (7.1 kgf-m, 51 ft-lb)
11) Install the shield cover.
and muffler. <Ref. to EX(H4SO 2.0)-8, INSTALLA-
TION, Front Exhaust Pipe.> <Ref. to EX(H4SO
2.0)-11, INSTALLATION, Rear Exhaust Pipe.>
<Ref. to EX(H4SO 2.0)-13, INSTALLATION, Muf-
fler.>
14) Install the transmission connector to the stay.
4AT-57
Rear Vehicle Speed Sensor
15.Rear Vehicle Speed Sensor • VTD model
A: REMOVAL
1) Set the vehicle on a lift, and then lift-up the vehi-
cle.
2) Disconnect the connector from rear vehicle
speed sensor.
• MPT model
(A)
AT-00309
B: INSTALLATION
NOTE:
Replace O-ring with a new one.
Tightening torque:
AT-02207
7 N!m (0.7 kgf-m, 5.1 ft-lb)
(A) Rear vehicle speed sensor
• VTD model
(A)
AT-00117
3) Remove the rear vehicle speed sensor.

• MPT model
AT-01341
4AT-58
Torque Converter Turbine Speed Sensor
16.Torque Converter Turbine

Speed Sensor
A: REMOVAL
For removal procedure of torque converter turbine
speed sensor, refer to “Front Vehicle Speed Sen-
sor”. <Ref. to 4AT-55, REMOVAL, Front Vehicle
Speed Sensor.>
B: INSTALLATION
For installation procedure of torque converter tur-
bine speed sensor, refer to “Front Vehicle Speed
Sensor”. <Ref. to 4AT-56, INSTALLATION, Front
Vehicle Speed Sensor.>
4AT-59
Control Valve Body
17.Control Valve Body 9) Clean the magnet.

10) Completely remove the remaining liquid gasket
A: REMOVAL on transmission case and oil pan.
1) Set the vehicle on a lift. 11) Disconnect the control valve connector.
CAUTION:
Directly after the engine has been running, the
AT-00058
12) Remove the oil cooler pipe.
AT-00055

NOTE:
Use a new gasket.
AT-00059
Tightening torque:
25 N!m (2.5 kgf-m, 18.1 ft-lb) 13) Remove the control valve body.
7) Remove the oil pan. NOTE:
Replace the control valve body as assembly, be-
CAUTION:
cause it is non-disassemble part.
Be sure to prevent the entering of dust and oth-
er foreign matters into oil pan.
AT-01717
AT-00056 B: INSTALLATION
8) Remove the magnet. 1) Check that the dust and other foreign matters
are not on control valve body.
2) Temporarily install the control valve body to
transmission.
3) Install the oil cooler pipe.
AT-00057
4AT-60
Control Valve Body
Tightening torque: 6) Attach the magnet at the specified position of oil

8 N!m (0.8 kgf-m, 5.8 ft-lb) pan.
AT-00059 AT-00057
4) Tighten the bolts equally. 7) Apply liquid gasket to the oil pan.
Tightening torque: Liquid gasket:
8 N!m (0.8 kgf-m, 5.8 ft-lb) THREE BOND 1217B (Part No. K0877YA020)
(A) (2) (2) (2)

(2)
(2)
(2)
(2)
(2)
(1) (2)
(1) (2)
(2)
AT-01718 AT-00051
8) Fill liquid gasket to the holes except for bolt

(A) Transmission ground holes (three) of transmission case.
Bolt length mm (in)
(1) 35 (1.38) Liquid gasket:
(2) 30 (1.18)
5) Connect the control valve connector.
AT-01339
9) Install the oil pan with equally tighten the bolts.

AT-00058
Tightening torque:
5 N!m (0.5 kgf-m, 3.6 ft-lb)
10) Fill ATF from oil charge pipe.
Recommended fluid:
J”.
NOTE:
If the ATFs above are not available, use Dexron III.
4AT-61
Control Valve Body
Capacity:
Fill the same amount of ATF drained.
11) Bleed the air of control valve. <Ref. to 4AT-63,
Air Bleeding of Control Valve.>
12) Check the ATF level.
<Ref. to 4AT-31, Automatic Transmission Fluid.>
tor.>
C: INSPECTION
Check that the holes, damages or other foreign
matters are not on each parts.
4AT-62
Air Bleeding of Control Valve
18.Air Bleeding of Control Valve

A: PROCEDURE
1) Lift-up the vehicle with setting the select lever to
“P” range and applying the parking brake.
2) Connect the Subaru Select Monitor to the vehi-
cle.
3) Using Subaru Select Monitor, check that the
DTC is not output.
ATF temperature is less than 60"C (140"F). <Ref.
to 4AT(diag)-17, OPERATION, Subaru Select
Monitor.>
5) Turn the Subaru Select Monitor switch to OFF.
6) Release the manual mode, and then turn the ig-
nition switch to OFF.
7) Set the select lever to “R” range.
8) Depress the brake pedal fully until the air bleed-
ing is completed.
9) Turn the ignition switch to ON.
10) Set the select lever to “P” range, and then wait
for more than 3 seconds.
11) Set the select lever to “R” range, and then wait
12) Set the select lever to “N” range, and then wait
13) Set the select lever to “D” range, and then wait
14) Set the select lever to “N” range, and then wait
15) Slowly depress the accelerator pedal fully.
16) Slowly release the accelerator pedal fully.
18) Set the select lever to “D” range.
19) Turn the Subaru Select Monitor switch to ON.
20) Select {Each System Check} in «Main Menu»
of Subaru Select Monitor.
21) On the «System Selection Menu» display
screen, select “Transmission”. Air bleeding of con-
trol valve starts on transmission. At this time, the
SPORT indicator light in combination meter blinks
at 2 Hz. When the SPORT indicator light does not
blink, repeat the procedures from step 4).
22) Air bleeding of control valve is finished when
blinking of SPORT indicator light in combination
meter goes off from 2 Hz.
NOTE:
When blinking of SPORT indicator light changes
from 2 Hz to 4 Hz during air bleeding, repeat the
procedure from step 4).
23) Set the select lever to “N” range, and then turn
the ignition switch to OFF.
24) Set the select lever to “P” range, and then finish
the air bleeding.
4AT-63
ATF Filter
19.ATF Filter
A: REMOVAL
NOTE:
The ATF filter is maintenance free.
2) Using the ST, remove the ATF filter.
ST 498545400 OIL FILTER WRENCH
(A)
ST
AT-00091
(A) ATF filter
B: INSTALLATION
1) Apply a thin coat of ATF to the oil seal part of
new ATF filter.
2) Install the ATF filter. Turn it by hand, being care-
ful not to damage oil seal.
3) Tighten the ATF filter using ST.
Calculate the ATF filter tightening torque using fol-
lowing formula.
T2 = L2/(L1 + L2) # T1
T1: 14 N!m (1.4 kgf-m, 10.1 ft-lb)
[Required torque setting]
T2: Tightening torque
L1: ST length 78 mm (3.07 in)
L2: Torque wrench length
Example:
Torque wrench length Tightening torque
mm (in) N!m (kgf-m, ft-lb)
100 (3.94) 7.7 (0.79, 5.7)
150 (5.91) 9.0 (0.92, 6.7)
200 (7.87) 10 (1.0, 7.2)
NOTE:
Install the ST straightly to converter case.
4) Fill the ATF.
5) Inspect the level of ATF. <Ref. to 4AT-31, Auto-
C: INSPECTION
Check for rust, hole, ATF leaks, and other damage.
4AT-64
Transmission Control Module (TCM)
20.Transmission Control Mod- B: INSTALLATION

ule (TCM) 1) Install the TCM.
• LHD model
A: REMOVAL Tightening torque:
1) Disconnect the ground cable from battery. 7.5 N!m (0.76 kgf-m, 5.5 ft-lb)
2) Remove the lower cover and the connector.
3) Replace the body integrated unit. <Ref. to SL-
46, REMOVAL, Body Integrated Unit.>
4) Disconnect the connector from TCM.
• LHD model
(A)
(B)
(A)
AT-02170
(B)
(A) Transmission control module (TCM)
(B) Brake pedal
AT-02170 • RHD model

(A) Transmission control module (TCM) Tightening torque:
(B) Brake pedal 7.5 N!m (0.76 kgf-m, 5.5 ft-lb)
• RHD model (B)
(B)
(A) AT-01342
(A) AT-01342 (A) Transmission control module (TCM)

(B) Steering column
(B) Steering column 2) Connect the connector to TCM.
5) Remove the TCM. 4) Execute the learning control promotion. <Ref. to
4AT(diag)-19, FACILITATION OF LEARNING
tor.>
4AT-65
Lateral G Sensor
21.Lateral G Sensor • RHD model

T1: 7.5 N!m (0.76 kgf-m, 5.5 ft-lb)
T2: 24.5 N!m (2.5 kgf-m, 18.1 ft-lb)
2) Disconnect the connector from lateral G sensor.
• LHD model
T2 T1
AT-01719
AT-02181
• RHD model
AT-01343
3) Remove the lateral G sensor.

B: INSTALLATION
• LHD model
Tightening torque:
24.5 N!m (2.5 kgf-m, 18.1 ft-lb)
AT-02181
4AT-66
ATF Cooler Pipe and Hose
22.ATF Cooler Pipe and Hose • When hard to remove the hose, wrap the hose
with cloth to prevent from damaging, and then turn
A: REMOVAL with pliers and pull out with hand straightly.
1. MODEL WITHOUT ATF COOLER WITH
WARMER FUNCTION
2) Remove the battery.
4) Remove the under cover.
5) Remove the radiator under cover.
AT-01333
8) Disconnect the ATF cooler pipe from frame.
AT-01344
6) Disconnect the ATF cooler hose from radiator.

NOTE:
• Do not use a screwdriver or other pointed tools.
• When hard to remove the hose, wrap the hose
with pliers and pull out with hand straightly.
AT-01347
9) Remove the oil cooler inlet and outlet pipes.

AT-01345
7) Disconnect the ATF cooler hoses from pipes.

NOTE:
4AT-67
NOTE: 6) Remove the ATF cooler assembly from trans-

When disconnecting the outlet pipe, be careful not mission body, and put it aside.
to lose the ball and spring used with retaining
screw.
(A)
(B)
AT-01348
(A) Inlet pipe

(B) Outlet pipe
2. MODEL WITH ATF COOLER WITH

WARMER FUNCTION
2) Remove the air intake chamber. <Ref. to
IN(H4SO 2.0)-8, REMOVAL, Air Intake Chamber.> AT-02164
3) Disconnect the transmission harness connector 7) Remove the oil charge pipe. <Ref. to 4AT-79,
and remove it from stay. REMOVAL, Oil Charge Pipe.>
4) Remove the harness bracket. 8) Remove the air breather hose. <Ref. to 4AT-78,
REMOVAL, Air Breather Hose.>
AT-02179
5) Disconnect the inlet and outlet hoses.
(A)
(B)
AT-02180
(A) Inlet hose

(B) Outlet hose
4AT-68
9) Remove the oil cooler inlet and outlet pipes. 2) Install the ATF cooler pipe to frame.
CAUTION:
When disconnecting the outlet pipe, be careful
not to lose the ball and spring used with retain-
ing screw.
(A)
(B)
(B)
(A)
AT-01347
3) Connect the ATF cooler hose to pipe on trans-

mission side.
NOTE:
AT-01870 • Install so that the hose is not folded over, exces-
sively bent, or twisted.
(A) ATF cooler outlet pipe
• Be careful to insert the hose to the specified po-
(B) ATF cooler inlet pipe sition.
B: INSTALLATION
1. MODEL WITHOUT ATF COOLER WITH
WARMER FUNCTION
1) Install the oil cooler inlet pipe and outlet pipe with
new washer.
Tightening torque:
T1: 25 N!m (2.5 kgf-m, 18.1 ft-lb)
T2: 44 N!m (4.5 kgf-m, 32.5 ft-lb)
AT-01333
4) Connect the ATF cooler hose to pipe on radiator

side.
NOTE:
T1 • Install so that the hose is not folded over, exces-
T2
T1
AT-01340
4AT-69
• Be careful to insert the hose to the specified po- 2. MODEL WITH ATF COOLER WITH
sition. WARMER FUNCTION
1) Install the ATF cooler inlet pipe and outlet pipe.
NOTE:
Use new washers.
Tightening torque:
T1: 25 N!m (2.5 kgf-m, 18.1 ft-lb)
T2: 21 N!m (2.1 kgf-m, 15.5 ft-lb)
T3: 41 N!m (4.2 kgf-m, 30.4 ft-lb)
T4: 45 N!m (4.6 kgf-m, 33.2 ft-lb)
AT-01345
5) Install the radiator under cover.

Tightening torque:
4.9 N!m (0.5 kgf-m, 3.6 ft-lb) T3
T1
T2
AT-01344

7) Install the battery.
8) Fill the ATF. <Ref. to 4AT-31, Automatic Trans-
mission Fluid.>
T2 T4
NOTE: AT-01871
Make sure there are no ATF leaks in joints between
the transmission, radiator, pipes, and hoses.
4AT-70
2) Install the ATF cooler assembly to transmission. 5) Install the harness bracket.
23 N!m (2.3 kgf-m, 16.6 ft-lb) T1: 16 N!m (1.6 kgf-m, 11.6 ft-lb)
T2: 36 N!m (3.6 kgf-m, 26.0 ft-lb)
T1
T2
AT-02208
6) Install the inhibitor switch and transmission har-

ness connector to the stay, and then connect the
harness connector.
7) Install the air breather hose. <Ref. to 4AT-78, IN-
STALLATION, Air Breather Hose.>
8) Install the air intake chamber. <Ref. to IN(H4SO
2.0)-8, INSTALLATION, Air Intake Chamber.>
9) Check the ATF level. <Ref. to 4AT-31, INSPEC-
TION, Automatic Transmission Fluid.>
AT-02164
C: INSPECTION
3) Install the oil charge pipe. <Ref. to 4AT-79, IN- Repair or replace any defective hoses, pipes,
STALLATION, Oil Charge Pipe.> clamps, and washers found in the inspection be-
4) Connect the inlet and outlet hoses. low.
1) Check for ATF leaks in joints between the trans-
mission, radiator, pipes, and hoses.
(A)
2) Check for deformed clamps.
3) Lightly bend the hose and check for cracks in the
(B) surface and other damage.
4) Pinch the hose with your fingers and check for
poor elasticity. Also check for poor elasticity in the
parts where the clamp was installed by pressing
with your fingernail.
5) Check for peeling, cracks and deformation at the
AT-02180
tip of the hose.
(A) Inlet hose
(B) Outlet hose
4AT-71
ATF Cooler (with warmer function)
23.ATF Cooler (with warmer 7) Disconnect the engine coolant inlet hose from
cylinder block.
function)
A: REMOVAL
1) Drain the engine coolant. <Ref. to CO(H4SO
2.0)-13, REPLACEMENT, Engine Coolant.>
IN(H4SO 2.0)-8, REMOVAL, Air Intake Chamber.>
3) Disconnect the engine harness, and then re-
move the engine harness connector from engine
harness bracket.
4) Remove the engine harness bracket. AT-02173
8) Remove the ATF cooler assembly from trans-

mission.
AT-02179
5) Disconnect the ATF cooler hose from the pipe

on transmission side.
AT-02171
AT-02164
6) Disconnect the engine coolant outlet hose from
warmer cock assembly.
AT-02172
4AT-72
B: INSTALLATION 4) Connect the ATF cooler hose to pipe on trans-

1) Install the ATF cooler assembly to transmission. mission side.
Tightening torque:
23 N!m (2.3 kgf-m, 16.6 ft-lb)
AT-02171
5) Install the engine harness bracket.

Tightening torque:
T1: 16 N!m (1.6 kgf-m, 11.6 ft-lb)
T2: 36 N!m (3.6 kgf-m, 26.0 ft-lb)
T1
T2
AT-02164
2) Connect the engine coolant inlet hose to cylinder AT-02208

block.
6) Install the harness connector to bracket, and
then connect the harness.
8) Fill the engine coolant. <Ref. to CO(H4SO 2.0)-
13, REPLACEMENT, Engine Coolant.>
9) Check the ATF level. <Ref. to 4AT-31, INSPEC-
TION, Automatic Transmission Fluid.>
AT-02173
3) Connect the engine coolant outlet hose to warm-

er cock assembly.
AT-02172
4AT-73
C: DISASSEMBLY D: ASSEMBLY
1) Remove each hose from ATF cooler. 1) Install the clip to bracket.
(A)
(D)
(B)
(C) AT-02176
2) Install the bracket.

Tightening torque:
23 N!m (2.3 kgf-m, 16.6 ft-lb)
(C)
AT-02174
(A) ATF cooler inlet hose

(B) ATF cooler outlet hose
AT-02175
(C) Engine coolant inlet hose
(D) Engine coolant outlet hose
2) Remove the bracket from ATF cooler.
AT-02175
3) Remove the clip from bracket.
AT-02176
4AT-74
3) Install each hose to ATF cooler.

NOTE:
Pay attention to the orientation of hose.
(A)
(D)
(B)
(C)
(C)
AT-02174
(A) ATF cooler inlet hose

(B) ATF cooler outlet hose
(C) Engine coolant inlet hose
(D) Engine coolant outlet hose
E: INSPECTION
Repair or replace any defective hoses, pipes,
clamps and washers found from the inspection be-
low.
1) Check each connection for ATF or engine cool-
ant leakage.
2) Check the clamp for deformation.
surface and other damage.
5) Check the end of each hose for peeling, cracks
and deformation.
6) Check the ATF cooler for damage.
4AT-75
Warmer Cock
24.Warmer Cock B: INSTALLATION

1) Install the bracket, and then install the throttle
A: REMOVAL body.
IN(H4SO 2.0)-8, REMOVAL, Air Intake Chamber.> Tightening torque:
2) Remove all hoses from warmer cock. 16 N!m (1.6 kgf-m, 11.6 ft-lb)
AT-02163 AT-02166
3) Remove the warmer cock. 2) Install the warmer cock.

Tightening torque:
T1: 6.4 N!m (0.65 kgf-m, 4.7 ft-lb)
T2: 15 N!m (1.5 kgf-m, 10.8 ft-lb)
T2
AT-02165
T1
4) Remove the throttle body as necessary, and
then remove the bracket.
AT-02168
3) Connect the hoses to warmer cock.
AT-02166
AT-02163

4AT-76
Warmer Cock
C: DISASSEMBLY
Remove the bolt on warmer cock, and remove the
thermostat.
AT-02177
D: ASSEMBLY
Assemble in the reverse order of disassembly.
Tightening torque:
6.4 N!m (0.65 kgf-m, 4.7 ft-lb)
E: INSPECTION
Replace the thermostat if the valve does not close
completely at an ambient temperature or if the fol-
lowing test shows unsatisfactory results.
• Inspection method
Immerse the thermostat and a thermometer in wa-
ter. Raise water temperature gradually, and mea-
sure the temperature and valve lift when the valve
begins to open and when the valve is fully opened.
During the test, agitate the water for even temper-
ature distribution. The measurement should con-
form to the specification.
Starting temperature to open:
69 — 73"C (156 — 163"F)
Fully opens:
84"C (183"F)
Valve lift:
8.0 mm (0.315 in) or more
(A)
(B)
CO-00033
(A) Thermometer
(B) Thermostat
4AT-77
Air Breather Hose
25.Air Breather Hose

A: REMOVAL
Chamber.>
2) Disconnect the air breather hose.
AT-00099
(A) Air breather hose (Transmission case)

(B) Air breather hose (Oil pump housing)
B: INSTALLATION
1) Install the air breather hose.
AT-00099

(B) Air breather hose (Oil pump housing)

take Chamber.>
C: INSPECTION
Make sure the hose is not cracked or clogged.
4AT-78
Oil Charge Pipe
26.Oil Charge Pipe B: INSTALLATION

1) Install the oil charge pipe with a new O-ring ap-
A: REMOVAL plied with ATF.
1) Remove the air intake chamber. • Model with ATF cooler with warmer function
Chamber.> Tightening torque:
2) Remove the oil charge pipe, and then remove 41 N!m (4.2 kgf-m, 30.4 ft-lb)
the O-ring from flange side.
• Model with ATF cooler with warmer function (A)
(A)
(B)
AT-02178
(B)
AT-02178 (A) Oil level gauge
(B) Oil charge pipe
(A) Oil level gauge
(B) Oil charge pipe
• Model without ATF cooler with warmer function
Tightening torque:
• Model without ATF cooler with warmer function 41 N!m (4.2 kgf-m, 30.4 ft-lb)
(A)
(A)
(B)
(B)
AT-02209
AT-02209
(A) Oil level gauge

(A) Oil level gauge
(B) Oil charge pipe
(B) Oil charge pipe

take Chamber.>
C: INSPECTION
Make sure the oil charge pipe is not deformed or
damaged.
4AT-79
Torque Converter Clutch Assembly
27.Torque Converter Clutch As- B: INSTALLATION

sembly 1) Install the shaft to the converter case when oil
pump shaft is removed.
A: REMOVAL 2) Install the oil pump shaft to torque converter
1) Remove the transmission assembly from vehi- clutch, and then make sure that the clip is secured
cle. <Ref. to 4AT-40, REMOVAL, Automatic Trans- on groove.
mission Assembly.> 3) Apply ATF to O-ring and insert the input shaft
2) Pull out the torque converter clutch and oil pump with rotating it by hand lightly.
shaft horizontally. Normal protrusion A:
NOTE: 50 — 55 mm (1.97 — 2.17 in)
Be sure not to scratch the inside of bushing in oil
pump shaft.
AT-00291
4) With holding the torque converter clutch assem-

AT-00113
bly by hands, carefully install to the converter case.
3) Remove the input shaft. Take care not to damage the bushing. Do not con-
NOTE: tact the oil pump shaft bush with starter shaft part of
When removing the torque converter clutch assem- oil pump cover inappropriately.
bly, the input shaft is also removed. 5) Lightly rotating the shaft by hands to engage the
spline securely, and then check it is within the di-
mension A.
Dimension A:
2.0 L model
1.1 — 1.3 mm (0.043 — 0.051 in)
(A)
AT-00114
4) Remove the oil pump shaft from the torque con-

verter clutch as necessary.
AT-01352
(A) Dimension A
4AT-80
Torque Converter Clutch Assembly
2.5 L model
2.7 — 2.9 mm (0.106 — 0.114 in)
(A)
AT-00311
(A) Dimension A
6) Install the transmission assembly into vehicle.

<Ref. to 4AT-43, INSTALLATION, Automatic
Transmission Assembly.>
C: INSPECTION
Make sure the ring gear and protrusion of torque
converter clutch end are not deformed or damaged.
4AT-81
Extension Case
28.Extension Case 4) Tighten bolts to secure extension case.

25 N!m (2.5 kgf-m, 18.1 ft-lb)
1) Remove the transmission assembly.
<Ref. to 4AT-40, REMOVAL, Automatic Transmis-
sion Assembly.>
• MPT model
(A)
AT-00118
5) Install the rear vehicle speed sensor.

Tightening torque:
7 N!m (0.7 kgf-m, 5.1 ft-lb)
AT-02207
• MPT model
(A)
• VTD model
(A) AT-02207

AT-00117
• VTD model
3) Separate the transmission case and extension

case part.
(A)
AT-00117
AT-00118
6) Install the transmission assembly.
B: INSTALLATION Transmission Assembly.>
1) Attach the selected thrust needle bearing to the
end surface of reduction drive gear with vaseline.
NOTE:
Install the thrust needle bearing in correct direction.
2) Install a new gasket.
3) Install the extension case to transmission case.
4AT-82
Extension Case
C: DISASSEMBLY 2. VTD MODEL

1. MPT MODEL 1) Remove the snap ring using ST1, ST2, ST3 and
a press.
1) Take out the transfer clutch by lightly tapping the ST1 398673600 COMPRESSOR
end of rear drive shaft. ST2 498627100 SEAT
NOTE: ST3 398663600 PLIERS
Be careful not to damage the oil seal of extension
case. ST1
ST2
ST3
(A)
(B) AT-00121
2) Remove the test plug.

AT-00119
(A)
(A) Extension case
(B) Transfer clutch
2) Remove the transfer clutch pipe without deform-

ing the pipe.
(A)
(B)
AT-00122
(B)
(A) Extension case
(B) Test plug
3) Remove the clutch piston using compressed air.
AT-00120
(A) Extension case

(B) Transfer clutch pipe
3) Remove the dust cover from extension case.

4) Remove the oil seal from extension case.
AT-00123
4AT-83
Extension Case
4) Remove transfer clutch pipe without deforming • Press-fit the clutch assembly to bottom of bear-
the pipe. ing shoulder completely.
(A)
(B)
AT-00124 AT-00125
(A) Transfer clutch
(B) Extension case
D: ASSEMBLY
2. VTD MODEL
1. MPT MODEL
1) Press new oil seal using ST and press.
1) Press-fit new oil seal using ST and press.
2) Press-fit the dust cover.
3) Install the transfer clutch pipe to extension case
3) Install the transfer clutch pipe to extension case
without deforming the pipe.
without deforming the pipe.
(A)
(B)
AT-00124
AT-00120
4) Apply ATF to a new O-ring and install the test
(A) Extension case plug.
(B) Transfer pipe
Tightening torque:
4) Install the transfer clutch assembly to the case. 13 N!m (1.3 kgf-m, 9.4 ft-lb)
NOTE: (A)
• Be careful not to damage the seal ring.
(B)
AT-00122
(A) Test plug

(B) Extension case
4AT-84
Extension Case
5) Insert the multi-plate clutch, drive plates, driven

plates, and spring retainer.
(A)
(B)
AT-00126
(A) Spring retainer

(B) Multi-plate clutch (LSD) piston assembly
6) Install the snap ring using special tools 1, 2, and

3.
ST1 398673600 COMPRESSOR
ST2 498627100 SEAT
ST3 398663600 PLIERS
ST1
ST2
ST3
AT-00121
E: INSPECTION
• Spray compressed air, and make sure the trans-
fer pipe and extension case routes are not clogged
and have no leaks.
• Measure the extension end play and adjust it to
within specifications.
MPT model
<Ref. to 4AT-89, MPT MODEL, ADJUSTMENT,
Transfer Clutch.>
VTD model
<Ref. to 4AT-90, VTD MODEL, ADJUSTMENT,
Transfer Clutch.>
4AT-85
Transfer Clutch
29.Transfer Clutch C: DISASSEMBLY

1) Remove the seal ring.
A: REMOVAL
1) Remove the transmission assembly from vehi-
cle. <Ref. to 4AT-40, REMOVAL, Automatic Trans-
mission Assembly.>
2) Remove the extension case, and then remove
the transfer clutch. <Ref. to 4AT-82, REMOVAL,
Extension Case.> <Ref. to 4AT-83, DISASSEM-
BLY, Extension Case.>
B: INSTALLATION
1) Select the thrust needle bearing. <Ref. to 4AT-
AT-00127
89, ADJUSTMENT, Transfer Clutch.>
2) Install the transfer clutch assembly to the case. (A) Seal ring
(B) Transfer clutch
(A) 2) Remove the ball bearing using ST and press.

ST 498077600 REMOVER
(B)
AT-00125
(A) Transfer clutch

(B) Extension case
AT-00128
3) Tighten the bolts to secure the case.
3) Remove the snap ring, and then take out the
Tightening torque: pressure plate, drive plate and driven plate.
25 N!m (2.5 kgf-m, 18.1 ft-lb)
AT-00129
AT-00118
4) Install the transmission assembly into vehicle. (A) Snap ring

<Ref. to 4AT-43, INSTALLATION, Automatic (B) Transfer clutch
4) Using the ST1, ST2 and ST3, remove the snap
ring, and then take out the return spring and trans-
fer clutch piston seal.
4AT-86
Transfer Clutch
ST1 399893600 PLIERS 2) Install the return spring to transfer clutch piston.
ST3 398623600 SEAT
(A)
ST1 ST2
(A) ST3
(B)
AT-00133
(B) AT-00130 (A) Return spring

(B) Rear drive shaft
(A) Snap ring
(B) Transfer piston seal
3) Apply ATF to the lip of transfer clutch piston seal
and install it.
5) Apply compressed air to the rear drive shaft to
remove transfer clutch piston.
(B)
(A) AT-00134
AT-00131 (A) Transfer clutch piston seal

D: ASSEMBLY
1) Install the transfer clutch piston. 4) Install the ST to the rear drive shaft.
ST 499257300 SNAP RING OUTER GUIDE
ST
(A)
(A)
(B) AT-00132
AT-00135
(A) Transfer clutch piston
(B) Rear drive shaft (A) Transfer clutch
4AT-87
Transfer Clutch
5) Install the snap ring to ST. 8) Apply compressed air to see if the assembled
ST 499257300 SNAP RING OUTER GUIDE parts move smoothly.
(A) ST
(B)
AT-00136 AT-00139
9) Check clearance between snap ring and pres-

(A) Snap ring
sure plate. <Ref. to 4AT-89, INSPECTION, Trans-
(B) Transfer clutch
fer Clutch.>
6) Install the snap ring to rear drive shaft using ST1 10) Press-fit new ball bearing using ST.
and ST2. ST 899580100 INSTALLER
ST1 499257300 SNAP RING OUTER GUIDE
ST2 499247400 INSTALLER
ST
ST2
(A)
ST1
(A)
AT-00140
(B)
(A) Ball bearing
AT-00137
11) Apply vaseline to a new seal ring and attach to
(A) Snap ring
the seal ring groove of the shaft.
(B) Transfer clutch
NOTE:
7) Install the driven plate, drive plate, pressure While installing the seal ring, not to expand the seal
plate and snap ring. ring excessively.
(A)
(B)
(A)
AT-00138 AT-00141
(A) Snap ring (A) Seal ring

(B) Transfer clutch
4AT-88
Transfer Clutch
12) Install the transfer clutch assembly without 4) Check that the tight corner braking does not oc-
damaging seal ring. cur when the vehicle is started with steering wheel
held at fully turned position. If tight corner braking
occurs, perform the following procedures.
(A) (1) With the steering wheel held at fully turned
position, drive the vehicle in “D” range and with
vehicle speed at approx. 5 km/h (3 MPH) in both
clockwise and counterclockwise directions for
approx. ten times each, while repeating acceler-
ation and braking intermittently.
(B) (2) If the tight corner braking still persists, drive
the vehicle again in a circle for several laps.
AT-00125
F: ADJUSTMENT
(A) Transfer clutch
1. MPT MODEL
(B) Extension case
1) Measure the distance “A” from the end of exten-
E: INSPECTION sion case to rear drive shaft using ST.
• Inspect the drive plate facing for wear and dam- ST 398643600 GAUGE
age.
• Inspect the snap ring for wear, return spring for
permanent distortion, breakage and deformation.
• Inspect the D-ring for damage.
ST
• Inspect the extension end play and adjust it to
within specifications. <Ref. to 4AT-89, ADJUST-
MENT, Transfer Clutch.>
1) Check clearance between snap ring and pres-
sure gauge.
A
2) Before measuring clearance, place the same
AT-01029
thickness of shim on both sides to prevent pressure
plate from tilting. 2) Measure the distance “B” from the transmission
3) If the clearance is not within specification, adjust case mating surface to the reduction drive gear end
it by selecting a suitable pressure plate on transfer surface using ST1 and ST2.
clutch piston side. ST1 398643600 GAUGE
ST2 499577000 GAUGE
Initial standard:
0.7 — 1.1 mm (0.028 — 0.043 in)
ST2 ST1
Limit thickness:
1.6 mm (0.063 in)
AT-02210
AT-00142
Pressure plate
Part number Thickness mm (in)
31593AA151 3.3 (0.130)
31593AA161 3.7 (0.146)
31593AA171 4.1 (0.161)
31593AA181 4.5 (0.177)
4AT-89
Transfer Clutch
3) Calculation formula: 2. VTD MODEL

NOTE: 1) Insert the rear drive shaft into the reduction drive
Calculate “T”: gear and center differential assembly.
T = A $ B + 35.4 mm
[T = A $ B + 1.3937 in]
(A)
T: Thrust needle bearing thickness
A: Distance from end of extension case to end of
rear drive shaft
B: Distance from end of transmission case to end of
reduction drive gear
Example:
When, A = 33.6 mm (1.3228 in), B = 65.05 mm
(2.5610 in)
(B)
T = 33.6 $ 65.05 + 35.4 = 3.95 AT-02211
[T = 1.3228 $ 2.5610 + 1.3937 = 0.1555]

(A) Rear drive plate
After calculation, the value of “T” becomes 3.95,
(B) Center differential carrier
therefore select bearing thickness of 3.8 mm (0.150
in). 2) Using the ST, measure the distance “A” between
NOTE: the mating surface of extension case and the sur-
Calculation formula for “T” is applied when measur- face of rear drive shaft ball bearing outer race.
ing using ST (398643600 GAUGE, 499577000 ST 398643600 GAUGE
GAUGE). When not using ST, apply
T = (A $ % + 0.45 mm) $ (B $ &) $ H
[T = (A $ % + 0.0177 in) $ (B $ &) $ H] ST

A: Distance from end of extension case to end of A
reduction drive shaft
rear drive shaft
%: Collar thickness used when measuring “A”
AT-01031
&: Collar thickness used when measuring “B”
0.45: Gasket thickness (mm) A: Measured value
0.0177: Gasket thickness (in)
H: Shim clearance 3) Using the ST, measure the distance “B” between
the mating surface of transmission case and rear
Thrust needle bearing drive shaft ball bearing.
Part number Thickness mm (in) ST 398643600 GAUGE
806536020 3.8 (0.150)
806535030 4.0 (0.157) ST
806535040 4.2 (0.165)
806535050 4.4 (0.173)
806535060 4.6 (0.181)
806535070 4.8 (0.189)
806535090 5.0 (0.197)
AT-01032
B: Measured value
4AT-90
Transfer Clutch
4) Formula:
NOTE:
• Calculation of “T”:
When clearances are 0.05 mm (0.0020 in), select
up to four adjusting shims from the table, suitable
for clearance value.
When clearances are 0.05 mm (0.0020 in)
T = A $ B + 0.40 mm
[T = A $ B + 0.0157 in]
When clearances are 0.25 mm (0.0098 in)
T = A $ B + 0.20 mm
[T = A $ B + 0.0079 in]
T: Shim clearance
A: Distance between extension case edge and rear
driveshaft edge
B: Distance between transmission case edge and
reduction drive gear edge
T: Shim thickness
0.05 — 0.25 mm (0.0020 — 0.0098 in)
Example:
When, A = 90.50 mm (3.5630 in), B = 90.35 mm
(3.5571 in)
Calculation for 0.05 mm (0.0020 in) of clearance
T = 90.50 $ 90.35 + 0.4 = 0.55
[T = 3.5630 $ 3.5571 + 0.0157 = 0.0216]
Calculation when clearance is 0.25 mm (0.0098 in)
T = 90.50 $ 90.35 + 0.2 = 0.35
[T = 3.5630 $ 3.5571 + 0.0079 = 0.0138]
• Calculation formula for “T” is applied when mea-
suring using ST (398643600 GAUGE). When not
using ST, apply
T = (A $ % + 0.45 mm) $ (B $ &) $ H
[T = (A $ % + 0.0177 in) $ (B $ &) $ H].
A: Distance from end of extension case to end of
surface of rear drive shaft ball bearing outer race
rear drive shaft ball bearing
0.45: Gasket thickness (mm)
H: Shim clearance
After calculation, the value of “T” becomes between
0.35 mm (0.0138 in) and 0.55 mm (0.0216 in),
therefore select two shims with thickness of 0.2 mm
(0.010 in) or one shim with thickness of 0.5 mm
(0.020 in).
Adjusting shim
Part No. Thickness mm (in)
33281AA001 0.2 (0.008)
33281AA011 0.5 (0.020)
4AT-91
Multi-plate Clutch
30.Multi-plate Clutch ST 398744300 GAUGE
A: REMOVAL
Remove the multi-plate clutch following the same
instructions as for the extension case. <Ref. to
4AT-82, REMOVAL, Extension Case.>
ST
B: INSTALLATION B
Install the multi-plate clutch following the same in-

structions as for the extension case. <Ref. to 4AT-
82, INSTALLATION, Extension Case.>
C: INSPECTION AT-01033
• Inspect the drive plate facing for wear and dam-

B: Measured value
age.
• Make sure the snap ring is not worn and the re- 4) Calculation formula
turn spring has no permanent distortion, damage, T = A $ B + 0.45 mm
or deformation. [T = A $ B + 0.0177 in]
• Inspect the lathe cut seal ring for damage.
• Measure the multi-plate clutch clearance and ad- NOTE:
just it to within the specification range. <Ref. to • Calculation formula for “T” is applied when mea-
4AT-92, ADJUSTMENT, Multi-plate Clutch.> suring using ST (398643600 GAUGE, 398744300
GAUGE). When not using ST, apply
D: ADJUSTMENT T = (A $ % + 0.45 mm) $ (B $ &)
1) Remove the drive plate and driven plate from [T = (A $ % + 0.0177 in) $ (B $ &)].
center differential carrier. T: Thrust needle bearing thickness
2) Using the ST, measure the distance “A” from the A: Distance from end of extension case to end of
extension case joining surface to the multi-plate reduction drive shaft
clutch piston. B: Distance from end of transmission case to end of
ST 398643600 GAUGE rear drive shaft
ST 0.45: Gasket thickness (mm)
• Measure the multi-plate clutch (LSD) driven and
drive plate thickness to find the clearance between
A
measurement value and “T”.
Initial standard:
0.2 — 0.6 mm (0.008 — 0.024 in)
Limit thickness:
AT-01031
1.6 mm (0.063 in)
A: Measured value If the clearance exceeds the limit thickness, re-
place the plate set (drive and driven plate). Select a
3) Using the ST, measure the height “B” from the multi-plate clutch (LSD) piston driven plate that will
transmission case joining edge to the center differ- bring clearance within the standard value.
ential clutch drum edge.
Obtainable driven plates
31589AA041 1.6 (0.063)
31589AA050 2.0 (0.079)
31589AA060 2.4 (0.094)
31589AA070 2.8 (0.110)
4AT-92
Rear Drive Shaft
31.Rear Drive Shaft 2) Using a press, remove the front and rear side
ball bearings and clutch hub.
A: REMOVAL
1) Remove the transmission assembly. <Ref. to (B)
4AT-40, REMOVAL, Automatic Transmission As-
(A)
sembly.>
(C)
2) Remove the rear wheel speed sensor, and sep-
arate the extension case from transmission case.
<Ref. to 4AT-82, REMOVAL, Extension Case.>
3) Pull out the rear driveshaft from center differen-
tial assembly.
AT-00151
(A)
(A) Rear ball bearing
(B) Rear driveshaft
(C) Clutch hub
D: ASSEMBLY
NOTE:
(B) AT-02211 • Use a new revolution gear and ball bearings.
• Make sure the clutch hub is in the correct direc-
(A) Rear driveshaft
tion.
4) Remove the drive plate and driven plate. (B)
B: INSTALLATION
1) Select the appropriate shim. <Ref. to 4AT-90,
VTD MODEL, ADJUSTMENT, Transfer Clutch.> (A) (C)
2) Install the drive plate and driven plate.
3) Insert the rear driveshaft into center differential
assembly.
4) Combine the transmission case and extension (D)
case. Install the rear wheel speed sensor. <Ref. to AT-00152
4AT-82, INSTALLATION, Extension Case.>
5) Install the transmission assembly. <Ref. to 4AT- (A) Front side
43, INSTALLATION, Automatic Transmission As- (B) Clutch hub
sembly.> (C) Rear side
C: DISASSEMBLY (D) Revolution gear
1) Using a press, remove the revolution gear. E: INSPECTION
(A) • Inspect the parts to make sure there are no
holes, cuts, and that they are not dusty.
• Inspect the extension end play, and adjust it to
within the standard value. <Ref. to 4AT-90, VTD
MODEL, ADJUSTMENT, Transfer Clutch.>
AT-00149
(A) Revolution gear
4AT-93
Reduction Driven Gear
32.Reduction Driven Gear 3) Remove the rear drive shaft. <Ref. to 4AT-93,
REMOVAL, Rear Drive Shaft.>
A: REMOVAL 4) Set the range select lever to “P”.
5) Straighten the staked portion, and remove the
1. MPT MODEL lock nut.
mission Assembly.>
2) Remove the rear vehicle speed sensor, and then
separate the extension case from transmission
case. <Ref. to 4AT-82, REMOVAL, Extension
Case.>
3) Set the select lever to “P” range.
4) Remove the caulking part, and then remove the
lock nut.
AT-00155
(B) 6) Using the ST1 and ST2, extract the reduction
driven gear.
ST1 499737000 PULLER
(A) ST2 899524100 PULLER SET
7) Pull out the center differential assembly. <Ref.
to 4AT-98, REMOVAL, Center Differential Carri-
er.>
B: INSTALLATION
AT-02212
1. MPT MODEL
(A) Reduction driven gear 1) Set the select lever to “P” range.
(B) Reduction drive gear 2) Using a plastic hammer, install the reduction
driven gear assembly and new washer, and tighten
5) Using the ST1 and ST2, extract the reduction new drive pinion lock nut.
driven gear.
ST1 499737000 PULLER Tightening torque:
ST2 899524100 PULLER SET 100 N!m (10.2 kgf-m, 73.8 ft-lb)
(B) (B)
ST2 (A)
ST1
(A)
AT-00154 AT-02212
(A) Reduction driven gear (A) Reduction driven gear

(B) Reduction drive gear (B) Reduction drive gear
2. VTD MODEL 3) After tightening, stake the lock nut securely.

4) Combine the transmission case with extension
1) Remove the transmission assembly from vehi- case, and then install the rear vehicle speed sen-
cle. <Ref. to 4AT-40, REMOVAL, Automatic sor. <Ref. to 4AT-82, INSTALLATION, Extension
Transmission Assembly.> Case.>
2) Remove rear vehicle speed sensor, and sepa- 5) Install the transmission assembly into vehicle.
rate the extension case from transmission case. <Ref. to 4AT-43, INSTALLATION, Automatic
<Ref. to 4AT-82, REMOVAL, Extension Case.> Transmission Assembly.>
4AT-94
2. VTD MODEL 2) Remove the ball bearing from reduction driven

gear using ST.
2) Using a plastic hammer, install the reduction
driven gear assembly.
ST
3) Using a plastic hammer, install the center differ- (A)
ential assembly.
4) Install a new self-lock nut and a washer.
Tightening torque:
100 N!m (10.2 kgf-m, 73.8 ft-lb)
AT-00157
(A) Ball bearing
3) Remove the snap ring from reduction driven

gear.
D: ASSEMBLY
AT-00155 1) Install the snap ring to reduction driven gear.
5) After tightening, stake the lock nut securely. 2) Install the new ball bearing to reduction driven
gear using press.
6) Insert the rear drive shaft assembly. <Ref. to
4AT-93, INSTALLATION, Rear Drive Shaft.>
case, and install the rear vehicle speed sensor.
<Ref. to 4AT-82, INSTALLATION, Extension
Case.> (A)
8) Install the transmission assembly to vehicle.
C: DISASSEMBLY
1) Remove the snap ring from reduction driven AT-00158
gear.
(A) Ball bearing
3) Install the snap ring to reduction driven gear.
(A)
(A)
AT-00156
(A) Snap ring

AT-00156
(A) Snap ring
E: INSPECTION
Make sure the ball bearing and gear is not de-
formed or damaged.
4AT-95
Reduction Drive Gear
33.Reduction Drive Gear C: DISASSEMBLY

1) Take out the seal ring.
A: REMOVAL
mission Assembly.>
(A)
Case.>
3) Remove the reduction driven gear. <Ref. to 4AT-
94, REMOVAL, Reduction Driven Gear.>
(B)
4) Using the ST, extract the reduction drive gear. AT-00161
ST2 899524100 PULLER SET (A) Seal ring
(B) Reduction drive shaft
(A)
2) Remove the ball bearing using ST.
ST1
ST
(A)
ST2
AT-00159
(B)
(A) Reduction drive gear
B: INSTALLATION AT-00162
1) Install the reduction drive gear assembly.
(A) Ball bearing
NOTE: (B) Reduction drive gear
Press-fit it to the bottom of bearing shoulder com-
pletely. 3) Using the press, remove the reduction drive
gear.
(A)
(A)
AT-02213
AT-00163
2) Install the reduction driven gear. <Ref. to 4AT-
94, INSTALLATION, Reduction Driven Gear.> D: ASSEMBLY
3) Combine the transmission case with extension 1) Press-fit the reduction drive gear to shaft.
case, and then install the rear vehicle speed sen- 2) Press-fit the new ball bearing into reduction drive
sor. <Ref. to 4AT-82, INSTALLATION, Extension gear.
Case.> 3) Apply vaseline to the outer surface of seal ring
4) Install the transmission assembly into vehicle. and shaft groove.
4AT-96
Reduction Drive Gear
4) Apply ATF to new seal rings and install them.
(A)
(B)
AT-00161
(A) Seal ring

(B) Reduction drive shaft
E: INSPECTION
• Rotate the bearing by hand, make sure it rotates
smoothly.
• Check that the holes, damages or other foreign
matters are not on each parts.
4AT-97
Center Differential Carrier
34.Center Differential Carrier C: DISASSEMBLY

1) Remove the seal rings.
A: REMOVAL
cle. <Ref. to 4AT-40, REMOVAL, Automatic
arate the extension case from transmission case.
<Ref. to 4AT-82, REMOVAL, Extension Case.>
3) Pull out the rear driveshaft. <Ref. to 4AT-93,
4) Using the STs, pull out the center differential car-
(A)
rier assembly. AT-00166
ST2 899524100 PULLER SET (A) Seal ring
2) Using a press and the ST, remove the ball bear-

ST1 ing.
ST2
AT-00164
5) Pull out the shim(s) from transmission case.

B: INSTALLATION
AT-00167
1) Install the center differential assembly with the
shim(s). 3) Remove the snap ring, and pull out the shaft
NOTE: from center differential assembly.
Insert the center differential assembly and shim(s)
completely into bearing shoulder bottom. (A)
(B)
AT-00168
(A) Snap ring

AT-00165
(B) Shaft
2) Insert the rear driveshaft. <Ref. to 4AT-93, IN-
STALLATION, Rear Drive Shaft.>
3) Connect the transmission case and extension
case, and install the rear wheel speed sensor.
<Ref. to 4AT-82, INSTALLATION, Extension
Case.>
4) Install the transmission assembly onto vehicle.
4AT-98
4) Remove the thrust washers, pinion gears, and

washers from center differential assembly.
(A)
AT-00169
(A) Pinion gear
5) Pull out the intermediate shaft and thrust bear-

ing.
D: ASSEMBLY
1) Install the thrust washer onto intermediate shaft.
2) Install the thrust bearing onto the intermediate
shaft.
3) Install the pinion gears and washers.
4) Insert the shaft into center differential assembly.
5) Install the snap ring.
6) Using a press, install a new ball bearing into cen-
ter differential assembly.
(A)
ST
(B)
AT-00170
(A) Plate
7) Apply vaseline onto the seal ring outer surface

and shaft grooves.
8) Install new seal rings.
E: INSPECTION
• Check all the parts for hole, score, or dirt.
• Check the play of the extension end, and if nec-
essary, adjust it. <Ref. to 4AT-90, VTD MODEL,
ADJUSTMENT, Transfer Clutch.>
4AT-99
CONTROL SYSTEMS CS

(DIAGNOSTICS)


approval.

4AT
Page
4. Road Test..................................................................................................34
5. Stall Test ...................................................................................................35
6. Time Lag Test ...........................................................................................37
19. ATF Filter ..................................................................................................64
21. Lateral G Sensor .......................................................................................66
24. Warmer Cock ............................................................................................76
26. Oil Charge Pipe.........................................................................................79
28. Extension Case .........................................................................................82
29. Transfer Clutch..........................................................................................86
31. Rear Drive Shaft........................................................................................93
35. Parking Pawl ...........................................................................................100
36. Converter Case .......................................................................................101
37. Oil Pump Housing ...................................................................................103
40. AT Main Case .........................................................................................119
Parking Pawl
35.Parking Pawl
A: REMOVAL
mission Assembly.>
Case.>
3) Remove the reduction drive gear. <Ref. to 4AT-
96, REMOVAL, Reduction Drive Gear.>
4) Remove the parking pawl, return spring and
shaft.
(A) (B)
AT-02214
(A) Return spring

(B) Parking pawl
B: INSTALLATION
1) Install the parking pawl, return spring and shaft.
(A) (B)
AT-02214
(A) Return spring

(B) Parking pawl
2) Install the reduction drive gear. <Ref. to 4AT-96,

INSTALLATION, Reduction Drive Gear.>
3) Install the extension case and rear vehicle speed
sensor. <Ref. to 4AT-82, INSTALLATION, Exten-
sion Case.>
4) Install the transmission assembly into the vehi-
cle. <Ref. to 4AT-43, INSTALLATION, Automatic
C: INSPECTION
Make sure that the tab of parking pawl on reduction
gear is not worn or otherwise damaged.
4AT-100
Converter Case
36.Converter Case • Be careful not to loosen the rubber seal.
A: REMOVAL
mission Assembly.>
2) Pull out the torque converter clutch assembly.
<Ref. to 4AT-80, REMOVAL, Torque Converter
Clutch Assembly.>
3) Remove the input shaft.
AT-00175
9) Remove the seal pipe.
AT-00114
4) Lift-up the lever on the rear side of connector,

and then disconnect it from the stay.
5) Disconnect the inhibitor switch connector from AT-00176
the stay.
(A) Seal pipe
(B) (A)
10) Remove the differential assembly. <Ref. to
4AT-113, REMOVAL, Front Differential Assem-
bly.>
11) Remove the oil seal from converter case.
B: INSTALLATION
1) Check the appearance of each component and
clean them.
2) Press-fit the oil seal to converter case using ST.
AT-01351 ST 398437700 DRIFT
(B) Inhibitor switch connector
6) Remove the oil charge pipe. <Ref. to 4AT-79,

REMOVAL, Oil Charge Pipe.>
<Ref. to 4AT-67, REMOVAL, ATF Cooler Pipe and
Hose.>
8) Remove the converter case aligning bolt, and
then separate the transmission case and converter
AT-00177
case by lightly tapping with plastic hammer.
3) Install the differential assembly to case. <Ref. to
NOTE:
4AT-113, INSTALLATION, Front Differential As-
• Be careful not to damage the oil seal and bush in-
sembly.>
side the converter case by the oil pump cover.
4) Install the left and right side retainers. <Ref. to
4AT-117, ADJUSTMENT, Front Differential As-
sembly.>
4AT-101
Converter Case
5) Install the new seal pipe to converter case. 8) Install the converter case assembly without
damaging bushing and oil seal.
Tightening torque:
41 N!m (4.2 kgf-m, 30.4 ft-lb)
AT-00176
(A) Seal pipe
6) Install the rubber seal to converter case. AT-00175
(A)
9) Insert the inhibitor switch and transmission con-
nector to the stay.
10) Install the air breather hose. <Ref. to 4AT-78,
INSTALLATION, Air Breather Hose.>
11) Install the oil cooler pipe. <Ref. to 4AT-69, IN-
STALLATION, ATF Cooler Pipe and Hose.>
12) Install the oil charge pipe with O-ring. <Ref. to
4AT-79, INSTALLATION, Oil Charge Pipe.>
13) Insert the input shaft with rotating it by hand
AT-00178 lightly, and then check the protrusion amount.
Normal protrusion A:
(A) Rubber seal
50 — 55 mm (1.97 — 2.17 in)
tire matching surface of converter case.
Liquid gasket:
THREE BOND 1215 (Part No. 004403007) A
(B)
AT-00291
14) Install the torque converter clutch assembly.

<Ref. to 4AT-80, INSTALLATION, Torque Convert-
er Clutch Assembly.>
(A) 15) Install the transmission assembly into vehicle.
AT-00179
(A) THREE BOND 1215 Transmission Assembly.>
(B) Rubber seal C: INSPECTION
Measure the backlash, and then adjust it within
specification. <Ref. to 4AT-110, ADJUSTMENT,
Drive Pinion Shaft Assembly.>
4AT-102
Oil Pump Housing
37.Oil Pump Housing NOTE:

• Be careful not to scratch the rear mating surface
A: REMOVAL of transmission case.
1) Remove the transmission assembly from vehi- • Note that the parking rod and drive pinion pro-
cle. <Ref. to 4AT-40, REMOVAL, Automatic Trans- trudes from mating surface.
mission Assembly.>
Clutch Assembly.>
55mm
(2.17in)
AT-00181
14) Remove the oil pump housing and adjusting

thrust washer.
AT-00114 (A)
4) Lift-up the lever on the rear side of transmission

harness connector, and then remove it from stay.
Hose.> AT-00182
8) Separate the converter case and transmission
case part. <Ref. to 4AT-101, REMOVAL, Converter (A) Oil pump housing
Case.>
9) Separate the transmission case and extension B: INSTALLATION
case part. <Ref. to 4AT-82, REMOVAL, Extension 1) Secure the oil pump housing with two nuts and a
Case.> bolt.
10) Remove the reduction drive gear. <Ref. to 4AT- Tightening torque:
96, REMOVAL, Reduction Drive Gear.> 42 N!m (4.3 kgf-m, 31 ft-lb)
11) Remove the reduction driven gear. <Ref. to
4AT-94, REMOVAL, Reduction Driven Gear.>
(A)
12) Loosen the oil pump housing mounting bolts.
AT-01035
(A) Oil pump housing

AT-01034
13) Place two wooden blocks on the workbench,

and stand the transmission case with its rear end
facing down.
4AT-103
Oil Pump Housing
2) Install the converter case assembly into trans- C: DISASSEMBLY

mission case assembly. <Ref. to 4AT-80, INSTAL-
LATION, Torque Converter Clutch Assembly.> 1. OIL PUMP COVER
3) Install the reduction driven gear. <Ref. to 4AT- 1) Remove four seal rings.
94, INSTALLATION, Reduction Driven Gear.>
4) Install the reduction drive gear. <Ref. to 4AT-96,
INSTALLATION, Reduction Drive Gear.>
(A)
case, and then install the rear vehicle speed sen-
sor. <Ref. to 4AT-82, INSTALLATION, Extension
Case.>
nector to the stay.
(B) (A) AT-00189
(A) Seal ring
2) Remove the cover by lightly tapping the end of

stator shaft.
(B)
(A)
AT-01351


8) Install the oil charge pipe with a O-ring. <Ref. to AT-00190
9) Insert the input shaft with rotating it by hand (A) Oil pump cover
lightly, and then check the protrusion amount. (B) Oil pump housing
Normal protrusion A: 3) Remove the inner and outer rotor.

50 — 55 mm (1.97 — 2.17 in)
(B)
(A)
AT-01036
AT-00291
(A) Inner rotor
10) Install the torque converter clutch assembly. (B) Outer rotor
4AT-104
Oil Pump Housing
2. OIL SEAL RETAINER D: ASSEMBLY

1) Remove the oil seal retainer. 1. OIL PUMP COVER
1) Install the oil pump rotor assembly to oil pump
housing.
(B)
(B)
(A)
(A)
AT-00183
(A) Oil seal retainer

(B) Drive pinion shaft AT-01036
2) Remove the O-ring. (A) Inner rotor

(B) Outer rotor
2) Align both pivots with the pivot holes of cover,

and then install the oil pump cover being careful not
to apply excessive force to the pivots.
(A)
Tightening torque:
25 N!m (2.5 kgf-m, 18.1 ft-lb)
(B)
(A)
AT-00186
(A) O-ring
3) Remove the oil seal from oil seal retainer.
(A)
AT-00190
(A) Oil pump cover

(B) Oil pump housing
3) After assembling, turn the oil pump shaft to

check the smooth rotation of rotor.
(B)
AT-00185
(A) Oil seal

(B) Oil seal retainer
4AT-105
Oil Pump Housing
4) Apply vaseline to the oil seal retainer and new 3) Install the oil seal and secure it using three bolts
seal rings, and install them. After installing, adjust being careful not to damage oil seal lip.
the tooth contact and backlash of drive pinion.
Tightening torque:
<Ref. to 4AT-107, ADJUSTMENT, Oil Pump Hous-
7 N!m (0.7 kgf-m, 5.1 ft-lb)
ing.>
(A)
(B)
(B)
(A)
AT-01307 AT-00183
(A) Seal ring (Black) (A) Oil seal retainer

(B) Seal ring (Brown) (B) Drive pinion shaft
2. OIL SEAL RETAINER E: INSPECTION

1) Check the seal ring and oil seal for breaks and
1) Apply ATF to new oil seals (two), and install damages.
them to the oil seal retainer in proper direction us- 2) Check other parts for dents or abnormalities.
ing ST. 3) Selection of oil pump rotor assembly
ST 499247300 INSTALLER (1) Tip clearance
(A)
Install the inner rotor and outer rotor to oil pump.
With rotor gears facing each other, measure the
crest-to-crest clearance.
Tip clearance:
0.02 — 0.15 mm (0.0008 — 0.0059 in)
(A)
(C)
(B)
AT-00185
(A) Oil seal

(B) Oil seal retainer (B)
2) Apply ATF to a new O-ring and install it to the oil

seal retainer. Install the seal to oil pump housing
AT-01038
bore.
(A) Thickness gauge
(B) Inner rotor
(C) Outer rotor
(A)
AT-00186
(A) O-ring
4AT-106
Oil Pump Housing
(2) Side clearance ST 398643600 GAUGE

Set a depth gauge to oil pump housing, then
measure the oil pump housing-to-rotor clear- ST
ance.
Side clearance:
0.02 — 0.04 mm (0.0008 — 0.0016 in)
(A)
(C) AT-00195
(B) 3) Calculation of total end play

Select the suitable bearing race from among those
listed in this table so that clearance C to be within
0.25 to 0.55 mm (0.0098 to 0.0217 in).
AT-01039
C = (L + G) "2
Clearance between concave portion of high
(A) Depth gauge C
clutch and end of clutch drum support
(B) Inner rotor Length from case mating surface to concave
(C) Outer rotor L
portion of high clutch
G Gasket thickness [0.28 mm (0.0110 in)]
(3) If the depth and/or side clearance are not
within the specifications, replace the rotor as- Height from housing mating surface to upper
2
surface of clutch drum support
sembly.
Oil pump rotor ASSY G
15008AA060 11.37 — 11.38 (0.4476 — 0.4480)
15008AA070 11.38 — 11.39 (0.4480 — 0.4484)
15008AA080 11.39 — 11.40 (0.4484 — 0.4488)
L
Measure the total end play and adjust it within
specifications. <Ref. to 4AT-107, ADJUST-
MENT, Oil Pump Housing.>
F: ADJUSTMENT AT-00196
1) Using the ST, measure the length “L”, which is
from the mating surface of transmission to the re- Thrust needle bearing
cessed portion of high clutch drum. Part number Thickness mm (in)
ST 398643600 GAUGE 806528050 4.1 (0.161)
806528060 4.3 (0.169)
806528070 4.5 (0.177)
ST 806528080 4.7 (0.185)
806528090 4.9 (0.193)
806528100 5.1 (0.201)
4) After completing the end play adjustment, insert

the bearing race in recess of the high clutch. Install
L
the thrust needle bearing to oil pump cover using
vaseline.
AT-00194 5) After correctly install the new gasket to the case
2) Using the ST, measure the length from oil pump mating surface, carefully install the oil pump hous-
housing mating surface to the top surface of oil ing assembly. Be careful to avoid hitting the drive
pump cover with thrust needle bearing. pinion against the inside of case.
6) Install both parts with dowel pins aligned. Make
sure no clearance at mating surface.
4AT-107
Drive Pinion Shaft Assembly
38.Drive Pinion Shaft Assembly 13) Remove the drive pinion shaft mounting bolt
and remove the drive shaft assembly from oil pump
A: REMOVAL housing.
mission Assembly.>
Clutch Assembly.>
AT-01252
B: INSTALLATION
1) Assemble the drive pinion assembly to oil pump
housing.
NOTE:
• Be careful not to bend the shim.
AT-00114 • Be careful not to press-fit the pinion into housing
4) Lift-up the lever on rear side of transmission har- bore.
ness connector, and then disconnect it from the Tightening torque:
stay. 40 N!m (4.0 kgf-m, 30 ft-lb)
5) Disconnect the inhibitor switch connector from
the stay.
6) Disconnect the air breather hose. <Ref. to 4AT-
78, REMOVAL, Air Breather Hose.>
Hose.>
case part. <Ref. to 4AT-101, REMOVAL, Converter AT-01252
Case.> 2) Combine the torque converter case with trans-
10) Separate the transmission case and extension mission case. <Ref. to 4AT-101, INSTALLATION,
case part. <Ref. to 4AT-82, REMOVAL, Extension Converter Case.>
Case.> 3) Install the reduction driven gear. <Ref. to 4AT-
11) Remove the reduction drive gear. <Ref. to 4AT- 94, INSTALLATION, Reduction Driven Gear.>
96, REMOVAL, Reduction Drive Gear.> 4) Install the reduction drive gear. <Ref. to 4AT-96,
12) Remove the reduction driven gear. <Ref. to INSTALLATION, Reduction Drive Gear.>
4AT-94, REMOVAL, Reduction Driven Gear.> 5) Combine the transmission case with the exten-
sion case, and then install the rear vehicle speed
sensor. <Ref. to 4AT-82, INSTALLATION, Exten-
sion Case.>
nector to the stay.
7) Install the oil cooler inlet and outlet pipes. <Ref.
to 4AT-69, INSTALLATION, ATF Cooler Pipe and
Hose.>
8) Install the oil charge pipe with O-ring.
lightly, and then check the protrusion amount.
4AT-108
Normal protrusion A: 4) Separate the front roller bearing from shaft using
50 — 55 mm (1.97 — 2.17 in) a press and ST.
ST 498517000 REPLACER
A (A)
ST
AT-00291
AT-00199
<Ref. to 4AT-80, INSTALLATION, Torque Convert- (A) Front roller bearing
11) Install the transmission assembly into vehicle. D: ASSEMBLY
<Ref. to 4AT-43, INSTALLATION, Automatic 1) Measure the dimension “A” of drive pinion shaft
Transmission Assembly.> ST 398643600 GAUGE
C: DISASSEMBLY
1) Remove the caulking part of lock nut, and then
remove the lock nut with holding the rear spline part
of shaft using ST1 and ST2. Pull out the drive pin-
ion collar.
ST1 498937110 HOLDER
ST2 499787700 WRENCH
ST3 499787500 ADAPTER
A AT-00200
ST3 2) Using a press, press-fit the new roller bearing

into specified position.
ST2 NOTE:
If excessive force is applied to roller bearing, the
ST1 roller bearing will not turn easily.
AT-00197
(A)
2) Remove the O-ring.
3) Separate the roller bearing and outer race from
shaft using press.
(B)
(A)
AT-00201
(A) Drive pinion shaft

(B) Roller bearing
3) After applying ATF to a new O-ring and fitting it

AT-00198 to the shaft, attach the drive pinion collar to shaft.
4) Install the lock washer to drive pinion shaft in
(A) Outer race proper direction.
4AT-109
5) Tighten the new lock nuts using ST1, ST2 and ST 398643600 GAUGE
ST3.
Calculate the lock washer and lock nut specifica-
tions using following formula.
T2 = L2/(L1 + L2) # T1
T1: 116 N!m (11.8 kgf-m, 85.3 ft-lb)
L1: ST2 length 0.072 m (2.83 in)
B
Example:
AT-00204
9) Calculate the thickness “t” (mm) of drive pinion
m (in) N!m (kgf-m, ft-lb)
shim.
0.4 (15.75) 98 (10.0, 72)
t = 6.5 $ 0.0625 " (B " A)
0.45 (17.72) 100 (10.2, 73.8)
10) Select three or less shims from following table.
0.5 (19.69) 101 (10.3, 74.5)
0.55 (21.65) 102 (10.4, 75) Drive pinion shim
ST1 498937110 HOLDER 31451AA050 0.150 (0.0059)
ST2 499787700 WRENCH 31451AA060 0.175 (0.0069)
ST3 499787500 ADAPTER 31451AA070 0.200 (0.0079)
NOTE: 31451AA080 0.225 (0.0089)
Install the ST2 to torque wrench as straight as pos- 31451AA090 0.250 (0.0098)
sible. 31451AA100 0.275 (0.0108)
ST3
E: INSPECTION
• Make sure that all component parts are free of
harmful cut, gouges, and other faults.
ST2 • Adjust the teeth alignment. <Ref. to 4AT-110,
ADJUSTMENT, Drive Pinion Shaft Assembly.>
L1 [m (in)]
F: ADJUSTMENT
L2 [m (in)] 1) Remove the liquid gasket completely.
ST1 2) Install the oil pump housing assembly to convert-
AT-00202 er case, and secure them with tightening four bolts
evenly.
6) Measure the starting torque of bearing. Make
sure the starting torque is within the specified NOTE:
range. If the torque is not within specified range, re- Use an old gasket or an aluminum washer so as not
place the roller bearing. to damage the mating surface of housing.
Starting torque: Tightening torque:
7.6 — 38.1 N (0.776 — 3.88 kgf, 1.7 — 8.6 lb) 41 N!m (4.2 kgf-m, 30.4 ft-lb)
AT-00203 AT-00205
7) Stake the lock nut at two points. 3) Rotate the drive pinion several times using ST1
8) Measure the dimension “B” of drive pinion shaft and ST2.
4AT-110
ST1 498937110 HOLDER • Face contact

ST2 499787700 WRENCH Checking item: Backlash is too large.
Contact pattern
ST2
ST1
AT-00206
AT-00208
4) Adjust backlash between drive pinion and crown
gear. <Ref. to 4AT-117, ADJUSTMENT, Front Dif- Corrective action: Increase thickness of pinion
ferential Assembly.> height adjusting washer in order to bring drive pin-
5) Apply red lead evenly to the surfaces of three or ion close to driven gear.
four teeth on crown gear. Rotate the drive pinion in
the forward and reverse directions for several
times. Remove the oil pump housing, and check
the tooth contact pattern.
If the tooth contact is improper, readjust the back-
lash or shim thickness. <Ref. to 4AT-117, AD-
JUSTMENT, Front Differential Assembly.>
• Correct tooth contact
Checking item: Tooth contact pattern is slightly
shifted toward to toe side under no-load
rotation. [When loaded, contact pattern moves AT-00212
toward heel.] • Flank contact
Checking item: Backlash is too small.
Contact pattern
(A)
(B)
AT-00207
(A) Toe side

AT-00209
(B) Heel side
Corrective action: Reduce thickness of pinion
height adjusting washer in order to bring drive pin-
ion away from driven gear.
AT-00213
4AT-111
• Toe contact (inside end contact) 6) If tooth contact is correct, mark the retainer posi-
Checking item: Contact area is small. tion and loosen it. After fitting a new O-ring and oil
Contact pattern 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, 18.1 ft-lb)
(A)
AT-00210

ion away from driven gear. AT-00214
(A) Lock plate
AT-00213
• Heel contact (outside end contact)

Checking item: Contact area is small.
Contact pattern
AT-00211
Corrective action: Increase thickness of pinion

ion close to driven gear.
AT-00212
4AT-112
Front Differential Assembly
39.Front Differential Assembly B: INSTALLATION

1) When installing the differential assembly to
A: REMOVAL case, be careful not to damage the inside of case
1) Remove the transmission assembly from vehi- (particularly, the differential side retainer mating
cle. <Ref. to 4AT-40, REMOVAL, Automatic Trans- surface).
mission Assembly.>
2) Pull out the torque converter clutch assembly. (A)
Clutch Assembly.>
AT-00215
(A) Differential assembly
2) Install the O-ring to left and right side retainer.

AT-00114 3) Install the side retainers using ST. <Ref. to 4AT-
117, ADJUSTMENT, Front Differential Assembly.>
4) Lift-up the lever on rear side of transmission har- ST 499787000 WRENCH ASSY
ness connector, and then remove it from the stay.
4) Adjust the front differential backlash. <Ref. to
5) Remove the inhibitor switch from the stay. 4AT-117, ADJUSTMENT, Front Differential As-
6) Remove the oil charge pipe. <Ref. to 4AT-79, sembly.>
REMOVAL, Oil Charge Pipe.> 5) Install the lock plate.
<Ref. to 4AT-67, REMOVAL, ATF Cooler Pipe and Tightening torque:
Hose.> 25 N!m (2.5 kgf-m, 18.1 ft-lb)
case. <Ref. to 4AT-101, REMOVAL, Converter (A)
Case.>
9) Remove the seal pipe.
10) Remove the differential side retainers using
ST.
NOTE:
Hold the differential case assembly by hand to
avoid damaging retainer mounting hole of convert-
er case.
AT-00214
ST 499787000 WRENCH ASSY
11) Remove the differential assembly without dam- (A) Lock plate
aging installation part of retainer.
6) Install the new seal pipe to converter case.
AT-00176
(A) Seal pipe
4AT-113
7) Install the converter case to transmission case. C: DISASSEMBLY

<Ref. to 4AT-101, INSTALLATION, Converter
Case.> 1. DIFFERENTIAL CASE ASSEMBLY
8) Insert the inhibitor switch and transmission con- 1) Remove taper roller bearing using ST and press.
nector to the stay. ST 498077000 REMOVER
(B) (A)
AT-01351 AT-00216
(A) Transmission connector 2) Secure the case in a vise and remove the hypoid
(B) Inhibitor switch connector driven gear tightening bolts, then separate the hy-
poid driven gear, case (RH) and case (LH).
STALLATION, ATF Cooler Pipe and Hose.> (A)
10) Install the oil charge pipe with a O-ring. <Ref. to
lightly, and then check the protrusion amount. (B)
Normal protrusion A: (C)

50 — 55 mm (1.97 — 2.17 in)
AT-00217
A
(A) Hypoid driven gear
(B) Differential case (RH)
(C) Differential case (LH)
3) Pull out the straight pin and shaft, and then re-
move the differential bevel gear, washer and differ-
ential bevel pinion.
AT-00291

(A)
AT-00218
(A) Differential case (RH)
4AT-114
2. SIDE RETAINER ST 398527700 PULLER ASSY

NOTE:
After adjusting the drive pinion backlash and tooth
contact, remove and install the oil seal and O-ring.
AT-00222
(A) Shaft
(B) Claw
AT-00219 5) Restore the removed claws to original position,

and install the pin and split pin.
2) Remove the oil seal. 6) Hold the shaft of ST to avoid removing from side
retainer, and then remove the bearing outer race.
NOTE:
Replace the bearing inner and outer races as a sin-
gle unit.
AT-00220
3) Remove the split pin, and then remove the claw.

AT-00223
(A) Shaft
(B) Side retainer
AT-00221
(A) Claw
(B) Split pin
(C) Pin
4) Attach two claws to the outer race, and set the

ST to side retainer.
4AT-115
D: ASSEMBLY • Fix the bevel pinion gear in place with a screw-

driver or similar tool when measuring.
1. DIFFERENTIAL CASE ASSEMBLY
Standard value:
1) Install the washer, differential bevel gear and dif- 0.13 — 0.18 mm (0.0051 — 0.0071 in)
ferential bevel pinion in differential case (RH). In-
sert the pinion shaft.
2) Install the straight pin in reverse direction. ST1
ST2
AT-00224
(3) If the backlash is not within specified, select

(A) a washer from the table below.
AT-00218
Washer
3) Install the washer and differential bevel gear to 803038021 0.95 (0.037)
differential case (LH). Put the differential case (RH) 803038022 1.00 (0.039)
on the case, and then combine the both cases. 803038023 1.05 (0.041)
4) Install the hypoid driven gear and secure by
tightening the bolt. 6) Using the ST, install the taper roller bearing.
ST 398487700 DRIFT
Tightening torque:
62 N!m (6.3 kgf-m, 45.6 ft-lb)
(A)
(B)
(C)
AT-00225
AT-00217 (A) Taper roller bearing
(A) Hypoid driven gear 2. SIDE RETAINER

1) Install the bearing outer race to side retainer.
(C) Differential case (LH) 2) Install a new oil seal using ST and hammer.
5) Measurement of backlash (Selection of washer) ST 18675AA000 DIFFERENTIAL SIDE OIL
(1) Install the SUBARU genuine axle shaft to SEAL INSTALLER
differential case.
Parts No. 38415AA070 AXLE SHAFT ST
(2) Measure the gear backlash using ST1 and
ST2, and then insert the ST2 from the access
window of case.
ST1 498247001 MAGNET BASE
ST2 498247100 DIAL GAUGE
NOTE:
• Measure the backlash by applying a pinion tooth
between two bevel gear teeth. AT-00226
4AT-116
3) Apply gear oil to a new O-ring and install it. Tightening torque:
41 N!m (4.2 kgf-m, 30.4 ft-lb)
AT-00219
E: INSPECTION AT-00205
• Check each component for scratches, damage 5) Rotate the drive pinion several times using ST1
and other faults. and ST2.
• Measure the backlash, and then adjust it within ST1 498937110 HOLDER
specification. ST2 499787700 WRENCH
<Ref. to 4AT-117, ADJUSTMENT, Front Differen-
tial Assembly.> ST2
F: ADJUSTMENT
1) Using the ST, screw-in the retainer until light ST1
contact is felt.
NOTE:
Screw-in the RH side slightly deeper than the LH
side.
AT-00206
ST
AT-00227
2) Remove the oil pump housing.

3) Remove the liquid gasket completely.
4) Install the oil pump housing assembly to convert-
er case, and secure them with tightening four bolts
evenly.
NOTE:
Use an old gasket or an aluminum washer so as not
to damage the mating surface of housing.
4AT-117
6) Tighten the retainer LH until contact is felt while 9) Turn the drive pinion several times with ST1 and
rotating the shaft. Then loosen the retainer RH. check to see if the backlash is within the specified
Keep tightening the retainer LH, and loosening the value with ST2, ST3, ST4 and ST5.
retainer RH until the pinion shaft cannot be turned. ST1 499787700 WRENCH
This is the “zero” state. ST2 498247001 MAGNET BASE
ST5 498255400 PLATE
Backlash:
0.13 — 0.18 mm (0.0051 — 0.0071 in)
ST1
(A) ST4
AT-00229
ST5
(A) Retainer
7) After the “zero” state is established, back off the

retainer LH 3 notches and secure it with the lock ST2
plate. Then back off the retainer RH and retighten ST3 AT-00231
until it stops. Rotate the drive pinion few times.
Tighten the retainer RH 1-3/4 notches further. This 10) Adjust the tooth contact between front differen-
sets the preload. Finally, secure the retainer with its tial and drive shaft. <Ref. to 4AT-110, ADJUST-
lock plate. MENT, Drive Pinion Shaft Assembly.>
(A)
AT-00214
(A) Lock plate
NOTE:
Turning the retainer by one tooth changes the
backlash about 0.05 mm (0.0020 in).
0.05 mm
(0.0020 in)
AT-00230
8) Install the SUBARU genuine axle shaft to both

side of front differential part.
Parts No. 38415AA000 AXLE SHAFT
4AT-118
AT Main Case
40.AT Main Case 12) Take out the high clutch hub and thrust bear-
ing.
A: REMOVAL
1) Remove the transmission assembly from vehi- (A)
mission Assembly.>
Clutch Assembly.>
3) Remove the input shaft. (B)
AT-00233
(A) High clutch hub

(B) Thrust needle bearing
13) Take out the front sun gear and thrust needle
bearing.
(A)
AT-00114

harness connector, and then disconnect it from the
stay.
5) Disconnect the inhibitor switch connector from
the stay. (B)
REMOVAL, Oil Charge Pipe.> AT-00251
<Ref. to 4AT-67, REMOVAL, ATF Cooler Pipe and (A) Front sun gear
Hose.> (B) Thrust needle bearing
14) Pull out the leaf spring without folding.
case. <Ref. to 4AT-101, REMOVAL, Converter
Case.> NOTE:
10) Remove the oil pump housing. Remove it while pressing down on lower leaf
<Ref. to 4AT-103, REMOVAL, Oil Pump Housing.> spring.
11) Take out the high clutch, thrust needle bearing
and reverse clutch assembly.
(A)
(A)
(B)
(B)
AT-00252
AT-00232 (A) Leaf spring

(B) Retaining plate
(A) High clutch and reverse clutch ASSY
4AT-119
AT Main Case
15) Remove the snap ring and thrust needle bear- 19) Remove the snap ring.
ing.
(A)
(A) (B)
(B)
AT-00285
AT-00253
(A) Snap ring
(A) Snap ring (B) 2-4 brake piston
20) Take out the 2-4 brake return spring.
16) Take out the retaining plate, drive plate and
driven plate of 2-4 brake.
AT-00286
21) Remove the 2-4 brake piston and piston retain-

AT-00254
er without damaging.
17) Take out the thrust needle bearing, planetary
(A)
gear assembly and low clutch assembly.
(B)
AT-00287
AT-00255 (A) 2-4 brake piston

(B) 2-4 brake piston retainer
18) Remove the 2-4 brake seal.
AT-02215
4AT-120
AT Main Case
22) Pull out the leaf spring without folding. 26) Remove the spring retainer.
(A)
AT-00293 AT-00302
27) Take out the return spring.

(A) Leaf spring
23) Remove the snap ring.
(A)
AT-00301
28) Apply compressed air.

AT-00294
(A) Snap ring
24) Take out the retaining plate, drive plate, driven

plate and dish plate.
AT-00297
29) Take out the low & reverse piston.
AT-00295
25) Turn the transmission case upside down, and

then take out the socket bolts while holding the
one-way clutch inner race with hand.
AT-00300
AT-00296
4AT-121
AT Main Case
B: INSTALLATION Tightening torque:

1) Install the low & reverse brake piston. 25 N!m (2.5 kgf-m, 18.1 ft-lb)
NOTE:
• Be careful not to damage the lip seal.
• Apply ATF to the lip.
AT-00296
6) Place the front side of transmission body up.

7) Install the thrust needle bearing.
AT-00300 8) Place the dish plate, driven plate, drive plate and
retaining plate neatly in this order on surface table.
2) Install the return spring. 9) Set the micro 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 plates.
NOTE:
• Use a stiff flat board which does not bend against
load.
• Use a flat board of its weight less than 83 N (8.5
AT-00301
kgf, 18.7 lb).
3) Install the spring retainer. 11) Put the flat board on retaining plate.
AT-00302
AT-01720
4) Install the one-way clutch inner race, spring re- 12) Using the following formula, calculate “N” indi-
tainer and return spring. cated on the push/pull gauge.
5) Tighten the socket bolts evenly from the rear N = 83 N (8.5 kgf, 18.7 lb) " Z
side of transmission case. N: Value indicated on push/pull gauge
83 N (8.5 kgf, 18.7 lb): Load applied to clutch plate
Z: Flat board weight
13) Press the center of retaining plate applying
force of N with push/pull gauge, and then measure
and record the height A. Make more than three
measurements at even distance and take the aver-
age value.
4AT-122
AT Main Case
NOTE: 15) Apply compressed air intermittently to check for

If three points, measure the height every 120%. If operation.
four points, measure the height every 90%.
AT-00297
16) Place the same thickness of shim on both sides

to prevent the plate from tilting, and then measure
and record the clearance B.
A (D) NOTE:
Do not press the shim downward with excessive
force, or else the waveform of drive plates will be
broken down.
(B)
(C) B
(A)
AT-01721
(A) Dish plate

(B) Driven plate
(C) Drive plate
(D) Retaining plate
AT-02216
14) Installation of the low & reverse brake:
17) Piston stroke calculation
Install the dish plate, driven plate and retaining
Select the retaining plate within the specification by
plate, and then secure them with snap ring.
calculating with A and B dimensions which have
NOTE: been recorded before. If the calculated value ex-
Pay attention to the orientation of dish plate. ceeds the service limit, replace the drive plate with
a new one and adjust it within the specitication.
(A) T=A+B
T: Piston stroke
A: Collapse amount of drive plate
B: Clearance between retaining plate and snap ring
Initial standard:
2.15 — 2.65 mm (0.085 — 0.104 in)
Limit thickness:
2.95 mm (0.116 in)
AT-00294
(A) Snap ring
4AT-123
AT Main Case
21) Position the snap ring in transmission. Using

Retaining plate
the ST, press the snap ring into specified place.
ST 498677100 COMPRESSOR
31667AA420 3.8 (0.150)
31667AA320 4.1 (0.161)
31667AA330 4.4 (0.173) ST
31667AA340 4.7 (0.185)
31667AA350 5.0 (0.197)
31667AA360 5.3 (0.209)
31667AA370 5.6 (0.220)
31667AA380 5.9 (0.232)
18) Install the leaf spring of low & reverse brake.

AT-00289
(A)
22) Install the planetary gear and low clutch as-
sembly to transmission case.
Install carefully while slowly rotating the low clutch
and planetary gear assembly paying special atten-
tion not to damage the seal ring.
AT-00293
(A) Leaf spring
19) Install the 2-4 brake piston and 2-4 brake re-
tainer by aligning the holes of 2-4 brake retainer
and hole of transmission case.
AT-00255
(A)
23) Place the dish plate, driven plate, drive plate
and retaining plate neatly in this order on surface
table.
24) Set the micro gauge to clutch, and read its
scale.
(B) NOTE:
zero point.
AT-00287 25) Scale and record the weight “Z” of a flat board
(A) 2-4 brake piston
NOTE:
(B) 2-4 brake piston retainer • Use a stiff flat board which does not bend against
20) Install 2-4 brake piston return spring to trans- load.
mission case. • Use a flat board of its weight less than 100 N
(10.2 kgf, 22.5 lb).
AT-00286
4AT-124
AT Main Case
26) Put the flat board on retaining plate. 29) Install the pressure plate, drive plate, driven
plate, retaining plate and snap ring.
AT-01720
AT-00254
27) Using the following formula, calculate “N” indi-
cated on the push/pull gauge. 30) Install a new 2-4 brake oil seal to transmission
N = 100 N (10.2 kgf, 22.5 lb) " Z case.
N: Value indicated on push/pull gauge
100 N (10.2 kgf, 22.5 lb): Load applied to clutch
plate
28) Press the center of retaining plate applying
and record the height A. Make more than three
measurements at even distance and take the aver-
age value.
NOTE: AT-02215
If three points, measure the height every 120%. If
four points, measure the height every 90%. 31) After all 2-4 brake component parts have been
installed, blow air intermittently and confirm the op-
eration of brake.
AT-00290
32) Measure and record the clearance B between

the retaining plate and snap ring.
A (C)
B
(B)
(A)
AT-01723
(A) Driven plate

(B) Drive plate
AT-01724
(C) Retaining plate
4AT-125
AT Main Case
33) Piston stroke calculation 35) Install the thrust needle bearing in correct di-
Select the retaining plate within the specification by rection.
calculating with A and B dimensions which have
(A) (C)
been recorded before. If the calculated value ex-
ceeds the usage limit, replace the drive plate with a (E)
new one and adjust it within the specitication. (D)
T=A+B
T: Piston stroke
A: Collapse amount of drive plate
(B)
2.0 L SOHC model:
Initial standard: AT-02217
1.4 — 1.8 mm (0.055 — 0.071 in)
Limit thickness: (A) Snap ring
1.95 mm (0.077 in) (B) Thrust needle bearing
Except for 2.0 L SOHC model: (C) Upside
Initial standard: (D) Downside
1.7 — 2.1 mm (0.067 — 0.083 in) (E) Outside
Limit thickness: 36) Install the front sun gear and thrust needle
2.3 mm (0.091 in) bearing.
Retaining plate (C)
(A)
Part number Thickness mm (in) (E)
31567AA991 5.6 (0.220) (D)
31567AB001 5.8 (0.228)
31567AB011 6.0 (0.236)
31567AB021 6.2 (0.244)
31567AB031 6.4 (0.252) (B)
31567AB041 6.6 (0.260)
34) Be careful not to mistake the location of the leaf AT-02218

spring to be inserted.
(A) Front sun gear
(A) (C) Upside
(D) Downside
(E) Outside
37) Install the high clutch hub.

Attach the thrust needle bearing to hub using vase-
(B) line, and then install the hub by correctly engaging
the splines of the front planetary carrier.
AT-00252
(A) Leaf spring

(B) Retaining plate
4AT-126
AT Main Case
38) Install the thrust needle bearing in proper direc- 42) Install the oil pump housing assembly with a
tion. new gasket. <Ref. to 4AT-103, Oil Pump Housing.>
43) Install the converter case assembly into trans-
(C)
mission case assembly. <Ref. to 4AT-101, IN-
(E)
STALLATION, Converter Case.>
(D)
44) Insert the inhibitor switch and transmission
connector to the stay.
(B) INSTALLATION, Air Breather Hose.>
(B) (A)
(A)
AT-02219
(A) High clutch hub

(C) Upside
(D) Downside
(E) Outside
AT-01351
39) Install the high clutch assembly.
(A)

47) Install the oil charge pipe with a O-ring. <Ref. to
AT-00235
50 — 55 mm (1.97 — 2.17 in)
40) Adjust the total end play. <Ref. to 4AT-107, AD-

JUSTMENT, Oil Pump Housing.>
A
41) Install the thrust needle bearing in proper direc-
tion.
(C)
(A)
(B)
(E)
(D)
AT-00291

AT-02220
(C) Upside
(D) Downside
(E) Outside
4AT-127
AT Main Case
C: DISASSEMBLY 4) Take out the clutch cover, spring retainer, high

clutch piston and reverse clutch piston.
1) Remove the snap ring, and then take out the re- (A) (B)
taining plate, drive plate and driven plate.
(A)
(C)
AT-00239
(A) Reverse clutch piston

AT-00236
(B) Cover
(C) Return spring
(A) Snap ring
5) Remove the seal ring and lip seal from the high
2) Remove the snap ring, and then take out the re- clutch piston and reverse clutch piston.
taining plate, drive plate and driven plate.
(A) (A)
(B)
AT-00240
AT-00237
(A) High clutch piston
(A) Snap ring (B) Reverse clutch piston
3) Using the ST1 and ST2, remove the snap ring. 2. PLANETARY GEAR AND LOW CLUTCH
ST2 498627100 SEAT 1) Remove the snap ring from low clutch drum.
ST1
(A) (A)
ST2
(B)
AT-00259
AT-00238
(A) Snap ring

(A) Snap ring
(B) Low clutch dram
4AT-128
AT Main Case
2) Take out the front planetary carrier. 5) Take out the rear internal gear.
(A) (A)
(B)
(B)
AT-00260 AT-00263
(A) Front planetary carrier (A) Rear internal gear

(B) Low clutch dram (B) Low clutch dram
3) Take out the rear sun gear. 6) Remove the snap ring from low clutch drum.
(A) (A)
(B)
(B)
AT-00261 AT-00264
(A) Rear sun gear (A) Snap ring

(B) Rear planetary carrier (B) Low clutch dram
4) Take out the rear planetary carrier, washer and 7) Compress the spring retainer, and remove the
thrust needle bearing. snap ring from low clutch drum using ST1 and ST2.
ST1 498627100 SEAT
(A)
ST2
ST1
(B)
AT-00262 (B)
(A)
(A) Rear planetary carrier AT-00265

(B) Low clutch dram
(A) Snap ring
(B) Low clutch dram
8) Remove the one-way clutch. <Ref. to 4AT-119,

REMOVAL, AT Main Case.>
4AT-129
AT Main Case
9) Install the one-way clutch inner race to low 3. 2-4 BRAKE

clutch drum, and then apply compressed air to re-
Separate the 2-4 brake piston and piston retainer.
move the low clutch piston.
(A) (B)
(A)
(B)
AT-00288
AT-00266
(A) 2-4 brake piston

(A) Apply compressed air.
(B) One-way clutch inner race
10) Remove the one-way clutch inner race. 4. ONE-WAY CLUTCH INNER RACE
11) Remove the one-way clutch after taking out the 1) Remove the seal ring.
snap ring.
(C) (A)
(A)
(B)
(B)
AT-00298
AT-00267
(A) One-way clutch inner race
(A) Snap ring (B) Seal ring
(B) Plate
(C) One-way clutch 2) Remove the needle bearing using ST.
12) Remove the needle bearing after taking out the
snap ring. 5. ONE-WAY CLUTCH OUTER RACE
1) Remove the one-way clutch after taking out the
(A)
(B) snap ring.
(C)
(A)
(B)
AT-00268
(A) Needle bearing AT-00267

(B) Snap ring
(A) Snap ring
(B) Plate
(C) One-way clutch
4AT-130
AT Main Case
2) Remove the needle bearing after taking out the 4) Install the spring retainer to high clutch piston.
snap ring.
(B) (A)
(A)
(B)
AT-00242
AT-00268
(A) Spring retainer
(A) Needle bearing (B) High clutch drum
(B) Snap ring
5) Install the ST to high clutch piston.
D: ASSEMBLY ST 498437000 HIGH CLUTCH PISTON
GUIDE
1) Install the seal ring and lip seal to the high clutch
piston and reverse clutch piston. ST
2) Install the high clutch piston to reverse clutch
piston.
(A)
AT-00243
6) Install the cover to high clutch piston without

folding the high clutch piston seal.
(B)
7) Install the snap ring using ST1 and ST2.
AT-00240 ST2 498627100 SEAT
ST3 498437000 HIGH CLUTCH PISTON
(A) High clutch piston
GUIDE
(B) Reverse clutch piston
3) Install the reverse clutch piston to high clutch ST1

drum. Align the groove on reverse clutch piston
with the groove on high clutch drum during installa- ST3
tion.
(A)
ST2
AT-00244
8) Place the dish plate, driven plate, drive plate and

retaining plate neatly in this order on surface table.
(B) 9) Set the micro gauge to clutch, and read its scale.
NOTE:
AT-00241
(A) Reverse clutch piston
zero point.
(B) High clutch drum 10) Scale and record the weight “Z” of a flat board
4AT-131
AT Main Case
NOTE: NOTE:
• Use a stiff flat board which does not bend against If three points, measure the height every 120%. If
load. four points, measure the height every 90%.
• Use a flat board of its weight less than 250 N
(25.5 kgf, 56.2 lb).
11) Put the flat board on retaining plate.
AT-01720
12) Using the following formula, calculate “N” indi- A (C)

cated on the push/pull gauge. (B)
N = 250 N (25.5 kgf, 56.2 lb) " Z (A)
N: Value indicated on push/pull gauge
250 N (25.5 kgf, 56.2 lb): Load applied to clutch
plate
13) Press the center of retaining plate applying AT-01725
and record the height A. Make more than three (A) Driven plate
measurements at even distance and take the aver- (B) Drive plate
age value. (C) Retaining plate
14) Install the thickest driven plate to piston side,

and then install the driven plate, drive plate, retain-
ing plate to high clutch drum.
AT-00245
15) Install the snap ring to high clutch drum.
4AT-132
AT Main Case
16) Apply compressed air intermittently to check for 19) Place the dish plate, driven plate, drive plate
operation. and retaining plate neatly in this order on surface
table.
20) Set the micro gauge to clutch, and read its
scale.
NOTE:
zero point.
21) Scale and record the weight “Z” of a flat board
NOTE:
AT-00246 • Use a stiff flat board which does not bend against
17) Measure and record the clearance B between load.
the retaining plate and snap ring. (High clutch) • Use a flat board of its weight less than 150 N
At this time, do not press down the retaining plate. (15.3 kgf, 33.7 lb).
22) Put the flat board on retaining plate.
(A)
B
AT-01726
AT-01720
(A) Thickness gauge
23) Using the following formula, calculate “N” indi-
18) Piston stroke calculation cated on the push/pull gauge.
Select the retaining plate within the specification by N = 150 N (15.3 kgf, 33.7 lb) " Z
calculating with A and B dimensions which have N: Value indicated on push/pull gauge
been recorded before. If the calculated value ex- 150 N (15.3 kgf, 33.7 lb): Load applied to clutch
ceeds the usage limit, replace the drive plate with a plate
new one and adjust it within the specitication. Z: Flat board weight
T=A+B 24) Press the center of retaining plate applying
T: Piston stroke force of N with push/pull gauge, and then measure
A: Collapse amount of drive plate and record the height A. Make more than three
B: Clearance between retaining plate and snap ring measurements at even distance and take the aver-
age value.
Initial standard:
2.0 — 2.3 mm (0.079 — 0.091 in)
Limit thickness:
2.6 mm (0.102 in)
High clutch retaining plate
31567AA670 5.1 (0.201)
31567AA680 5.2 (0.205)
31567AA690 5.3 (0.209)
31567AA700 5.4 (0.213)
31567AA710 5.5 (0.217)
31567AA720 5.6 (0.220)
31567AA730 5.7 (0.224)
31567AA740 5.8 (0.228)
4AT-133
AT Main Case
NOTE: 27) Measure and record the clearance B between

If three points, measure the height every 120%. If the retaining plate and snap ring. (Reverse clutch)
four points, measure the height every 90%. At this time, do not press down the retaining plate.
(A)
AT-01728
(A) Thickness gauge
28) Piston stroke calculation

Select the retaining plate within the specification by
A calculating with A and B dimensions which have
(C)
been recorded before. If the calculated value ex-
(B)
ceeds the usage limit, replace the drive plate with a
(A) new one and adjust it within the specitication.
T=A+B
T: Piston stroke
AT-01727 A: Collapse amount of drive plate
(A) Driven plate
Initial standard:
(B) Drive plate
1.1 — 1.4 mm (0.043 — 0.055 in)
(C) Retaining plate
Limit thickness:
25) Install the driven plate, drive plate, retaining 1.6 mm (0.063 in)
plate and snap ring.
Reverse clutch retaining plate
31567AA910 4.0 (0.157)
31567AA920 4.2 (0.165)
31567AA930 4.4 (0.173)
31567AA940 4.6 (0.181)
31567AA950 4.8 (0.189)
31567AA960 5.0 (0.197)
31567AA970 5.2 (0.205)
AT-00247 31567AA980 5.4 (0.213)
26) Apply compressed air intermittently to check for

operation.
AT-00248
4AT-134
AT Main Case
2. PLANETARY GEAR AND LOW CLUTCH ST1 498627100 SEAT

1) Apply ATF to D-ring and install it to low clutch
piston. ST3 498437100 LOW CLUTCH PISTON
GUIDE
2) Install the low clutch piston to low clutch drum.
ST2
(A)
ST3
ST1
(B)
AT-00272
AT-00269
6) Install the dish plate, driven plate and retaining
(A) Low clutch piston plate, and then secure them with snap ring.
(B) Low clutch dram
(A)
3) Install the spring retainer to low clutch piston. (C)
(A)
(D)
(B)
AT-02221
(B)
(A) Snap ring
AT-00270 (B) Low clutch dram
(C) Dish plate
(A) Spring retainer
(D) Low clutch piston side
(B) Low clutch dram
7) Check the low clutch for operation.
4) Install the ST to low clutch drum.
(1) Remove the one-way clutch. <Ref. to 4AT-
ST 498437100 LOW CLUTCH PISTON
119, REMOVAL, AT Main Case.>
GUIDE
(2) Set the one-way clutch inner race, and apply
compressed air for checking.
ST (A)
(B)
AT-00271
5) Set the cover on the piston with a press using AT-00274

ST1 and ST2, and attach the snap ring. At this time,
be careful not to fold the cover seal during installa- (A) Apply compressed air.
tion. (B) Low clutch dram
8) Check the low clutch clearance.

(1) Place the same thickness of shim on both
sides to prevent pressure plate from tilting.
4AT-135
AT Main Case
(2) Check the clearance between retaining 10) Install the rear internal gear.
plate and low clutch operation.
Initial standard: (A)
0.7 — 1.1 mm (0.028 — 0.043 in)
Limit thickness:
1.5 mm (0.059 in)
(A)
(B)
AT-00276
(A) Rear internal gear

(B) Low clutch dram
(B) 11) Install the thrust needle bearing in correct di-

rection.
AT-00283
(A) Thickness gauge (A) (C)

(B) Low clutch dram
If the clearance is out of specification, select a (D)
suitable retaining plate. (B)
Retaining plate
31567AB050 3.8 (0.150)
31567AB060 4.0 (0.157) AT-02222
31567AB070 4.2 (0.165)
(A) Thrust needle bearing
31567AB080 4.4 (0.173)
(B) Low clutch dram
31567AB090 4.6 (0.181)
(C) Rear planetary carrier side
9) Install the washer to rear internal gear. (D) Low clutch piston side
12) Install the washer by aligning protrusion of

(A)
(B) washer and hole of rear planetary carrier.
(A)
AT-00275 (B)
(A) Rear internal gear

(B) Washer AT-00278
(A) Washer
(B) Rear planetary carrier
4AT-136
AT Main Case
13) Install the rear planetary carrier to low clutch 16) Install the thrust needle bearing in proper direc-
drum. tion.
(A)
(A)
(C)
(D)
(B)
(B)
AT-00262 AT-00280
(A) Rear planetary carrier (A) Thrust needle bearing

(B) Low clutch dram (B) Front planetary carrier
(C) Rear sun gear side
14) Install the thrust needle bearing in correct di-
(D) Front planetary carrier side
rection.
17) Install the front planetary carrier to low clutch
drum.
(A)
(B)
(A)
AT-02223 (B)
(A) Rear sun gear side AT-00260

(B) Rear planetary carrier side
(A) Front planetary carrier
15) Install the rear sun gear in proper direction.
(B) Low clutch dram
(A) 18) Install the snap ring to low clutch drum.
(A)
(B)
(B)
AT-00261
(A) Rear sun gear AT-00281

(B) Rear planetary carrier
(A) Snap ring
(B) Front planetary carrier
4AT-137
AT Main Case
19) Install the needle bearing, and then secure with 4. ONE-WAY CLUTCH INNER RACE
the snap ring.
1) Install the needle bearing to inner race using ST
and press.
(B)
(A) ST 398497701 SEAT
ST
AT-00268
(A) Needle bearing

AT-00299
(B) Snap ring
2) Apply vaseline to the groove of inner race and
20) Install the one-way clutch and one-way clutch seal ring.
inner race, and then secure with the snap ring. 3) Install two seal rings to one-way clutch inner
21) Set the inner race. Make sure that the clutch race.
locks in the clockwise direction and rotates freely in
the counterclockwise direction.
(A)
(A)
(B)
(B)
AT-00298
AT-00282 (A) One-way clutch inner race

(B) Seal ring
(A) Locked
(B) Free 5. ONE-WAY CLUTCH OUTER RACE
3. 2-4 BRAKE 1) Install the needle bearing, and then secure with
the snap ring.
1) Apply ATF to D-ring, and install it to 2-4 brake
piston. (B)
2) Install the 2-4 brake piston to 2-4 brake piston (A)
retainer.
(A) (B)
AT-00268
(A) Needle bearing

(B) Snap ring
AT-00288
2) Install the one-way clutch and one-way clutch in-
(A) 2-4 brake piston ner race, and then secure with the snap ring.
4AT-138
AT Main Case
3) Set the inner race. Make sure that the clutch 4. ONE-WAY CLUTCH
locks in the clockwise direction and rotates freely in
• Make sure the snap ring is not worn and the seal
the counterclockwise direction.
rings are not deformed.
• Measure the total end play and adjust it within
specifications. <Ref. to 4AT-107, ADJUSTMENT,
Oil Pump Housing.>
(A)
(B)
5. LOW & REVERSE BRAKE
Check the following items:
• Drive plate facing for wear and damage
• Driven plate for discoloration (burned color)
• Snap ring for wear and spring retainer for defor-
AT-00282 mation
(A) Locked
(B) Free
E: INSPECTION
• Snap ring for wear, return spring for setting and
breakage, and snap ring retainer for deformation
• Lip seal and D-ring for damage
• Piston and drum check ball for operation
• Adjust the total end play. <Ref. to 4AT-107, AD-
JUSTMENT, Oil Pump Housing.>
2. PLANETARY GEAR AND LOW CLUTCH
• Snap ring for wear, return spring for setting and
breakage, and spring retainer for deformation
• Piston check ball for operation
Oil Pump Housing.>
3. 2-4 BRAKE
• Snap ring for wear and spring retainer for defor-
mation
Oil Pump Housing.>
4AT-139
Transmission Control Device
41.Transmission Control Device NOTE:

Be careful not to damage the lips of press-fitted oil
A: REMOVAL seal in the case.
cle. <Ref. to 4AT-40, REMOVAL, Automatic Trans- (A)
mission Assembly.>
<Ref. to 4AT-80, REMOVAL, Torque Converter (C)
Clutch Assembly.>
3) Remove the input shaft. (B)
(D)
harness connector, and then remove it from stay.
78, REMOVAL, Air Breather Hose.> AT-02225
7) Wrap vinyl tape around the nipple attached to (A) Bolt
the air breather hose. (B) Range select lever
8) Remove the pitching stopper bracket. (C) Manual plate
9) Remove the inhibitor switch. (D) Parking rod
13) Remove the detention spring.
AT-00304
10) Remove the control valve body assembly. AT-00307

<Ref. to 4AT-60, REMOVAL, Control Valve Body.>
11) Pull out the straight pin of manual plate. B: INSTALLATION
1) Install the detention spring to transmission case.
Tightening torque:
6 N!m (0.6 kgf-m, 4.3 ft-lb)
AT-02224
12) Remove the bolts securing select lever, and

then remove the select lever, manual plate and
parking rod. AT-00307
2) Insert the select lever, and then tighten the bolt.
4AT-140
Tightening torque: 9) Insert the inhibitor switch and transmission con-

6 N!m (0.6 kgf-m, 4.3 ft-lb) nector to the stay.
(B) (A)
AT-00308 AT-01351
3) Insert the manual plate and parking rod. (A) Transmission connector
(A)
(C) 11) Insert the input shaft with rotating it by hand
(D)
(B)
50 — 55 mm (1.97 — 2.17 in)
AT-02225
(A) Bolt
A
(C) Manual plate
(D) Parking rod
4) Insert a new straight pin to manual plate.
AT-00291

C: INSPECTION
AT-02224 Make sure the manual lever and detention spring
5) Install the oil pan and control valve assembly. are not worn or otherwise damaged.
<Ref. to 4AT-60, INSTALLATION, Control Valve
Body.>
6) Turn over the transmission case to its original
position.
7) Install the pitching stopper bracket.
Tightening torque:
41 N!m (4.2 kgf-m, 30.4 ft-lb)
8) Install and adjust the inhibitor switch. <Ref. to
4AT-52, Inhibitor Switch.>
4AT-141
4AT-142
CONTROL SYSTEMS CS

(DIAGNOSTICS)


approval.

(DIAGNOSTICS)
4AT(diag)
Page
1. Basic Diagnostic Procedure ........................................................................2
2. Check List for Interview...............................................................................4
4. Electrical Component Location ...................................................................7
5. Transmission Control Module (TCM) I/O Signal .......................................14
6. Subaru Select Monitor...............................................................................17
7. Read Diagnostic Trouble Code (DTC) ......................................................20
8. Inspection Mode........................................................................................21
9. Clear Memory Mode..................................................................................22
10. SPORT Indicator Light Display .................................................................23
11. Diagnostic Procedure for Select Monitor Communication.........................27
12. List of Diagnostic Trouble Code (DTC) .....................................................32
13. Diagnostic Procedure with Diagnostic Trouble Code (DTC) .....................34
14. Diagnostic Procedure without Diagnostic Trouble Code (DTC) ..............123
15. Diagnostics with Phenomenon................................................................138
Basic Diagnostic Procedure
AUTOMATIC TRANSMISSION (DIAGNOSTICS)
1. Basic Diagnostic Procedure

A: PROCEDURE
Step Check Yes No
1 CHECK PRE-INSPECTION. Is the unit that might influence Go to step 2. Repair or replace
1) Ask the customer when and how the trou- the AT problem normal? each item.
ble occurred using the interview checklist.
<Ref. to 4AT(diag)-4, Check List for Interview.>
2) Before performing diagnosis, inspect the
following items which might influence the AT
problems.
• General inspection <Ref. to 4AT(diag)-5,
INSPECTION, General Description.>
• Disconnection of harness connector
• Visual check for harness damage
• Oil Leaking
• Stall speed test <Ref. to 4AT-35, Stall Test.>
• Line pressure test <Ref. to 4AT-38, Line
Pressure Test.>
• Transfer clutch pressure test <Ref. to 4AT-
39, Transfer Clutch Pressure Test.>
• Time lag test <Ref. to 4AT-37, Time Lag
Test.>
• Road test <Ref. to 4AT-34, Road Test.>
• Inhibitor switch <Ref. to 4AT-52, Inhibitor
Switch.>
2 CHECK SPORT INDICATOR LIGHT. Does the SPORT indicator Go to step 4. Go to step 3.
After starting the engine, wait for at least 2 sec- light blink?
onds.
1) Turn the ignition switch to OFF. light blink?
2) Check the SPORT indicator light.
<Ref. to 4AT(diag)-24, INSPECTION, SPORT
Indicator Light Display.>
3) After the ignition switch is turned to “ON”,
wait for at least 2 seconds.
4 CHECK INDICATION OF DTC. Is DTC displayed? Go to step 6. Go to step 5.
Display DTC. NOTE:
NOTE: Record all DTC.
If the communication function of Subaru Select
Monitor cannot be executed normally, check
communication circuit. <Ref. to 4AT(diag)-27,
COMMUNICATION FOR INITIALIZING IM-
POSSIBLE, Diagnostic Procedure for Select
Monitor Communication.>
5 PERFORM GENERAL DIAGNOSTICS. Is DTC displayed? Go to step 6. Finish the diagno-
1) Inspect using “Diagnostic Procedure with- sis.
out Diagnostic Trouble Code (DTC)”. <Ref. to
4AT(diag)-123, Diagnostic Procedure without
Diagnostic Trouble Code (DTC).>
2) Inspect using “General Diagnostic Chart”.
<Ref. to 4AT(diag)-138, Diagnostics with Phe-
nomenon.>
3) Perform the inspection mode. <Ref. to
4AT(diag)-21, Inspection Mode.>
4) Display DTC.
4AT(diag)-2
Basic Diagnostic Procedure
Step Check Yes No

6 PERFORM DIAGNOSIS. Is DTC displayed? Inspect using Finish the diagno-
1) Inspect using the “Diagnostic Procedure “Diagnostic Proce- sis.
with Diagnostic Trouble Code (DTC)”. <Ref. to dure with Diagnos-
4AT(diag)-34, Diagnostic Procedure with Diag- tic Trouble Code
nostic Trouble Code (DTC).> (DTC)”. <Ref. to
NOTE: 4AT(diag)-34,
For DTC table, refer to “List of Diagnostic Trou- Diagnostic Proce-
ble Code (DTC)”. <Ref. to 4AT(diag)-32, List of dure with Diagnos-
Diagnostic Trouble Code (DTC).> tic Trouble Code
2) Repair the trouble cause. (DTC).>
3) Perform the clear memory mode.
5) Display DTC.
4AT(diag)-3
Check List for Interview
2. Check List for Interview

A: CHECK
Check the following items when problem has occurred.
NOTE:
Use copies of this page for interviewing customers.
Customer’s name
Date of sale
Date of repair
Trans. model Transmission V.I.N.
Odometer reading km (miles)
Frequency ❏ Continuous ❏ Intermittent ( times a day)
Weather ❏ Fine ❏ Cloudy ❏ Rainy ❏ Snowy
❏ Others
( )
Place ❏ Highland ❏ Suburbs ❏ Inner city ❏ Uphill ❏ Rough road
❏ Others
( )
Ambient air temperature ❏ Hot ❏ Warm ❏ Cool ❏ Cold
Vehicle speed km/h (MPH)
AT warning light (SPORT indicator ❏ Blinks continuously ❏ Not blink
light)
Select lever position ❏ P ❏ R ❏ N ❏ D ❏ SPORT mode
Driving condition ❏ Not affected ❏ At starting ❏ While idling
❏ At racing ❏ When accelerating ❏ While cruising
❏ When decelerating ❏ While turning (❏ RH / ❏ LH)
SPORT mode ❏ ON ❏ OFF
Symptom ❏ No up-shift
❏ No down-shift
❏ No kick down
❏ Vehicle does not move (❏ Any position ❏ Particular position)
❏ Lock-up malfunction
❏ Noise or vibration
❏ Shift shock or slip
❏ Select lever does not move
❏ Others
( )
4AT(diag)-4
General Description
3. General Description 3. ATF LEVEL

A: CAUTION Make sure that ATF level is within the specification.
<Ref. to 4AT-31, INSPECTION, Automatic Trans-
• SUPPLEMENTAL RESTRAINT SYSTEM
mission Fluid.>
“AIRBAG”
The airbag system wiring harness is routed near (A)
the TCM.
CAUTION:
• All airbag system wiring harnesses and con-
F
nectors are colored yellow. Do not use an elec- (C) (B)
HOT
L
tric test equipment on these circuits. (D)
• Be careful not to damage the airbag system
(C)
F
wiring harness when performing diagnostics or
COLD
(E)
L
servicing the TCM. (D)
• MEASUREMENT PI-00105
When measuring the voltage and resistance of the

(A) Level gauge
ECM, TCM or each sensor, use a tapered pin with
a diameter of less than 0.64 mm (0.025 in) in order (B) “HOT” side
to avoid poor contact. Do not insert a pin of more (C) Upper level
than 0.65 mm (0.026 in) diameter. (D) Lower level
(E) “COLD” side
B: INSPECTION
1. BATTERY 4. FRONT DIFFERENTIAL OIL LEVEL
Measure the battery voltage and specific gravity of Make sure the front differential oil level is within the
electrolyte. specification. <Ref. to 4AT-33, INSPECTION, Dif-
ferential Gear Oil.>
Standard voltage: 12 V or more
Specific gravity: More than 1.260
2. TRANSMISSION GROUND
Make sure that the ground terminal bolt is tightened
F
(A)
securely. (B)
• Chassis side
L
Tightening torque:
13 N!m (1.3 kgf-m, 9.4 ft-lb)
AT-00317
(A) Upper level

(B) Lower level
AT-01464
4AT(diag)-5
General Description
5. OPERATION OF SHIFT SELECT LEVER

Make sure there is no noise, dragging or contact
pattern in each select lever range.
WARNING:
Stop the engine while checking operation of the
selector lever.
AT-02048
C: PREPARATION TOOL
1. SPECIAL TOOL
ST24082AA230
ST22771AA030
2. GENERAL TOOL
TOOL NAME REMARKS
Circuit tester Used for measuring resistance, voltage and current.
Oscilloscope Used for measuring sensor.
4AT(diag)-6
Electrical Component Location
4. Electrical Component Location

A: LOCATION
1. CONTROL MODULE
• LHD model
(1)
(5) (3) (4) (2)

AT-01873
(1) Engine control module (ECM) (3) Transmission control module (4) Data link connector
(2) SPORT indicator light (AT warning (TCM) (5) Body integrated unit
light)
4AT(diag)-7
(1)
(2)
AT-01874 AT-01470
(4)
(3)
AT-01875 AT-01877
(5)
AT-01876
4AT(diag)-8
• RHD model
(3) (2) (4) (5)
(1)
AT-01467
light)
4AT(diag)-9
(1)
(2)
AT-01468 AT-01470
(4)
(3)
AT-01469 AT-01471
(5)
AT-01472
4AT(diag)-10
2. SENSOR
• LHD model
(3) (6) (7)
(5) (1) (2) (4)

AT-01878
• RHD model
(3) (1) (6) (7)
(5) (2) (4)

AT-01879
(1) Throttle position sensor (4) Rear vehicle speed sensor (6) ATF temperature sensor
(2) Front vehicle speed sensor (5) Torque converter turbine speed (7) Lateral G sensor
(3) Inhibitor switch sensor
4AT(diag)-11
Model without vehicle dynamics control (VDC)

(2) (4)
(1)
AT-00375 AT-01474
Model with vehicle dynamics control (VDC)
(2)
(4)
AT-01880 (3) AT-00330
(5)
(6)
AT-00331 AT-00378
LHD model RHD model
(7)
(7)
AT-01882 AT-01475
4AT(diag)-12
3. SOLENOID
(6) (5)
(7)
(1)
(2) (3) (4)
AT-00379
(1) Line pressure linear solenoid (4) Low & reverse duty solenoid (7) Lock-up duty solenoid
(2) High clutch duty solenoid (5) Low clutch duty solenoid
(3) 2-4 brake duty solenoid (6) Transfer duty solenoid
(2) (3) (4)
(1)
(7) (6) (5)
AT-00380
4AT(diag)-13
Transmission Control Module (TCM) I/O Signal
5. Transmission Control Module (TCM) I/O Signal

A: ELECTRICAL SPECIFICATION
To B54 To B55
7 6 5 4 3 2 1 9 8 7 6 5 4 3 2 1
16 15 14 13 12 11 10 9 8 21 20 19 18 17 16 15 14 13 12 11 10
24 23 22 21 20 19 18 17 31 30 29 28 27 26 25 24 23 22
AT-01476
Check with ignition switch ON.

Resistance
Connector
Item Terminal No. Measuring conditions Voltage (V) to chassis
No.
ground (")
27
Back-up power supply B55 28 Ignition switch OFF 10 — 13 —
29
ACC power supply B55 16 Ignition switch ACC 10 — 13 —
21 Ignition switch ON (with
Ignition power supply B55 10 — 13 —
31 engine OFF)
Selector lever in “P” range Less than 1
“P” range Select lever in any other
B54 5 —
switch than “P” range (except “N” More than 8
range)
Selector lever in “N” range Less than 1
“N” range
B54 22 Selector lever in any other —
Inhibitor switch More than 8
than “N” range
switch
Selector lever in “R” range Less than 1
“R” range
switch More than 8
than “R” range
Selector lever in “D” range Less than 1
“D” range
switch More than 8
than “D” range
Accelerator pedal position Throttle fully closed. More than 0.2
B54 19 —
sensor Throttle fully open. 4.6 or less
Accelerator pedal position Ignition switch ON (with
B54 10 4.6 — 5.4 —
sensor power supply engine OFF)
ATF temperature 20#C
3.5 — 4.3 3.9 k — 4.7 k
(68#F)
ATF temperature sensor B54 21
ATF temperature 80#C
1.5 — 1.9 500 — 600
(176#F)
Vehicle speed at least 20
Rear vehicle speed sensor B54 24 More than 2 (AC range) —
km/h (12 MPH)
4AT(diag)-14

Resistance
Connector
No.
ground (")
Vehicle stopped 0
Front vehicle speed sensor B54 6 Vehicle speed at least 20 450 — 750
More than 1 (AC range)
km/h (12 MPH)
Engine idling after warm-
0
Torque converter turbine up (“D” range)
B54 7 450 — 750
speed sensor Engine idling after warm-
up (“N” range)
Ignition switch ON (with
Less than 1
engine OFF)
Engine speed signal B54 13 —
Ignition switch ON (engine
ON)
Ignition switch ON (with
engine OFF)
3.7 — 7.5
Throttle fully closed in “R”
Line pressure linear sole- range after warm-up.
B54 20 4.0 — 8.0
noid Ignition switch ON (with
engine OFF)
1.0 — 5.1
Throttle fully open in “R”
range after warm-up.
When lock up occurs. More than 10.5
Lock-up duty solenoid B55 5 2.0 — 6.0
When lock up is released. Less than 1
“P” or “N” range Less than 1
Transfer duty solenoid B55 4 2.0 — 6.0
1st gear 1.7 — 4.0
“P” or “N” range More than 10.5
2-4 brake duty solenoid B55 6 2.0 — 6.0
2nd or 4th gear Less than 1
3rd or 4th gear Less than 1
High clutch duty solenoid B55 8 2.0 — 6.0
1st or 2nd gear Less than 1
Low clutch duty solenoid B55 9 2.0 — 6.0
Low & reverse duty solenoid B55 7 Driving at 1st on manual 2.0 — 6.0
mode (15 km/h (9.3 MPH) 5 — 10
or more)
Front vehicle speed sensor
B54 15 — 0 Less than 1
ground
Rear vehicle speed sensor
ground
Torque converter turbine
speed sensor ground
B54 17
B55 2
System ground circuit — 0 Less than 1
B55 3
B54 8
Sensor ground line 3 B55 19 — 0 Less than 1
Sensor ground line 4 B54 9 — 0 Less than 1
Vehicle speed in “D” range
More than 10.5
0 km/h (0 MPH)
Range lock signal B55 18 7 — 18
Vehicle speed in “D” range
Less than 1
20 km/h (12 MPH)
Data link signal (Subaru
B55 12 — — —
Select Monitor)
4AT(diag)-15

Resistance
Connector
No.
ground (")
CAN communication signal
B54 3 Ignition switch ON Pulse signal —
(+)
CAN communication signal
B54 12 Ignition switch ON Pulse signal —
($)
Fuse removed 10.5 or more
FWD switch B55 17 —
Fuse installed 1 or less
Ignition switch ON (Lateral
Lateral G sensor B54 11 G sensor in horizontal 2.0 — 3.0 —
position)
Lateral G sensor power sup-
B54 2 Ignition switch ON 4.75 — 5.25 —
ply
4AT(diag)-16
Subaru Select Monitor
6. Subaru Select Monitor NOTE:

Do not connect scan tools except for Subaru Select
A: OPERATION Monitor.
1. READ DIAGNOSTIC TROUBLE CODE 5) Turn the ignition switch to ON (engine OFF) and
(DTC) Subaru Select Monitor switch to ON.
1) Prepare the Subaru Select Monitor kit.
(A)
AT-00341
AT-00338 (A) Power switch

2) Connect the diagnosis cable to Subaru Select 6) On the «Main Menu» display screen, select the
Monitor. {Each System Check} and press the [YES] key.
3) Insert the cartridge to Subaru Select Monitor. 7) On the «System Selection Menu» display
<Ref. to 4AT(diag)-6, PREPARATION TOOL, Gen- screen, select the {Transmission} and press the
eral Description.> [YES] key.
8) Press the [YES] key after the information of
transmission type is displayed.
9) On the «Transmission Diagnosis» display
screen, select the {Diagnosis Code(s) Display} and
press [YES] key.
NOTE:
• For details concerning operation procedure, re-
fer to the “SUBARU SELECT MONITOR OPERA-
TION MANUAL”.
AT-00339 • For details concerning DTC, refer to the List of
4) Connect the Subaru Select Monitor to data link Diagnostic Trouble Code (DTC). <Ref. to 4AT(di-
connector. ag)-32, List of Diagnostic Trouble Code (DTC).>
(1) Data link connector is located in the lower 2. READ CURRENT DATA
portion of instrument panel (on the driver’s side).
1) On the «Main Menu» display screen, select the
{Each System Check} and press the [YES] key.
screen, select the {Transmission} and press the
(1) [YES] key.
screen, select the {Current Data Display & Save}
and press the [YES] key.
AT-01712 5) On the «Transmission Diagnosis» display
screen, select the {Data Display} and press the
(1) Data link connector [YES] key.
6) Using the scroll key, scroll the display screen up
(2) Connect the diagnosis cable to data link or down until the desired data is shown.
connector.
4AT(diag)-17
• A list of the support data is shown in the following table.

Item Display Unit of measure
Battery voltage Battery Voltage V
Rear vehicle speed sensor signal Rear Wheel Speed km/h or MPH
Front vehicle speed sensor signal Front Wheel Speed km/h or MPH
Engine speed signal Engine speed rpm
Automatic transmission fluid temperature signal ATF Temp. #C or #F
Accelerator pedal position sensor Throttle Sensor Voltage V
Gear position Gear position —
Line pressure control duty ratio Line pressure duty %
Lock up clutch control duty ratio L/U Duty %
Transfer clutch control duty ratio AWD duty %
Accelerator pedal position sensor power supply Throttle sensor power supply V
Torque converter turbine speed signal Turbine Revolution Speed rpm
2-4 Brake timing pressure control duty ratio 2-4 B Pressure Duty %
Low clutch duty ratio L/C Duty %
High clutch duty ratio H/C Duty %
Low & reverse brake duty ratio L&R/B Duty %
Throttle position Throttle opening angle %
FWD switch signal FWD SW ON or OFF
Stop light switch signal Stop Light SW ON or OFF
Anti lock brake system signal ABS signal ON or OFF
Parking range signal P range ON or OFF
Neutral range signal N range ON or OFF
Reverse range signal R Range ON or OFF
Drive range signal D Range ON or OFF
Automatic transmission diagnosis light output signal Diagnosis Lamp ON or OFF
Cruise control signal Cruise control signal ON or OFF
AT OIL TEMP warning light ATF Temperature Lamp ON or OFF
Up-shift signal UP SW ON or OFF
Down shift signal Down SW ON or OFF
Tip signal Tip mode SW ON or OFF
Shift lock solenoid signal Shift lock solenoid ON or OFF
Lateral G sensor Lateral G sensor V
NOTE:
For details concerning operation procedure, refer to the “SUBARU SELECT MONITOR OPERATION MAN-
UAL”.
4AT(diag)-18
3. CLEAR MEMORY MODE 15) Shift the select lever to “N” range, and then wait
16) Shift the select lever to “D” range, and then wait
17) Shift the select lever to “N” range, and then wait
[YES] key.
3) Press the [YES] key after the information of 18) Slowly depress the accelerator pedal fully.
transmission type is displayed. 19) Slowly release the accelerator pedal fully.
4) On the «Transmission Diagnosis» display 20) Start the engine, and idle it.
screen, select the {Clear Memory} and press the 21) Shift the select lever to “D” range.
[YES] key. 22) Start the facilitation of learning control. At this
time, the SPORT indicator light in the combination
NOTE: meter start blinking at 2 Hz. When the SPORT indi-
When {Clear Memory 2} is selected and executed, cator light does not blink, turn the ignition switch to
DTC and learned control memory is cleared. If OFF and repeat the procedures from step 4). When
Clear Memory 2 has been performed, execute the the SPORT indicator light stop blinking at 2 Hz and
learning control. <Ref. to 4AT(diag)-19, FACILITA- goes OFF, facilitation of learning control is complet-
TION OF LEARNING CONTROL, OPERATION, ed.
Subaru Select Monitor.>
NOTE:
4. FACILITATION OF LEARNING CON- When blinking of SPORT indicator light changes
TROL from 2 Hz to 4 Hz during facilitation of learning con-
trol, repeat the procedure from step 4).
1) Shift the select lever to “P” range, and apply
parking brake. 23) Shift the select lever to “N” range, and then turn
2) Lift-up the vehicle. the ignition switch to OFF.
3) Connect the Subaru Select Monitor to data link 24) Shift the select lever to “P” range to complete
connector, and then turn the ignition switch to ON. the facilitation of learning control.
4) Perform the {Clear Memory 2} using Subaru Se-
lect Monitor. <Ref. to 4AT(diag)-19, CLEAR MEM-
ORY MODE, OPERATION, Subaru Select
Monitor.>
DTC is not output. <Ref. to 4AT(diag)-17, READ
DIAGNOSTIC TROUBLE CODE (DTC), OPERA-
TION, Subaru Select Monitor.>
6) Warm-up the engine until the ATF temperature
which is displayed on the Subaru Select Monitor
reaches 60 — 90#C (140 — 194#F). <Ref. to
7) Shift the select lever to “R” range.
8) Turn all switches including headlight, air condi-
tioner, seat heater, rear defogger and etc. to OFF.
9) Wait for 30 seconds with turning ignition key to
OFF until ACC goes OFF.
10) Depress the brake pedal fully until the facilita-
tion of learning control is completed when the
“Communication Failed!” is displayed on Subaru
Select Monitor.
12) Check that the Subaru Select Monitor is re-
turned to normal operation.
13) Shift the select lever to “P” range, and then wait
14) Shift the select lever to “R” range, and then wait
4AT(diag)-19
Read Diagnostic Trouble Code (DTC)
7. Read Diagnostic Trouble

Code (DTC)
A: OPERATION
Refer to “Subaru Select Monitor” for information
about how to display DTC. <Ref. to 4AT(diag)-17,
OPERATION, Subaru Select Monitor.>
For details concerning DTCs, refer to “List of Diag-
nostic Trouble Code (DTC)”. <Ref. to 4AT(diag)-
32, List of Diagnostic Trouble Code (DTC).>
NOTE:
DTC can not be read by SPORT indicator light.
4AT(diag)-20
Inspection Mode
8. Inspection Mode
A: PROCEDURE
WARNING:
Observe the traffic law during actual driving.
1) Shift the select lever to “D” range, and then drive
the vehicle at 60 km/h (37 MPH) for at least 10 sec-
onds.
2) Drive the vehicle with manual mode.
4AT(diag)-21
Clear Memory Mode
9. Clear Memory Mode

A: OPERATION
about how to clear DTC.
<Ref. to 4AT(diag)-19, CLEAR MEMORY MODE,
4AT(diag)-22
SPORT Indicator Light Display
10.SPORT Indicator Light Display

A: OPERATION
When any on-board diagnostics item is malfunctioning, the display on the SPORT indicator light blinks from
the time the malfunction is detected after starting the engine until the ignition switch is turned OFF. The mal-
functioning part or unit can be determined by a DTC during the on-board diagnostics operation. Problems
which occurred previously can also be identified through the memory function. If the SPORT indicator light
does not show a problem (although a problem is occurring), the problem can be determined by checking the
performance characteristics of each sensor using Subaru Select Monitor. Indicator light signal patterns are
as shown in the figure.
(A)
(1)
(2)
(B)
(1)
(3)
(2)
(4)
(C)
(1)
(3)
(2)
(5)
(D)
(1)
(3)
(2)
(7) (6)
AT-01109
(A) Ignition switch (Engine OFF) (C) Faulty (Engine ON) (D) Normal (SPORT mode ON)
(B) Normal (Engine ON)
(1) ON (4) 0.25 seconds (7) SPORT mode OFF

(2) OFF (5) Blink
(3) 2 seconds (6) SPORT mode ON
Perform the inspection when the SPORT indicator light does not operate correctly. <Ref. to 4AT(diag)-24, IN-
SPECTION, SPORT Indicator Light Display.>
4AT(diag)-23
B: INSPECTION
DIAGNOSIS:
SPORT indicator light circuit is open or shorted.
TROUBLE SYMPTOM:
When the ignition switch is turned to ON (engine OFF), SPORT indicator light does not illuminate.
WIRING DIAGRAM:
• LHD model
IGNITION i10
SWITCH
SBF-1 SBF-7 1 2 3 4 5 6 7 8 9 10
11 12 13 14 15 16 17 18 19 20 21 22
No.5
i77
1 2 3 4 5 6 7 8 9 10 11 12
BATTERY
A: i84
3
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
SPORT COMBINATION 24 25 26 27 28 29 30 31 32 33 34 35
E METER
i10
B: B280
1 2 3 4 5 6 7
21
22
8 9 10 11 12 13 14 15 16 17 18 19 20
21 22 23 24 25 26 27 28 29 30
1
JOINT
CONNECTOR
B54
i77
2
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16
A26
A27
17 18 19 20 21 22 23 24
A: i84 B: B280 BODY INTEGRATED UNIT

B352
B20
B30
B355
1 2 3 4
5
JOINT 5 6 7 8
CONNECTOR
B352
1
3
2
JOINT
CONNECTOR
B355
5
7
12
3
B54 TCM
AT-01883
4AT(diag)-24
• RHD model
IGNITION i10
SWITCH
SBF-1 SBF-7 1 2 3 4 5 6 7 8 9 10
11 12 13 14 15 16 17 18 19 20 21 22
No.5
i77
1 2 3 4 5 6 7 8 9 10 11 12
BATTERY
A: i84
3
4
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
SPORT COMBINATION 24 25 26 27 28 29 30 31 32 33 34 35
E METER
i10
B: B280
1 2 3 4 5 6 7
21
22
8 9 10 11 12 13 14 15 16 17 18 19 20
21 22 23 24 25 26 27 28 29 30
1
JOINT
CONNECTOR
B54
i77
2
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16
A26
A27
17 18 19 20 21 22 23 24
A: i84 B: B280 BODY INTEGRATED UNIT
B352
B20
B30
1 2 3 4
5 6 7 8
JOINT
3
CONNECTOR
B352
B53
2
1 2 3 4 5 6 7 8 9 10
11 12 13 14 15 16 17 18 19 20
19
JOINT
9
CONNECTOR
B53
18
10
12
3
B54 TCM
AT-01884
4AT(diag)-25
Step Check Yes No

1 CHECK SPORT INDICATOR LIGHT. Does the SPORT indicator Go to step 2. Perform the self-
Turn the ignition switch to ON. light illuminate? diagnosis of com-
bination meter.
After the ignition switch is “ON”, wait for at least light illuminate?
2 seconds.
3 CHECK SPORT INDICATOR LIGHT. Does the SPORT indicator Normal. Return to Go to step 7.
Start the engine. light go off? Basic Diagnostic
Procedure. <Ref.
to 4AT(diag)-2,
Basic Diagnostic
Procedure.>
4 CHECK SUBARU SELECT MONITOR COM- Is the communication between Go to step 5. Check the power
MUNICATION. Subaru Select Monitor and supply ground cir-
Connect the Subaru Select Monitor to data link TCM normal? cuit of TCM and
connector. Subaru Select
Monitor communi-
cation. <Ref. to
4AT(diag)-27,
Diagnostic Proce-
dure for Select
Monitor Communi-
cation.>
5 CHECK TCM. Is the “Diagnosis light” output Go to step 6. Replace the TCM.
Display the current data of TCM using Subaru signal “ON”? <Ref. to 4AT-65,
Select Monitor. Transmission Con-
trol Module
(TCM).>
6 CHECK BODY INTEGRATED UNIT. Is the “SPORT light” input sig- Replace the com- Check DTC of
Display the current data of body integrated unit nal “Illuminate”? bination meter body integrated
using Subaru Select Monitor. <Ref. to assembly. <Ref. to unit. <Ref. to
LAN(diag)-14, OPERATION, Subaru Select IDI-16, Combina- LAN(diag)-14,
Monitor.> tion Meter Assem- OPERATION,
bly.> Subaru Select
Monitor.>
7 CHECK TCM. Is the “Diagnosis light” output Replace the TCM. Go to step 8.
1) Start the engine. signal “ON”? <Ref. to 4AT-65,
2) Display the current data of TCM using Sub- Transmission Con-
aru Select Monitor. <Ref. to 4AT(diag)-17, trol Module
OPERATION, Subaru Select Monitor.> (TCM).>
8 CHECK BODY INTEGRATED UNIT. Is the “SPORT light” input sig- Check DTC of Perform the self-
Display the current data of body integrated unit nal “Illuminate”? body integrated diagnosis for com-
using Subaru Select Monitor. <Ref. to unit. Perform the bination meter.
LAN(diag)-14, OPERATION, Subaru Select diagnosis accord- <Ref. to IDI-3,
Monitor.> ing to DTC. <Ref. INSPECTION,
to LAN(diag)-14, Combination
OPERATION, Meter System.>
Subaru Select
Monitor.>
4AT(diag)-26
Diagnostic Procedure for Select Monitor Communication
11.Diagnostic Procedure for Select Monitor Communication

A: COMMUNICATION FOR INITIALIZING IMPOSSIBLE
DIAGNOSIS:
Faulty harness connector
TROUBLE SYMPTOM:
Subaru Select Monitor communication failure
WIRING DIAGRAM:
• LHD model
BATTERY
B11
NO.13 1 3 4
2
SBF-1
5 6 7 8
9 10 11 12
13 14 15 16
17 18 19 20
E
NO.12
SBF-7
B40
1 2 3 4 5 6 7 8
IGNITION
SWITCH B40 9 10 11 12 13 14 15 16
1
10
DATA LINK B53
NO.12
CONNECTOR
12
1 2 3 4 5 6 7 8 9 10
13 11 12 13 14 15 16 17 18 19 20
2
4
JOINT
*
JOINT CONNECTOR A: B54

CONNECTOR
B122
B53 1 2 3 4 5 6 7
*
8 9 10 11 12 13 14 15 16
14
15
13
5
17 18 19 20 21 22 23 24
B: B55
B21
B31
B27
B28
B29
B12
B21 1 2 3 4 5 6 7 8 9
36
A: B54 B: B55 TCM 10 11 12 13 14 15 16 17 18 19 20 21

E2 22 23 24 25 26 27 28 29 30 31
A17
A8
B2
B3
B122
1 2 3 4
19
18
16
6
5 6 7 8
JOINT
CONNECTOR
E
B53 B21
8
7
1 2 3 4 5 6 7 8 9 10 11
B11 12 13 14 15 16 17 18 19 20 21 22
20
19
23 24 25 26 27 28 29 30 31 32 33
T4 * : TERMINAL NO. RANDOM ARRANGEMENT
34 35 36 37 38 39 40 41
42 43 44 45 46 47
48 49 50 51 52 53 54
E E TRANSMISSION
AT-01885
4AT(diag)-27
• RHD model
BATTERY
NO.13
SBF-1
E
SBF-7
NO.12
IGNITION
SWITCH B40
1
10
DATA LINK
NO.12
CONNECTOR
12
13
B27
B28
B29
B21
B31
B12
*
JOINT
CONNECTOR
A: B54 B: B55 TCM 25E : B138
*
O25 : B83
A17
A8
B2
B3
15
16
17
14
B21
36
JOINT
CONNECTOR E2
B53
* : TERMINAL NO. RANDOM ARRANGEMENT
6
25E : 2.5 L EK MODEL

B11
O25 : EXCEPT 2.5 L EK MODEL
19
20
T4
E
E E TRANSMISSION
B11 B21 B40 B53 B21
1 2 3 4 1 2 3 4
1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10 11
5 6 7 8 5 6 7 8
11 12 13 14 15 16 17 18 19 20 12 13 14 15 16 17 18 19 20 21 22
9 10 11 12 9 10 11 12 9 10 11 12 13 14 15 16 23 24 25 26 27 28 29 30 31 32 33
13 14 15 16 13 14 15 16
17 18 19 20 34 35 36 37 38 39 40 41
A: B54 B: B55
42 43 44 45 46 47
B83 B138 48 49 50 51 52 53 54
1 2 3 4 5 6 7 1 2 3 4 5 6 7 8 9
1 2 3 4 8 9 10 11 12 13 14 15 16 10 11 12 13 14 15 16 17 18 19 20 21
5 6 7 8 17 18 19 20 21 22 23 24 22 23 24 25 26 27 28 29 30 31
AT-01886
4AT(diag)-28
Step Check Yes No

1 CHECK SUBARU SELECT MONITOR POW- Is the voltage more than 10 V? Go to step 2. Repair the har-
ER SUPPLY CIRCUIT. ness connector
Measure the voltage between data link con- and connector
nector and chassis ground. between battery
Connector & terminal and data link con-
(B40) No. 1 (+) — Chassis ground ($): nector, and poor
contact in cou-
pling connector.
2 CHECK SUBARU SELECT MONITOR Is the resistance less than 1 Go to step 3. Repair the open
GROUND CIRCUIT. "? circuit in harness
1) Disconnect the connectors from ECM. between data link
2) Measure the resistance of harness connec- connector and
tor between data link connector and ECM. ECM.
Connector & terminal
(B40) No. 12 — Chassis ground:
3 CHECK SUBARU SELECT MONITOR Is the resistance more than 1 Go to step 4. Repair the short
GROUND CIRCUIT. M"? circuit in harness
Measure the resistance of harness connector between data link
between data link connector and chassis connector and
ground. ground terminal.
4 CHECK ENGINE GROUND CIRCUIT. Is the engine ground circuit Go to step 5. Repair the ground
Check engine ground circuit. <Ref. to normal? circuit of ECM.
4AT(diag)-92, DTC P1708 THROTTLE POSI-
TION SENSOR CIRCUIT LOW INPUT, Diag-
nostic Procedure with Diagnostic Trouble Code
(DTC).>
5 CHECK COMMUNICATION OF SUBARU SE- Are the name of system dis- Go to step 10. Go to step 6.
LECT MONITOR. played on Subaru Select Moni-
1) Turn the ignition switch to ON. tor?
2) Using the Subaru Select Monitor, check
whether communication to transmission sys-
tems can be executed normally.
6 CHECK COMMUNICATION OF SUBARU SE- Are the name of system dis- Go to step 8. Go to step 7.
1) Turn the ignition switch to OFF. tor?
2) Disconnect the TCM connector.
3) Check whether communication to engine
systems can be executed normally.
7 CHECK COMMUNICATION OF SUBARU SE- Are the name of system dis- Inspect the ECM. Go to step 8.
1) Turn the ignition switch to OFF. tor?
2) Connect the TCM connector.
3) Disconnect the ECM connector.
4) Check whether communication to transmis-
sion systems can be executed normally.
8 CHECK HARNESS CONNECTOR BETWEEN Is the resistance more than 1 Go to step 9. Check harness
EACH CONTROL UNIT AND DATA LINK M"? and connector
CONNECTOR. between each con-
1) Turn the ignition switch to OFF. trol unit and data
2) Disconnect the TCM and ECM connector. link connector.
3) Measure the resistance between TCM con-
nector and chassis ground.
4AT(diag)-29
Step Check Yes No

9 CHECK OUTPUT SIGNAL FOR TCM. Is the voltage more than 1 V? Check harness Go to step 10.
1) Turn the ignition switch to ON. and connector
2) Measure the voltage between TCM and between each con-
chassis ground. trol unit and data
Connector & terminal link connector.
(B40) No. 10 (+) — Chassis ground ($):
10 CHECK HARNESS CONNECTOR BETWEEN Is the resistance less than 1 Go to step 11. Repair the har-
TCM AND DATA LINK CONNECTOR. "? ness and connec-
Measure the resistance between TCM connector between TCM
tor and data link connector. and data link con-
Connector & terminal nector.
(B55) No. 12 — (B40) No. 10:
11 CHECK INSTALLATION OF TCM CONNEC- Is TCM connector inserted into Go to step 12. Connect the TCM
TOR. TCM? connector to TCM.
Turn the ignition switch to OFF.
12 CHECK TRANSMISSION HARNESS CON- Is the transmission harness Go to step 13. Connect the bulk-
NECTOR. connector connected to bulk- head harness con-
head harness connector? nector to
transmission har-
ness connector.
13 CHECK POOR CONTACT IN CONNECTORS. Is there poor contact in control Repair the poor Go to step 14.
unit power supply and data link contact.
connector?
14 CHECK POWER SUPPLY OF TCM. Is the voltage 10 — 13 V? Go to step 16. Go to step 15.
3) Measure the voltage between TCM con-
15 CHECK FUSE (No. 12). Is the fuse (No. 12) blown? Replace the fuse Repair the open
1) Turn the ignition switch to OFF. (No. 12). If the circuit in harness
2) Remove the fuse (No. 12). replaced fuse (No. between fuse (No.
12) blown out eas- 12) and TCM, or
ily, repair the short fuse (No. 12) and
circuit in harness battery, and poor
between fuse (No. contact in cou-
12) and TCM. pling connector.
16 CHECK IGNITION POWER SUPPLY CIR- Is the voltage 10 — 13 V? Go to step 18. Go to step 17.
CUIT.
1) Turn the ignition switch to ON (engine
OFF).
2) Measure the ignition power supply voltage
between TCM connector and chassis ground.
17 CHECK FUSE (No. 12). Is the fuse (No. 12) blown? Replace the fuse Repair the open
Remove the fuse (No. 12). (No. 12). If the circuit in harness
replaced fuse (No. between fuse (No.
12) blown out eas- 12) and TCM, or
ily, repair the short fuse (No. 12) and
circuit in harness battery, and poor
between fuse (No. contact in connec-
12) and TCM. tor.
4AT(diag)-30
Step Check Yes No

18 CHECK HARNESS CONNECTOR BETWEEN Is the resistance less than 1 Go to step 19. Repair the open
TCM AND TRANSMISSION. "? circuit in harness
1) Turn the ignition switch to OFF. between TCM and
2) Disconnect the connector from TCM and transmission har-
transmission. ness connector,
3) Measure the resistance of harness and poor contact
between TCM and transmission connector. in connector.
(B54) No. 8 — (B11) No. 19:
(B54) No. 17 — (B11) No. 19:
(B55) No. 2 — (B11) No. 20:
(B55) No. 3 — (B11) No. 20:
TRANSMISSION AND TRANSMISSION "? circuit in harness
GROUND. between transmis-
Measure the resistance of harness between sion and transmis-
transmission and transmission ground. sion ground.
(T4) No. 19 — Transmission ground:
20 CHECK POOR CONTACT IN CONNECTORS. Is there poor contact in TCM Repair the con- Replace the TCM.
power supply, ground and data nector. <Ref. to 4AT-65,
link connector? Transmission Con-
trol Module
(TCM).>
4AT(diag)-31
List of Diagnostic Trouble Code (DTC)
12.List of Diagnostic Trouble Code (DTC)

A: LIST
DTC Item Content of diagnosis Reference target
<Ref. to 4AT(diag)-34, DTC P0705 TRANS-
Transmission Range
Inhibitor switch malfunction short MISSION RANGE SENSOR CIRCUIT (PRNDL
P0705 Sensor Circuit (PRNDL
circuit INPUT), Diagnostic Procedure with Diagnostic
INPUT)
Trouble Code (DTC).>
Transmission Fluid Tem-
ATF temperature sensor is faulty MISSION FLUID TEMPERATURE SENSOR
P0712 perature Sensor Circuit
or input signal circuit is open. CIRCUIT LOW INPUT, Diagnostic Procedure
Low Input
with Diagnostic Trouble Code (DTC).>
ATF temperature sensor is faulty MISSION FLUID TEMPERATURE SENSOR
or input signal circuit is shorted. CIRCUIT HIGH INPUT, Diagnostic Procedure
High Input
<Ref. to 4AT(diag)-48, DTC P0715 INPUT/
Torque Converter Tur- Torque converter turbine speed
TURBINE SPEED SENSOR CIRCUIT, Diag-
P0715 bine Speed Signal Cir- sensor malfunction, short input
nostic Procedure with Diagnostic Trouble Code
cuit Malfunction signal circuit
(DTC).>
<Ref. to 4AT(diag)-50, DTC P0719 TORQUE
Torque Converter/Brake Brake switch malfunction, open CONVERTER/BRAKE SWITCH “B” CIRCUIT
P0719
Switch “B” Circuit Low input signal circuit LOW, Diagnostic Procedure with Diagnostic
Front vehicle speed sensor mal- <Ref. to 4AT(diag)-53, DTC P0720 OUTPUT
AT Vehicle Speed Sen-
P0720 function, open or short input sig- SPEED SENSOR CIRCUIT, Diagnostic Proce-
sor Circuit Malfunction
nal circuit dure with Diagnostic Trouble Code (DTC).>
Torque Converter/Brake Brake switch malfunction, short CONVERTER/BRAKE SWITCH “B” CIRCUIT
P0724
Switch “B” Circuit High input signal circuit HIGH, Diagnostic Procedure with Diagnostic
<Ref. to 4AT(diag)-59, DTC P0725 ENGINE
Engine Speed Input Cir- Open or short engine speed out-
P0725 SPEED INPUT CIRCUIT, Diagnostic Proce-
cuit Malfunction put signal circuit
dure with Diagnostic Trouble Code (DTC).>
Vehicle sensor, torque converter <Ref. to 4AT(diag)-61, DTC P0731 GEAR 1
P0731 Gear 1 Incorrect Ratio turbine speed sensor, or control INCORRECT RATIO, Diagnostic Procedure
valve malfunction with Diagnostic Trouble Code (DTC).>
Vehicle sensor, torque converter <Ref. to 4AT(diag)-62, DTC P0736 REVERSE
P0736 Reverse Incorrect Ratio turbine speed sensor, or control INCORRECT RATIO, Diagnostic Procedure
Torque Converter Clutch
Lock-up clutch is faulty or valve is CONVERTER CLUTCH CIRCUIT PERFOR-
P0741 Circuit Performance or
stuck. MANCE OR STUCK OFF, Diagnostic Proce-
Stuck Off
Lock-up solenoid is faulty or out-
Torque Converter Clutch CONVERTER CLUTCH CIRCUIT ELECTRI-
P0743 put signal circuit is open or
Circuit Electrical CAL, Diagnostic Procedure with Diagnostic
shorted.
4AT(diag)-32

<Ref. to 4AT(diag)-68, DTC P0748 PRES-
Line pressure linear solenoid is
Pressure Control Sole- SURE CONTROL SOLENOID “A” ELECTRI-
P0748 faulty or output signal circuit is
noid “A” Electrical CAL, Diagnostic Procedure with Diagnostic
open or shorted.
Low clutch duty solenoid is faulty <Ref. to 4AT(diag)-71, DTC P0753 SHIFT
Shift Solenoid “A” Elec-
P0753 or output signal circuit is open or SOLENOID “A” ELECTRICAL, Diagnostic Pro-
trical
shorted. cedure with Diagnostic Trouble Code (DTC).>
2-4 brake duty solenoid is faulty <Ref. to 4AT(diag)-74, DTC P0758 SHIFT
Shift Solenoid “B” Elec-
P0758 or output signal circuit is open or SOLENOID “B” ELECTRICAL, Diagnostic Pro-
trical
High clutch duty solenoid is faulty <Ref. to 4AT(diag)-77, DTC P0763 SHIFT
Shift Solenoid “C” Elec-
P0763 or output signal circuit is open or SOLENOID “C” ELECTRICAL, Diagnostic Pro-
trical
Low & reverse clutch duty sole- <Ref. to 4AT(diag)-80, DTC P0768 SHIFT
Shift Solenoid “D” Elec-
P0768 noid is faulty or output signal cir- SOLENOID “D” ELECTRICAL, Diagnostic Pro-
trical
cuit is open or shorted. cedure with Diagnostic Trouble Code (DTC).>
Range lock solenoid is faulty or <Ref. to 4AT(diag)-83, DTC P0801 REVERSE
Reverse Inhibit Control
P0801 output signal circuit is open or INHIBIT CONTROL CIRCUIT, Diagnostic Pro-
Circuit
<Ref. to 4AT(diag)-86, DTC P1706 AT VEHI-
AT Vehicle Speed Sen- Rear vehicle speed sensor is
CLE SPEED SENSOR CIRCUIT MALFUNC-
P1706 sor Circuit Malfunction faulty or input signal circuit is
TION (REAR WHEEL), Diagnostic Procedure
(Rear Wheel) open or shorted.
<Ref. to 4AT(diag)-89, DTC P1707 AT AWD
Transfer duty solenoid is faulty or
SOLENOID VALVE CIRCUIT MALFUNC-
P1707 AT AWD Solenoid Valve output signal circuit is open or
TION, Diagnostic Procedure with Diagnostic
shorted.
<Ref. to 4AT(diag)-92, DTC P1708 THROTTLE
Accelerator pedal position sen-
Throttle Position Sensor POSITION SENSOR CIRCUIT LOW INPUT,
P1708 sor is faulty or input signal circuit
Circuit Low Input Diagnostic Procedure with Diagnostic Trouble
is open.
Code (DTC).>
<Ref. to 4AT(diag)-98, DTC P1709 THROTTLE
Throttle Position Sensor POSITION SENSOR CIRCUIT HIGH INPUT,
Circuit High Input Diagnostic Procedure with Diagnostic Trouble
is shorted.
Code (DTC).>
<Ref. to 4AT(diag)-104, DTC P1714 THROT-
Throttle Position Sensor TLE POSITION SENSOR POWER SUPPLY
Power Supply Circuit CIRCUIT, Diagnostic Procedure with Diagnos-
is open or shorted.
tic Trouble Code (DTC).>
<Ref. to 4AT(diag)-109, DTC P1718 CAN
CAN Communication CAN communication circuit is
P1718 COMMUNICATION CIRCUIT, Diagnostic Pro-
Circuit open or shorted.
cedure with Diagnostic Trouble Code (DTC).>
<Ref. to 4AT(diag)-110, DTC P1760 LATERAL
Lateral Acceleration
ACCELERATION SENSOR PERFORMANCE
P1760 Sensor Performance Lateral G sensor is faulty.
PROBLEM, Diagnostic Procedure with Diag-
Problem
nostic Trouble Code (DTC).>
Lateral Acceleration Lateral G sensor is faulty or input ACCELERATION SENSOR CIRCUIT LOW,
P1761
Sensor Circuit Low signal circuit is open. Diagnostic Procedure with Diagnostic Trouble
Code (DTC).>
Lateral Acceleration Lateral G sensor is faulty or input ACCELERATION SENSOR CIRCUIT HIGH,
P1762
Sensor Circuit High signal circuit is shorted. Diagnostic Procedure with Diagnostic Trouble
Code (DTC).>
manual mode switch is faulty or <Ref. to 4AT(diag)-119, DTC P1817 SPORTS
Sports Mode Switch Cir-
P1817 input signal circuit is open or MODE SWITCH CIRCUIT, Diagnostic Proce-
cuit
shorted. dure with Diagnostic Trouble Code (DTC).>
4AT(diag)-33
Diagnostic Procedure with Diagnostic Trouble Code (DTC)
13.Diagnostic Procedure with Diagnostic Trouble Code (DTC)

A: DTC P0705 TRANSMISSION RANGE SENSOR CIRCUIT (PRNDL INPUT)
DTC DETECTING CONDITION:
• Inhibitor switch is faulty.
• More than 2 range signal is input.
TROUBLE SYMPTOM:
• Shift characteristics are erroneous.
• Range position of select lever and AT select lever position indicator light on the combination meter is not
matched.
4AT(diag)-34
WIRING DIAGRAM:
• LHD model
SBF-1 SBF-7 No.5
i10
4
BATTERY
1 2 3 4 5 6 7 8 9 10
COMBINATION 11 12 13 14 15 16 17 18 19 20 21 22
METER
P R N D
i10
i77
E 1 2 3 4 5 6 7 8 9 10 11 12
21
22
A: i84
1
7
JOINT
CONNECTOR
1 2 3 4 5 6 7 8
i77
9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
2
8
24 25 26 27 28 29 30 31 32 33 34 35
A27
A26
BODY INTEGRATED
UNIT
B: B280
A: i84
1 2 3 4 5 6 7
B20
B30
B: B280
8 9 10 11 12 13 14 15 16 17 18 19 20
21 22 23 24 25 26 27 28 29 30
5
JOINT
CONNECTOR
B54
B352
1
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16
17 18 19 20 21 22 23 24
2
JOINT
CONNECTOR
B355
B12
5
1 2 3 4
12
3
5 6 7 8
9 10 11 12
B54 TCM
14
22
5
T7
B12
1 2 3 4 5 6
3
2
1
8
T3 7 8 9 10 11 12
10
9
8
B352
P INHIBITOR
R SWITCH
B355
N T7
D
1 2 3 4
5 6 7 8
5
T3
4
B12
E
AT-01888
4AT(diag)-35
• RHD model
SBF-1 SBF-7 No.5
i10
4
BATTERY
1 2 3 4 5 6 7 8 9 10
COMBINATION 11 12 13 14 15 16 17 18 19 20 21 22
METER P R N D
i10
i77
E
1 2 3 4 5 6 7 8 9 10 11 12
21
22
JOINT
7
A: i84
CONNECTOR
i77 1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
2
8
24 25 26 27 28 29 30 31 32 33 34 35
A27
A26
BODY INTEGRATED UNIT
B: B280
A: i84
1 2 3 4 5 6 7
B20
B30
B: B280
8 9 10 11 12 13 14 15 16 17 18 19 20
21 22 23 24 25 26 27 28 29 30
JOINT
3
CONNECTOR
B352
B352
2
1 2 3 4
5 6 7 8
19
JOINT
9
CONNECTOR
B53 B53
18
10
1 2 3 4 5 6 7 8 9 10
11 12 13 14 15 16 17 18 19 20
12
3
B54 TCM
B54
14
22
5
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16
B12
17 18 19 20 21 22 23 24
3
2
1
8
T3
10
B12
9
8
P INHIBITOR
SWITCH 1 2 3 4
R
5 6 7 8
N T7 9 10 11 12
D
5
T7
T3
4
1 2 3 4 5 6
B12
7 8 9 10 11 12
E
AT-02356
Step Check Yes No

1 CHECK INDICATOR LIGHT. Does the “P” range indicator Go to step 2. Go to step 12.
1) Turn the ignition switch to ON. light on combination meter illu-
2) Shift the select lever to “P” range. minate?
2 CHECK INDICATOR LIGHT. Does the “R” range indicator Go to step 26. Go to step 3.
light on combination meter illu-
minate?
4AT(diag)-36
Step Check Yes No

3 CHECK INDICATOR LIGHT. Does the “N” range indicator Go to step 33. Go to step 4.
minate?
4 CHECK INDICATOR LIGHT. Does the “D” range indicator Go to step 40. Go to step 5.
minate?
5 CHECK “P” RANGE SWITCH. Does the “P” range LED of Go to step 19. Go to step 6.
1) Connect the Subaru Select Monitor to data Subaru Select Monitor illumi-
link connector. nate?
6 CHECK INDICATOR LIGHT. Does the “R” range indicator Go to step 8. Go to step 7.
minate?
7 CHECK “R” RANGE SWITCH. Does the “R” range LED of Go to step 23. Go to step 20.
Subaru Select Monitor illumi-
nate?
8 CHECK INDICATOR LIGHT. Does the “P” range indicator Go to step 10. Go to step 9.
Shift the select lever to the “N” range. light on combination meter illu-
minate?
9 CHECK “N” RANGE SWITCH. Does the “N” range LED of Go to step 30. Go to step 27.
nate?
10 CHECK INDICATOR LIGHT. Does the “D” range indicator Even if the SPORT Go to step 11.
Shift the select lever to “D” range. light on combination meter illu- indicator light is
minate? blinking, the cir-
cuit has returned
to normal condi-
tion at this time. A
temporary poor
contact of connec-
tor or harness may
be the cause.
Repair the har-
ness or connector
in TCM and trans-
mission.
11 CHECK “D” RANGE SWITCH. Does the “D” range LED of Go to step 37. Go to step 34.
nate?
INHIBITOR SWITCH AND CHASSIS "? circuit in harness
GROUND. between inhibitor
1) Turn the ignition switch to OFF. switch connector
2) Disconnect the connector from inhibitor and chassis
switch. ground, and poor
3) Measure the resistance of harness contact in cou-
between inhibitor switch and chassis ground. pling connector.
(T7) No. 5 — Chassis ground:
TCM AND INHIBITOR SWITCH. "? circuit in harness
2) Disconnect the connector from TCM and inhibitor switch
inhibitor switch. connector, and
3) Measure the resistance of harness poor contact in
between TCM and inhibitor switch connector. coupling connec-
Connector & terminal tor.
(B54) No. 5 — (T7) No. 9:
4AT(diag)-37
Step Check Yes No

14 CHECK INPUT SIGNAL FOR TCM. Is the voltage less than 1 V? Go to step 15. Go to step 41.
1) Turn the ignition switch to OFF.
2) Connect the connector to TCM and inhibitor
switch.
4) Shift the select lever to “P” range.
5) Measure the voltage between TCM and
chassis ground.
15 CHECK INPUT SIGNAL FOR TCM. Is the voltage more than 8 V? Go to step 41. Replace the TCM.
1) Shift the select lever to any range other <Ref. to 4AT-65,
than “P”. Transmission Con-
2) Measure the voltage between TCM and trol Module
chassis ground. (TCM).>
16 CHECK BODY INTEGRATED UNIT. Is “7” displayed? Go to step 17. Check the body
Read the data of the inhibitor switch from Sub- integrated unit.
aru Select Monitor. <Ref. to LAN(diag)-14,
17 CHECK BODY INTEGRATED UNIT. Is DTC of CAN communication Perform the diag- Go to step 18.
Check DTC of body integrated unit. displayed? nosis according to
DTC.
18 CHECK COMBINATION METER. Is the “P” range indicator light Go to step 41. Replace the com-
Check the “P” range indicator light. <Ref. to OK? bination meter
IDI-3, INSPECTION, Combination Meter Sys- assembly. <Ref. to
tem.> IDI-16, Combina-
tion Meter Assem-
bly.>
19 CHECK HARNESS CONNECTOR BETWEEN Is the resistance less than 1 Go to step 42. Repair the ground
TCM AND INHIBITOR SWITCH. M"? short circuit in “P”
1) Turn the ignition switch to OFF. range circuit.
2) Disconnect the connectors from TCM,
inhibitor switch and combination meter.
3) Measure the resistance of harness
(B54) No. 14 — (T7) No. 8:
switch.
chassis ground.
4AT(diag)-38
Step Check Yes No

1) Shift the select lever to other than “R” <Ref. to 4AT-65,
range. Transmission Con-
Read the data of shift position from Subaru integrated unit.
Select Monitor. <Ref. to LAN(diag)-14, OPER-
ATION, Subaru Select Monitor.>
DTC.
25 CHECK COMBINATION METER. Is the “R” range indicator light Go to step 41. Replace the com-
Check the “R” range indicator light. <Ref. to OK? bination meter
tion Meter Assem-
bly.>
26 CHECK HARNESS CONNECTOR BETWEEN Is the resistance more than 1 Go to step 41. Repair the ground
TCM AND INHIBITOR SWITCH. M"? short circuit in “R”
(B54) No. 22 — (T7) No. 10:
switch.
chassis ground.
1) Shift the select lever to other than “N” <Ref. to 4AT-65,
Read the data of shift position from Subaru integrated unit.
4AT(diag)-39
Step Check Yes No

DTC.
32 CHECK COMBINATION METER. Is the “N” range indicator light Go to step 41. Replace the com-
Check the “N” range indicator light. <Ref. to OK? bination meter
tion Meter Assem-
bly.>
TCM AND INHIBITOR SWITCH. M"? short circuit in “N”
(B54) No. 4 — (T7) No. 3:
switch.
4) Shift the select lever to “D” range.
chassis ground.
1) Shift the select lever to other than “D” <Ref. to 4AT-65,
Read the data of inhibitor switch from Subaru integrated unit.
the DTC.
39 CHECK COMBINATION METER. Is the “D” range indicator light Go to step 41. Replace the com-
Check the “D” range indicator light. <Ref. to OK? bination meter
tion Meter Assem-
bly.>
4AT(diag)-40
Step Check Yes No

TCM AND INHIBITOR SWITCH. M"? short circuit in “D”
41 CHECK POOR CONTACT. Is there poor contact in inhibi- Repair the poor Go to step 42.
tor switch circuit? contact.
42 CHECK INHIBITOR SWITCH. Is the inhibitor switch in normal Replace the TCM. Adjust inhibitor
position? <Ref. to 4AT-65, switch and select
Transmission Con- cable. <Ref. to
trol Module 4AT-52, Inhibitor
(TCM).> Switch.> and <Ref.
to CS-12, Select
Cable.>
4AT(diag)-41
B: DTC P0712 TRANSMISSION FLUID TEMPERATURE SENSOR CIRCUIT LOW

INPUT
Input signal circuit of TCM to ATF temperature sensor is open or shorted.
TROUBLE SYMPTOM:
Excessive shift shock
WIRING DIAGRAM:
AT2
1 2
3 4
B11
B54 TCM
1 2 3 4
5 6 7 8
9 10 11 12
13 14 15 16
21
9
17 18 19 20
B54
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16
17 18 19 20 21 22 23 24
B11
11
15
T4
AT2
3
1
ATF TEMPERATURE
SENSOR
TRANSMISSION
AT-02227
4AT(diag)-42
Step Check Yes No

TCM AND ATF TEMPERATURE SENSOR. "? circuit in harness
2) Disconnect the connector from transmis- transmission con-
sion and TCM. nector.
between TCM and transmission connector.
(B54) No. 21 — (B11) No. 11:
TCM AND ATF TEMPERATURE SENSOR. "? circuit in harness
Measure the resistance of harness between between TCM and
TCM and transmission connector. transmission con-
(B54) No. 9 — (B11) No. 15:
3 CHECK ATF TEMPERATURE SENSOR. Is the resistance 500 — 600 Go to step 4. Go to step 7.
1) Turn the ignition switch to OFF. "?
2) Connect the connectors to transmission
and TCM.
3) Turn the ignition switch to ON and start
engine.
4) Warm-up the transmission until the ATF
temperature reaches to 80#C (176#F).
NOTE:
If the ambient temperature is below 0#C (32#F),
drive the vehicle until the ATF reaches its oper-
ating temperature.
5) Disconnect the connector from transmis-
sion.
6) Measure the resistance between transmis-
sion connector terminals.
(T4) No. 11 — No. 15:
4 CHECK ATF TEMPERATURE SENSOR. Does the resistance value Go to step 5. Go to step 7.
Measure the resistance between transmission increase while the ATF temper-
connector terminals. ature decreases?
(T4) No. 11 — No. 15:
5 CHECK INPUT SIGNAL FOR TCM USING Does the ATF temperature Even if the SPORT Go to step 6.
SUBARU SELECT MONITOR. gradually decrease? indicator light is
1) Connect the connector to transmission. blinking, the cir-
2) Connect the Subaru Select Monitor to data cuit has returned
link connector. to normal condi-
3) Turn the ignition switch to ON (engine tion at this time. A
OFF). temporary poor
4) Read the data of ATF temperature using contact of connec-
Subaru Select Monitor. tor or harness may
be the cause.
Repair the har-
ness or contact in
the ATF tempera-
ture sensor and
transmission con-
nector.
6 CHECK POOR CONTACT. Is there poor contact in ATF Repair the poor Replace the TCM.
temperature sensor circuit? contact. <Ref. to 4AT-65,
Transmission Con-
trol Module
(TCM).>
4AT(diag)-43
Step Check Yes No

TRANSMISSION AND ATF TEMPERATURE "? circuit in harness
SENSOR. between ATF tem-
1) Turn the ignition switch to OFF. perature sensor
2) Disconnect the connector from transmis- and transmission
sion. connector.
3) Remove the transmission connector from
bracket.
4) Lift-up the vehicle and support with rigid
racks.
NOTE:
Raise all wheels off floor.
5) Drain the ATF.
CAUTION:
Do not drain the ATF until it cools down.
6) Remove the oil pan, and disconnect the
connector from control valve.
between ATF temperature sensor and trans-
mission connector.
(T4) No. 11 — (AT2) No. 1:
TRANSMISSION AND ATF TEMPERATURE "? circuit in harness
Measure the resistance of harness between perature sensor
ATF temperature sensor and transmission con- and transmission
nector. connector.
(T4) No. 15 — (AT2) No. 3:
9 CHECK HARNESS CONNECTOR BETWEEN Is the resistance more than 1 Go to step 10. Repair the short
TRANSMISSION AND ATF TEMPERATURE M"? circuit in harness
Measure the resistance of harness between perature sensor
transmission connector and transmission and transmission
ground. connector.
10 CHECK HARNESS CONNECTOR BETWEEN Is the resistance more than 1 Replace the con- Repair the short
TRANSMISSION AND ATF TEMPERATURE M"? trol valve body. circuit in harness
SENSOR. <Ref. to 4AT-60, between ATF tem-
Measure the resistance of harness between Control Valve perature sensor
transmission connector and transmission Body.> and transmission
ground. connector.
4AT(diag)-44
C: DTC P0713 TRANSMISSION FLUID TEMPERATURE SENSOR CIRCUIT HIGH

INPUT
Input signal circuit of TCM to ATF temperature sensor is shorted.
TROUBLE SYMPTOM:
WIRING DIAGRAM:
AT2
1 2
3 4
B11
B54 TCM
1 2 3 4
5 6 7 8
9 10 11 12
13 14 15 16
21
9
17 18 19 20
B54
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16
17 18 19 20 21 22 23 24
B11
11
15
T4
AT2
3
1
ATF TEMPERATURE
SENSOR
TRANSMISSION
AT-02227
4AT(diag)-45
Step Check Yes No

1 CHECK HARNESS CONNECTOR BETWEEN Is the resistance more than Go to step 2. Go to step 4.
TCM AND ATF TEMPERATURE SENSOR. 500 "?
nector terminals.
(B54) No. 21 — No. 9:
2 CHECK HARNESS CONNECTOR BETWEEN Is the resistance more than 1 Go to step 3. Go to step 4.
TCM AND ATF TEMPERATURE SENSOR. M"?
Measure the resistance of harness between
TCM connector and chassis ground.
3 CHECK HARNESS. Does the resistance change? Go to step 4. Replace the TCM.
Measure the resistance between TCM connec- <Ref. to 4AT-65,
tor terminals while shaking the harness. Transmission Con-
Connector & terminal trol Module
(B54) No. 21 — No. 9: (TCM).>
TCM AND ATF TEMPERATURE SENSOR. M"? circuit in harness
2) Disconnect the connector from transmis- transmission har-
sion. ness.
TCM AND ATF TEMPERATURE SENSOR. M"? circuit in harness
TCM connector and chassis ground. transmission har-
Connector & terminal ness.
6 CHECK ATF TEMPERATURE SENSOR. Is the resistance more than Even if the SPORT Go to step 7.
Measure the resistance between transmission 500 "? indicator light is
connector terminals. blinking, the cir-
Connector & terminal cuit has returned
(T4) No. 11 — No. 15: to normal condi-
temporary short
circuit of connector
or harness may be
the cause. Repair
the harness or
connector.
4AT(diag)-46
Step Check Yes No

7 CHECK TRANSMISSION HARNESS. Is the resistance more than 1 Go to step 8. Replace the trans-
1) Lift-up the vehicle and place it on rigid M"? mission harness.
racks.
2) Drain the ATF.
NOTE:
3) Remove the oil pan.
4) Disconnect the harness connector from
control valve.
5) Measure the resistance between ATF tem-
perature sensor connector terminals
sion connector and transmission ground.
8 CHECK TRANSMISSION HARNESS. Is the resistance more than 1 Go to step 9. Replace the trans-
Measure the resistance between transmission M"? mission harness.
connector and transmission ground,
9 CHECK ATF TEMPERATURE SENSOR. Is the resistance more than Even if the SPORT Replace the con-
Measure the resistance between control valve 500 "? indicator light is trol valve body.
connector terminals blinking, the cir- <Ref. to 4AT-60,
Terminal cuit has returned Control Valve
No. 1 — No. 3: to normal condi- Body.>
temporary short
or harness may be
the cause. Repair
the harness or
connector.
4AT(diag)-47
D: DTC P0715 INPUT/TURBINE SPEED SENSOR CIRCUIT

Input signal circuit of TCM is open or shorted.
TROUBLE SYMPTOM:
WIRING DIAGRAM:
B11
1 2 3 4
5 6 7 8
B54 TCM
9 10 11 12
13 14 15 16
17 18 19 20
16
7
LH RH
2
9 B54
1 2 3 4 5 6 7
13 20 JOINT 8 9 10 11 12 13 14 15 16
CONNECTOR 17 18 19 20 21 22 23 24
3 10 B53
RH LH
B53
1 2 3 4 5 6 7 8 9 10
11 12 13 14 15 16 17 18 19 20
B11
10
5
T4
RH : RHD MODEL
LH : LHD MODEL
TORQUE
CONVERTER
TURBINE SPEED
SENSOR
AT-01889
Step Check Yes No

1 CHECK TORQUE CONVERTER TURBINE Is the resistance 450 — 650 Go to step 2. Replace the
SPEED SENSOR. "? torque converter
1) Turn the ignition switch to OFF. turbine speed sen-
2) Disconnect the connector from transmis- sor. <Ref. to 4AT-
sion. 59, Torque Con-
3) Measure the resistance between transmis- verter Turbine
sion connector receptacle’s terminals. Speed Sensor.>
(T4) No. 5 — No. 10:
4AT(diag)-48
Step Check Yes No

1) Disconnect the connector from TCM. between TCM and
2) Measure the resistance of harness transmission con-
between TCM and transmission connector. nector.
(B54) No. 7 — (B11) No. 5:
Connector & terminal nector, and poor
(B54) No. 16 — (B11) No. 10: contact in connec-
tor.
TCM AND TRANSMISSION. M"? circuit in harness
TCM connector and chassis ground. transmission con-
(B54) No. 7 — Chassis ground: contact in connec-
tor.
6 CHECK INPUT SIGNAL FOR TCM USING Is the revolution value same as Even if the SPORT Go to step 7.
SUBARU SELECT MONITOR. the tachometer reading shown indicator light is
1) Connect the connectors to TCM and trans- on the combination meter? blinking, the cir-
mission. cuit has returned
2) Connect the Subaru Select Monitor to data to normal condi-
link connector. tion at this time. A
3) Turn the ignition switch to ON, and the Sub- temporary poor
aru Select Monitor switch to ON. contact of connec-
4) Start the engine. tor or harness may
5) Shift the select lever to “P” or “N” range. be the cause.
6) Read the data of turbine speed using Sub- Repair the har-
aru Select Monitor. ness or connector
• Compare the tachometer with Subaru Select in TCM and trans-
Monitor indications. mission.
7 CHECK POOR CONTACT. Is there poor contact in torque Repair the poor Replace the TCM.
converter turbine speed sensor contact. <Ref. to 4AT-65,
circuit? Transmission Con-
trol Module
(TCM).>
4AT(diag)-49
E: DTC P0719 TORQUE CONVERTER/BRAKE SWITCH “B” CIRCUIT LOW

Brake switch malfunction, open input signal circuit
TROUBLE SYMPTOM:
• Gear is not shifted down when driving a down hill.
• The neutral control does not operate.
WIRING DIAGRAM:
• LHD model
SBF-1 SBF-3
WC : B65
1 2
BATTERY
No.8
3 4
OC : B64
WC OC
1
1 2
2
STOP LIGHT
SWITCH
OC : B64 B159
E WC : B65 1 2 3 4
OC WC
5 6 7 8 9
2 3
B: B280
9
JOINT
CONNECTOR
1 2 3 4 5 6 7
B159 8 9 10 11 12 13 14 15 16 17 18 19 20
5
21 22 23 24 25 26 27 28 29 30
C23
BODY INTEGRATED
UNIT
C: B281
B: B280
1 2 3 4 5 6 7
B20
B30
C: B281 8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23 24 25 26 27 28
5
JOINT
CONNECTOR
B54
OC : WITHOUT CRUISE CONTROL B352
1
WC : WITH CRUISE CONTROL 1 2 3 4 5 6 7

8 9 10 11 12 13 14 15 16
2
17 18 19 20 21 22 23 24
JOINT
CONNECTOR
B355
5
B352
B355
12
3
B54 TCM 1 2 3 4
5 6 7 8
AT-01890
4AT(diag)-50
• RHD model
SBF-1 SBF-3
B64
1 2
BATTERY
No.8
B159
1 2 3 4
5 6 7 8 9
1
E STOP LIGHT
SWITCH
B64 B: B280
1 2 3 4 5 6 7
2
8 9 10 11 12 13 14 15 16 17 18 19 20
21 22 23 24 25 26 27 28 29 30
JOINT
9
CONNECTOR
B159 C: B281
5
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
C23
BODY INTEGRATED
UNIT 20 21 22 23 24 25 26 27 28
B: B280
B20
B30
C: B281
B352
1 2 3 4
3
JOINT 5 6 7 8
CONNECTOR
B352
2
B53
1 2 3 4 5 6 7 8 9 10
19
JOINT
9
CONNECTOR 11 12 13 14 15 16 17 18 19 20
B53
18
10
B54
12
1 2 3 4 5 6 7
3
8 9 10 11 12 13 14 15 16
B54 TCM 17 18 19 20 21 22 23 24
AT-02357
4AT(diag)-51
Step Check Yes No

1 CHECK DTC. Does the DTC of CAN commu- Perform the diag- Go to step 2.
nication appear in the on-board nosis according to
diagnostics test mode? DTC.
2 CHECK BODY INTEGRATED UNIT. Is ON displayed? Go to step 3. Go to step 4.
2) Connect the Subaru Select Monitor to data
link connector.
3) Turn the ignition switch to ON. (engine
OFF)
4) Turn the Subaru Select Monitor switch to
ON.
5) Depress the brake pedal.
6) Read the data of brake pedal switch using
Subaru Select Monitor. <Ref. to LAN(diag)-14,
3 CHECK TCM. Is ON displayed? A temporary poor Replace the TCM.
Read the data of brake pedal switch using contact of connec- <Ref. to 4AT-65,
Subaru Select Monitor. <Ref. to 4AT(diag)-17, tor or harness may Transmission Con-
OPERATION, Subaru Select Monitor.> be the cause. trol Module
Check the poor (TCM).>
contact.
4 CHECK BODY INTEGRATED UNIT INPUT Is the voltage more than 10 V? Go to step 7. Go to step 5.
SIGNAL.
2) Disconnect the connector from body inte-
grated unit.
3) Measure the voltage of harness between
body integrated unit and stop light switch.
BODY INTEGRATED UNIT AND STOP LIGHT "? circuit of harness
SWITCH. between the body
1) Turn the ignition switch to OFF. integrated unit and
2) Disconnect the connector from stop light stop light switch.
switch.
between body integrated unit and stop light
switch.
Model with cruise control
(B281) No. 23 — (B65) No. 3:
Model without cruise control
(B281) No. 23 — (B64) No. 2:
BODY INTEGRATED UNIT AND STOP LIGHT M"? circuit of harness
Measure the resistance of harness between integrated unit and
body integrated unit and stop light switch. stop light switch.
7 CHECK POOR CONTACT. Is there poor contact in input Repair the poor Check the body
signal of brake switch? contact. integrated unit.
4AT(diag)-52
F: DTC P0720 OUTPUT SPEED SENSOR CIRCUIT

• The vehicle speed signal is abnormal.
• The harness connector between TCM and vehicle speed sensor is shorted or open.
TROUBLE SYMPTOM:
• The slip lock up control does not operate.
• Poor driving performance
WIRING DIAGRAM:
B11
B54 TCM
1 2 3 4
5 6 7 8
9 10 11 12
15
13 14 15 16
6
17 18 19 20
RH LH
12
1
B54
1 11 JOINT
CONNECTOR
1 2 3 4 5 6 7
11 12 B53
8 9 10 11 12 13 14 15 16
LH RH 17 18 19 20 21 22 23 24
B53
1 2 3 4 5 6 7 8 9 10
11 12 13 14 15 16 17 18 19 20
B11
14
18
T4
LH : LHD MODEL
RH : RHD MODEL
FRONT
VEHICLE SPEED
SENSOR
AT-01891
4AT(diag)-53
Step Check Yes No

2) Disconnect the connector from TCM and transmission con-
transmission. nector.
(B54) No. 6 — (B11) No. 14:
(B54) No. 15 — (B11) No. 18: contact in cou-
pling connector.
(B54) No. 15 — Chassis ground: contact in cou-
pling connector.
5 CHECK FRONT VEHICLE SPEED SENSOR. Is the resistance 450 — 650 Go to step 6. Replace the front
Measure the resistance between transmission "? vehicle speed sen-
connector receptacle’s terminals. sor. <Ref. to 4AT-
Connector & terminal 55, Front Vehicle
(T4) No. 14 — No. 18: Speed Sensor.>
4AT(diag)-54
Step Check Yes No

6 CHECK INPUT SIGNAL FOR TCM USING Does the speedometer indica- Even if the SPORT Go to step 7.
SUBARU SELECT MONITOR. tion increase as the Subaru indicator light is
1) Connect all the connectors. Select Monitor data increases? blinking, the cir-
3) Lift-up the vehicle and support with rigid tion at this time. A
racks. temporary poor
NOTE: contact of connec-
Raise all wheels off floor. tor or harness may
4) Turn the ignition switch to ON, and Subaru be the cause.
Select Monitor switch to ON. Repair the har-
5) Start the engine. ness in the front
6) Read the data of vehicle speed using Sub- vehicle speed sen-
aru Select Monitor. sor circuit.
• Compare the speedometer with Subaru
Select Monitor indications.
• Vehicle speed is indicated either in “km/h” or
“MPH”.
7) Slowly increase the vehicle speed to 60 km/
h (37 MPH).
NOTE:
The speed difference between front and rear
wheels may light the ABS warning light or VDC
warning light, but this indicates no malfunction.
When AT control diagnosis is finished, perform
the ABS memory clearance procedure or VDC
memory clearance procedure of on-board diag-
nostics system. <Ref. to ABS(diag)-27, Clear
Memory Mode.> <Ref. to VDC(diag)-24, Clear
Memory Mode.>
7 CHECK POOR CONTACT. Is there poor contact in front Repair the poor Replace the TCM.
vehicle speed sensor circuit? contact. <Ref. to 4AT-65,
Transmission Con-
trol Module
(TCM).>
4AT(diag)-55
G: DTC P0724 TORQUE CONVERTER/BRAKE SWITCH “B” CIRCUIT HIGH

TROUBLE SYMPTOM:
• Gear is not shifted down when driving a down hill.
WIRING DIAGRAM:
• LHD model
SBF-1 SBF-3
WC : B65
1 2
BATTERY
No.8
3 4
OC : B64
WC OC
1
1 2
2
STOP LIGHT
SWITCH
OC : B64 B159
E WC : B65 1 2 3 4
OC WC
5 6 7 8 9
2 3
B: B280
9
JOINT
CONNECTOR
1 2 3 4 5 6 7
B159 8 9 10 11 12 13 14 15 16 17 18 19 20
5
21 22 23 24 25 26 27 28 29 30
C23
BODY INTEGRATED
UNIT
C: B281
B: B280
1 2 3 4 5 6 7
B20
B30
C: B281 8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23 24 25 26 27 28
5
JOINT
CONNECTOR
B54
OC : WITHOUT CRUISE CONTROL B352
1
WC : WITH CRUISE CONTROL 1 2 3 4 5 6 7

8 9 10 11 12 13 14 15 16
2
17 18 19 20 21 22 23 24
JOINT
CONNECTOR
B355
5
B352
B355
12
3
B54 TCM 1 2 3 4
5 6 7 8
AT-01890
4AT(diag)-56
• RHD model
SBF-1 SBF-3
B64
1 2
BATTERY
No.8
B159
1 2 3 4
5 6 7 8 9
1
E STOP LIGHT
SWITCH
B64 B: B280
1 2 3 4 5 6 7
2
8 9 10 11 12 13 14 15 16 17 18 19 20
21 22 23 24 25 26 27 28 29 30
JOINT
9
CONNECTOR
B159 C: B281
5
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
C23
BODY INTEGRATED
UNIT 20 21 22 23 24 25 26 27 28
B: B280
B20
B30
C: B281
B352
1 2 3 4
3
JOINT 5 6 7 8
CONNECTOR
B352
2
B53
1 2 3 4 5 6 7 8 9 10
19
JOINT
9
CONNECTOR 11 12 13 14 15 16 17 18 19 20
B53
18
10
B54
12
1 2 3 4 5 6 7
3
8 9 10 11 12 13 14 15 16
B54 TCM 17 18 19 20 21 22 23 24
AT-02357
4AT(diag)-57
Step Check Yes No

1 CHECK DTC. Does the DTC of CAN commu- Perform the diag- Go to step 2.
nication appear in the on-board nosis according to
diagnostics test mode? DTC.
2 CHECK BODY INTEGRATED UNIT. Is OFF displayed? Go to step 3. Go to step 4.
link connector.
OFF)
ON.
Subaru Select Monitor. <Ref. to 4AT(diag)-17,
3 CHECK TCM. Is OFF displayed? A temporary poor Replace the TCM.
contact.
SIGNAL.
1) Disconnect harness connector of body inte-
grated unit.
body integrated unit and stop light switch.
5 CHECK STOP LIGHT SWITCH. Is the resistance more than 1 Go to step 6. Replace the stop
1) Turn the ignition switch to OFF. M"? light switch.
2) Disconnect the connector from stop light
switch.
between stop light switch connectors.
Terminals
MODEL WITH CRUISE CONTROL
No. 2 — No. 3:
MODEL WITHOUT CRUISE CONTROL
No. 1 — No. 2:
6 CHECK HARNESS CONNECTOR BETWEEN Is the voltage less than 1 V? Go to step 7. Repair the short
BODY INTEGRATED UNIT AND STOP LIGHT circuit in harness
SWITCH. between TCM and
1) Turn the ignition switch to ON. stop light switch.
body integrated unit and chassis ground.
4AT(diag)-58
H: DTC P0725 ENGINE SPEED INPUT CIRCUIT

Engine speed input signal circuit is open or shorted.
TROUBLE SYMPTOM:
• No lock-up occurs. (After engine is warmed-up)
• SPORT indicator light remains on when the vehicle speed is “0”.
WIRING DIAGRAM:
B54
B54 TCM 1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16
17 18 19 20 21 22 23 24
13
ND : B134
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23 24 25 26 27
28 29 30 31 32 33 34
HU : B135
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23 24 25 26 27
28 29 30 31 32 33 34 35
ND
23
HU
27
ND : B134
ECM
HU : B135
ND : 2.5 L EK AND 2.5 L K4 MODEL
HU : EXCEPT 2.5 L EK AND 2.5 L K4 MODEL
AT-01892
4AT(diag)-59
Step Check Yes No

TCM AND ECM. "? circuit in harness
2) Disconnect the connector from TCM and ECM connector.
ECM.
between TCM and ECM.
2.5 L EK and 2.5 L K4 model
(B54) No. 13 — (B134) No. 23:
Except for 2.5 L EK and 2.5 L K4 model
(B54) No. 13 — (B135) No. 27:
TCM AND ECM. M"? circuit in harness
TCM connector and chassis ground. ECM connector.
3 CHECK INPUT SIGNAL FOR TCM USING Is the revolution value same as Even if the SPORT Go to step 4.
SUBARU SELECT MONITOR. the tachometer reading shown indicator light is
1) Connect the connectors to TCM and ECM. on the combination meter? blinking, the cir-
3) Start the engine, and turn the Subaru tion at this time. A
Select Monitor switch to ON. temporary poor
4) Run the engine at idle. contact of connec-
5) Read the data of engine speed using Sub- tor or harness may
aru Select Monitor. be the cause.
• Display shows the engine speed signal value Repair the har-
sent from ECM. ness or connector
in the TCM and
ECM.
4 CHECK POOR CONTACT. Is there poor contact in engine Repair the poor Go to step 5.
speed signal circuit? contact.
5 CONFIRM DTC P0725. Does the DTC appear again, Replace the TCM. Replace the ECM.
Replace the ECM with a new one. after the memory has been <Ref. to 4AT-65,
cleared? Transmission Con-
trol Module
(TCM).>
4AT(diag)-60
I: DTC P0731 GEAR 1 INCORRECT RATIO

NOTE:
Refer to DTC P0736 for diagnostic procedure. <Ref. to 4AT(diag)-62, DTC P0736 REVERSE INCORRECT
RATIO, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
J: DTC P0732 GEAR 2 INCORRECT RATIO
NOTE:
K: DTC P0733 GEAR 3 INCORRECT RATIO
NOTE:
L: DTC P0734 GEAR 4 INCORRECT RATIO
NOTE:
4AT(diag)-61
M: DTC P0736 REVERSE INCORRECT RATIO

Vehicle sensor, torque converter turbine speed sensor or control valve malfunction
TROUBLE SYMPTOM:
• Shift point is too high or too low.
• Excessive shift shock
• Tight corner braking phenomenon is occurred.
• Gear is not shifted to reverse.
• Gear position is held by fail safe function.
Step Check Yes No

1 PREPARE SUBARU SELECT MONITOR. Do you have a Subaru Select Go to step 2. Go to step 5.
Monitor?
2 CHECK ACCELERATOR PEDAL POSITION Does the value of accelerator Go to step 3. Check the acceler-
SENSOR. pedal position sensor change ator position sen-
1) Connect the Subaru Select Monitor to data from 0% to 100% smoothly sor circuit. <Ref. to
link connector. when throttle was operated 4AT(diag)-92, DTC
2) Turn the ignition switch to ON. from fully closing to fully open- P1708 THROT-
3) Read the value of accelerator pedal posi- ing? TLE POSITION
tion sensor on Subaru Select Monitor display. SENSOR CIR-
CUIT LOW INPUT,
Diagnostic Proce-
dure with Diagnos-
tic Trouble Code
(DTC).>
3 CHECK FRONT VEHICLE SPEED SENSOR. Does the vehicle speed dis- Go to step 4. Check the front
1) Lift-up the vehicle and support with rigid played by Subaru Select Moni- vehicle speed sen-
racks. tor almost correspond with sor circuit.
2) Start the engine. vehicle speed indicated by
3) Shift the select lever to “D” range and combination meter?
slowly increase vehicle speed.
NOTE:
Memory Mode.>
4 CHECK TORQUE CONVERTER TURBINE Does the turbine speed sen- There are mal- Check the torque
SPEED SENSOR. sor revolution displayed by functions in TCM, converter turbine
1) Shift the select lever to “P” or “N” range. Subaru Select Monitor almost TCM connector speed sensor cir-
2) Idle the engine. correspond with engine revolu- poor contact, or cuit.
tion indicated by tachometer? transmission
assembly mechan-
ical malfunction.
5 CHECK ACCELERATOR PEDAL POSITION Is the voltage 0.8 — 1.2 V? Go to step 6. Check the acceler-
SENSOR. ator pedal position
1) Turn the ignition switch to ON. sensor circuit.
2) Fully close the throttle. <Ref. to 4AT(diag)-
3) Measure the voltage between TCM and 92, DTC P1708
chassis ground. THROTTLE POSI-
Connector & terminal TION SENSOR
(B54) No. 19 (+) — Chassis ground ($): CIRCUIT LOW
INPUT, Diagnostic
Procedure with
Diagnostic Trou-
ble Code (DTC).>
4AT(diag)-62
Step Check Yes No

6 CHECK ACCELERATOR PEDAL POSITION Is the voltage 3.3 — 4.6 V? Go to step 7. Check the acceler-
SENSOR. ator pedal position
1) Fully open the throttle. sensor circuit.
2) Measure the voltage between TCM and <Ref. to 4AT(diag)-
chassis ground. 92, DTC P1708
Connector & terminal THROTTLE POSI-
(B54) No. 19 (+) — Chassis ground ($): TION SENSOR
CIRCUIT LOW
INPUT, Diagnostic
Procedure with
Diagnostic Trou-
ble Code (DTC).>
7 CHECK FRONT VEHICLE SPEED SENSOR. Is the front vehicle speed sen- Go to step 8. Repair or replace
Diagnose according to DTC P0720 procedure. sor OK? the front vehicle
speed sensor cir-
cuit.
8 CHECK TORQUE CONVERTER TURBINE Is the torque converter turbine There are mal- Repair or replace
SPEED SENSOR. speed sensor OK? functions in TCM, the torque con-
Diagnose according to DTC P0715 procedure. TCM connector verter turbine
poor contact, or speed sensor cir-
transmission cuit.
assembly mechan-
ical malfunction.
4AT(diag)-63
N: DTC P0741 TORQUE CONVERTER CLUTCH CIRCUIT PERFORMANCE OR

STUCK OFF
• Lock up clutch malfunction
• Locking of bulb
TROUBLE SYMPTOM:
No lock-up occurs.
Step Check Yes No

1 CHECK LOCK-UP DUTY SOLENOID CIR- Is there any trouble? Repair or replace Go to step 2.
CUIT. the lock-up duty
Diagnose according to DTC P0743 procedure. solenoid circuit.
2 CHECK INHIBITOR SWITCH CIRCUIT. Is there any trouble? Repair or replace Go to step 3.
Diagnose according to DTC P0705 procedure. the inhibitor switch
circuit.
3 CHECK STOP LIGHT SWITCH CIRCUIT. Is there any trouble? Repair or replace Go to step 4.
Diagnose according to DTC P0719 and P0724 the stop light
procedure. switch circuit.
4 CHECK ATF TEMPERATURE SENSOR CIR- Is there any trouble? Repair or replace Go to step 5.
CUIT. the ATF tempera-
Diagnose according to DTC P0712 and P0713 ture sensor circuit.
procedure.
Monitor?
6 CHECK ACCELERATOR PEDAL POSITION Does the value of accelerator Go to step 7. Check the acceler-
SENSOR. pedal position sensor change ator pedal position
1) Connect the Subaru Select Monitor to data from 0% to 100% smoothly sensor circuit.
link connector. when throttle was operated
2) Turn the ignition switch to ON. from fully closing to fully open-
3) Read the value of accelerator pedal posi- ing?
tion sensor on Subaru Select Monitor display.
7 CHECK TORQUE CONVERTER TURBINE Does the turbine revolution dis- Go to step 8. Check the torque
SPEED SENSOR. played by Subaru Select Moni- converter turbine
1) Shift the select lever to “P” or “N” range. tor almost correspond with speed sensor cir-
2) Idle the engine. engine revolution indicated by cuit.
tachometer?
8 CHECK ENGINE SPEED SIGNAL. Does the turbine revolution dis- There is transmis- Check the engine
Idle the engine. played by Subaru Select Moni- sion assembly speed signal cir-
tor almost correspond with mechanical mal- cuit.
engine revolution indicated by function.
tachometer?
9 CHECK ACCELERATOR PEDAL POSITION Is there any trouble? Go to step 10. Repair or replace
SENSOR. the accelerator
Diagnose according to DTC P1708, P1709, pedal position sen-
P1714 procedure. sor circuit.
10 CHECK TORQUE CONVERTER TURBINE Is there any trouble? Go to step 11. Repair or replace
SPEED SENSOR. the torque con-
Diagnose according to DTC P0715 procedure. verter turbine
speed sensor cir-
cuit.
11 CHECK ENGINE SPEED SIGNAL. Is there any trouble? Repair or replace There is transmis-
Diagnose according to DTC P0725 procedure. the engine speed sion assembly
input circuit. mechanical mal-
function.
4AT(diag)-64
O: DTC P0743 TORQUE CONVERTER CLUTCH CIRCUIT ELECTRICAL

Output signal circuit of lock-up duty solenoid is open or shorted.
TROUBLE SYMPTOM:
No lock-up occurs. (After engine is warmed-up)
WIRING DIAGRAM:
B11
1 23 4
5 6 7 8
9 10 11 12
13 14 15 16
17 18 19 20
B55 TCM
B55
5
1 2 3 4 5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20 21
22 23 24 25 26 27 28 29 30 31
AT3
1 2 3
B11
4 5 6
12
T4
AT3
4
LOCK-UP
DUTY
SOLENOID
TRANSMISSION
AT-01485
Step Check Yes No

1 CHECK DTC. Do multiple DTC appear in the Go to another Go to step 2.
on-board diagnostics test DTC.
mode?
4AT(diag)-65
Step Check Yes No

(B55) No. 5 — (B11) No. 12:
Measure the resistance of harness connector between TCM and
between TCM and chassis ground. transmission con-
4 CHECK LOCK-UP DUTY SOLENOID. Is the resistance 2.0 — 6.0 "? Go to step 5. Go to step 8.
Measure the resistance between transmission
connector receptacle’s terminals.
(T4) No. 12 — No. 19:
5 CHECK OUTPUT SIGNAL EMITTED FROM Is the value 95%? Go to step 6. Go to step 7.
TCM USING SUBARU SELECT MONITOR.
1) Connect the connectors to TCM and trans-
mission.
racks.
NOTE:
link connector.
4) Start the engine, and turn the Subaru
Select Monitor switch to ON.
5) Start the engine and warm-up the engine
until the ATF temperature is above 80#C
(176#F).
NOTE:
ating temperature.
6) Read the data of lock-up duty solenoid
using Subaru Select Monitor.
• Lock-up duty solenoid is indicated in “%”.
7) Shift the select lever to “D”, and slowly
increase vehicle speed to 60 km/h (37 MPH).
NOTE:
Memory Mode.>
4AT(diag)-66
Step Check Yes No

6 CHECK OUTPUT SIGNAL EMITTED FROM Is the value 5%? Even if the SPORT Go to step 7.
TCM USING SUBARU SELECT MONITOR. indicator light is
Return the engine to idling speed, shift the blinking, the cir-
select lever to “N” range and read data. cuit has returned
NOTE: to normal condi-
The speed difference between front and rear tion at this time. A
wheels may light the ABS warning light or VDC temporary poor
warning light, but this indicates no malfunction. contact of connec-
When AT control diagnosis is finished, perform tor or harness may
the ABS memory clearance procedure or VDC be the cause.
memory clearance procedure of on-board diag- Repair the har-
nostics system. <Ref. to ABS(diag)-27, Clear ness or connector
Memory Mode.> <Ref. to VDC(diag)-24, Clear in TCM and trans-
Memory Mode.> mission.
7 CHECK POOR CONTACT. Is there poor contact in lock-up Repair the poor Replace the TCM.
duty solenoid circuit? contact. <Ref. to 4AT-65,
Transmission Con-
trol Module
(TCM).>
8 CHECK LOCK-UP DUTY SOLENOID (IN Is the resistance 2.0 — 6.0 "? Go to step 9. Replace the con-
TRANSMISSION). trol valve body.
1) Disconnect the transmission connector. <Ref. to 4AT-60,
2) Drain the ATF. Control Valve
CAUTION: Body.>
connector from control valve body.
4) Measure the resistance between lock-up
duty solenoid and transmission ground.
(AT3) No. 4 — Transmission ground:
LOCK-UP DUTY SOLENOID AND TRANS- "? circuit in harness
MISSION. between TCM and
Measure the resistance of harness between transmission con-
lock-up duty solenoid and transmission connector.
nector.
(T4) No. 12 — (AT3) No. 4:
10 CHECK HARNESS CONNECTOR BETWEEN Is the resistance more than 1 Even if the SPORT Repair the short
LOCK-UP DUTY SOLENOID AND TRANS- M"? indicator light is circuit in harness
MISSION. blinking, the cir- between lock-up
Measure the resistance of harness between cuit has returned duty solenoid and
transmission connector and transmission to normal condi- transmission con-
ground. tion at this time. A nector.
Connector & terminal temporary poor
(T4) No. 12 — Transmission ground: contact of connec-
tor or harness may
be the cause.
Repair the har-
ness or connector
in lock-up duty
solenoid and
transmission.
4AT(diag)-67
P: DTC P0748 PRESSURE CONTROL SOLENOID “A” ELECTRICAL

Output signal circuit of line pressure linear solenoid is open or shorted.
TROUBLE SYMPTOM:
WIRING DIAGRAM:
B55 TCM
20
19
B11
1
2
T4
AT2
2
4
LINE
PRESSURE
LINEAR
SOLENOID
TRANSMISSION
B11 B55 AT2
1 2 3 4
1 2 3 4 5 6 7 8 9 1 2
5 6 7 8
10 11 12 13 14 15 16 17 18 19 20 21 3 4
9 10 11 12
22 23 24 25 26 27 28 29 30 31
13 14 15 16
17 18 19 20
AT-01486
Step Check Yes No

(B55) No. 19 — (B11) No. 2:
(B55) No. 20 — (B11) No. 1:
TCM AND CHASSIS GROUND. M"? circuit in harness
3 CHECK LINE PRESSURE LINEAR SOLE- Is the resistance 4 — 8 "? Go to step 4. Go to step 7.
NOID.
(T4) No. 1 — No. 2:
4AT(diag)-68
Step Check Yes No

4 CHECK OUTPUT SIGNAL EMITTED FROM Is the value 45 — 50%? Go to step 5. Go to step 6.
mission.
link connector.
temperature exceeds approx. 80#C (176#F).
NOTE:
ating temperature.
5) Stop the engine and turn the ignition switch
to ON (engine OFF).
7) Read the data of line pressure linear sole-
noid using Subaru Select Monitor.
• Line pressure linear solenoid is indicated in
“%”.
8) Fully close the throttle.
5 CHECK OUTPUT SIGNAL EMITTED FROM Is the value 20 — 40%? Even if the SPORT Go to step 6.
Fully open the throttle. blinking, the cir-
cuit has returned
to normal condi-
temporary poor
contact of connec-
tor or harness may
be the cause.
Repair the har-
ness or connector
in transmission.
6 CHECK POOR CONTACT. Is there poor contact in line Repair the poor Replace the TCM.
pressure linear solenoid cir- contact. <Ref. to 4AT-65,
cuit? Transmission Con-
trol Module
(TCM).>
7 CHECK LINE PRESSURE LINEAR SOLE- Is the resistance 4 — 8 "? Go to step 8. Replace the con-
NOID (IN TRANSMISSION). trol valve body.
1) Remove the transmission connector from <Ref. to 4AT-60,
bracket. Control Valve
2) Drain the ATF. Body.>
CAUTION:
4) Measure the resistance between line pres-
sure linear solenoid connector terminals.
(AT2) No. 2 — No. 4:
4AT(diag)-69
Step Check Yes No

TRANSMISSION AND LINE PRESSURE LIN- "? circuit in harness
EAR SOLENOID. between line pres-
Measure the resistance of harness between sure linear sole-
line pressure linear solenoid and transmission noid and
connector. transmission con-
(T4) No. 2 — (AT2) No. 4:
(T4) No. 1 — (AT2) No. 2:
TRANSMISSION AND LINE PRESSURE LIN- M"? indicator light is circuit in harness
EAR SOLENOID. blinking, the cir- between line pres-
Measure the resistance of harness between cuit has returned sure linear sole-
transmission connector and transmission to normal condi- noid and
ground. tion at this time. A transmission con-
Connector & terminal temporary poor nector.
(T4) No. 2 — Transmission ground: tor or harness may
be the cause.
Repair the har-
ness or connector
in line pressure lin-
ear solenoid and
transmission.
4AT(diag)-70
Q: DTC P0753 SHIFT SOLENOID “A” ELECTRICAL

Output signal circuit of low clutch duty solenoid is open or shorted.
TROUBLE SYMPTOM:
WIRING DIAGRAM:
B11
1 23 4
5 6 7 8
9 10 11 12
13 14 15 16
17 18 19 20
B55 TCM
B55
9
1 2 3 4 5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20 21
22 23 24 25 26 27 28 29 30 31
AT3
1 2 3
B11
4 5 6
4
T4
AT3
2
LOW CLUTCH
DUTY
SOLENOID
TRANSMISSION
AT-01487
4AT(diag)-71
Step Check Yes No

(B55) No. 9 — (B11) No. 4:
TCM connector and transmission ground. transmission con-
3 CHECK LOW CLUTCH DUTY SOLENOID. Is the resistance 2.0 — 6.0 "? Go to step 4. Go to step 7.
(T4) No. 4 — No. 20:
mission.
link connector.
temperature exceed approx. 80#C (176#F).
NOTE:
drive the vehicle until ATF reaches its operating
temperature.
to ON (engine OFF).
6) Shift the select lever to “P” or “N” range,
and depress the accelerator pedal.
7) Read the data of low clutch duty solenoid
• Low clutch duty solenoid is indicated in “%”.
1) Turn the ignition switch to ON (engine blinking, the cir-
OFF). cuit has returned
2) Shift the select lever to “D” range. to normal condi-
3) Read the data of low clutch duty solenoid. tion at this time. A
temporary poor
contact of connec-
tor or harness may
be the cause.
Repair the har-
ness or connector
in transmission.
6 CHECK POOR CONTACT. Is there poor contact in low Repair the poor Replace the TCM.
clutch duty solenoid circuit? contact. <Ref. to 4AT-65,
Transmission Con-
trol Module
(TCM).>
4AT(diag)-72
Step Check Yes No

7 CHECK LOW CLUTCH DUTY SOLENOID (IN Is the resistance 2.0 — 6.0 "? Go to step 8. Replace the con-
CAUTION:
4) Measure the resistance between low clutch
duty solenoid connector and transmission
ground.
TRANSMISSION AND LOW CLUTCH DUTY "? circuit in harness
SOLENOID. between low clutch
Measure the resistance of harness between duty solenoid and
low clutch duty solenoid and transmission con- transmission con-
nector. nector.
(T4) No. 4 — (AT3) No. 2:
TRANSMISSION AND LOW CLUTCH DUTY M"? indicator light is circuit of harness
SOLENOID. blinking, the cir- between low clutch
tor or harness may
be the cause.
Repair the har-
ness or connector
in low clutch duty
solenoid and
transmission.
4AT(diag)-73
R: DTC P0758 SHIFT SOLENOID “B” ELECTRICAL

Output signal circuit of 2-4 brake duty solenoid is open or shorted.
TROUBLE SYMPTOM:
WIRING DIAGRAM:
B55 TCM
6
B11
3
T4
AT3
6
2-4 BRAKE
DUTY
SOLENOID
TRANSMISSION
B11 B55 AT3
1 2 3 4
1 2 3 4 5 6 7 8 9 1 2 3
5 6 7 8
10 11 12 13 14 15 16 17 18 19 20 21 4 5 6
9 10 11 12
22 23 24 25 26 27 28 29 30 31
13 14 15 16
17 18 19 20
AT-01488
Step Check Yes No

(B55) No. 6 — (B11) No. 3:
3 CHECK 2-4 BRAKE DUTY SOLENOID. Is the resistance 2.0 — 6.0 "? Go to step 4. Go to step 7.
(T4) No. 3 — No. 20:
4AT(diag)-74
Step Check Yes No

1) Connect all the connectors.
link connector.
temperature exceed approx. 80#C (176#F).
NOTE:
ating temperature.
to ON (engine OFF).
6) Shift the select lever to “N” range, and
depress the accelerator pedal.
7) Read the data of 2-4 brake duty solenoid
• 2-4 brake duty solenoid is indicated in “%”.
Shift the select lever to 2nd on manual mode. blinking, the cir-
cuit has returned
to normal condi-
temporary poor
contact of connec-
tor or harness may
be the cause.
Repair the har-
ness or connector
in TCM and trans-
mission.
6 CHECK POOR CONTACT. Is there poor contact in 2-4 Repair the poor Replace the TCM.
brake duty solenoid circuit? contact. <Ref. to 4AT-65,
Transmission Con-
trol Module
(TCM).>
7 CHECK 2-4 BRAKE DUTY SOLENOID (IN Is the resistance 2.0 — 6.0 "? Go to step 8. Replace the con-
CAUTION:
connector from 2-4 brake duty solenoid.
between 2-4 brake duty solenoid connector
and transmission ground.
4AT(diag)-75
Step Check Yes No

2-4 BRAKE DUTY SOLENOID AND TRANS- "? circuit in harness
MISSION. between 2-4 brake
Measure the resistance of harness between 2- duty solenoid and
4 brake duty solenoid and transmission con- transmission con-
nector. nector.
(T4) No. 3 — (AT12) No. 6:
2-4 BRAKE DUTY SOLENOID AND TRANS- M"? indicator light is circuit in harness
MISSION. blinking, the cir- between 2-4 brake
tor or harness may
be the cause.
Repair the har-
ness or connector
in 2-4 brake duty
solenoid and
transmission.
4AT(diag)-76
S: DTC P0763 SHIFT SOLENOID “C” ELECTRICAL

Output signal circuit of high clutch duty solenoid is open or shorted.
TROUBLE SYMPTOM:
WIRING DIAGRAM:
B55 TCM B11
1 23 4
5 6 7 8
8
9 10 11 12
13 14 15 16
17 18 19 20
B55
B11
1 2 3 4 5 6 7 8 9
7
T4 10 11 12 13 14 15 16 17 18 19 20 21
22 23 24 25 26 27 28 29 30 31
AT3
AT3 1 2 3
3
4 5 6
HIGH CLUTCH
DUTY
SOLENOID
TRANSMISSION
AT-01489
Step Check Yes No

(B55) No. 8 — (B11) No. 7:
3 CHECK HIGH CLUTCH DUTY SOLENOID. Is the resistance 2.0 — 6.0 "? Go to step 4. Go to step 7.
(T4) No. 7 — No. 20:
4AT(diag)-77
Step Check Yes No

mission.
racks.
NOTE:
link connector.
5) Start the engine and warm-up the engine
until the ATF temperature is above 80#C
(176#F).
NOTE:
ating temperature.
6) Read the data of high clutch duty solenoid
• High clutch duty solenoid is indicated in “%”.
7) Shift the select lever to “D”, and slowly
increase vehicle speed at 3rd or 4th to mea-
sure.
NOTE:
Memory Mode.>
Return the engine to idling speed and shift the blinking, the cir-
select lever to “N” range. cuit has returned
The speed difference between front and rear tion at this time. A
wheels may light the ABS warning light or VDC temporary poor
warning light, but this indicates no malfunction. contact of connec-
When AT control diagnosis is finished, perform tor or harness may
the ABS memory clearance procedure or VDC be the cause.
memory clearance procedure of on-board diag- Repair the har-
nostics system. <Ref. to ABS(diag)-27, Clear ness or connector
Memory Mode.> <Ref. to VDC(diag)-24, Clear in TCM and trans-
Memory Mode.> mission.
6 CHECK POOR CONTACT. Is there poor contact in high Repair the poor Replace the TCM.
clutch duty solenoid circuit? contact. <Ref. to 4AT-65,
Transmission Con-
trol Module
(TCM).>
4AT(diag)-78
Step Check Yes No

7 CHECK HIGH CLUTCH DUTY SOLENOID (IN Is the resistance 2.0 — 6.0 "? Go to step 8. Replace the con-
CAUTION:
4) Measure the resistance between high
clutch duty solenoid connector and transmis-
sion ground.
HIGH CLUTCH DUTY SOLENOID AND "? circuit in harness
TRANSMISSION. between TCM and
Measure the resistance of harness between transmission con-
high clutch duty solenoid and transmission nector.
connector.
(T4) No. 7 — (AT3) No. 3:
HIGH CLUTCH DUTY SOLENOID AND M"? indicator light is circuit of harness
TRANSMISSION. blinking, the cir- between high
Measure the resistance of harness between cuit has returned clutch duty sole-
transmission connector and transmission to normal condi- noid and transmis-
ground. tion at this time. A sion connector.
tor or harness may
be the cause.
Repair the har-
ness or connector
in high clutch duty
solenoid and
transmission.
4AT(diag)-79
T: DTC P0768 SHIFT SOLENOID “D” ELECTRICAL

The output signal circuit of low & reverse duty solenoid is open or shorted.
TROUBLE SYMPTOM:
Gear is not changed.
WIRING DIAGRAM:
B55 TCM
7
B11
6
T4
AT3
1
LOW & REVERSE
DUTY
SOLENOID
TRANSMISSION
B11 B55 AT3
1 23 4
1 2 3 4 5 6 7 8 9 1 2 3
5 6 7 8
10 11 12 13 14 15 16 17 18 19 20 21 4 5 6
9 10 11 12
22 23 24 25 26 27 28 29 30 31
13 14 15 16
17 18 19 20
AT-01490
Step Check Yes No

(B55) No. 7 — (B11) No. 6:
3 CHECK LOW & REVERSE DUTY SOLENOID. Is the resistance 2.0 — 6.0 "? Go to step 4. Go to step 7.
(T4) No. 6 — No. 20:
4AT(diag)-80
Step Check Yes No

link connector.
temperature is above approx. 80#C (176#F).
NOTE:
ating temperature.
to ON (engine OFF).
6) Shift the select lever to the “N” range.
7) Read the data of low & reverse duty sole-
noid using Subaru Select Monitor.
• Low & reverse duty solenoid is indicated in
“%”.
1) Lift-up the vehicle and support with rigid blinking, the cir-
racks. cuit has returned
Raise all wheels off floor. tion at this time. A
2) Shift the select lever to manual mode, and temporary poor
then hold it on 1st. Slowly increase the vehicle contact of connec-
speed up to 15 km/h (9 MPH), and then return tor or harness may
the accelerator pedal. be the cause.
Repair the har-
NOTE:
The speed difference between front and rear ness or connector
wheels may light the ABS warning light or VDC in TCM and trans-
warning light, but this indicates no malfunction. mission.
Memory Mode.>
3) Read the data of low & reverse duty sole-
noid.
6 CHECK POOR CONTACT. Is there poor contact in low & Repair the poor Replace the TCM.
reverse duty solenoid circuit? contact. <Ref. to 4AT-65,
Transmission Con-
trol Module
(TCM).>
4AT(diag)-81
Step Check Yes No

7 CHECK LOW & REVERSE DUTY SOLENOID Is the resistance 2.0 — 6.0 "? Go to step 8. Replace the con-
(IN TRANSMISSION). trol valve body.
CAUTION:
4) Measure the resistance between low &
reverse duty solenoid connector and transmis-
sion ground.
TRANSMISSION AND LOW & REVERSE "? circuit in harness
DUTY SOLENOID. between low &
Measure the resistance of harness between reverse duty sole-
low & reverse duty solenoid and transmission noid and transmis-
connector. sion connector.
(T4) No. 6 — (AT3) No. 1:
TRANSMISSION AND LOW & REVERSE M"? indicator light is circuit in harness
DUTY SOLENOID. blinking, the cir- between low &
Measure the resistance of harness between cuit has returned reverse brake
transmission connector and transmission to normal condi- solenoid and
ground. tion at this time. A transmission con-
Connector & terminal temporary poor nector.
tor or harness may
be the cause.
Repair the har-
ness or connector
in low & reverse
duty solenoid and
transmission.
4AT(diag)-82
U: DTC P0801 REVERSE INHIBIT CONTROL CIRCUIT

Shift lock solenoid malfunction, open or short reverse inhibitor control circuit
TROUBLE SYMPTOM:
• Gear is shifted from “N” range to “R” range during driving at 20 km/h (12 MPH) or more.
• Gear cannot be shifted from “N” range to “R” range.
WIRING DIAGRAM:
B55
1 2 3 4 5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20 21
22 23 24 25 26 27 28 29 30 31
B55
TCM
18
B116
1 2 3 4
5 6 7 8 9 10
SHIFT LOCK
SOLENOID
B116
3
4
AT-01893
4AT(diag)-83
Step Check Yes No

TCM AND SHIFT LOCK SOLENOID. "? circuit in harness
2) Disconnect the connector from TCM and shift lock solenoid
shift lock solenoid. connector.
between TCM and shift lock solenoid connec-
tor.
(B55) No. 18 — (B116) No. 3:
TCM AND SHIFT LOCK SOLENOID. M"? circuit in harness
TCM and chassis ground. shift lock solenoid
Connector & terminal connector.
3 CHECK HARNESS BETWEEN SHIFT LOCK Is the resistance less than 1 Go to step 4. Repair the open
SOLENOID AND CHASSIS GROUND TERMI- "? circuit in harness
NAL. between chassis
Measure the resistance of harness between ground and shift
shift lock solenoid and chassis ground. lock solenoid con-
terminals.
(B116) No. 3 — No. 4:
5 CHECK OUTPUT SIGNAL FOR TCM. Is the voltage more than 10.5 Go to step 6. Go to step 7.
1) Connect all the connectors. V?
chassis ground.
6 CHECK OUTPUT SIGNAL FOR TCM. Is the voltage less than 1 V? Even if the SPORT Go to step 7.
1) Lift-up the vehicle and support with rigid indicator light is
racks. blinking, the cir-
NOTE: cuit has returned
Raise all wheels off floor. to normal condi-
2) Start the engine. tion at this time. A
3) Shift the select lever to “D” range and temporary poor
slowly increase vehicle speed to 20 km/h (12 contact of connec-
MPH). tor or harness may
be the cause.
NOTE:
The speed difference between front and rear Repair the har-
wheels may light the ABS warning light or VDC ness or connector
warning light, but this indicates no malfunction. in reverse inhibitor
When AT control diagnosis is finished, perform control circuit.
Memory Mode.>
chassis ground.
4AT(diag)-84
Step Check Yes No

7 CHECK POOR CONTACT. Is there poor contact in the Repair the poor Replace the TCM.
reverse inhibitor control circuit? contact. <Ref. to 4AT-65,
Transmission Con-
trol Module
(TCM).>
4AT(diag)-85
V: DTC P1706 AT VEHICLE SPEED SENSOR CIRCUIT MALFUNCTION (REAR

WHEEL)
TROUBLE SYMPTOM:
No lock-up or occurring tight corner braking phenomenon
WIRING DIAGRAM:
BATTERY
SBF-1
E
SBF-7
B54 TCM
IGNITION
SWITCH
23
24
NO.12
B11
17
13
9
T4
AT1
3
1
2
REAR VEHICLE
SPEED SENSOR
AT1 B11 B54
1 2 3 1 2 3 4 1 2 3 4 5 6 7
5 6 7 8 8 9 10 11 12 13 14 15 16
9 10 11 12 17 18 19 20 21 22 23 24
13 14 15 16
17 18 19 20
AT-01492
4AT(diag)-86
Step Check Yes No

1 CHECK IGNITION POWER SUPPLY CIR- Is the voltage more than 10 V? Go to step 2. Check the harness
CUIT. between rear vehi-
1) Turn the ignition switch to OFF. cle speed sensor
2) Disconnect the connector from rear vehicle and battery for
speed sensor. open circuit, short
Turn the ignition switch to ON. or poor contact.
3) Measure the ignition power supply voltage Repair the har-
between rear vehicle speed sensor connector ness if required.
and transmission ground.
(AT1) No. 3 (+) — Transmission ground ($):
TCM AND TRANSMISSION. "? circuit or poor con-
1) Turn the ignition switch to OFF. tact of connector in
2) Measure the resistance of harness harness between
between TCM and rear vehicle speed sensor TCM and rear
connector. vehicle speed sen-
Connector & terminal sor connector.
(B54) No. 23 — (AT1) No. 1:
TCM AND TRANSMISSION. "? circuit or poor con-
Measure the resistance of harness between tact of connector in
TCM and rear vehicle speed sensor connector. harness between
Connector & terminal TCM and rear
(B54) No. 24 — (AT1) No. 2: vehicle speed sen-
sor connector.
TCM connector and chassis ground. rear vehicle speed
Connector & terminal sensor connector.
TCM connector and chassis ground. rear vehicle speed
Connector & terminal sensor connector.
6 PREPARE OSCILLOSCOPE. Do you have an oscilloscope? Go to step 8. Go to step 7.
4AT(diag)-87
Step Check Yes No

7 CHECK INPUT SIGNAL FOR TCM. Is the voltage approx. 5 V? Go to step 9. Replace the rear
1) Connect the connectors to TCM and trans- vehicle speed sen-
mission. sor.
racks.
NOTE:
3) Start the engine and set vehicle in 20 km/h
(12 MPH) condition.
NOTE:
Memory Mode.>
4) Measure the AC voltage between TCM
(B54) No. 24 (+) — No. 23 ($):
8 CHECK INPUT SIGNAL FOR TCM USING Is the pulse voltage approx. 5 Go to step 9. Replace the rear
OSCILLOSCOPE. V? vehicle speed sen-
1) Connect the connectors to TCM and trans- sor.
mission.
racks.
NOTE:
3) Set the oscilloscope to TCM connector ter-
minals.
Positive probe; (B54) No. 24:
Ground lead; (B54) No. 23:
4) Start the engine and set vehicle in 20 km/h
(12 MPH) condition.
NOTE:
Memory Mode.>
5) Measure the signal voltage indicated on
oscilloscope.
9 CHECK POOR CONTACT. Is there poor contact in rear Repair the poor Replace the TCM.
vehicle speed sensor circuit? contact. <Ref. to 4AT-65,
Transmission Con-
trol Module
(TCM).>
4AT(diag)-88
W: DTC P1707 AT AWD SOLENOID VALVE CIRCUIT MALFUNCTION

Output signal circuit of transfer duty solenoid is open or shorted.
TROUBLE SYMPTOM:
• Front wheel slips on the slippery road.
WIRING DIAGRAM:
B55 TCM B11
1 23 4
5 6 7 8
4 9 10 11 12
13 14 15 16
17 18 19 20
B55
B11 1 2 3 4 5 6 7 8 9
8
10 11 12 13 14 15 16 17 18 19 20 21
T4 22 23 24 25 26 27 28 29 30 31
AT3
1 2 3
AT3
5
4 5 6
TRANSFER
DUTY
SOLENOID
TRANSMISSION
AT-01493
Step Check Yes No

(B55) No. 4 — (B11) No. 8:
Measure the resistance harness connector between TCM and
3 CHECK TRANSFER DUTY SOLENOID. Is the resistance 2.0 — 6.0 "? Go to step 4. Go to step 7.
connector and transmission terminals.
(T4) No. 8 — No. 20:
4AT(diag)-89
Step Check Yes No

4 CHECK OUTPUT SIGNAL EMITTED FROM Is the value approx. 5%? Go to step 5. Go to step 6.
mission.
link connector.
3) Turn the ignition switch to ON (engine OFF)
and Subaru Select Monitor switch to ON.
4) Shift the select lever to “N” range, and fully
close the throttle pedal. (Vehicle speed is 0 km/
h (0 MPH))
5) Read the data of transfer duty solenoid
• Transfer duty solenoid is indicated in “%”.
5 CHECK OUTPUT SIGNAL EMITTED FROM Is the value 18 — 35%? Even if the SPORT Go to step 6.
1) Shift the select lever to “D” range. blinking, the cir-
2) Read the data of transfer duty solenoid cuit has returned
using Subaru Select Monitor. to normal condi-
• Transfer duty solenoid is indicated in “%”. tion at this time. A
temporary poor
contact of connec-
tor or harness may
be the cause.
Repair the har-
ness or connector
in TCM and trans-
mission.
6 CHECK POOR CONTACT. Is there poor contact in transfer Repair the poor Replace the TCM.
duty solenoid circuit? contact. <Ref. to 4AT-65,
Transmission Con-
trol Module
(TCM).>
7 CHECK TRANSFER DUTY SOLENOID (IN Is the resistance 2.0 — 6.0 "? Go to step 8. Replace the con-
1) Lift-up the vehicle and support with rigid <Ref. to 4AT-60,
racks. Control Valve
NOTE: Body.>
2) Drain the ATF.
CAUTION:
3) Remove the extension case, and discon-
nect the connector from transfer duty solenoid.
4) Measure the resistance between transfer
duty solenoid connector and transmission
ground.
TRANSFER DUTY SOLENOID AND TRANS- "? circuit in harness
MISSION. between transfer
Measure the resistance of harness between duty solenoid and
transfer duty solenoid and transmission con- transmission con-
nector. nector.
(T4) No. 8 — (AT3) No. 5:
4AT(diag)-90
Step Check Yes No

TRANSFER DUTY SOLENOID AND TRANS- M"? indicator light is circuit in harness
MISSION. blinking, the cir- between transfer
tor or harness may
be the cause.
Repair the har-
ness or poor con-
tact in the transfer
duty solenoid and
transmission.
4AT(diag)-91
X: DTC P1708 THROTTLE POSITION SENSOR CIRCUIT LOW INPUT

The input signal circuit of accelerator pedal position sensor is open or shorted.
TROUBLE SYMPTOM:
WIRING DIAGRAM:
• 2.0 L LHD and 2.5 L KS model
A: B134
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23 24 25 26 27
28 29 30 31 32 33 34
ECM
B54 TCM
A: B134 B: B135 C: B136 D: B137
C18 B: B135
D30
C17
D18
1 2 3 4 5 6 7
C6
C1
C5
A2
D1
A7
C2
B6
B5
8 9 10 11 12 13 14 15 16 17 18 19
10
19
20 21 22 23 24 25 26 27
28 29 30 31 32 33 34 35
C: B136
1 2 3 4 5 6
7 8 9 10 11 12 13 14 15 16
17 18 19 20 21 22 23 24 25 26 27
28 29 30 31 32 33 34 35
D: B137
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23 24 25
26 27 28 29 30 31
B54
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16
17 18 19 20 21 22 23 24
B83
1 2 3 4
5 6 7 8
B21 B21
36
35
34
37
52
E2
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
34 35 36 37 38 39 40 41
42 43 44 45 46 47
48 49 50 51 52 53 54
B315
1
2
6
B315
1 2 3 4 5 6
2
1
B83
E E
JOINT CONNECTOR
ACCELERATOR PEDAL POSITION SENSOR
AT-01894
4AT(diag)-92
• 2.5 L EC, K4 model
A: B134
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23 24 25 26 27
28 29 30 31 32 33 34
ECM
B54 TCM
A: B134 B: B135 C: B136 D: B137
B: B135
C35
B12
C28
C16
1 2 3 4 5 6 7
D7
D3
B4
B1
D2
D1
A7
A6
8 9 10 11 12 13 14 15 16 17 18 19
10
19
20 21 22 23 24 25 26 27
28 29 30 31 32 33 34 35
C: B136
1 2 3 4 5 6
7 8 9 10 11 12 13 14 15 16
17 18 19 20 21 22 23 24 25 26 27
28 29 30 31 32 33 34 35
D: B137
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23 24 25
26 27 28 29 30 31
B54
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16
6
JOINT
17 18 19 20 21 22 23 24
CONNECTOR
1
B122 B83
5
B122
1 2 3 4
5 6 7 8
B21
B21
37
34
35
36
47
52
E2
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
34 35 36 37 38 39 40 41
42 43 44 45 46 47
48 49 50 51 52 53 54
B315
1
2
6
B315
1 2 3 4 5 6
1
8
B83
E E
JOINT CONNECTOR
AT-02370
4AT(diag)-93
• 2.0 L RHD and 2.5 L KA model
A: B134
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23 24 25 26 27
28 29 30 31 32 33 34
ECM
B54 TCM
A: B134 B: B135 C: B136 D: B137
B: B135
C18
C17
D30
D19
D18
1 2 3 4 5 6 7
C1
A7
C2
A2
D1
C5
C6
B5
B6
8 9 10 11 12 13 14 15 16 17 18 19
10
19
20 21 22 23 24 25 26 27
28 29 30 31 32 33 34 35
C: B136
1 2 3 4 5 6
7 8 9 10 11 12 13 14 15 16
17 18 19 20 21 22 23 24 25 26 27
28 29 30 31 32 33 34 35
7
JOINT
CONNECTOR
D: B137
B53
6
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23 24 25
26 27 28 29 30 31
B54
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16
* 17 18 19 20 21 22 23 24
*
* B183
JOINT
CONNECTOR B122
B122 1 2 3 4
5 6 7 8
B11
19
B21 B21
34
T4
37
35
36
52
E2
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
34 35 36 37 38 39 40 41
42 43 44 45 46 47
E 48 49 50 51 52 53 54
B315
* :
1
2
6
TERMINAL NO. B315

RANDOM
ARRANGEMENT 1 2 3 4 5 6
*
*
B183
E E
JOINT CONNECTOR
AT-01895
4AT(diag)-94
• 2.5 L EK model
A: B134
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23 24 25 26 27
28 29 30 31 32 33 34
ECM
B54 TCM
A: B134 B: B135 C: B136 D: B137
B: B135
C35
B12
C28
C16
1 2 3 4 5 6 7
D7
D3
B4
B1
D2
D1
A7
A6
8 9 10 11 12 13 14 15 16 17 18 19
10
19
20 21 22 23 24 25 26 27
28 29 30 31 32 33 34 35
C: B136
1 2 3 4 5 6
7 8 9 10 11 12 13 14 15 16
17 18 19 20 21 22 23 24 25 26 27
28 29 30 31 32 33 34 35
D: B137
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23 24 25
26 27 28 29 30 31
B54
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16
5
JOINT
17 18 19 20 21 22 23 24
CONNECTOR
1
B122 B83
6
B122
1 2 3 4
5 6 7 8
B21
B21
37
34
35
36
47
52
E2
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
: TERMINAL NO. 23 24 25 26 27 28 29 30 31 32 33
* RANDOM
34 35 36 37 38 39 40 41
ARRANGEMENT
42 43 44 45 46 47
48 49 50 51 52 53 54
B315
1
2
6
B315
1 2 3 4 5 6
*
*
B83
E E
JOINT CONNECTOR
AT-01896
Step Check Yes No

1 CHECK ENGINE GROUND TERMINALS. Have engine ground terminals Go to step 2. Tighten the engine
been tightened securely? ground terminals.
4AT(diag)-95
Step Check Yes No

2 CHECK GROUND CIRCUIT FOR ECM. Is the resistance less than 5 Go to step 3. Repair the open
1) Turn the ignition switch to OFF. "? circuit in harness
2) Disconnect the connector from ECM. between ECM
3) Measure the resistance of harness connector and
between ECM and engine ground. engine grounding
Connector & terminal terminal.
2.0 L model and 2.5 L KS, KA model
(B134) No. 2 — Engine ground:
2.5 L EC, EK, K4 model
3 CHECK ACCELERATOR PEDAL POSITION Is the resistance 0.75 — 3.15 Go to step 4. Replace the accel-
SENSOR. k"? erator pedal posi-
1) Disconnect the connectors from accelerator tion sensor.
pedal position sensor.
2) Measure the resistance between accelera-
tor pedal position sensor connector recepta-
cle’s terminals.
No. 1 — No. 6:
Measure the resistance between accelerator tion sensor.
pedal position sensor connector receptacle’s
terminals.
No. 6 — No. 2:
TCM AND ACCELERATOR PEDAL POSI- "? circuit in harness
TION SENSOR. between TCM and
1) Disconnect the connector from TCM. accelerator pedal
2) Measure the resistance of harness position sensor
between TCM and accelerator pedal position connector, and
sensor connector. poor contact in
Connector & terminal coupling connec-
(B54) No. 19 — (B315) No. 2: tor.
TCM AND ACCELERATOR PEDAL POSI- M"? circuit in harness
Measure the resistance of harness between accelerator pedal
TCM connector and chassis ground. position sensor
4AT(diag)-96
Step Check Yes No

ECM AND ACCELERATOR PEDAL POSI- M"? circuit in harness
TION SENSOR. between ECM and
1) Remove the connector from ECM. accelerator pedal
2) Measure the resistance of harness position sensor.
between the accelerator pedal position sensor
connector and chassis ground.
8 CHECK INPUT SIGNAL FOR TCM USING Is the voltage more than 0.2 V? Even if the SPORT Go to step 9.
SUBARU SELECT MONITOR. indicator light is
1) Connect the connectors to TCM, accelera- blinking, the cir-
tor pedal position sensor, and ECM. cuit has returned
3) Turn the ignition switch to ON (engine temporary poor
OFF). contact of connec-
4) Turn the Subaru Select Monitor switch to tor or harness may
ON. be the cause.
5) Fully close the throttle. Repair the har-
6) Read the data of accelerator pedal position ness or connector
sensor using Subaru Select Monitor. in accelerator
• Accelerator pedal position sensor input sig- pedal position sen-
nal is indicated. sor circuit.
9 CHECK POOR CONTACT. Is there poor contact in accel- Repair the poor Replace the TCM.
erator pedal position sensor contact. <Ref. to 4AT-65,
trol Module
(TCM).>
4AT(diag)-97
Y: DTC P1709 THROTTLE POSITION SENSOR CIRCUIT HIGH INPUT

The input signal circuit of accelerator pedal position sensor is shorted.
TROUBLE SYMPTOM:
WIRING DIAGRAM:
A: B134
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23 24 25 26 27
28 29 30 31 32 33 34
ECM
B54 TCM
A: B134 B: B135 C: B136 D: B137
C18 B: B135
D30
C17
D18
1 2 3 4 5 6 7
C6
C1
C5
A2
D1
A7
C2
B6
B5
8 9 10 11 12 13 14 15 16 17 18 19
10
19
20 21 22 23 24 25 26 27
28 29 30 31 32 33 34 35
C: B136
1 2 3 4 5 6
7 8 9 10 11 12 13 14 15 16
17 18 19 20 21 22 23 24 25 26 27
28 29 30 31 32 33 34 35
D: B137
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23 24 25
26 27 28 29 30 31
B54
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16
17 18 19 20 21 22 23 24
B83
1 2 3 4
5 6 7 8
B21 B21
36
35
34
37
52
E2
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
34 35 36 37 38 39 40 41
42 43 44 45 46 47
48 49 50 51 52 53 54
B315
1
2
6
B315
1 2 3 4 5 6
2
1
B83
E E
JOINT CONNECTOR
AT-01894
4AT(diag)-98
A: B134
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23 24 25 26 27
28 29 30 31 32 33 34
ECM
B54 TCM
A: B134 B: B135 C: B136 D: B137
B: B135
C35
B12
C28
C16
1 2 3 4 5 6 7
D7
D3
B4
B1
D2
D1
A7
A6
8 9 10 11 12 13 14 15 16 17 18 19
10
19
20 21 22 23 24 25 26 27
28 29 30 31 32 33 34 35
C: B136
1 2 3 4 5 6
7 8 9 10 11 12 13 14 15 16
17 18 19 20 21 22 23 24 25 26 27
28 29 30 31 32 33 34 35
D: B137
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23 24 25
26 27 28 29 30 31
B54
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16
6
JOINT
17 18 19 20 21 22 23 24
CONNECTOR
1
B122 B83
5
B122
1 2 3 4
5 6 7 8
B21
B21
37
34
35
36
47
52
E2
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
34 35 36 37 38 39 40 41
42 43 44 45 46 47
48 49 50 51 52 53 54
B315
1
2
6
B315
1 2 3 4 5 6
2
1
B83
E E
JOINT CONNECTOR
AT-01494
4AT(diag)-99
A: B134
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23 24 25 26 27
28 29 30 31 32 33 34
ECM
B54 TCM
A: B134 B: B135 C: B136 D: B137
B: B135
C18
C17
D30
D19
D18
1 2 3 4 5 6 7
C1
A7
C2
A2
D1
C5
C6
B5
B6
8 9 10 11 12 13 14 15 16 17 18 19
10
19
20 21 22 23 24 25 26 27
28 29 30 31 32 33 34 35
C: B136
1 2 3 4 5 6
7 8 9 10 11 12 13 14 15 16
17 18 19 20 21 22 23 24 25 26 27
28 29 30 31 32 33 34 35
7
JOINT
CONNECTOR
D: B137
B53
6
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23 24 25
26 27 28 29 30 31
B54
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16
* 17 18 19 20 21 22 23 24
*
* B183
JOINT
CONNECTOR B122
B122 1 2 3 4
5 6 7 8
B11
19
B21 B21
34
T4
37
35
36
52
E2
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
34 35 36 37 38 39 40 41
42 43 44 45 46 47
E 48 49 50 51 52 53 54
B315
* :
1
2
6
TERMINAL NO. B315

RANDOM
*
*
B183
E E
JOINT CONNECTOR
AT-01895
4AT(diag)-100
• 2.5 L EK model
A: B134
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23 24 25 26 27
28 29 30 31 32 33 34
ECM
B54 TCM
A: B134 B: B135 C: B136 D: B137
B: B135
C35
B12
C28
C16
1 2 3 4 5 6 7
D7
D3
B4
B1
D2
D1
A7
A6
8 9 10 11 12 13 14 15 16 17 18 19
10
19
20 21 22 23 24 25 26 27
28 29 30 31 32 33 34 35
C: B136
1 2 3 4 5 6
7 8 9 10 11 12 13 14 15 16
17 18 19 20 21 22 23 24 25 26 27
28 29 30 31 32 33 34 35
D: B137
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23 24 25
26 27 28 29 30 31
B54
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16
5
JOINT
17 18 19 20 21 22 23 24
CONNECTOR
1
B122 B83
6
B122
1 2 3 4
5 6 7 8
B21
B21
37
34
35
36
47
52
E2
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
: TERMINAL NO. 23 24 25 26 27 28 29 30 31 32 33
* RANDOM
34 35 36 37 38 39 40 41
ARRANGEMENT
42 43 44 45 46 47
48 49 50 51 52 53 54
B315
1
2
6
B315
1 2 3 4 5 6
*
*
B83
E E
JOINT CONNECTOR
AT-01896
Step Check Yes No

1 CHECK ENGINE GROUND TERMINALS. Have engine ground terminals Go to step 2. Tighten the engine
been tightened securely? ground terminals.
4AT(diag)-101
Step Check Yes No

2 CHECK GROUND CIRCUIT FOR ECM. Is the resistance less than 5 Go to step 3. Repair the open
2) Disconnect the connector from ECM. between ECM
3) Measure the resistance of harness connector and
between ECM and engine ground. engine grounding
Connector & terminal terminal.
1) Disconnect the connectors from accelerator tion sensor.
pedal position sensor.
2) Measure the resistance between accelera-
tor pedal position sensor connector recepta-
cle’s terminals.
No. 1 — No. 6:
Measure the resistance between accelerator tion sensor.
pedal position sensor connector receptacle’s
terminals.
No. 2 — No. 6:
between TCM connector and chassis ground. connector.
4AT(diag)-102
Step Check Yes No

ECM AND ACCELERATOR PEDAL POSI- "? circuit in harness
TION SENSOR. between ECM and
1) Remove the connector from ECM. accelerator pedal
2) Measure the resistance of harness position sensor.
between ECM connector and accelerator pedal
position sensor connector.
(B135) No. 6 — (B136) No. 18:
(B135) No. 6 — (B136) No. 35:
7 CHECK INPUT SIGNAL FOR TCM USING Is the voltage less than 4.6 V? Go to step 8. Even if the SPORT
SUBARU SELECT MONITOR. indicator light is
1) Connect the connectors to TCM, accelera- blinking, the cir-
tor pedal position sensor and ECM. cuit has returned
3) Turn the ignition switch to ON (engine temporary poor
OFF). contact of connec-
4) Turn the Subaru Select Monitor switch to tor or harness may
ON. be the cause.
5) Fully open the throttle. Repair the har-
6) Read the data of accelerator pedal position ness or connector
sensor using Subaru Select Monitor. in accelerator
• Accelerator pedal position sensor input sig- pedal position sen-
nal is indicated. sor circuit.
trol Module
(TCM).>
4AT(diag)-103
Z: DTC P1714 THROTTLE POSITION SENSOR POWER SUPPLY CIRCUIT

The power supply circuit of accelerator pedal position sensor is open or shorted.
TROUBLE SYMPTOM:
WIRING DIAGRAM:
A: B134
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23 24 25 26 27
28 29 30 31 32 33 34
ECM
B54 TCM
A: B134 B: B135 C: B136 D: B137
C18 B: B135
D30
C17
D18
1 2 3 4 5 6 7
C6
C1
C5
A2
D1
A7
C2
B6
B5
8 9 10 11 12 13 14 15 16 17 18 19
10
19
20 21 22 23 24 25 26 27
28 29 30 31 32 33 34 35
C: B136
1 2 3 4 5 6
7 8 9 10 11 12 13 14 15 16
17 18 19 20 21 22 23 24 25 26 27
28 29 30 31 32 33 34 35
D: B137
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23 24 25
26 27 28 29 30 31
B54
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16
17 18 19 20 21 22 23 24
B83
1 2 3 4
5 6 7 8
B21 B21
36
35
34
37
52
E2
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
34 35 36 37 38 39 40 41
42 43 44 45 46 47
48 49 50 51 52 53 54
B315
1
2
6
B315
1 2 3 4 5 6
2
1
B83
E E
JOINT CONNECTOR
AT-01894
4AT(diag)-104
A: B134
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23 24 25 26 27
28 29 30 31 32 33 34
ECM
B54 TCM
A: B134 B: B135 C: B136 D: B137
B: B135
C35
B12
C28
C16
1 2 3 4 5 6 7
D7
D3
B4
B1
D2
D1
A7
A6
8 9 10 11 12 13 14 15 16 17 18 19
10
19
20 21 22 23 24 25 26 27
28 29 30 31 32 33 34 35
C: B136
1 2 3 4 5 6
7 8 9 10 11 12 13 14 15 16
17 18 19 20 21 22 23 24 25 26 27
28 29 30 31 32 33 34 35
D: B137
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23 24 25
26 27 28 29 30 31
B54
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16
6
JOINT
17 18 19 20 21 22 23 24
CONNECTOR
1
B122 B83
5
B122
1 2 3 4
5 6 7 8
B21
B21
37
34
35
36
47
52
E2
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
34 35 36 37 38 39 40 41
42 43 44 45 46 47
48 49 50 51 52 53 54
B315
1
2
6
B315
1 2 3 4 5 6
2
1
B83
E E
JOINT CONNECTOR
AT-01494
4AT(diag)-105
A: B134
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23 24 25 26 27
28 29 30 31 32 33 34
ECM
B54 TCM
A: B134 B: B135 C: B136 D: B137
B: B135
C18
C17
D30
D19
D18
1 2 3 4 5 6 7
C1
A7
C2
A2
D1
C5
C6
B5
B6
8 9 10 11 12 13 14 15 16 17 18 19
10
19
20 21 22 23 24 25 26 27
28 29 30 31 32 33 34 35
C: B136
1 2 3 4 5 6
7 8 9 10 11 12 13 14 15 16
17 18 19 20 21 22 23 24 25 26 27
28 29 30 31 32 33 34 35
7
JOINT
CONNECTOR
D: B137
B53
6
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23 24 25
26 27 28 29 30 31
B54
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16
* 17 18 19 20 21 22 23 24
*
* B183
JOINT
CONNECTOR B122
B122 1 2 3 4
5 6 7 8
B11
19
B21 B21
34
T4
37
35
36
52
E2
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
34 35 36 37 38 39 40 41
42 43 44 45 46 47
E 48 49 50 51 52 53 54
B315
* :
1
2
6
TERMINAL NO. B315

RANDOM
*
*
B183
E E
JOINT CONNECTOR
AT-01895
4AT(diag)-106
• 2.5 L EK model
A: B134
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23 24 25 26 27
28 29 30 31 32 33 34
ECM
B54 TCM
A: B134 B: B135 C: B136 D: B137
B: B135
C35
B12
C28
C16
1 2 3 4 5 6 7
D7
D3
B4
B1
D2
D1
A7
A6
8 9 10 11 12 13 14 15 16 17 18 19
10
19
20 21 22 23 24 25 26 27
28 29 30 31 32 33 34 35
C: B136
1 2 3 4 5 6
7 8 9 10 11 12 13 14 15 16
17 18 19 20 21 22 23 24 25 26 27
28 29 30 31 32 33 34 35
D: B137
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23 24 25
26 27 28 29 30 31
B54
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16
5
JOINT
17 18 19 20 21 22 23 24
CONNECTOR
1
B122 B83
6
B122
1 2 3 4
5 6 7 8
B21
B21
37
34
35
36
47
52
E2
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
: TERMINAL NO. 23 24 25 26 27 28 29 30 31 32 33
* RANDOM
34 35 36 37 38 39 40 41
ARRANGEMENT
42 43 44 45 46 47
48 49 50 51 52 53 54
B315
1
2
6
B315
1 2 3 4 5 6
*
*
B83
E E
JOINT CONNECTOR
AT-01896
4AT(diag)-107
Step Check Yes No

TCM AND ACCELERATOR PEDAL POSI- "? circuit in harness
between TCM and accelerator pedal position connector, and
sensor connector. poor contact in
Connector & terminal coupling connec-
2.0 L model and 2.5 L KS, KA model tor.
(B54) No. 10 — (B137) No. 18:
(B54) No. 10 — (B315) No. 1:
Measure the resistance of harness between accelerator pedal
TCM connector and chassis ground. position sensor
3 CHECK HARNESS CONNECTOR BETWEEN Is the voltage 4.6 — 5.4 V? Go to step 4. Even if the SPORT
TCM AND ECM. indicator light is
1) Connect all the connectors. blinking, the cir-
2) Turn the ignition switch to ON. cuit has returned
3) Measure the voltage of harness between to normal condi-
TCM and chassis ground. tion at this time. A
(B54) No. 10 (+) — Chassis ground ($): contact of connec-
tor or harness may
be the cause.
Repair the har-
ness or connector
in accelerator
pedal position sen-
sor circuit.
trol Module
(TCM).>
4AT(diag)-108
AA:DTC P1718 CAN COMMUNICATION CIRCUIT

NOTE:
Refer to “Body Integrated Unit” for diagnosis of P1718. <Ref. to LAN(diag)-2, Basic Diagnostic Procedure.>
4AT(diag)-109
AB:DTC P1760 LATERAL ACCELERATION SENSOR PERFORMANCE PROB-

LEM
Faulty lateral G sensor output voltage
WIRING DIAGRAM:
B54
1 2 3 4 5 6 7
B54 TCM 8 9 10 11 12 13 14 15 16
17 18 19 20 21 22 23 24
11
B359
1 2 3
1
B359
G SENSOR
AT-01496
4AT(diag)-110
Step Check Yes No

1 CHECK OUTPUT OF LATERAL G SENSOR Is the reading on display 2.3 — Go to step 2. Go to step 7.
USING SUBARU SELECT MONITOR. 2.7 V when the vehicle is on a
1) Select {Current Data Display & Save} in level?
Subaru Select Monitor.
2) Read the Subaru Select Monitor display.
2 CHECK OUTPUT OF LATERAL G SENSOR Is the value on the monitor dis- Go to step 3. Replace the lat-
USING SUBARU SELECT MONITOR. play 3.3 — 4.3 V when lateral eral G sensor.
1) Turn the ignition switch to OFF. G sensor is inclined to the right <Ref. to 4AT-66,
2) Remove the console box. to 90#? Lateral G Sensor.>
3) Remove the lateral G sensor from vehicle.
(Do not disconnect connector.)
5) Select {Current Data Display & Save} in
Read the Subaru Select Monitor display.
G sensor is inclined to the left <Ref. to 4AT-66,
to 90#? Lateral G Sensor.>
4 CHECK POOR CONTACT IN CONNECTOR. Is there poor contact in con- Repair the con- Go to step 5.
Turn the ignition switch to OFF. nector between TCM and the nector.
lateral G sensor?
5 CHECK ABSCM&H/U. Is the same DTC still output? Replace the TCM. Go to step 6.
1) Connect all the connectors. <Ref. to 4AT-65,
2) Erase the memory. Transmission Con-
3) Perform the inspection mode. trol Module
4) Read the DTC. (TCM).>
6 CHECK OTHER DTC DETECTION. Is any other DTC detected? Perform the diag- Temporary poor
nosis according to contact occurs.
DTC.
7 CHECK OPEN CIRCUIT IN LATERAL G SEN- Is the resistance 5.0 — 6.0 Go to step 8. Repair the har-
SOR OUTPUT HARNESS AND GROUND k"? ness connector
HARNESS. between lateral G
1) Turn the ignition switch to OFF. sensor and TCM.
nector terminals.
(B54) No. 2 — No. 9:
8 CHECK LATERAL G SENSOR. Is the voltage 2.3 — 2.7 V Go to step 9. Replace the lat-
1) Remove the console box. when the lateral G sensor is eral G sensor.
2) Remove the lateral G sensor from vehicle. horizontal? <Ref. to 4AT-66,
3) Connect the connector to lateral G sensor. Lateral G Sensor.>
4) Connect the connector to ABSCM&H/U.
6) Measure the voltage between lateral G
sensor connector terminals.
(B359) No. 3 (+) — No. 2 ($):
Measure the voltage between lateral G sensor when lateral G sensor is eral G sensor.
connector terminals. inclined to the right to 90#? <Ref. to 4AT-66,
Connector & terminal Lateral G Sensor.>
(B359) No. 3 (+) — No. 2 ($):
connector terminals. inclined to the left to 90#? <Ref. to 4AT-66,
(B359) No. 3 (+) — No. 2 ($):
4AT(diag)-111
Step Check Yes No

1) Turn the ignition switch to OFF. <Ref. to 4AT-65,
2) Connect all the connectors. Transmission Con-
3) Erase the memory. trol Module
4) Perform the inspection mode. (TCM).>
5) Read the DTC.
DTC.
4AT(diag)-112
AC:DTC P1761 LATERAL ACCELERATION SENSOR CIRCUIT LOW

WIRING DIAGRAM:
B54
1 2 3 4 5 6 7
B54 TCM 8 9 10 11 12 13 14 15 16
17 18 19 20 21 22 23 24
11
B359
1 2 3
1
B359
G SENSOR
AT-01496
4AT(diag)-113
Step Check Yes No

1 CHECK OUTPUT OF LATERAL G SENSOR Is the value on the monitor dis- Go to step 2. Go to step 5.
USING SUBARU SELECT MONITOR. play 2.3 — 2.7 V when the lat-
1) Select {Current Data Display & Save} in eral G sensor is in horizontal
Subaru Select Monitor. position?
2) Read the lateral G sensor output on the
Subaru Select Monitor display.
2 CHECK POOR CONTACT IN CONNECTOR. Is there poor contact in the Repair the con- Go to step 3.
Turn the ignition switch to OFF. connector between TCM and nector.
the lateral G sensor?
3 CHECK TCM. Is the same DTC still output? Replace the TCM. Go to step 4.
DTC.
nector terminals.
(B54) No. 2 — No. 9:
6 CHECK GROUND SHORT OF HARNESS. Is the resistance more than 1 Go to step 7. Repair the har-
Measure the resistance between TCM connec- M"? ness between lat-
tor and chassis ground. eral G sensor and
Connector & terminal TCM.
(B54) No. 9 — Chassis ground: Replace the TCM.
<Ref. to 4AT-65,
Transmission Con-
trol Module
(TCM).>
4) Connect the connector to the TCM.
(B359) No. 3 (+) — No. 2 ($):
(B359) No. 3 (+) — No. 2 ($):
(B359) No. 3 (+) — No. 2 ($):
4AT(diag)-114
Step Check Yes No

5) Read the DTC.
DTC.
4AT(diag)-115
AD:DTC P1762 LATERAL ACCELERATION SENSOR CIRCUIT HIGH

WIRING DIAGRAM:
B54
1 2 3 4 5 6 7
B54 TCM 8 9 10 11 12 13 14 15 16
17 18 19 20 21 22 23 24
11
B359
1 2 3
1
B359
G SENSOR
AT-01496
4AT(diag)-116
Step Check Yes No

USING SUBARU SELECT MONITOR. play between 2.3 and 2.7 V
1) Select {Current Data Display & Save} in when the lateral G sensor is in
Subaru Select Monitor. horizontal position?
2 CHECK POOR CONTACT IN CONNECTOR. Is there poor contact in the Repair the con- Go to step 3.
connector between TCM and nector.
lateral G sensor?
DTC.
5 CHECK CONDITIONAL INFORMATION Is the reading on monitor dis- Go to step 6. Go to step 12.
WHEN FAULTY. play 4.65 V or more?
Read the lateral G sensor output on Subaru
Select Monitor display.
1) Turn the ignition switch to OFF. sensor and
2) Disconnect the connector from TCM. ABSCM&H/U.
nector terminals.
(B54) No. 2 — No. 9:
7 CHECK BATTERY SHORT OF HARNESS. Is the voltage less than 1 V? Go to step 8. Repair the har-
1) Turn the ignition switch to OFF. ness between lat-
2) Remove the console box. eral G sensor and
3) Disconnect the connector from lateral G TCM.
sensor.
1) Turn the ignition switch to ON. ness between lat-
2) Measure the voltage between TCM con- eral G sensor and
nector and chassis ground. TCM.
nector between TCM and lat- nector.
eral G sensor?
DTC.
4AT(diag)-117
Step Check Yes No

12 CHECK INPUT VOLTAGE OF LATERAL G Is the voltage 4.75 — 5.25 V? Go to step 13. Repair the har-
SENSOR. ness connector
1) Turn the ignition switch to OFF. between lateral G
2) Remove the console box. sensor and TCM.
(Do not disconnect the connector.)
(B359) No. 1 (+) — No. 2 ($):
nector terminals.
(B54) No. 2 — No. 9:
1) Connect the connector to lateral G sensor. when lateral G sensor is in hor- eral G sensor.
2) Connect the connector to the TCM. izontal? <Ref. to 4AT-66,
3) Turn the ignition switch to ON. Lateral G Sensor.>
(B359) No. 3 (+) — No. 2 ($):
(B359) No. 3 (+) — No. 2 ($):
(B359) No. 3 (+) — No. 2 ($):
Turn the ignition switch to OFF. nector between TCM and lat- nector.
eral G sensor?
DTC.
4AT(diag)-118
AE:DTC P1817 SPORTS MODE SWITCH CIRCUIT

Input signal circuit of SPORT shift switch is open or shorted.
TROUBLE SYMPTOM:
• The manual mode is not engaged.
• The SPORT indicator light does not illuminate.
• No SPORT mode occurs.
WIRING DIAGRAM:
• LHD model
A: i84
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
24 25 26 27 28 29 30 31 32 33 34 35
B: B280
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19 20
21 22 23 24 25 26 27 28 29 30
A: i84 B: B280
C: B281
B54
C26
B20
B30
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16
17 18 19 20 21 22 23 24
B116
5
JOINT
CONNECTOR
1 2 3 4
7
B352 5 6 7 8 9 10
1
SELECT
SPORT
LEVER
MODE
SWITCH
B116
C: B281
8
2
JOINT 1 2 3 4 5 6 7
CONNECTOR 8 9 10 11 12 13 14 15 16 17 18 19
B355 20 21 22 23 24 25 26 27 28
5
B352
E B355
12
3
1 2 3 4
B54 TCM
5 6 7 8
AT-01897
4AT(diag)-119
• RHD model
A: i84
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
24 25 26 27 28 29 30 31 32 33 34 35
B: B280
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19 20
21 22 23 24 25 26 27 28 29 30
A: i84 B: B280
C: B281
B54
C26
B20
B30
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16
17 18 19 20 21 22 23 24
JOINT
3
CONNECTOR
B116
7
B352
2
SELECT 1 2 3 4
SPORT
LEVER 5 6 7 8 9 10
MODE
SWITCH
B116
19
JOINT
CONNECTOR
8
B53 C: B281
18
10
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23 24 25 26 27 28
12
3
E
B54 TCM
B352
1 2 3 4
5 6 7 8
B53
1 2 3 4 5 6 7 8 9 10
11 12 13 14 15 16 17 18 19 20
AT-02200
4AT(diag)-120
Step Check Yes No

1 CHECK BODY INTEGRATED UNIT. Is DTC displayed? Perform the diag- Go to step 2.
1) Connect the Subaru Select Monitor to data nosis according to
link connector. DTC.
2) Turn the ignition switch to ON. (Engine
OFF)
3) Read the DTC of body integrated unit using
2 CHECK INPUT SIGNAL TO BODY INTE- Is the OFF displayed? Go to step 3. Go to step 7.
GRATED UNIT.
2) Read the Tiptronic Mode Switch data of
body integrated unit using Subaru Select Moni-
tor. <Ref. to LAN(diag)-14, OPERATION, Sub-
aru Select Monitor.>
3 CHECK INPUT SIGNAL TO BODY INTE- Is the indication per range Go to step 4. Replace the select
GRATED UNIT. OFF? lever assembly.
1) Shift the select lever from “P” to “D” range. <Ref. to CS-7,
2) Read the Tiptronic Mode Switch data of Select Lever.>
4 CHECK INPUT SIGNAL TO BODY INTE- Is the OFF displayed? Go to step 5. Replace the select
GRATED UNIT. lever assembly.
1) Shift the select lever to SPORT mode. <Ref. to CS-7,
2) Shift the select lever to any other than “D” Select Lever.>
range.
3) Read the Tiptronic Mode Switch data of
5 CHECK INHIBITOR SWITCH. Is the indication of range posi- Go to step 6. Adjust the inhibi-
Shift the select lever from “P” to “D” range. tion indicator light in combina- tor switch and
tion meter synchronized with select cable. <Ref.
position of select lever? to 4AT-52,
ADJUSTMENT,
Inhibitor Switch.>
<Ref. to CS-15,
ADJUSTMENT,
Select Cable.>
6 CHECK INPUT SIGNAL TO TCM. Is the indication per range Even if the SPORT Replace the TCM.
1) Shift the select lever from “P” to “D” range. OFF? indicator light is <Ref. to 4AT-65,
2) Read the Tiptronic Mode Switch data of blinking, the cir- Transmission Con-
TCM unit using Subaru Select Monitor. <Ref. cuit has returned trol Module
to 4AT(diag)-17, OPERATION, Subaru Select to normal condi- (TCM).>
Monitor.> tion at this time. A
temporary short
or harness may be
the cause. Repair
the harness or
connector.
4AT(diag)-121
Step Check Yes No

7 CHECK HARNESS BETWEEN BODY INTE- Is the resistance more than 1 Go to step 8. Repair the short
GRATED UNIT AND SPORT SHIFT SWITCH. M"? circuit in harness
1) Turn the ignition switch to OFF. between body inte-
2) Disconnect the harness connector from grated unit and
body integrated unit and select lever. SPORT shift
3) Measure the resistance of body integrated switch.
unit and chassis ground.
8 CHECK SPORT SHIFT SWITCH. Is the resistance more than 1 Check the body Replace the select
1) Shift the select lever to “P” range. M"? integrated unit. lever assembly.
2) Measure the resistance of SPORT shift <Ref. to CS-7,
switch connector terminals. Select Lever.>
Terminals
No. 7 — No. 8
4AT(diag)-122
Diagnostic Procedure without Diagnostic Trouble Code (DTC)
14.Diagnostic Procedure without Diagnostic Trouble Code (DTC)

A: CHECK FWD SWITCH
DIAGNOSIS:
• The LED does not come on even if FWD switch is ON.
• The FWD signal circuit is open or shorted.
WIRING DIAGRAM:
• LHD model
i10
3
4
1 2 3 4 5 6 7 8 9 10
No.5
11 12 13 14 15 16 17 18 19 20 21 22
AWD COMBINATION
METER i77
IGNITION
SWITCH
i10
1 2 3 4 5 6 7 8 9 10 11 12
21
22
A: i84
SBF-7
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
JOINT
1
24 25 26 27 28 29 30 31 32 33 34 35
CONNECTOR
i77
SBF-1
A: B54
1 2 3 4 5 6 7
A27
A26
8 9 10 11 12 13 14 15 16
BODY INTEGRATED UNIT 17 18 19 20 21 22 23 24
BATTERY
A: i84
B: B55
B20
B30
B: B281
1 2 3 4 5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20 21
22 23 24 25 26 27 28 29 30 31
5
JOINT
CONNECTOR
E
B352 B: B281
1
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23 24 25 26 27 28
2
JOINT
CONNECTOR
F108
B355
1 2 3 4 5 6 7 8
5
9 10 11 12 13 14 15 16 17 18
A12
A3
B361
A: B54
TCM 1 2 3 4 5 6
B: B55 7 8 9 10 11 12 13 14
B17
F27
B361
13
JOINT 1
THROUGH 2 4 5
CONNECTOR
3 6
11
F108
10 13 7
8 9 11 14 16 17
18
12 15
18 19
FWD A/C RELAY HOLDER 24 25 30
28 29
SWITCH 22 26 31
F27 20 21
23 27
19
B352 B355
E 1 2 3 4
5 6 7 8
AT-01898
4AT(diag)-123
• RHD model
i10
1 2 3 4 5 6 7 8 9 10
4
No.5 11 12 13 14 15 16 17 18 19 20 21 22
i77
AWD COMBINATION
METER
IGNITION
SWITCH
1 2 3 4 5 6 7 8 9 10 11 12
i10
A: i84
21
22
1 2 3 4 5 6 7 8
SBF-7
9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
24 25 26 27 28 29 30 31 32 33 34 35
JOINT
1
7
CONNECTOR
A: B54
SBF-1
i77
2
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16
17 18 19 20 21 22 23 24
A27
A26

BATTERY
B: B55
A: i84
B20
B30
1 2 3 4 5 6 7 8 9
B: B281
10 11 12 13 14 15 16 17 18 19 20 21
22 23 24 25 26 27 28 29 30 31
JOINT
3
CONNECTOR
E B: B281
B352 1 2 3 4 5 6 7
2
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23 24 25 26 27 28
19
JOINT F108 B361

CONNECTOR
1 2 3 4 5 6 7 8 1 2 3 4 5 6
B53
9 10 11 12 13 14 15 16 17 18
18
10
7 8 9 10 11 12 13 14
B352
A12
A3
A: B54 1 2 3 4
TCM 5 6 7 8
B: B55
B17
B53
B361 1 2 3 4 5 6 7 8 9 10
13
JOINT 11 12 13 14 15 16 17 18 19 20
THROUGH
CONNECTOR
11
F108 F27
1
18
2 4 5
3 6
FWD A/C RELAY HOLDER
SWITCH 10 13 7
F27 8 9 11 14 16 17
12 15
19
18 19
24 25 30
28 29
22 26 31
20 21
23 27
E
AT-02201
4AT(diag)-124
Step Check Yes No

1 CONFIRM EQUIPMENT OF VEHICLE. Is the vehicle equipped with Go to INSPEC- Go to step 2.
VDC? TION FOR
SPORT SHIFT
SWITCH. <Ref. to
4AT(diag)-127,
CHECK SPORT
SHIFT SWITCH,
Diagnostic Proce-
dure without Diag-
nostic Trouble
Code (DTC).>
2 CHECK SPARE FUSE. Is the spare fuse OK? Go to step 3. Replace the fuse.
3 CHECK FWD SWITCH. When the fuse is inserted to Go to step 4. Go to step 5.
Connect the Subaru Select Monitor to data link FWD switch, does the LED
connector. light up?
4 CHECK COMBINATION METER. Does the AWD warning light Go to INSPEC- Go to step 10.
illuminate? TION FOR
SPORT SHIFT
SWITCH. <Ref. to
4AT(diag)-127,
CHECK SPORT
SHIFT SWITCH,
Diagnostic Proce-
dure without Diag-
nostic Trouble
Code (DTC).>
TCM AND FWD SWITCH. "? circuit in harness
2) Disconnect the connector from TCM. FWD switch con-
3) Measure the resistance of harness nector.
between TCM and FWD switch connector.
(B55) No. 17 — (F27) No. 18:
FWD SWITCH AND CHASSIS GROUND. "? circuit in harness
Measure the resistance of harness between between FWD
FWD switch and chassis ground. switch connector
Connector & terminal and chassis
(F27) No. 19 — Chassis ground: ground.
TCM AND FWD SWITCH. M"? circuit in harness
between TCM and body to make sure that cir- FWD switch con-
cuit does not short. nector.
2) Connect the connector to TCM.
4) Measure the signal voltage for TCM while
installing the fuse to FWD switch connector.
4AT(diag)-125
Step Check Yes No

9 CHECK INPUT SIGNAL FOR TCM. Is the voltage more than 10.5 Go to step 10. Replace the TCM.
Measure the signal voltage for TCM while V? <Ref. to 4AT-65,
removing the fuse from FWD switch connector. Transmission Con-
(B55) No. 17 (+) — Chassis ground ($): (TCM).>
DTC.
11 CHECK COMBINATION METER. Is the AWD warning light OK? Go to step 12. Replace the com-
Check the AWD warning light. <Ref. to IDI-3, bination meter
INSPECTION, Combination Meter System.> assembly. <Ref. to
IDI-16, Combina-
tion Meter Assem-
bly.>
12 CHECK POOR CONTACT. Is there poor contact in FWD Repair the poor Replace the TCM.
switch circuit? contact. <Ref. to 4AT-65,
Transmission Con-
trol Module
(TCM).>
4AT(diag)-126
B: CHECK SPORT SHIFT SWITCH

DIAGNOSIS:
TROUBLE SYMPTOM:
Does not shift gears in manual mode.
WIRING DIAGRAM:
• LHD model
B: B280
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19 20
21 22 23 24 25 26 27 28 29 30
B: B280
C: B281 C: B281
1 2 3 4 5 6 7
B20
B30
C15
C25
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23 24 25 26 27 28
5
JOINT
5
CONNECTOR B54
B352 SELECT
DOWN
1
UP SHIFT LEVER 1 2 3 4 5 6 7
SHIFT
SWITCH 8 9 10 11 12 13 14 15 16
SWITCH B116
17 18 19 20 21 22 23 24
10
2
JOINT
CONNECTOR
B355 B116
5
1 2 3 4
5 6 7 8 9 10
E
12
3
B54 TCM B352
B355
1 2 3 4
5 6 7 8
AT-01900
4AT(diag)-127
• RHD model
B352
1 2 3 4
5 6 7 8
B53
B: B280 1 2 3 4 5 6 7 8 9 10
BODY INTEGRATED UNIT 11 12 13 14 15 16 17 18 19 20
C: B281
B54
B20
B30
C15
C25
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16
JOINT 17 18 19 20 21 22 23 24
3
CONNECTOR
5
9
B352 SELECT
2
DOWN LEVER B116

UP SHIFT
SHIFT
SWITCH
SWITCH B116 1 2 3 4
5 6 7 8 9 10
19
JOINT
9
10
6
CONNECTOR
B53
18
10
B: B280
1 2 3 4 5 6 7
12
3
8 9 10 11 12 13 14 15 16 17 18 19 20
E 21 22 23 24 25 26 27 28 29 30
B54 TCM
C: B281
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23 24 25 26 27 28
AT-02358
Step Check Yes No

1 CHECK SPORT SHIFT SWITCH. Does the LED light up? Go to step 2. Go to step 3.
1) Shift the select lever to manual mode.
2) Shift and hold the select lever to up side.
2 CHECK SPORT SHIFT SWITCH. Does the LED light up? Go to the proce- Go to step 12.
Shift and hold the select lever to down side. dure “INSPEC-
TION FOR
SPORT SHIFT
INDICATOR
LIGHT”. <Ref. to
4AT(diag)-132,
CHECK SPORT
SHIFT INDICA-
TOR, Diagnostic
Procedure without
Diagnostic Trou-
ble Code (DTC).>
4AT(diag)-128
Step Check Yes No

2) Shift and hold the select lever to up side.
3) Read the data of up-shift switch using Sub-
4 CHECK BODY INTEGRATED UNIT. Is DTC of CAN communication Perform the diag- Check the TCM.
Check the DTC of body integrated unit. <Ref. displayed? nosis according to
to LAN(diag)-14, OPERATION, Subaru Select DTC.
Monitor.>
5 CHECK SPORT SHIFT SWITCH GROUND Is the resistance less than 1 Go to step 6. Repair the open
CIRCUIT. "? circuit in harness
1) Turn the ignition switch to OFF. between SPORT
2) Disconnect the connector from SPORT shift switch and
shift switch. chassis ground.
between SPORT shift switch connector and
chassis ground.
6 CHECK SPORT SHIFT SWITCH. Is the resistance more than 1 Go to step 7. Replace the guide
Measure the resistance between SPORT shift M"? plate assembly.
switch terminals.
(B116) No. 6 — No. 5:
7 CHECK SPORT SHIFT SWITCH. Is the resistance less than 1 Go to step 8. Replace the guide
1) Shift and hold the select lever to up side. "? plate assembly.
2) Measure the resistance between SPORT
shift switch terminals.
(B116) No. 6 — No. 5:
BODY INTEGRATED UNIT AND SPORT "? circuit in harness
SHIFT SWITCH. between SPORT
1) Disconnect the connector from body inte- shift switch con-
grated unit. nector and TCM
2) Measure the resistance of harness connector, or poor
between body integrated unit and SPORT shift contact in cou-
switch connector. pling connector.
(B116) No. 5 — (B281) No. 15:
TCM AND SPORT SHIFT SWITCH. M"? circuit in harness
Measure the resistance of harness between between SPORT
SPORT shift switch connector and chassis shift switch con-
ground. nector and TCM
10 CHECK INPUT SIGNAL TO BODY INTE- Is the voltage 1.5 — 8 V? Go to step 11. Replace the TCM.
GRATED UNIT. <Ref. to 4AT-65,
2) Turn the ignition switch to ON (engine trol Module
OFF). (TCM).>
3) Check the signal voltage for body inte-
grated unit.
4AT(diag)-129
Step Check Yes No

11 CHECK INPUT SIGNAL TO BODY INTE- Is the voltage less than 1 V? Go to step 12. Replace the TCM.
GRATED UNIT. <Ref. to 4AT-65,
1) Shift and hold the select lever to up side. Transmission Con-
2) Check the signal voltage for body inte- trol Module
grated unit. (TCM).>
2) Shift and hold the select lever to down side.
3) Read the data of up-shift switch using Sub-
13 CHECK BODY INTEGRATED UNIT. Is DTC of CAN communication Perform the diag- Check the TCM.
Check the DTC of body integrated unit. displayed? nosis according to
DTC.
14 CHECK SPORT SHIFT SWITCH CIRCUIT. Is the resistance less than 1 Go to step 15. Repair the open
2) Disconnect the connector from SPORT between SPORT
shift switch. shift switch and
3) Measure the resistance of harness chassis ground.
chassis ground.
Measure the resistance between SPORT shift M"? plate assembly.
switch terminals.
(B116) No. 10 — No. 9:
1) Shift and hold the select lever to down side. "? plate assembly.
2) Measure the resistance between SPORT
(B116) No. 10 — No. 9:
between body integrated unit and SPORT shift contact in cou-
switch connector. pling connector.
(B116) No. 9 — (B281) No. 25:
BODY INTEGRATED UNIT AND SPORT M"? circuit in harness
Measure the resistance of harness between shift switch con-
SPORT shift switch connector and chassis nector and TCM
ground. connector.
4AT(diag)-130
Step Check Yes No

19 CHECK THE INPUT SIGNAL TO BODY INTE- Is the voltage 1.5 — 8 V? Go to step 20. Go to step 21.
GRATED UNIT.
OFF).
grated unit.
20 CHECK THE INPUT SIGNAL TO BODY INTE- Is the voltage less than 1 V? Go to step 21. Replace the body
GRATED UNIT. integrated unit.
1) Shift and hold the select lever to up side. <Ref. to 4AT-65,
2) Check the signal voltage for body inte- Transmission Con-
grated unit. trol Module
Connector & terminal (TCM).>
21 CHECK POOR CONTACT. Is there poor contact in SPORT Repair the poor A temporary poor
shift switch circuit? contact. contact of SPORT
shift switch con-
nector or harness.
4AT(diag)-131
C: CHECK SPORT SHIFT INDICATOR

DIAGNOSIS:
Output signal circuit of SPORT shift indicator is open or shorted.
TROUBLE SYMPTOM:
• SPORT shift indicator does not display or remains displayed.
• SPORT shift indicator display does not change.
WIRING DIAGRAM:
• LHD model
i10
1 2 3 4 5 6 7 8 9 10
3
11 12 13 14 15 16 17 18 19 20 21 22
No.5
SPORT SHIFT
INDICATOR
COMBINATION
i77
METER
IGNITION
SWITCH
i10 1 2 3 4 5 6 7 8 9 10 11 12
21
22
SBF-7
A: i84
JOINT 1 2 3 4 5 6 7 8
1
CONNECTOR 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
24 25 26 27 28 29 30 31 32 33 34 35
SBF-1
i77
2
B: B280
A27
A26
BODY INTEGRATED UNIT 1 2 3 4 5 6 7

BATTERY
8 9 10 11 12 13 14 15 16 17 18 19 20
A: i84 21 22 23 24 25 26 27 28 29 30
B: B280
B20
B30
B54
JOINT 1 2 3 4 5 6 7
E
5
CONNECTOR 8 9 10 11 12 13 14 15 16
17 18 19 20 21 22 23 24
B352
1
B352
JOINT B355
2
CONNECTOR
B355 1 2 3 4
5
5 6 7 8
12
3
B54 TCM
AT-01901
4AT(diag)-132
• RHD model
i10
1 2 3 4 5 6 7 8 9 10
3
4
11 12 13 14 15 16 17 18 19 20 21 22
No.5
SPORT SHIFT
INDICATOR
COMBINATION
METER i77
IGNITION
SWITCH
i10
1 2 3 4 5 6 7 8 9 10 11 12
21
22
A: i84
SBF-7
1 2 3 4 5 6 7 8
JOINT
1
9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
CONNECTOR
24 25 26 27 28 29 30 31 32 33 34 35
SBF-1
i77
2
B: B280
A27
A26
1 2 3 4 5 6 7
BATTERY
8 9 10 11 12 13 14 15 16 17 18 19 20
21 22 23 24 25 26 27 28 29 30
A: i84
B: B280
B20
B30
B352
1 2 3 4
E JOINT
3
5 6 7 8
CONNECTOR
B352
2
B53
1 2 3 4 5 6 7 8 9 10
19
JOINT 11 12 13 14 15 16 17 18 19 20
CONNECTOR
B53
18
10
B54
1 2 3 4 5 6 7
12
3
8 9 10 11 12 13 14 15 16
17 18 19 20 21 22 23 24
B54 TCM
AT-02359
4AT(diag)-133
Step Check Yes No

DTC.
2 CHECK TCM. Is the gear position 1? Go to step 3. Replace the TCM.
2) Connect the Subaru Select Monitor to data Transmission Con-
link connector. trol Module
3) Turn the ignition switch to ON. (Engine (TCM).>
OFF)
4) Turn Subaru Select Monitor switch to ON.
5) Shift the select lever to manual mode side.
6) Read the data of gear position using Sub-
aru Select Monitor.
3 CHECK TCM. Is the gear position 2? Go to step 4. Replace the TCM.
1) Up-shift the select lever. <Ref. to 4AT-65,
2) Read the data of gear position using Sub- Transmission Con-
aru Select Monitor. trol Module
(TCM).>
4 CHECK BODY INTEGRATED UNIT. Is the SPORT shift gear posi- Go to step 5. Check the body
Read the data of SPORT shift gear position tion 2? integrated unit.
5 CHECK COMBINATION METER. Is the SPORT shift indicator Check the buzzer. Replace the com-
<Ref. to IDI-3, INSPECTION, Combination OK? <Ref. to 4AT(diag)- bination meter
Meter System.> 138, Diagnostics assembly. <Ref. to
with Phenome- IDI-16, Combina-
non.> tion Meter Assem-
bly.>
4AT(diag)-134
D: CHECK BUZZER
DIAGNOSIS:
Output signal circuit of buzzer is open or shorted.
TROUBLE SYMPTOM:
Buzzer remains sounded.
WIRING DIAGRAM:
• LHD model
IGNITION
SWITCH
SBF-1 SBF-7
No.5
i10
1 2 3 4 5 6 7 8 9 10
11 12 13 14 15 16 17 18 19 20 21 22
BATTERY
i77
SPORT
SHIFT COMBINATION 1 2 3 4 5 6 7 8 9 10 11 12
BUZZER METER
E i10
A: i84
21
22
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
24 25 26 27 28 29 30 31 32 33 34 35
JOINT
1
CONNECTOR
B: B280
i77
2
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19 20
21 22 23 24 25 26 27 28 29 30
A26
A27
A: i84 B: B280 BODY INTEGRATED UNIT B54
1 2 3 4 5 6 7
B20
B30
8 9 10 11 12 13 14 15 16
17 18 19 20 21 22 23 24
JOINT
5
CONNECTOR
B352
B352
B355
1
1 2 3 4
5 6 7 8
JOINT
2
CONNECTOR
B355
5
7
12
3
B54 TCM
AT-01902
4AT(diag)-135
• RHD model
IGNITION
SWITCH
SBF-1 SBF-7
No.5
i10
1 2 3 4 5 6 7 8 9 10
11 12 13 14 15 16 17 18 19 20 21 22
BATTERY
4
i77
SPORT
SHIFT COMBINATION
BUZZER 1 2 3 4 5 6 7 8 9 10 11 12
METER
E i10
A: i84
21
22
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
24 25 26 27 28 29 30 31 32 33 34 35
JOINT
1
CONNECTOR
B: B280
i77
2
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19 20
21 22 23 24 25 26 27 28 29 30
A26
A27
A: i84 B: B280 BODY INTEGRATED UNIT B352

B20
B30
1 2 3 4
5 6 7 8
JOINT
3
CONNECTOR B53
B352
1 2 3 4 5 6 7 8 9 10
2
11 12 13 14 15 16 17 18 19 20
19
JOINT
9
CONNECTOR B54
B53
18
10
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16
17 18 19 20 21 22 23 24
12
3
B54 TCM
AT-02360
4AT(diag)-136
Step Check Yes No

1 CHECK BODY INTEGRATED UNIT. Is the SPORT shift buzzer dis- Replace the TCM. Go to step 2.
1) Turn the ignition switch to OFF. play “ON”? <Ref. to 4AT-65,
3) Turn the ignition switch to ON. (Engine (TCM).>
OFF)
4) Turn Subaru Select Monitor switch to ON.
5) Read the data of sport shift buzzer using
2 CHECK COMBINATION METER. Is the buzzer OK? Perform Diagnos- Replace the com-
<Ref. to IDI-3, INSPECTION, Combination tics with Phenom- bination meter
Meter System.> enon. <Ref. to assembly. <Ref. to
4AT(diag)-138, IDI-16, Combina-
Diagnostics with tion Meter Assem-
Phenomenon.> bly.>
4AT(diag)-137
Diagnostics with Phenomenon
15.Diagnostics with Phenomenon

A: INSPECTION
Symptom Problem parts
• Inhibitor switch
Starter does not operate when select lever is in “P” or “N” • Select cable
range. Starter operates when select lever is in “R” or “D” range. • Select lever
• Starter motor and harness
• Strainer
• Transfer duty solenoid
Abnormal noise when select lever is in “P” or “N”. • Oil pump
• Drive plate
• ATF level too high or too low
• Strainer
Hissing noise occurs during standing start.
• ATF level too high or too low
Noise occurs while driving in “D1”. • Final gear
• Planetary gear
Noise occurs while driving in “D2”. • Reduction gear
• Differential gear oil level too high or too low
• Final gear
• Low & reverse brake
Noise occurs while driving in “D3”.
• Reduction gear
• Final gear
• Low & reverse brake
Noise occurs while driving in “D4”. • Planetary gear
• Reduction gear
• Select cable
Vehicle moves when select lever is in “N”.
• TCM
• Low clutch
• Accelerator pedal position sensor
• ATF temperature sensor
• Line pressure linear solenoid
• Low clutch duty solenoid
Shock occurs when select lever is shifted from “N” to “D” range. • Low clutch
• TCM
• Harness
• Control valve
• ATF deterioration
• Control valve
• Low clutch
Excessive time lag occurs when select lever is shifted from “N”
to “D” range.
• Seal ring
• Front gasket of transmission case
Shock occurs when select lever is shifted from “N” to “R” range. • TCM
• Harness
• Control valve
• Control valve
• Low & reverse clutch
Excessive time lag occurs when select lever is shifted from “N” • Reverse clutch
to “R” range. • Line pressure linear solenoid
• Seal ring
4AT(diag)-138

• Parking brake mechanism
Vehicle does not start in any shift range. (Engine stalls)
• Planetary gear
• Strainer
• Control valve
• Drive pinion
• Hypoid gear
• Axle shaft
• Differential gear
Vehicle does not start in any shift range. (Engine operates)
• Oil pump
• Input shaft
• Output shaft
• Planetary gear
• Drive plate
• ATF level too low.
• Select cable
• Select lever
Vehicle does not start in “R” range only. (Engine operates)
• Control valve
• Reverse clutch
• Low clutch
• 2-4 brake
Vehicle does not start in “R” range only. (Engine stalls)
• Planetary gear
• Parking brake mechanism
• Low clutch
Vehicle does not start in “D” range. (Engine operates)
• One-way clutch
Vehicle does not start in “D” range. (Engine stalls) • Reverse clutch
Vehicle does not start in “R” range only. (Engine operates) • Control valve
• Control valve
• Low clutch
• Reverse clutch
Acceleration during standing start is poor. (High rpm stall) • ATF level too low.
• Oil pump
Acceleration during standing start is poor. (Low rpm stall) • Torque converter one-way clutch
• Engine performance
• TCM
• Control valve
Acceleration is poor when select lever is in “D” range. (Normal
• High clutch
rpm stall)
• 2-4 brake
• Planetary gear
• Control valve
Acceleration is poor when select lever is in “R” range. (Normal • High clutch
rpm stall) • 2-4 brake
• Planetary gear
• TCM
• Rear vehicle speed sensor
• Front vehicle speed sensor
No shift occurs from 1st to 2nd gear.
• Throttle position sensor
• Control valve
• 2-4 brake
• TCM
No shift occurs from 2nd to 3rd gear. • Control valve
• High clutch
4AT(diag)-139

• TCM
No shift occurs from 3rd to 4th gear.
• Control valve
• 2-4 brake
Engine brake is not effected when select lever is shifted from • TCM
4th gear to 3rd gear. • Throttle position sensor
• Control valve
Engine brake is not effected when select lever is shifted from • Control valve
3rd gear to 2nd gear.
Engine brake is not effected when select lever is shifted from • Control valve
2nd gear to 1st gear. • Low & reverse brake
• TCM
Shift characteristics are erroneous. • Rear vehicle speed sensor
• Control valve
• Ground
• TCM
No lock-up occurs.
• Control valve
• Lock-up facing
• Engine speed signal
Parking brake is not effected. • Select cable
• Select lever
Shift lever cannot be moved or is hard to move from “P” range. • Parking mechanism
ATF spurts out. • ATF level too high.
Differential oil spurts out. • Differential gear oil level too high.
• Seal pipe
Differential oil level changes excessively.
• Double oil seal
• High clutch
• 2-4 brake
Odor is produced from ATF supply pipe.
• Reverse clutch
• Lock-up facing
• TCM
• Torque converter turbine speed sensor
• 2-4 brake duty solenoid
Shock occurs from 1st to 2nd gear. • Line pressure linear solenoid
• Control valve
• 2-4 brake
• Low & reverse duty solenoid
• TCM
Slippage occurs from 1st to 2nd gear. • ATF temperature sensor
• Control valve
• 2-4 brake
4AT(diag)-140

• TCM
Shock occurs from 2nd to 3rd gear. • Low & reverse duty solenoid
• Control valve
• High clutch
• 2-4 brake
• High clutch duty solenoid
• TCM
Slippage occurs from 2nd to 3rd gear. • Line pressure linear solenoid
• Control valve
• High clutch
• 2-4 brake
• Low & reverse duty solenoid
• TCM
Shock occurs from 3rd to 4th gear. • Line pressure linear solenoid
• Control valve
• Low clutch duty solenoid
• 2-4 brake
• TCM
Slippage occurs from 3rd to 4th gear. • ATF temperature sensor
• Control valve
• 2-4 brake
• TCM
Shock occurs when select lever is shifted from 3rd gear to 2nd • Line pressure linear solenoid
gear. • Control valve
• 2-4 brake
• High clutch duty solenoid
• TCM
Shock occurs when select lever is shifted from 2nd gear to 1st • Line pressure linear solenoid
gear. • Control valve
• Low & reverse brake duty solenoid
4AT(diag)-141

• TCM
Shock occurs when accelerator pedal is released at medium
speeds.
• Control valve
• Lock-up damper
• TCM
• Lock-up duty solenoid
Vibration occurs during straight-forward operation.
• Lock-up facing
• Lock-up damper
• TCM
• Rear vehicle speed sensor
Vibration occurs during turns. (tight corner braking phenome- • ATF temperature sensor
non) • Transfer clutch
• Transfer valve
• Harness
• TCM
Front wheel slippage occurs during standing starts. • Control valve
• Transfer clutch
• Transfer valve
• Transfer pipe
• TCM
• Transfer clutch
Vehicle is not set in FWD mode.
• Transfer valve
• Select cable
• Select lever
Select lever is hard to move.
• Detent spring
• Manual plate
Select lever is excessively hard to move. (Unreasonable resis- • Detent spring
tance) • Manual plate
• Select cable
Select lever slips out of operation during acceleration or while • Select lever
driving on rough terrain. • Detent spring
• Manual plate
• SPORT shift switch
Manual mode is not engaged. • TCM
• Body integrated unit
• Up shift switch
Gear does not change though the select lever is operated in • Down shift switch
manual mode. • TCM
• Body integrated unit
4AT(diag)-142
CONTROL SYSTEMS CS

(DIAGNOSTICS)


approval.

5AT
Page
4. Road Test..................................................................................................30
5. Stall Test ...................................................................................................31
6. Time Lag Test ...........................................................................................33
16. Turbine speed sensor 1 ............................................................................57
18. ATF Filter ..................................................................................................60
20. Lateral G Sensor .......................................................................................63
21. ATF Cooler Pipe & Hose...........................................................................64
23. Oil Charge Pipe.........................................................................................70
24. Torque Converter Assembly .....................................................................71
25. Extension Case & Intermediate Case .......................................................72
26. Transfer Clutch..........................................................................................74
27. Multi-Plate Clutch ......................................................................................76
28. Rear Drive Shaft........................................................................................77
31. Parking Pawl .............................................................................................82
32. Converter Case .........................................................................................84
33. Oil Pump Cover.........................................................................................86
34. Drive Pinion Shaft Assembly.....................................................................89
35. Front Differential........................................................................................94
36. AT Main Case ...........................................................................................99
General Description
1. General Description Model Turbo

Non-
turbo
A: SPECIFICATION Drive plate number of high & low
4 4
reverse clutch
1. TORQUE CONVERTER CLUTCH
Drive plate number of direct clutch 5
Model Turbo Non-turbo Drive plate number of reverse brake 5 6
Symmetric, 3 element, single stage, Drive plate number of forward brake 5 4
Type Drive plate number of low coast brake 3
2 phase torque converter
Stall torque ratio 2.1 6. SELECTOR POSITION
Nominal diameter 250 mm (9.84 in)
Stall speed (at sea 3,100 — 3,500 2,400 — 2,800 Transmission in neutral, output mem-
level) rpm rpm P (Park) ber immovable, and engine start possi-
One-way clutch Sprague type one-way clutch ble
R (Reverse) Transmission in reverse for backing
2. OIL PUMP Transmission in neutral and engine
N (Neutral)
start possible
Type Internal gear fixed displacement pump Automatic gear change
D (Drive)
Driving method Driven by engine 1st ! " 2nd !" 3rd ! " 4th ! " 5th
Inner rotor 9
Number of teeth Manual gear change
Outer rotor 10 Manual mode (+)
1st " 2nd " 3rd " 4th " 5th
Manual gear change
3. TRANSMISSION CONTROL ELEMENT Manual mode (#)
1st ! 2nd ! 3rd ! 4th ! 5th
Control method Wire cable type
5-forward, 1-reverse,
Type
double-row planetary gears
7. HYDRAULIC CONTROL & LUBRICA-
Multi-plate clutch 3 sets
TION
Multi-plate brake 4 sets
One-way clutch Electronic/hydraulic control
3 sets
(sprague type) [5 forward speed changes by
Type electrical signals of vehicle
4. TRANSMISSION GEAR RATIO speed and accelerator
(throttle) opening]
1st 3.540 Specified fluid: SUBARU
2nd 2.264 ATF (Part No. K0140Y0700)
3rd 1.471 Recommended fluid: IDE-
4th 1.000 MITSU ATF HP
Castrol Transmax J
5th 0.834 Fluid
NOTE:
Rev 2.370 Using of recommended fluid
is permitted only on the area
5. PLANETARY GEAR AND PLATE where the specified is not
available.
Non- Fluid capacity 9.6 — 10.0 (10.1 — 10.6,
Model Turbo
turbo 2 (US qt, Imp qt) 8.4 — 8.8)
Tooth number of front internal gear 106 Forced feed lubrication with
Lubrication system
Tooth number of front carrier 28 oil pump
Tooth number of front sun gear 50
Tooth number of mid internal gear 78 8. COOLING & HARNESS
Tooth number of mid carrier 18
Liquid-cooled cooler incorpo-
Tooth number of mid sun gear 42 Cooling system rated in radiator or ATF liquid-
Tooth number of rear internal gear 110 cooled cooler
Tooth number of rear carrier 24 Transmission harness 20+ 8 poles
Tooth number of rear sun gear 62
Drive plate number of front brake 2
Drive plate number of input clutch 6 5
5AT-2
General Description
9. TRANSFER
Model Turbo Non-turbo
Transfer type Variable torque distribution (VTD)
Drive & driven
plate number of 4 3
transfer clutch
Reduction gear
1.000 (41/41)
ratio
10.FINAL REDUCTION
Model Turbo NA (OUTBACK) NA (except for OUTBACK)
Front final reduction gear ratio 3.272 3.083
11.RECOMMENDED GEAR OIL
(1)
(2)
(3)
GL-5
(4)
( C) -30 -26 -15 -5 0 15 25 30
( F) -22 -15 5 23 32 59 77 86
90
Lubrication oil 85W
80W
75W -90
MT-00001
(1) Item (3) API classification

(2) Front differential gear oil (4) SAE viscosity No. and applica-
ble temperature
Front differential gear oil capacity

1.3 — 1.5 (1.4 — 1.6, 1.1 — 1.3)
2 (US qt, Imp qt)
5AT-3
General Description
B: COMPONENT
1. TORQUE CONVERTER CLUTCH & TRANSMISSION ASSEMBLY
(40) (37)
(36)
(39)
(38)
(24)
(13)
(14)
(30)
(29)
(34)
T5 (5)
(15)
T1
(4)
(33)
(32)
(16)
(35)
(8)
(17)
(17)
(1)
(3) (18)
(2) (23)
(22) (19) T1
(20)
T2
T4 (21)
(27)
(25) T1
(28)
(6) (7) (26)
T3
(9)
(31) T1
(11)
(10) (12)
AT-02024
5AT-4
General Description
(1) Torque converter ASSY (19) Ball (35) Turbine speed sensor 1
(2) Circlip (20) Spring (36) ATF cooler inlet hose
(3) Oil pump shaft (21) Union screw (37) ATF cooler outlet hose
(4) Differential oil level gauge (22) ATF outlet pipe (38) Hose clamp (model with ATF
(5) Pitching stopper bracket (23) ATF inlet pipe (model without ATF warmer)
(6) Differential oil drain plug warmer) (39) ATF cooler ASSY (model with ATF
(7) Gasket (24) ATF inlet pipe (model with ATF warmer)
(8) Oil seal warmer) (40) ATF cooler bracket (model with
(9) Lock plate (25) Magnet ATF warmer)
(10) Side retainer (26) Oil pan
(11) O-ring (27) Gasket Tightening torque: N$m (kgf-m, ft-lb)
(12) Oil seal (28) ATF drain plug T1: 25 (2.5, 18.1)
(13) ATF level gauge (29) Breather hose T2: 70 (7.1, 51.6)
(14) O-ring (30) Nipple T3: 20 (2.0, 14.8)
(15) Oil charge pipe (31) O-ring T4: 5 (0.5, 3.7)
(16) O-ring (32) Oil seal T5: 40 (4.1, 29.5)
(17) Gasket (33) Dust cover
(18) Union screw (34) Floating bracket
5AT-5
General Description
2. OIL PUMP & FRONT BRAKE
(9)
(6)
(7)
(4)
(3)
(2)
(1)
(8)
(5)
(18)
(2)
(15)
(14) (20)
(13)
(19)
(12)
(11)
(17)
(10) (16)
AT-02016
(1) O-ring (8) O-ring (15) Retainer

(2) Washer (9) Nipple (16) Snap ring
(3) Oil pump housing (10) Needle bearing (17) Driven plate
(4) Oil pump rotor (11) D-ring (Inner) (18) Drive plate
(5) O-ring (12) D-ring (Outer) (19) Retaining plate
(6) Air breather hose (13) Front brake piston (20) Snap ring
(7) Oil pump cover (14) Return spring
5AT-6
General Description
3. FRONT PLANETARY CARRIER and MIDDLE & REAR PLANETARY CARRIER
(5)
(4)
(3)
(2)
(1) (9)
(8) (20)
(19)
(18)
(7)
(6)
(17)
(16)
(15)
(14)
(13)
(12)
(11)
(10)
AT-02017
(1) Thrust bearing (8) Thrust bearing (15) Rear carrier ASSY
(2) Front sun gear ASSY (9) Input clutch ASSY (16) Thrust bearing
(3) Snap ring (10) Rear internal gear ASSY (17) Middle & Rear sun gear ASSY
(4) Front carrier ASSY (11) Thrust bearing (18) Washer
(5) Race bearing (12) Middle carrier ASSY (19) Thrust bearing
(6) O-ring (13) Thrust bearing (20) Seal ring
(7) Seal ring (14) Race bearing
5AT-7
General Description
4. DIRECT CLUTCH and HIGH & LOW REVERSE CLUTCH
(3)
(2)
(1)
AT-02018
(1) Thrust bearing (2) High & low reverse clutch ASSY (3) Direct clutch ASSY
5AT-8
General Description
5. REVERSE BRAKE
(4)
(13)
(3)
(2)
(1)
(5)
(12)
(11)
(10)
(9)
(8)
(7)
(6)
AT-02019
(1) Snap ring (6) Dish plate (11) D-ring (Outer)

(2) Retainer plate (7) Snap ring (12) D-ring (Inner)
(3) Leaf spring (8) Retainer (13) AT main case
(4) Drive plate (9) Leaf spring
(5) Driven plate (10) Reverse brake piston
5AT-9
General Description
6. CONTROL VALVE & TRANSMISSION HARNESS
(1)
(3)
(2)
(4)
(5)
(6)
AT-02020
(1) Transmission harness ASSY (3) Sensor cover (5) Clip

(2) Front vehicle speed sensor (4) Harness bracket (6) Control valve ASSY
5AT-10
General Description
7. DIFFERENTIAL GEAR
(1)
(7)
(13)
(12)
(14)
(12)
(13)
(8)
(4)
(2)
(3)
(14)
(5)
(6)
(9)
(10) (1)
(11)
(5)
(3)
(15)
(4)
AT-02021
(1) Retainer plate RH (6) Hypoid driven gear (11) Differential case LH
(2) Differential side retainer RH (7) Drive pinion shaft (12) Differential bevel gear
(3) O-ring (8) Pinion shaft (13) Washer
(4) Oil seal (9) Straight pin (14) Differential bevel pinion
(5) Taper roller bearing (10) Differential case RH (15) Differential side retainer LH
5AT-11
General Description
8. TRANSFER CASE, EXTENSION CASE & REDUCTION GEAR
(11)
(15)
(9)
(8)
(6) (31)
(14)
(5)
(13) (30)
(12)
(29)
(28)
(7) (10)
(27)
(4) (26)
(3) (25)
(2) (24)
(23)
(1) (44)
(22)
(21) (43)
(20) (42)
(19) (40)
(18) (39)
(17)
(38)
(16)
(37) (41)
(36)
(35)
(34)
(49)
(33)
(47)
(46)
(50)
(45)
(48)
(32)
AT-02022
5AT-12
General Description
(1) Seal ring (18) Transfer clutch hub (35) Snap ring
(2) Reduction gear shim (19) Transfer clutch plate (36) Ball bearing
(3) Ball bearing (20) Driven plate No. 3. (37) Shim
(4) Snap ring (21) Ball bearing (38) Gasket
(5) Planetary pinion washer (22) Rear drive shaft shim (39) Intermediate case
(6) Needle bearing (23) Revolution gear (40) Shim
(7) Spacer (24) Snap ring (41) Extension case
(8) Pinion gear (25) Clutch spring retainer (42) Transmission hanger
(9) Washer (26) Return spring (43) Oil seal
(10) Planetary carrier ASSY (27) Spring retainer (44) Dust cover
(11) Planetary pinion shaft ASSY (28) Pressure plate (45) Taper roller bearing
(12) Snap ring (29) Ball bearing (46) Drive pinion shim
(13) Thrust bearing (30) O-ring (47) Oil seal
(14) Intermediate shaft (31) C-ring (48) Drive pinion collar
(15) Thrust washer (32) Drive pinion shaft (49) O-ring
(16) Rear drive shaft (33) Ball bearing (50) Lock nut
(17) Ball bearing (34) Reduction driven gear
5AT-13
General Description
9. TRANSMISSION CONTROL DEVICE & PARKING SUPPORT
(1)
T1
T1
(2)
(3)
T3
(12)
(11)
(10)
(9)
(5)
(4)
T2
(8)
(6)
(7)
T2
AT-02089
(1) Bracket (7) Manual plate Tightening torque: N$m (kgf-m, ft-lb)
(2) Floating bracket (8) Parking rod T1: 25 (2.5, 18.4)
(3) AT main case (9) Parking support actuator T2: 6 (0.6, 4.4)
(4) Range select lever (10) Parking pawl shaft T3: <Ref. to 5AT-82, Parking Pawl.>
(5) Straight pin (11) Return spring
(6) Dimension spring (12) Parking pawl
5AT-14
General Description
10.TRANSMISSION CONTROL MODULE
T2
T1 (3)
T1
T1
(1)
(2)
(2)
(4)
AT-02036
(1) Transmission control module (3) Lateral G sensor Tightening torque: N$m (kgf-m, ft-lb)
(TCM) (RHD model) (4) Transmission control module T1: 7.5 (0.76, 5.5)
(2) Relay (TCM) (LHD model) T2: 24.5 (2.5, 18.1)
5AT-15
General Description
11.TRANSMISSION MOUNTING
T2
(2)
T2
T4
(1) (3)
T5
T3 (4)
T1
T5
AT-01738
(1) Pitching stopper (3) Crossmember Tightening torque: N$m (kgf-m, ft-lb)
(2) Rear cushion rubber (4) Stopper T1: 35 (3.6, 26)
T2: 40 (4.1, 29.5)
T3: 50 (5.1, 36.9)
T4: 58 (5.9, 42.8)
T5: 70 (7.1, 51.6)
5AT-16
General Description
C: CAUTION
goggles, and protective shoes during operation.
• Until the oil pan is removed, do not place with the
oil pan side facing up to prevent foreign matter from
entering the valve body.
moval, disassembly and replacement.
• When disassembling the case and other light al-
loy parts, disassemble them by slightly tapping with
a plastic hammer. Do not pry it apart with a screw-
driver or other tool.
• Be careful not to burn yourself, because each
part on the vehicle is hot after running.
• Use SUBARU genuine gear oil, grease etc. or
the equivalent. Do not mix them with that of another
grade or from other manufacturers.
• Be sure to tighten fasteners including bolts and
nuts to the specified torque.
points.
• Apply gear oil onto sliding or revolution surfaces
before installation.
• Replace deformed or otherwise damaged snap
rings with new ones.
• Before installing O-rings or oil seals, apply suffi-
cient amount of ATF fluid to avoid damage and de-
formation.
• Be careful not to incorrectly install or fail to install
O-rings, snap rings and other such parts.
• Before securing a part on a vice, place cushion-
ing material such as wood blocks, aluminum plate,
or 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.
5AT-17
General Description
D: PREPARATION TOOL
1. SPECIAL TOOL
498575400 OIL PRESSURE Used for measuring oil pressure.
GAUGE ASSY
ST-498575400
498897200 ADAPTER • Used with oil pump cover installed on when
measuring line pressure.
• Used with extension case installed on when
measuring transfer clutch pressure.
ST-498897200
498545400 FILTER WRENCH Used for removing and installing ATF filter.
ST-498545400
498277200 STOPPER SET Used for removing and installing automatic

transmission assembly to engine.
ST-498277200
5AT-18
General Description

41099AC000 ENGINE SUPPORT Used for supporting engine.
ASSEMBLY (1) ENGINE SUPPORT BRACKET
(41099AC010)
(1) (2) ENGINE SUPPORT ROD (41099AC020)
(2)
ST41099AC000
398527700 PULLER ASSY • Used for removing extension case roller bear-
ing.
• Used for removing extension oil seal.
retainer bearing outer race.
retainer oil seal.
ST-398527700
ST-498057300
498077000 REMOVER Used for removing differential taper roller bear-
ing.
ST-498077000
5AT-19
General Description

18630AA010 WRENCH COMPL Used for removing and installing differential side
(Newly adopted tool) RETAINER retainer.
ST18630AA010
398487700 DRIFT Used for installing front differential taper roller

bearing.
ST-398487700
498255400 PLATE Used for measuring backlash of hypoid gear.
ST-498255400
498247001 MAGNET BASE • Used for measuring gear backlash.
ST-498247001
5AT-20
General Description

498247100 DIAL GAUGE • Used for measuring gear backlash.
ST-498247100
498517000 REPLACER Used for removing front roller bearing.
ST-498517000
499787700 WRENCH Used for removing and installing drive pinion lock
nut.
ST-499787700
ST-398643600
5AT-21
General Description

398744300 GAUGE Used for measuring contact surface between
multi-plate clutch end and transmission.
ST-398744300
499737100 PULLER SET Used for removing reduction drive gear assem-
bly.
ST-499737100
498077600 REMOVER Used for removing ball bearing.
ST-498077600
18667AA010 HOLDER • Used for removing and installing drive pinion

(Newly adopted tool) lock nut.
• Used as a handle to rotate gear when check-
ing tooth contact.
ST18667AA010
5AT-22
General Description

ST24082AA230
ST22771AA030
18675AA000 DIFFERENTIAL Used for installing differential side retainer oil

SIDE OIL SEAL seal.
INSTALLER
ST18675AA000
28399SA010 OIL SEAL PROTEC- Used for protecting oil seal when installing front
TOR drive shaft.
ST28399SA010
5AT-23
General Description

18680AA000 HOLDER GEAR Used for removing reduction driven gear assem-
(Newly adopted tool) bly. (2-piece)
ST18680AA000
18762AA000 COMPRESSOR Used for disassembling multiplate clutch for shift

(Newly adopted tool) SPECIAL TOOL transmission.
ST18762AA000

(Newly adopted tool) SHAFT transmission.
ST18673AA000

(Newly adopted tool) SUPPORT transmission.
ST18765AA000
5AT-24
General Description

18676AA020 TORX® WRENCH Used for disassembling torque converter case.
(Newly adopted tool)
ST18676AA020
18854AA000 ANGLE GAUGE Used for tightening parking support.

(Newly adopted tool)
ST18854AA000
18679AA000 ADJUSTER Used for adjusting position when tightening park-

(Newly adopted tool) ing support.
ST18679AA000
498077310 REMOVER Used for removing ball bearing of reduction

driven gear.
ST-498077310
5AT-25
General Description

499587100 OIL SEAL Used for installing oil seal.
INSTALLER
ST-499587100
499787500 ADAPTER Used for removing and installing drive pinion lock
nut.
ST-499787500
499575400 GAUGE Used for measuring height of total end play.
ST-499575400
2. GENERAL TOOL
TOOL NAME REMARKS
Depth gauge Used for measuring transmission end play.
Thickness gauge Used for measuring clearance of clutch, brake and oil pump.
Micro meter Used for measuring thickness of drive pinion.
Spring balance Used for measuring starting torque of drive pinion.
Circuit tester Used for measuring resistance and voltage.
TORX® T70 Used for removing and installing differential gear oil drain plug.
Snap ring pliers Used for removing and installing each snap ring.
5AT-26
2. Automatic Transmission Flu- B: REPLACEMENT

id 1) Lift-up the vehicle.
A: INSPECTION CAUTION:
NOTE: Directly after the engine has been running, the
The level of ATF varies with fluid temperature. Pay ATF is hot. Be careful not to burn yourself.
attention to the ATF temperature when checking 3) Check the condition of ATF.
ATF level. <Ref. to 5AT-28, CONDITION CHECK, Automatic
1) Raise the ATF temperature by driving a distance Transmission Fluid.>
of 5 to 10 km (3 to 6 miles). Otherwise, idle the en- 4) Tighten the ATF drain plug.
gine to raise ATF temperature to 70 to 80%C (158 to NOTE:
176%F) on Subaru Select Monitor. <Ref. to 5AT(di- Use a new gasket.
ag)-16, READ CURRENT DATA, OPERATION,
Subaru Select Monitor.> Tightening torque:
2) Park the vehicle on a level surface. 20 N$m (2.0 kgf-m, 14.8 ft-lb)
3) After selecting all positions (P, R, N, D), set the
select lever in “P” range. Measure the ATF level (A)
with engine idling for one or two minutes. (B)
(A)
F
(B)
HOT
L
(C)
F
(B) AT-01361
COLD
L
(C) (A) Oil pan

AT-00674 (B) ATF drain plug
(A) ATF level gauge 5) Lower the vehicle.

(B) Upper level 6) Pour ATF from the oil charge pipe.
(C) Lower level Specified fluid:
SUBARU ATF (Part No. K0140Y0700)
4) Make sure that ATF level is above the center be-
tween upper and lower marks at HOT side. Recommended fluid:
5) If the ATF level is below the center between up- IDEMITSU ATF HP
per and lower marks, add the recommended ATF Castrol Transmax J
until the fluid level is found above the center be- NOTE:
tween upper and lower marks. Using of recommended fluid is permitted only on
CAUTION: the area where the specified is not available.
• Use care not to exceed the upper level.
Capacity:
• When the transmission is cold, be careful not
to add ATF to the upper level on HOT side. Fill the same amount of ATF drained.
Overfilling of ATF may cause oil splashing. Capacity when transmission is overhauled:
6) Raise the ATF temperature by driving a distance 9.6 — 10.0 2 (10.1 — 10.6 US qt, 8.4 — 8.8 Imp
of 5 to 10 km (3 to 6 miles). Otherwise, idle the en- qt)
gine to raise ATF temperature to 70 to 80%C (158 to 7) Check the level and leaks of ATF.
176%F) on Subaru Select Monitor. <Ref. to 5AT(di- <Ref. to 5AT-27, INSPECTION, Automatic Trans-
ag)-16, READ CURRENT DATA, OPERATION, mission Fluid.>
7) Check the ATF for leaks.
Visually check for leaks in the transmission. If there
are leaks, replace the gasket, oil seals, plugs or
other parts.
5AT-27
C: CONDITION CHECK
NOTE:
When replacing ATF, check the inside condition of transmission body by inspecting the drained ATF.
Fluid condition Trouble and possible cause Corrective action
Large amount of metallic pieces are Excessive wear of the internal of the trans- Replace ATF and check if AT operates
found. mission body correctly.
Replace ATF and check if AT or vehicle
Thick and varnish-form fluid. Burned clutch and etc.
for faulty.
Clouded fluid or bubbles are found in Replace ATF and check the water enter-
Water mixed in fluid
fluid. ing point.
5AT-28
Differential Gear Oil
3. Differential Gear Oil Tightening torque:

70 N$m (7.1 kgf-m, 51.6 ft-lb)
A: INSPECTION
1) Park the vehicle on a level surface.
2) Remove the collector cover. (A)
(B)
proper orientation.
5) Remove the oil level gauge again, and check the
level of differential gear oil. If the differential gear oil
level is below “L” line, add oil to bring the level up to
“F” line. AT-01362
NOTE: (A) Oil pan

To prevent overfilling the differential gear oil, do not
add oil above “F” line.
5) Pour gear oil into the gauge hole.
Recommended gear oil:
F
(A)
(B) Gear oil capacity:
1.3 — 1.5 2 (1.3 — 1.6 US qt, 1.1 — 1.3 Imp qt)
L
6) Check the level of differential gear oil.

<Ref. to 5AT-29, INSPECTION, Differential Gear
AT-00017
Oil.>
(A) Upper level
(B) Lower level
B: REPLACEMENT
TORX® BIT T70, and the drain the differential gear
oil.
CAUTION:
• Directly after the engine has been running,
the differential gear oil is 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. When the differential gear oil is
spilled on exhaust pipe, wipe it away complete-
ly.
3) Tighten the differential gear oil drain plug using
TORX® BIT T70.
NOTE:
Use a new gasket.
5AT-29
Road Test
4. Road Test 9. OIL LEAKAGE

A: INSPECTION After the driving test, inspect for oil leaks from the
transmission body.
1. GENERAL PRECAUTION
Road tests should be conducted to properly diag-
nose the condition of automatic transmission.
NOTE:
When performing the test, do not exceed posted
speed limit.
2. D RANGE SHIFT FUNCTION
Check shifting between 1st !" 2nd !" 3rd !"
4th !" 5th while driving on normal 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 the
kick-down shock level.
5. ENGINE BRAKE OPERATION
• Check the 4th gear engine brake when shifting
down from 5th to 4th range while driving in 5th gear
of manual mode [50 to 60 km/h (31 to 37 MPH)].
• Check the 3rd gear engine brake when shifting
down from 4th to 3rd range while driving in 4th gear
of manual mode [50 to 60 km/h (31 to 37 MPH)].
• Check the 2nd gear engine brake when shifting
down from 3rd to 2nd range while driving in 3rd
gear of manual mode [40 to 50 km/h (25 to 31
MPH)].
• Check the 1st gear engine brake when shifting
down from 2nd to 1st range while driving in 2nd
gear of manual mode [20 to 30 km/h (12 to 19
MPH)].
6. LOCK-UP FUNCTION
Check that engine speed does not change sharply
when the accelerator pedal is lightly depressed
while driving on flat roads at normal speed in the
lock-up range.
7. P RANGE OPERATION
Stop the vehicle on an uphill grade of 5% or more
and shift to “P” range. Check that the vehicle does
not move when the parking brake is released.
8. NOISE & VIBRATION
Check for unusual sounds and vibration while driv-
ing and during shifting.
5AT-30
Stall Test
5. Stall Test 9) While forcibly depressing the foot brake pedal,

gradually depress the accelerator pedal until the
A: INSPECTION engine operates at full throttle.
NOTE:
The stall test is of extreme importance in diagnos-
ing the condition of automatic transmission and en-
gine. 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 automatic transmis-
sion clutch.
(A) (B)
• To check the operation of torque converter
clutch.
AT-01326
• To check engine performance.
1) Check that the throttle valve opens fully. (A) Brake pedal
2) Check that the engine oil level is correct. (B) Accelerator pedal
3) Check that the coolant level is correct.
4) Check that the ATF level is correct. 10) When the engine speed is stabilized, quickly
5) Check that the differential gear oil level is cor- record that speed and release the accelerator ped-
rect. al.
6) Raise the ATF temperature by driving a distance 11) Shift the select lever to “N” range, and cool
of 5 to 10 km (3 to 6 miles). Otherwise, idle the en- down the engine by idling it for more than one
gine to raise ATF temperature to 70 to 80%C (158 to minute.
176%F) on Subaru Select Monitor. <Ref. to 5AT(di- 12) Perform the procedure for “R” range in the
ag)-16, READ CURRENT DATA, OPERATION, same way as “2nd on manual mode”.
Subaru Select Monitor.> NOTE:
7) Place the wheel chocks at the front and rear of • Do not continue the stall test for MORE THAN
all wheels and engage the parking brake. FIVE SECONDS at a time (from fully closed throttle
8) Move the manual linkage to ensure it operates to fully open throttle until stall speed reading). En-
properly, and then set “2nd on manual mode”. gine oil and ATF to deteriorate and the clutch and
brake to be adversely affected.
• Be sure to cool down the engine for at least one
minute with the select lever set in “P” or “N” range
and with the idle speed lower than 1,200 rpm after
performing stall test.
• 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.
AT-01325
Stall speed (at sea level):
TURBO MODEL
3,100 — 3,500 rpm
NON-TURBO MODEL
2,400 — 2,800 rpm
5AT-31
Stall Test
Stall speed (at sea level) Range Possible faulty part

• Engine
Less than standard R
• One-way clutch of the torque converter clutch
• Forward brake
2nd gear of manual
• Forward brake one-way clutch
mode
More than standard • Direct clutch
• 3rd one-way clutch
R
• Reverse clutch
2nd gear of manual • Reverse clutch
mode • One-way clutch of the torque converter
• Forward brake
Within specifications • Forward brake one-way clutch
R • Direct clutch
• 3rd one-way clutch
• One-way clutch of the torque converter
5AT-32
Time Lag Test
6. Time Lag Test

A: INSPECTION
NOTE:
When the select lever is shifted while the engine is
idling, there will be a certain time elapse or lag be-
fore the shock can be felt. Using this, check the
condition of forward brake, reverse brake, 1st one-
way clutch, forward one-way clutch and 3rd 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 between
tests.
• Make three measurements and take the average
value.
1) Fully apply the parking brake.
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 which takes
from shifting the lever until the shock is felt.
Time-lag
Standard: 1.2 sec. or less
If “N” " “D” time-lag is longer than specified:
• Forward brake worn
• One-way clutch not operating properly
4) In the same manner, measure the time lag for
“N” " “R”.
Time-lag
Standard: 1.5 sec. or less
If “N” " “R” time lag is longer than specified:
• Reverse brake worn
5AT-33
Line Pressure Test
7. Line Pressure Test (6) On the «Transmission Diagnosis» display

screen, select the {Current Data Display/Save},
A: MEASUREMENT and then press the [YES] key.
NOTE: (7) On the «Transmission Diagnosis» display
If the clutch or brake shows a sign of slippage, or screen, select the {Data Display} and press the
shifting interval is not correct, the line pressure [YES] key.
should be checked. (8) Using the scroll key, display the “P/L sole-
• Excessive shocks during up-shift or shifting noid target oil pressure”.
takes place at a higher point than under normal cir-
cumstances, may be due to the line pressure being
too high.
• Slippage or inability to operate the vehicle may,
in most cases, be due to loss of oil pressure for the
operation of the clutch, brake or control valve.
3) Remove the test plug and install the ST.
ST 498897200 OIL PRESSURE ADAPTER
AT-01752
4) Set the ST1 and ST2.

ST1 498897200 OIL PRESSURE ADAPTER
ASSY
5) Lower the vehicle, and pull the ST1 and ST2 into
vehicle.
ASSY
6) Connect the Subaru Select Monitor to data link
connector and read the current data. <Ref. to
(1) Start the engine.
(2) Turn the Subaru Select Monitor switch to
ON.
(3) On the «Main Menu» display screen, select
the {Each System Check} and press the [YES]
key.
(4) On the «System Selection Menu» display
[YES] key.
(5) Press the [YES] key after the information of
transmission type has been displayed.
5AT-34
Line Pressure Test
7) Perform the line pressure test.

NOTE:
• Do not perform the line pressure test for more than 5 seconds at a time. It makes engine oil and ATF de-
teriorate and the clutch and brake to be adversely affected.
• Be sure to cool down the engine for at least one minute with the select lever set in “P” or “N” range and with
the idle speed lower than 1,200 rpm after performing line pressure test.
• Adjust the throttle valve angle in order to obtain the “P/L solenoid target pressure” displayed on the Subaru
Select Monitor.
“P/L Solenoid Target Pressure”
Range of the Throttle valve ATF temperature displayed on the Subaru Select Standard line pressure
selector lever angle condition Monitor kPa (kg/cm2, psi)
kPa
385 — 555
Full closed 490
(3.93 — 5.66, 55.8 — 80.5)
D
45 — 55%C 1,235 — 1,475
Full open 1,370
(104 — 131 %F) (12.59 — 15.04, 179.1 — 213.9)
1,530 — 1,925
R Full closed 1,370
(15.60 — 19.6, 221.9 — 279.2)
5AT-35
8. Transfer Clutch Pressure 6) Connect the Subaru Select Monitor to data link
connector and read the current data. <Ref. to
Test 5AT(diag)-16, READ CURRENT DATA, OPERA-
A: INSPECTION TION, Subaru Select Monitor.>
1) Lift-up the vehicle. (1) Start the engine.
2) Remove the heat shield cover securing bolts to (2) Turn the Subaru Select Monitor switch to
slide the heat shield cover. ON.
the {Each System Check} and press the [YES]
key.
[YES] key.
(6) On the «Transmission Diagnosis» display
screen, select the {Current Data Display/Save},
AT-01754 and then press the [YES] key.
3) Remove the test plug and install the ST. (7) On the «Transmission Diagnosis» display
screen, select the {Data Display} and press the
ST 498897200 OIL PRESSURE ADAPTER
[YES] key.
CAUTION: (8) Using the scroll key, display the “T/F sole-
Be careful not to cut your arm with the heat noid target oil pressure”.
shield cover when removing the test plug and
installing the ST.
AT-01755
4) Set the ST1 and ST2.

ASSY
AT-01756
5) Lower the vehicle, and pull the ST1 and ST2 into
vehicle.
ASSY
5AT-36
7) Perform the transfer clutch pressure test.

NOTE:
• Do not perform the transfer clutch pressure test for more than 5 seconds at a time. It makes engine oil and
ATF deteriorate and the clutch and brake to be adversely affected.
• Be sure to cool down the engine for at least one minute with the select lever set in “P” or “N” range and with
the idle speed lower than 1,200 rpm after performing transfer clutch pressure test.
• Adjust the throttle valve angle in order to obtain the “T/F solenoid target pressure” displayed on the Subaru
Select Monitor.
“T/F Solenoid Target Pressure”
Range of the Throttle valve ATF temperature displayed on the Subaru Select Standard line pressure
selector lever angle condition Monitor kPa (kg/cm2, psi)
kPa
800 — 915
Full open 900
(8.16 — 9.33, 116.0 — 132.7)
D
45 — 55%C 400 — 535
Partial throttle 500
(104 — 131 %F) (4.08 — 5.46, 58.0 — 77.6)
0 — 50
N Full closed 0
(0 — 0.51, 0 — 7.3)
5AT-37
9. Automatic Transmission As- • Non-turbo model

sembly
(2)
A: REMOVAL
2) Fully open the front hood and support with the
hood stay.
4) Remove the collector cover. (1)
5) Remove the intercooler. (Turbo model)
<Ref. to IN(H4DOTC)-12, REMOVAL, Intercool- AT-02025
er.>
6) Remove the air intake chamber. (Non-turbo (1) Front oxygen (A/F) sensor
model) <Ref. to IN(H6DO)-7, REMOVAL, Air Intake (2) Transmission harness connector
Chamber.>
7) Remove the air cleaner case. (Non-turbo model) 11) Remove the intercooler stay and engine hang-
<Ref. to IN(H6DO)-5, REMOVAL, Air Cleaner er rear. (Turbo model)
Case.>
8) Remove the air breather hose. <Ref. to 5AT-69,
REMOVAL, Air Breather Hose.>
9) Remove the starter. <Ref. to SC(H4SO 2.0)-6,
REMOVAL, Starter.>
10) Disconnect the following connectors.
• Turbo model
AT-01365
12) Disconnect the engine harness connectors,

and then remove the engine hanger rear. (Non-tur-
bo model)
(B)
AT-01364 (A)
(2) Front oxygen (A/F) sensor
(A)
AT-02023
(A) Engine harness connectors

(B) Engine hanger rear
AT-01379
5AT-38
13) Remove the water by-pass pipe. (Turbo model) 19) Remove the ATF cooler inlet and outlet pipes.
(Non-turbo model) <Ref. to 5AT-64, REMOVAL,
ATF Cooler Pipe & Hose.>
AT-01366
14) Separate the torque converter from drive plate.

(1) Remove the service hole plug.
AT-01368
(2) Remove the bolts which hold torque con-
verter to drive plate. 21) Remove the pitching stopper bracket.
(3) Remove the four bolts by rotating the clamp
pulley a little at a time.
(4) Make sure the torque converter moves free-
ly by rotating with finger through the starter in-
stallation hole.
CAUTION:
Be careful not to drop bolts into converter
housing.
AT-01369
22) Set the ST.

ST 41099AC000 ENGINE SUPPORT ASSEM-
BLY
AT-01367

AT-01370
23) Remove the air intake duct. (Turbo model)

<Ref. to IN(H4DOTC)-9, REMOVAL, Air Intake
Duct.>
24) Remove the air cleaner case. (Turbo model)
ST
<Ref. to IN(H4DOTC)-8, REMOVAL, Air Cleaner
Case.>
AT-00103 25) Remove the linear motion mounting. (Turbo
model) <Ref. to ME(H4DOTC)-37, REMOVAL, Lin-
16) Lift-up the vehicle. ear Motion Mounting.>
17) Remove the under cover. (Non-turbo model)
18) Remove the front exhaust pipe, rear exhaust
pipe and muffler. (Non-turbo model) <Ref. to
EX(H6DO)-5, REMOVAL, Front Exhaust Pipe.>
5AT-39
26) Remove the transmission mounting bolt (upper 33) Remove the oil charge pipe.
side).
AT-01371
AT-00106
34) Disconnect the connector from turbine speed
27) Lift-up the vehicle. (Turbo model) sensor 1.
28) Remove the under cover. (Turbo model)
29) Remove the center exhaust pipe, rear exhaust
pipe and muffler. (Turbo model) <Ref. to
EX(H4DOTC)-6, REMOVAL, Center Exhaust
Pipe.> <Ref. to EX(H4DOTC)-11, REMOVAL,
Rear Exhaust Pipe.> <Ref. to EX(H4DOTC)-12,
REMOVAL, Muffler.>
30) Remove the front exhaust pipe, rear exhaust
pipe and muffler. (Non-turbo model) <Ref. to
<Ref. to EX(H6DO)-8, REMOVAL, Rear Exhaust AT-01642
Pipe.> <Ref. to EX(H6DO)-10, REMOVAL, Muf- 35) Remove the turbine speed sensor 1 connector
fler.> mounting bolt and rotate the sensor by 180%.
CAUTION:
Failure to follow this procedure may cause the
interference between vehicle body and sensor
while removing/installing transmission, result-
ing in damage.
AT-01331
(A)
(B)
AT-01640
36) Remove the propeller shaft. <Ref. to DS-10,

REMOVAL, Propeller Shaft.>
37) Remove the shift select cable. <Ref. to CS-12,
REMOVAL, Select Cable.>
AT-01361
(A) Oil pan

(B) Drain plug
5AT-40
38) Disconnect the hose from the ATF inlet and 41) Remove the two clutch housing cover securing
outlet pipes. bolts.
AT-01390 AT-01373
39) Remove the ATF cooler bracket from transmis-

sion body. (ATF cooler model with warmer func-
tion)
• Non-turbo model
AT-01374
42) Remove the front stabilizer bracket. <Ref. to

FS-16, REMOVAL, Front Stabilizer.>
43) Remove the bolts which secure front ball joint
to the housing. <Ref. to FS-17, REMOVAL, Front
Ball Joint.>
44) Pull out the drive shaft from transmission.
sion.
AT-02034
40) Remove the front crossmember support plate.

<Ref. to FS-15, REMOVAL, Front Crossmember
Support Plate.>
AT-01376
46) Remove the rear crossmember.
AT-01377
5AT-41
47) Remove the transmission mounting bolt (lower 4) Install the transmission rear crossmember.
side).
Tightening torque:
70 N$m (7.1 kgf-m, 51.6 ft-lb)
AT-00108
48) Remove the transmission. AT-01377

NOTE: 5) Take off the transmission jack.
• Turn the engine support assembly from the vehi- 6) Lower the vehicle.
cle under body to the left (to shorten the engine 7) Install the engine mounting bolt (upper side).
support length), and lower the rear of the engine for
easy disassembly. Tightening torque:
• Be careful not to allow breather pipe and etc. to 50 N$m (5.1 kgf-m, 36.9 ft-lb)
touch the vehicle body when detaching the auto- 8) Remove the ST from converter case.
matic transmission assembly by pulling it back- ST 498277200 STOPPER SET
ward. 9) Install the starter. <Ref. to SC(H4SO 2.0)-6, IN-
B: INSTALLATION STALLATION, Starter.>
1) Install the ST to torque converter case. 10) Install the torque converter to drive plate.
ST 498277200 STOPPER SET (1) Install the bolts which hold torque converter
to drive plate.
(2) Install all four bolts by rotating the crank pul-
ley a little at a time.
(3) Install the service hole.
Tightening torque:
25 N$m (2.5 kgf-m, 18.4 ft-lb)
11) Remove the ST and install the pitching stopper
bracket.
ST
Tightening torque:
AT-00103 40 N$m (4.1 kgf-m, 29.5 ft-lb)
(1) Lift up the transmission gradually using a
transmission jack.
(2) Engage them at splines.
3) Install the engine mounting bolt (lower side).
Tightening torque:
50 N$m (5.1 kgf-m, 36.9 ft-lb)
AT-01369
5AT-42
12) Install the pitching stopper. 17) Install the front drive shaft into transmission.
Tightening torque: NOTE:
T1: 50 N$m (5.1 kgf-m, 36.9 ft-lb) Replace the circlip of drive shaft with a new one.
T2: 58 N$m (5.9 kgf-m, 42.8 ft-lb) 18) Install the front drive shaft into transmission, re-
move the ST and insert the drive shaft securely.
19) Install the ATF cooler inlet and outlet pipes.
(Non-turbo model) <Ref. to 5AT-66, INSTALLA-
TION, ATF Cooler Pipe & Hose.>
20) Install the ATF cooler bracket to transmission
proper. (ATF cooler model with warmer function)
T2
Tightening torque:
25 N$m (2.5 kgf-m, 18.1 ft-lb)
T1
AT-01380 • Non-turbo model
14) Replace the front differential side retainer oil
seal.
(1) Remove the oil seal by using flat tip screw-
driver and etc.
(2) Fit a new oil seal using ST.
ST 18675AA000 DIFFERENTIAL SIDE OIL
SEAL INSTALLER
NOTE:
• Apply oil to the oil seal lips.
• Always replace the differential side oil seal after
extracting front drive shaft from the transmission.
AT-02034
21) Install the inlet and outlet hoses to the ATF inlet
AT-01378
and outlet pipes.
15) Apply grease to the oil seal lips.
16) Set the ST to the side retainer.
AT-01390
22) Insert the ball joint into housing.<Ref. to FS-17,

ST INSTALLATION, Front Ball Joint.>
AT-00110
23) Install the front stabilizer bracket. <Ref. to FS-
16, INSTALLATION, Front Stabilizer.>
5AT-43
24) Screw the securing bolts for clutch housing 29) Install the oil charge pipe.
cover.
Tightening torque:
41 N$m (4.2 kgf-m, 30.2 ft-lb)
AT-01373
AT-01371
AT-01374
25) Install the front crossmember support plate.

<Ref. to FS-15, INSTALLATION, Front Crossmem- AT-01331
ber Support Plate.>
26) Install the propeller shaft. <Ref. to DS-11, IN- 31) Install the center exhaust pipe, rear exhaust
STALLATION, Propeller Shaft.> pipe and muffler. (Turbo model) <Ref. to
27) Install the shift select cable. <Ref. to CS-13, IN- EX(H4DOTC)-7, INSTALLATION, Center Exhaust
STALLATION, Select Cable.> Pipe.> <Ref. to EX(H4DOTC)-11, INSTALLATION,
28) Install the turbine speed sensor 1 and harness, Rear Exhaust Pipe.> <Ref. to EX(H4DOTC)-12, IN-
and then connect the connector. STALLATION, Muffler.>
32) Install the front exhaust pipe, rear exhaust pipe
Tightening torque: and muffler. (Non-turbo model) <Ref. to
7 N$m (0.7 kgf-m, 5.2 ft-lb) EX(H6DO)-6, INSTALLATION, Front Exhaust
Pipe.> <Ref. to EX(H6DO)-8, INSTALLATION,
Rear Exhaust Pipe.> <Ref. to EX(H6DO)-10, IN-
35) Install the linear motion mounting. (Turbo mod-
el) <Ref. to ME(H4DOTC)-37, INSTALLATION,
Linear Motion Mounting.>
36) Install the air cleaner hose.
<Ref. to IN(H4DOTC)-8, INSTALLATION, Air
AT-01736 Cleaner Case.>
37) Install the air intake duct.
<Ref. to IN(H4DOTC)-9, INSTALLATION, Air In-
take Duct.>
5AT-44
38) Connect the following connectors. 40) Install the engine hanger rear, and then con-
• Turbo model nect the engine harness connector. (Non-turbo
(1) Transmission harness connectors model)
(B)
(A)
(A)
AT-01364 AT-02023
(2) Front oxygen (A/F) sensor (A) Engine harness connectors

(B) Engine hanger rear
41) Install the water by-pass pipe. (Turbo model)
AT-01379
• Non-turbo model
AT-01366
(2)
42) Pour ATF from the oil charge pipe. <Ref. to
5AT-27, REPLACEMENT, Automatic Transmis-
sion Fluid.>
44) Install the intercooler. (Turbo model) <Ref. to
(1)
IN(H4DOTC)-12, INSTALLATION, Intercooler.>
45) Install the air intake chamber. (Non-turbo mod-
AT-02025 el) <Ref. to IN(H6DO)-7, INSTALLATION, Air In-
take Chamber.>
46) Install the air cleaner case. (Non-turbo model)
(2) Transmission harness connector
<Ref. to IN(H6DO)-6, INSTALLATION, Air Cleaner
39) Install the intercooler stay RH and engine Case.>
hanger rear. (Turbo model) 47) Install the collector cover.
48) Connect the battery ground cable to battery.
49) Perform the Clear Memory 2. <Ref. to 5AT(di-
ag)-18, CLEAR MEMORY MODE, OPERATION,
(1) Connect the Subaru Select Monitor to data
link connector.
(2) Turn the ignition switch to ON (engine OFF)
and turn Subaru Select Monitor switch to ON.
(3) Ensure that the select lever is in “P” range.
AT-01365 the {Each System Check} and press the [YES]
key.
5AT-45

[YES] key.
screen, select the {Clear Memory 2} and press
the [YES] key.
50) Perform the inspection with driving the vehicle
at the end of repair work and make sure there is no
faulty as below;
• Oil leakage from transmission proper and etc.
• Occurrence of noise caused by interference etc.
NOTE:
If excessive shift shock is felt, execute the advance
operation of learning control. <Ref. to 5AT(diag)-
22, PROCEDURE, Learning Control.>
5AT-46
10.Transmission Mounting Sys- 7) Remove the transmission rear crossmember.

tem
A: REMOVAL
1. PITCHING STOPPER
<Ref. to IN(H4DOTC)-12, REMOVAL, Intercool-
er.>
3) Remove the air intake chamber. (Non-turbo AT-01377
model) <Ref. to IN(H6DO)-7, REMOVAL, Air Intake
Chamber.> 8) Remove the rear cushion rubber.
4) Remove the pitching stopper. B: INSTALLATION
1. PITCHING STOPPER
1) Install the pitching stopper.
Tightening torque:
T1: 50 N$m (5.1 kgf-m, 36.9 ft-lb)
T2: 58 N$m (5.9 kgf-m, 42.8 ft-lb)
AT-01368

2) Jack-up the vehicle and support it with rigid T2
racks. T1
3) Remove the center exhaust pipe, rear exhaust AT-01380
pipe and muffler. (Turbo model) 2) Install the intercooler. (Turbo model)
<Ref. to EX(H4DOTC)-6, REMOVAL, Center Ex- <Ref. to IN(H4DOTC)-12, INSTALLATION, Inter-
haust Pipe.> <Ref. to EX(H4DOTC)-11, REMOV- cooler.>
AL, Rear Exhaust Pipe.> <Ref. to EX(H4DOTC)- 3) Install the air intake chamber. (Non-turbo model)
12, REMOVAL, Muffler.> <Ref. to IN(H6DO)-7, INSTALLATION, Air Intake
4) Remove the front exhaust pipe, rear exhaust Chamber.>
pipe and muffler. (Non-turbo model) <Ref. to 4) Connect the battery ground cable to battery.
Pipe.> <Ref. to EX(H6DO)-10, REMOVAL, Muf-
fler.>
sion. Make sure that the support plate of transmis-
sion jack does not touch the oil pan.
5AT-47

1) Install the rear cushion rubber.
Tightening torque:
35 N$m (3.6 kgf-m, 26 ft-lb)
2) Install the crossmember.
Tightening torque:
70 N$m (7.1 kgf-m, 51.6 ft-lb)
AT-01377

5) Install the center exhaust pipe, rear exhaust pipe
and muffler. (Turbo model)
<Ref. to EX(H4DOTC)-7, INSTALLATION, Center
6) Install the front exhaust pipe, rear exhaust pipe
and muffler. (Non-turbo model) <Ref. to
EX(H6DO)-6, INSTALLATION, Front Exhaust
Pipe.> <Ref. to EX(H6DO)-8, INSTALLATION,
Rear Exhaust Pipe.> <Ref. to EX(H6DO)-10, IN-
C: INSPECTION
Repair or replace parts if the results of the inspec-
tion below are not satisfied.
1. PITCHING STOPPER
Check pitching stopper for bends or damage. En-
sure there are no cracks, hardening or damage on
rubbers.
Check the crossmember for bends or damage. En-
sure there are no cracks, hardening, or damage on
cushion rubbers.
5AT-48
Extension Case Oil Seal
11.Extension Case Oil Seal 8) Remove the propeller shaft. <Ref. to DS-10, RE-
A: INSPECTION 9) Using the ST, remove the oil seal.
Inspect there is no ATF leakage from the joint of ST 398527700 PULLER ASSY
transmission and propeller shaft. If so, replace the 10) Using the ST, install the oil seal.
oil seal. <Ref. to 5AT-49, REPLACEMENT, Exten- ST 498057300 INSTALLER
sion Case Oil Seal.> 11) Install the propeller shaft. <Ref. to DS-11, IN-
B: REPLACEMENT STALLATION, Propeller Shaft.>
1) Lift-up the vehicle. 12) Install the heat shield cover.
CAUTION:
NOTE:
Use a new gasket.
Tightening torque: AT-01331
20 N$m (2.0 kgf-m, 14.8 ft-lb) 13) Install the rear exhaust pipe and muffler. (Turbo
model)
(A) <Ref. to EX(H4DOTC)-11, INSTALLATION, Rear
(B) Exhaust Pipe.> <Ref. to EX(H4DOTC)-12, IN-
14) Install the rear exhaust pipe and muffler. (Non-
turbo model) <Ref. to EX(H6DO)-8, INSTALLA-
TION, Rear Exhaust Pipe.> <Ref. to EX(H6DO)-10,
15) Pour ATF into the oil charge pipe.
AT-01361 Specified fluid:
SUBARU ATF (Part No. K0140Y0700)
(A) Oil pan
Recommended fluid:
(B) ATF drain plug
IDEMITSU ATF HP
5) Remove the rear exhaust pipe and muffler. (Tur- Castrol Transmax J
bo model) NOTE:
<Ref. to EX(H4DOTC)-11, REMOVAL, Rear Ex- Use of recommended fluid is permitted only on the
haust Pipe.> <Ref. to EX(H4DOTC)-12, REMOV- area where the specified is not available.
AL, Muffler.>
6) Remove the rear exhaust pipe and muffler. Capacity:
(Non-turbo model) <Ref. to EX(H6DO)-8, REMOV- Fill the same amount of ATF drained.
AL, Rear Exhaust Pipe.> <Ref. to EX(H6DO)-10, 16) Check the level and leaks of ATF. <Ref. to 5AT-
REMOVAL, Muffler.> 27, Automatic Transmission Fluid.>
AT-01331
5AT-49
12.Differential Side Retainer Oil ST 18675AA000 DIFFERENTIAL SIDE OIL

SEAL INSTALLER
Seal
A: INSPECTION ST
Check the leakage of gear oil from differential side
retainer oil seal part. If there is oil leakage, replace
the oil seal.
B: REPLACEMENT
2) Remove the front exhaust pipe and center ex-
haust pipe. (Turbo model) <Ref. to EX(H4DOTC)-
5, REMOVAL, Front Exhaust Pipe.> <Ref. to AT-00029
EX(H4DOTC)-6, REMOVAL, Center Exhaust 9) Apply oil to the oil seal lips.
Pipe.> 10) Install the front drive shaft. <Ref. to DS-22, IN-
3) Remove the front exhaust pipe. (Non-turbo mod- STALLATION, Front Drive Shaft.>
el) <Ref. to EX(H6DO)-5, REMOVAL, Front Ex- 11) Install the front and center exhaust pipes. (Tur-
haust Pipe.> bo model) <Ref. to EX(H4DOTC)-5, INSTALLA-
4) Remove the differential gear oil drain plug using TION, Front Exhaust Pipe.> <Ref. to
TORX® BIT T70 to drain differential gear oil. EX(H4DOTC)-7, INSTALLATION, Center Exhaust
CAUTION: Pipe.>
• Directly after the engine has been running, 12) Install the front exhaust pipe. (Non-turbo mod-
the differential gear oil is hot. Be careful not to el) <Ref. to EX(H6DO)-6, INSTALLATION, Front
burn yourself. Exhaust Pipe.>
• Be careful not to spill the differential gear oil 13) Lower the vehicle.
on exhaust pipe to prevent it from emitting 14) Pour gear oil into the gauge hole.
smoke or fire. When the differential gear oil is Recommended gear oil:
spilled on exhaust pipe, wipe it away complete- <Ref. to 5AT-3, RECOMMENDED GEAR OIL,
ly. SPECIFICATION, General Description.>
Gear oil capacity:
(A)
1.3 — 1.5 2 (1.4 — 1.6 US qt, 1.1 — 1.3 Imp qt)
(B)
5AT-29, INSPECTION, Differential Gear Oil.>
AT-01362
(A) Oil pan

5) Tighten the differential gear oil drain plug.

NOTE:
Use a new gasket.
Tightening torque:
44 N$m (4.5 kgf-m, 32.5 ft-lb)
7) Remove the differential side retainer oil seal us-
ing driver wrapped with vinyl tape or etc.
8) Using the ST, install the differential side retainer
oil seal by slightly tapping with hammer.
5AT-50
Inhibitor Switch
13.Inhibitor Switch
A: INSPECTION
Inhibitor switch cannot be checked, because the in-
hibitor switch is installed on control valve assembly.
When the malfunction occurs, refer to 5AT (Diag-
nosis) section. <Ref. to 5AT(diag)-34, DTC P0705
TRANSMISSION RANGE SENSOR CIRCUIT
(PRNDL INPUT), Diagnostic Procedure with Diag-
5AT-51
14.Front Vehicle Speed Sensor 8) Disconnect the front vehicle speed sensor con-
nector.
A: REMOVAL
mission Assembly.>
NOTE:
Secure the harness of the rear vehicle speed sen-
sor to the transmission proper using wire etc.
AT-01953
9) Remove the front vehicle speed sensor securing

bolt.
AT-01950
3) Remove the extension case.
AT-01954
10) Remove the front vehicle speed sensor through

the hole of the AT transmission main case.
B: INSTALLATION
1) Install the front vehicle speed sensor.
Tightening torque:
AT-01951 7 N$m (0.7 kgf-m, 5.2 ft-lb)
4) Remove the intermediate case.
AT-01954
AT-01952 2) Connect the front vehicle speed sensor connec-

5) Remove the center differential carrier. <Ref. to tor.
5AT-80, REMOVAL, Center Differential Carrier.>
6) Lay along the transmission case, and then re-
move the oil pan.
7) Remove the old gasket on the oil pan and trans-
mission case completely.
5AT-52
3) Apply proper amount of liquid gasket to the en- 8) Install the rear vehicle speed sensor.
tire oil pan mating surface.
Tightening torque:
Liquid gasket: 7 N$m (0.7 kgf-m, 5.2 ft-lb)
AT-01950
AT-01955
4) Install the oil pan by equally tightening the bolts. cle. <Ref. to 5AT-42, INSTALLATION, Automatic
Tightening torque:
10) Pour ATF from the oil charge pipe. <Ref. to
5 N$m (0.5 kgf-m, 3.7 ft-lb)
5AT-27, REPLACEMENT, Automatic Transmis-
5) Install the center differential carrier. <Ref. to sion Fluid.>
5AT-80, INSTALLATION, Center Differential Carri- 11) Check the level and leaks of the ATF. <Ref. to
er.> 5AT-27, INSPECTION, Automatic Transmission
6) Install the intermediate case. Fluid.>
Tightening torque:
25 N$m (2.5 kgf-m, 18.4 ft-lb)
AT-01952
7) Install the extension case.

Tightening torque:
25 N$m (2.5 kgf-m, 18.4 ft-lb)
AT-01951
5AT-53
15.Rear Vehicle Speed Sensor • Non-turbo model
A: REMOVAL
(2)
(1)
AT-02025

(2) Transmission harness connector
IN-00203
6) Remove the transmission harness connector
3) Remove the intercooler. (Turbo model) and front oxygen (A/F) sensor connector from the
<Ref. to IN(H4DOTC)-12, REMOVAL, Intercool- stay.
er.> 7) Lift-up the vehicle.
4) Remove the air intake chamber. (Non-turbo 8) Clean the transmission exterior.
model) <Ref. to IN(H6DO)-7, REMOVAL, Air Intake 9) Drain ATF completely. <Ref. to 5AT-27, RE-
Chamber.> PLACEMENT, Automatic Transmission Fluid.>
5) Disconnect the following connectors. 10) Remove the center exhaust pipe, rear exhaust
• Turbo model pipe and muffler. (Turbo model) <Ref. to
(1) Transmission harness connectors EX(H4DOTC)-6, REMOVAL, Center Exhaust
Pipe.> <Ref. to EX(H4DOTC)-11, REMOVAL,
Rear Exhaust Pipe.> <Ref. to EX(H4DOTC)-12,
REMOVAL, Muffler.>
(Non-turbo model) <Ref. to EX(H6DO)-8, REMOV-
AL, Rear Exhaust Pipe.> <Ref. to EX(H6DO)-10,
REMOVAL, Muffler.>
AT-01364 14) Place the transmission jack under transmis-
(2) Front oxygen (A/F) sensor sion.
NOTE:
Make sure that the support plate of transmission
jack does not touch the crossmember.
15) Remove the transmission rear crossmember
bolt.
AT-01379
AT-01377
5AT-54
16) Lower the transmission jack. 23) Remove the control valve body.
NOTE:
Do not separate the transmission jack and trans-
mission.
18) Remove the ATF cooler inlet and outlet pipes.
NOTE:
When removing the outlet pipe, be careful not to
lose the ball and spring used with retaining screw.
19) Disconnect the connector from turbine speed AT-01957
sensor 1. 24) Remove the bolt securing harness of transmis-
sion main case.
AT-01387
20) Remove the rear vehicle speed sensor. AT-02035
25) Remove the harness assembly.

B: INSTALLATION
1) Pass the harness assembly through the hole in
transmission case.
AT-01950
21) Remove the oil pan.

22) Disconnect the control valve connector and
front vehicle speed sensor connector.
AT-00048
2) Install the securing bolt of transmission main

case.
(B)
Tightening torque:
(A) 7 N$m (0.7 kgf-m, 5.2 ft-lb)
AT-01956
(A) Control valve connector

(B) Front vehicle speed sensor connector
AT-02035
5AT-55
3) Install the control valve body. 7) Install the rear vehicle speed sensor and turbine
speed sensor 1, and then fasten the harness.
Tightening torque:
8 N$m (0.8 kgf-m, 58 ft-lb) Tightening torque:
NOTE: 7 N$m (0.7 kgf-m, 5.1 ft-lb)
Be careful not to catch harness in. 8) Install a new aluminum washer and oil cooler
pipe.
(1) (1)
(2) Tightening torque:
(1)
(1)
T: 25 N$m (2.5 kgf-m, 18.1 ft-lb)
(2)
(1) 9) Install the oil charge pipe. <Ref. to 5AT-70, IN-
(2) STALLATION, Oil Charge Pipe.>
(1) 10) Install the transmission rear crossmember bolt.
(2)
(1) Tightening torque:
(2)
(1) 70 N$m (7.1 kgf-m, 51 ft-lb)
AT-01958 STALLATION, Propeller Shaft.>
(1) 58 mm (2.28 in)
13) Install the center exhaust pipe, rear exhaust
(2) 65 mm (2.56 in) pipes and muffler. (Turbo model)
4) Connect the control valve connector and front <Ref. to EX(H4DOTC)-7, INSTALLATION, Center
vehicle speed sensor connector. Exhaust Pipe.> <Ref. to EX(H4DOTC)-11, IN-
14) Install the rear exhaust pipe and muffler. (Non-
turbo model) <Ref. to EX(H6DO)-8, INSTALLA-
(B) TION, Rear Exhaust Pipe.> <Ref. to EX(H6DO)-10,
(A)
16) Install the transmission connector to the stay,
and then connect the connector.
AT-01956 IN(H4DOTC)-12, INSTALLATION, Intercooler.>
18) Install the air intake chamber. (Non-turbo mod-
(A) Control valve connector el) <Ref. to IN(H6DO)-7, INSTALLATION, Air In-
(B) Front vehicle speed sensor connector take Chamber.>
19) Pour ATF through the oil charge pipe. <Ref. to
5) Apply proper amount of liquid gasket to the en- 5AT-27, REPLACEMENT, Automatic Transmis-
tire oil pan mating surface. sion Fluid.>
Liquid gasket 20) Check the level and leaks of ATF. <Ref. to 5AT-
THREE BOND 1217B (Part No. K0877YA020) 27, INSPECTION, Automatic Transmission Fluid.>
to 5AT(diag)-22, PROCEDURE, Learning Con-
trol.>
AT-01955
6) Install the oil pan by equally tightening the bolts.

Tightening torque:
5 N$m (0.5 kgf-m, 3.6 ft-lb)
5AT-56
Turbine speed sensor 1
16.Turbine speed sensor 1

A: REMOVAL
2) Remove the intercooler. (Turbo model) <Ref. to
IN(H4DOTC)-12, REMOVAL, Intercooler.>
3) Remove the air intake chamber. (Non-turbo
Chamber.>
4) Disconnect the turbine speed sensor 1 connec-
tor.
AT-01387
5) Remove the turbine speed sensor 1.

B: INSTALLATION
1) Install the turbine speed sensor 1.
Tightening torque:
7 N$m (0.7 kgf-m, 5.2 ft-lb)
2) Connect the turbine speed sensor 1 connector.
AT-01387

4) Install the air intake chamber. (Non-turbo model)
<Ref. to IN(H6DO)-7, INSTALLATION, Air Intake
Chamber.>
5AT-57
Control Valve Body
17.Control Valve Body 12) Remove the control valve body.

NOTE:
A: REMOVAL Replace the control valve body as assembly, be-
1) Set the vehicle on a lift. cause it is non-disassemble part.
CAUTION:
NOTE:
Use a new gasket. AT-01957
Tightening torque: B: INSTALLATION
25 N$m (2.5 kgf-m, 18.1 ft-lb) 1) Check the control valve body for dust and other
7) Remove the oil pan. foreign matters.
CAUTION: 2) Install the control valve body to transmission by
Be sure to prevent the entering of dust and oth- equally tightening the bolts.
er foreign matters into oil pan. Tightening torque:
8) Remove the magnet. 8 N$m (0.8 kgf-m, 5.8 ft-lb)
(1) (1)
(2)
(1)
(1)
(2)
(1)
(2)
(1)
(2)
(1)
(2)
(1)
AT-01959
AT-01958
9) Clean the magnet.
10) Completely remove the remaining liquid gasket (1) 58 mm (2.28 in)
on the transmission case and oil pan. (2) 65 mm (2.56 in)
11) Disconnect the control valve connector and
front vehicle speed sensor connector. 3) Connect the control valve connector.
(B)
(B)
(A)
(A)
AT-01956
AT-01956

5AT-58
Control Valve Body
4) Attach the magnet at the specified position of oil

pan.
AT-01959
5) Apply liquid gasket to the oil pan.

Liquid gasket:
AT-01955
6) Install the oil pan by equally tightening the bolts.

Tightening torque:
5 N$m (0.5 kgf-m, 3.6 ft-lb)
7) Pour ATF through the oil charge pipe.
Specified and recommended fluid:
<Ref. to 5AT-2, SPECIFICATION, General De-
scription.>
Capacity:
Fill the same amount of the drained ATF.
8) Check the ATF level.
<Ref. to 5AT-27, Automatic Transmission Fluid.>
9) Execute the learning control promotion. <Ref. to
5AT(diag)-22, PROCEDURE, Learning Control.>
C: INSPECTION
Check each parts for holes, damages or other for-
eign matters.
5AT-59
ATF Filter
18.ATF Filter B: INSTALLATION

1) Apply a thin coat of ATF to the oil seal part of
A: REMOVAL new ATF filter.
NOTE: 2) Install the ATF filter. Turn it by hand, being care-
ATF filter is maintenance free. ful not to damage oil seal.
1) Disconnect the ground cable from battery and 3) Tighten the ATF filter using ST.
remove the battery from vehicle. Calculate the ATF filter tightening torque using fol-
lowing formula.
T2 = L2/(L1 + L2) &T1
T1: 14 N$m (1.4 kgf-m, 10.1 ft-lb)
L1: ST length 78 mm (3.07 in)
Example:
mm (in) N$m (kgf-m, ft-lb)
IN-00203
100 (3.94) 7.7 (0.79, 5.7)
2) Remove the harness securing bracket. 150 (5.91) 9.0 (0.92, 6.7)
200 (7.87) 10 (1.0, 7.2)
NOTE:
Align the ST with torque wrench while tightening
the ATF filter.
4) Fill ATF.
5) Inspect the level of ATF. <Ref. to 5AT-27, Auto-
6) Install the harness securing bracket.
7) Install the battery.
C: INSPECTION
Check for rust, hole, ATF leaks and other damage.
Replace the part if any defect is found from the in-
spection.
AT-01381
3) Using the ST, remove the ATF filter.

5AT-60
19.Transmission Control Mod- • RHD model

ule (TCM) (B)
A: REMOVAL
2) Remove the lower cover and then disconnect
the connector.
3) Remove the body integrated unit. (RHD model)
<Ref. to SL-46, REMOVAL, Body Integrated Unit.>
• RHD model (A) AT-01342
• LHD model
(B)
(A) AT-01342 (B)

(A)
• LHD model AT-02026

(B) Steering column
3) Connect the connector to TCM.

5) Perform the Clear Memory 2. <Ref. to 5AT(di-
ag)-18, CLEAR MEMORY MODE, OPERATION,
(B) Subaru Select Monitor.>
(A) (1) Connect the Subaru Select Monitor to data
AT-02026 link connector.
(2) Turn ignition switch to ON (engine OFF) and
(A) Transmission control module (TCM) turn Subaru Select Monitor switch to ON.
(B) Steering column (3) Ensure that the select lever is in “P” range.
5) Remove the relay from TCM body. (4) On the «Main Menu» display screen, select
6) Remove the TCM. the {Each System Check} and press the [YES]
key.
B: INSTALLATION (5) On the «System Selection Menu» display
1) Install the relay to TCM body. screen, select the {Transmission} and press the
2) Install the TCM. [YES] key.
Tightening torque: (6) Press the [YES] key after the information of
7.5 N$m (0.76 kgf-m, 5.5 ft-lb) transmission type has been displayed.
screen, select the {Clear Memory 2} and press
the [YES] key.
6) Perform the inspection with driving the vehicle at
the end of repair work, and make sure there is no
faulty as below;
• Oil leakage from transmission proper and etc.
• Occurrence of noise caused by interference etc.
5AT-61
NOTE:
If excessive shift shock is felt, execute the advance
operation of learning control. <Ref. to 5AT(diag)-
22, PROCEDURE, Learning Control.>
5AT-62
Lateral G Sensor
20.Lateral G Sensor
A: REMOVAL
2) Disconnect the connector from lateral G sensor.
AT-01343
3) Remove the lateral G sensor.

B: INSTALLATION
Tightening torque:
T1: 7.5 N$m (0.76 kgf-m, 5.5 ft-lb)
T2: 24.5 N$m (2.5 kgf-m, 18.1 ft-lb)
T2 T1
AT-01719
5AT-63
CONTROL SYSTEMS CS

(DIAGNOSTICS)


approval.

5AT
Page
4. Road Test..................................................................................................30
5. Stall Test ...................................................................................................31
6. Time Lag Test ...........................................................................................33
16. Turbine speed sensor 1 ............................................................................57
18. ATF Filter ..................................................................................................60
20. Lateral G Sensor .......................................................................................63
21. ATF Cooler Pipe & Hose...........................................................................64
23. Oil Charge Pipe.........................................................................................70
24. Torque Converter Assembly .....................................................................71
25. Extension Case & Intermediate Case .......................................................72
26. Transfer Clutch..........................................................................................74
27. Multi-Plate Clutch ......................................................................................76
28. Rear Drive Shaft........................................................................................77
31. Parking Pawl .............................................................................................82
32. Converter Case .........................................................................................84
33. Oil Pump Cover.........................................................................................86
35. Front Differential........................................................................................94
36. AT Main Case ...........................................................................................99
ATF Cooler Pipe & Hose
21.ATF Cooler Pipe & Hose 7) Disconnect the ATF cooler hoses from pipes.
NOTE:
A: REMOVAL • Do not use a screwdriver or other pointed tools.
1. EXCEPT FOR ATF COOLER MODEL • When hard to remove the hose, wrap the hose
WITH WARMER FUNCTION with cloth to prevent from damaging, and then turn
2) Remove the battery.
5) Remove the radiator under cover.
AT-01388
8) Disconnect the ATF cooler pipe from frame.
AT-01344
6) Disconnect the ATF cooler hose from radiator.

NOTE:
• When hard to remove the hose, wrap the hose
AT-01345
AT-01347
5AT-64
9) Remove the oil cooler inlet and outlet pipes. 5) Remove the pipe securing bolts on the side of
NOTE: transmission.
When disconnecting the outlet pipe, be careful not
to lose the ball and spring used with retaining
screw.
AT-02028
(A) 6) Lower the vehicle.

(B)
AT-01383 <Ref. to IN(H6DO)-7, REMOVAL, Air Intake Cham-
ber.>
(A) Outlet pipe 8) Remove the resonator chamber.
(B) Inlet pipe <Ref. to IN(H6DO)-9, REMOVAL, Resonator
Chamber.>
2. ATF COOLER MODEL WITH WARMER 9) Remove the oil charge pipe. <Ref. to 5AT-70,
FUNCTION REMOVAL, Oil Charge Pipe.>
1) Lift-up the vehicle. 10) Disconnect the ATF cooler hoses and pipes.
2) Remove the front exhaust pipe.
<Ref. to EX(H6DO)-5, REMOVAL, Front Exhaust
Pipe.>
3) Disconnect the inlet and outlet hoses of the ATF
cooler pipe from oil cooler pipe.
AT-02030
11) Remove the pitching stopper bracket securing

bolt and bolt on the side of transmission, and then
remove ATF cooler pipe.
AT-02027
4) Remove the union screw of oil cooler inlet and

outlet pipes.
AT-02033
AT-02029
5AT-65
12) Remove the ATF cooler from the installation 2) Install the ATF cooler pipe to frame.
bracket as necessary.
AT-02031
13) Remove the ATF cooler bracket from transmis-

sion body as necessary.
AT-01347
3) Connect the ATF cooler hose to pipe on the

AT-02032
transmission side.
NOTE:
B: INSTALLATION • Install so that the hose is not folded over, exces-
1. EXCEPT FOR ATF COOLER MODEL sively bent or twisted.
WITH WARMER FUNCTION • Be careful to insert the hose to the specified po-
sition.
1) Install the oil cooler inlet and outlet pipes with
new washer.
Tightening torque:
T1: 25 N!m (2.5 kgf-m, 18.1 ft-lb)
T2: 44 N!m (4.5 kgf-m, 32.5 ft-lb)
T1 AT-01388
T2
T1
AT-01384
5AT-66
4) Connect the ATF cooler hose to pipe on radiator 2. ATF COOLER MODEL WITH WARMER
side. FUNCTION
NOTE: 1) Install the ATF cooler bracket if it is removed
• Install so that the hose is not folded over, exces- from transmission body.
• Be careful to insert the hose to the specified po- Tightening torque:
sition. 25 N!m (2.5 kgf-m, 18.1 ft-lb)
AT-01345 AT-02032
5) Install the radiator under cover. 2) Install the ATF cooler if it is removed from instal-
Tightening torque: lation bracket.
4.9 N!m (0.5 kgf-m, 3.6 ft-lb) Tightening torque:
25 N!m (2.5 kgf-m, 18.1 ft-lb)
AT-01344
6) Install the under cover. AT-02031

7) Install the battery. 3) Install the pitching stopper securing bracket and
8) Fill ATF. <Ref. to 5AT-27, Automatic Transmis- bolt on the side of transmission.
sion Fluid.>
NOTE:
Make sure there are no ATF leaks in joints between
the transmission, radiator, pipes, and hoses.
AT-02033
5AT-67
4) Install the ATF cooler hoses and pipes. 12) Install the inlet and outlet pipes of the ATF oil
cooler hose to oil cooler pipe.
AT-02030
AT-02027
5) Connect the engine harness connectors, and
then install the engine hanger rear. 13) Install the front exhaust pipe.
6) Install the oil charge pipe. <Ref. to 5AT-70, IN- <Ref. to EX(H6DO)-6, INSTALLATION, Front Ex-
STALLATION, Oil Charge Pipe.> haust Pipe.>
7) Install the resonator chamber.
C: INSPECTION
<Ref. to IN(H6DO)-9, INSTALLATION, Resonator
Repair or replace any defective hoses, pipes,
Chamber.>
clamps, and washers found from the inspection be-
low.
1) Check for ATF leaks in joints between the trans-
Chamber.>
mission, radiator, pipes, and hoses.
2) Check for deformed clamps.
10) Install the pipe securing bolts on the side of
transmission.
surface and other damages.
5) Check for peeling, cracks, and deformation at
the tip of the hose.
6) Check the ATF cooler for cracks or deformation.
(ATF cooler model with warmer function)
AT-02028
11) Install the union screw of oil cooler inlet and

outlet pipes.
Tightening torque:
T1: 25 N!m (2.5 kgf-m, 18.1 ft-lb)
T2: 44 N!m (4.5 kgf-m, 32.5 ft-lb)
AT-02029
5AT-68
Air Breather Hose
22.Air Breather Hose

A: REMOVAL
1) Remove the intercooler. (Turbo model) <Ref. to
IN(H4DOTC)-12, REMOVAL, Intercooler.>
Chamber.>
(A)
(B)
AT-01385

(B) Air breather hose (Oil pump cover)
B: INSTALLATION
1) Connect the air breather hose.
(A)
(B)
AT-01385

(B) Air breather hose (Oil pump cover)

Chamber.>
C: INSPECTION
Make sure the hose is not cracked or clogged.
5AT-69
Oil Charge Pipe
23.Oil Charge Pipe

A: REMOVAL
<Ref. to IN(H4DOTC)-12, REMOVAL, Intercool-
er.>
Chamber.>
3) Remove the oil charge pipe, and then remove
the O-ring from flange side.
(A)
(B)
AT-01386
(A) Oil level gauge

(B) Oil charge pipe
B: INSTALLATION
1) Install the oil charge pipe with a new O-ring.
Tightening torque:
41 N!m (4.2 kgf-m, 30.2 ft-lb)
(A)
(B)
AT-01386
(A) Oil level gauge

(B) Oil charge pipe

Chamber.>
C: INSPECTION
Make sure the oil charge pipe is not deformed or
damaged.
5AT-70
Torque Converter Assembly
24.Torque Converter Assembly 6) Install the transmission assembly into the vehi-
A: REMOVAL Transmission Assembly.>
C: INSPECTION
mission Assembly.> Make sure the ring gear and protrusion of torque
2) Pull out the torque converter and oil pump shaft converter end are not deformed or damaged.
horizontally.
NOTE:
• Be sure not to scratch the inside of bush in oil
pump shaft.
• Be careful that the oil pump shaft may drawn out
simultaneously.
AT-00113
3) Remove the oil pump shaft from torque convert-

er as necessary.
B: INSTALLATION
1) When the oil pump shaft is removed, install the
shaft to torque converter.
NOTE:
Make sure the clip 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 revolution and sliding surface
oil pump shaft.
4) Holding the torque converter assembly by hand,
lightly rotate the torque converter assembly to en-
gage the oil pump rotor.
5) Check the protruding dimension of the torque
converter assembly.
Dimension A:
Less than 8 mm (0.31 in)
(A)
AT-01641
(A) Dimension A
5AT-71
Extension Case & Intermediate Case
25.Extension Case & Intermedi- NOTE:

Use a new gasket.
ate Case
A: REMOVAL
1) Remove the transmission assembly.
<Ref. to 5AT-38, REMOVAL, Automatic Transmis-
sion Assembly.>
AT-01952
2) Attach the selected reduction driven gear shim

to end surface of reduction driven gear with vase-
line. <Ref. to 5AT-79, ADJUSTMENT, Reduction
Driven Gear.>
3) Install the extension case to intermediate case.
AT-01950
NOTE:
3) Separate the extension case and intermediate Use a new gasket.
case.
Tightening torque:
25 N!m (2.5 kgf-m, 18.4 ft-lb)
AT-01951
4) Separate the intermediate case and transmis-

AT-01951
sion main case.
4) Install the rear vehicle speed sensor.
Tightening torque:
7 N!m (0.7 kgf-m, 5.1 ft-lb)
AT-01952
B: INSTALLATION
1) Secure the intermediate case to transmission
main case. AT-01950
Tightening torque: 5) Install the transmission assembly.

25 N!m (2.5 kgf-m, 18.4 ft-lb) <Ref. to 5AT-42, INSTALLATION, Automatic
5AT-72
Extension Case & Intermediate Case
C: DISASSEMBLY 4) Using the ST and compressor, install the snap

1) Take out the transfer clutch and multi-plate ring.
clutch hub assembly by lightly tapping the end of ST 18762AA000 COMPRESSOR SPECIAL
rear drive shaft. TOOL
NOTE:
Be careful not to damage the oil seal of extension. ST
2) Remove snap ring using ST and press.

ST 18762AA000 COMPRESSOR SPECIAL
TOOL
ST
AT-01960
5) Install the transfer clutch. <Ref. to 5AT-74, IN-

STALLATION, Transfer Clutch.>
NOTE:
For 3-transfer clutch model, make sure the press
AT-01960 plate is included.
3) Supply compressed air to remove the clutch pis- 6) Install the multi-plate hub assembly.
ton. E: INSPECTION
• Use compressed air to make sure the extension
case routes are not clogged and not leaks.
within specifications.
<Ref. to 5AT-74, ADJUSTMENT, Transfer Clutch.>
AT-01961

D: ASSEMBLY
1) Press-fit new oil seal using ST and press.
3) Insert the multi-plate clutch, drive plate, driven
plate and spring retainer.
AT-01962
(A) Spring retainer

(B) Multi-plate clutch (LSD) piston assembly
5AT-73
Transfer Clutch
26.Transfer Clutch ST 398643600 GAUGE
A: REMOVAL
mission Assembly.>
2) Remove the extension case, and then remove
the transfer clutch. <Ref. to 5AT-72, REMOVAL, A
Extension Case & Intermediate Case.> <Ref. to
5AT-73, DISASSEMBLY, Extension Case & Inter-
mediate Case.>
AT-01964
B: INSTALLATION
1) Select the rear drive shaft shim. <Ref. to 5AT-74, A Measured value
2) Select the driven plate No. 3. <Ref. to 5AT-74, 3) Using the ST, measure the height “B” from the
ADJUSTMENT, Transfer Clutch.> intermediate case mating surface to ball bearing
3) Install the extension case and intermediate outer ring contact surface.
case. <Ref. to 5AT-72, INSTALLATION, Extension ST 398643600 GAUGE
Case & Intermediate Case.>
C: INSPECTION B
• Inspect the drive plate facing for wear and dam-
age.
• Inspect the snap ring for wear; return spring for
permanent distortion, breakage and deformation.
• Check that the D-ring is not damaged. AT-01965
within specifications. <Ref. to 5AT-74, ADJUST- B Measured value
4) Calculation formula:
D: ADJUSTMENT When clearances are 0.05 mm (0.0020 in):
1) Insert the rear drive shaft into the reduction drive T (mm) = A " (B " 0.28) " 0.05
gear and center differential assembly. [T (in) = A " (B " 0.011) " 0.0020]
When clearances are 0.25 mm (0.0098 in):
T (mm) = A " (B " 0.28) " 0.25
[T (in) = A " (B " 0.011) " 0.0098]
A: Depth from end of extension case to ball bearing
outer ring contact surface
B: Height from end of intermediate case to ball
bearing outer ring contact surface
T: Shim thickness
0.05 — 0.25 mm (0.0020 — 0.0098 in)
AT-01963
NOTE:
Calculation formula for “T” is applied when measur-
2) Using the ST, measure the depth “A”, which is ing using ST (398643600 GAUGE). When not us-
from mating surface of extension case to ball bearing ST, apply following.
ing outer ring contact surface. When clearances are 0.05 mm (0.0020 in):
T (mm) = (A " #) " ((B " $) " 0.28) " 0.05
[T (in) = (A " #) " ((B " $) " 0.011) " 0.0020]
T (mm) = (A " #) " ((B " $) " 0.28) " 0.25
[T (in) = (A " #) " ((B " $) " 0.011) " 0.0098]
5AT-74
Transfer Clutch
T: Shim thickness
A: Depth from end of extension case to ball bearing
outer ring contact surface
B: Height from end of intermediate case to ball
bearing outer ring contact surface
#: Collar thickness used when measuring “A”
$: Collar thickness used when measuring “B”
0.28 (0.011): Gasket thickness (Unit mm (in))
Adjustment shim
Part Number Thickness mm (in)
33281AA040 0.2 (0.008)
33281AA050 0.5 (0.020)
33281AA060 0.3 (0.012)
5AT-75
Multi-Plate Clutch
27.Multi-Plate Clutch NOTE:

Measure with driven plate No. 3 removed.
A: REMOVAL
Remove the multi-plate clutch following the same
instructions as for the extension case. <Ref. to
5AT-72, REMOVAL, Extension Case & Intermedi-
ate Case.>
B: INSTALLATION B
Install the multi-plate clutch following the same in-

structions as for the extension case. <Ref. to 5AT-
72, INSTALLATION, Extension Case & Intermedi-
ate Case.>
AT-01967
C: INSPECTION
• Inspect the drive plate facing for wear and dam- B Measured value
age.
• Inspect the snap ring for wear; return spring for
permanent distortion, breakage and deformation. When clearances are 0.2 mm (0.008 in):
• Inspect the damage for D-ring. T (mm) = A " (B " 0.28) " 0.2
• Measure the multi-plate clutch clearance and ad- [T (in) = A " (B " 0.011) " 0.008]
just it within specification. <Ref. to 5AT-76, AD- When clearances are 0.6 mm (0.024 in):
JUSTMENT, Multi-Plate Clutch.> T (mm) = A " (B " 0.28) " 0.6
[T (in) = A " (B " 0.011) " 0.024]
D: ADJUSTMENT NOTE:
1) Remove drive plate and driven plate from center
• Calculation formula for “T” is applied when mea-
differential carrier.
suring using ST (398643600 GAUGE, 398744300
2) Measure the depth “A” from mating surface of GAUGE). When not using ST, apply following.
extension case to multi-plate clutch (LSD) piston.
T (mm) = A " (B " # " 0.28) " 0.2
[T (in) = A " (B " # " 0.011) " 0.008]
T (mm) = A " (B " # " 0.28) " 0.6
A
[T (in) = A " (B " # " 0.011) " 0.024]
T: Thickness of driven plate No. 3
A: Measure the depth from mating surface of exten-
sion case to multi-plate clutch (LSD) piston
B: Height from end of intermediate case to center
AT-01966 differential clutch drum
#: Collar thickness used when measuring “B”
A Measured value 0.28 (0.011): Gasket thickness (Unit mm (in))
• Measure multi-plate clutch (LSD) driven and
3) Using the ST, measure the height “B” from inter- drive plate thickness to find the clearance between
mediate case mating surface to end of center differ- measurement value and “T”.
ential clutch drum, and then subtract the thickness
of ST gauge (50 mm (1.97 in)) from measured val- Standard value:
ue. 0.2 — 0.6 mm (0.008 — 0.024 in)
ST 378744300 GAUGE If outside the standard value, replace the plate set
(drive and driven plate) and select the driven plate
No. 3 to bring clearance within the standard value.
Driven plate No. 3
31589AA041 1.6 (0.063)
31589AA050 2.0 (0.079)
31589AA060 2.4 (0.094)
31589AA070 2.8 (0.110)
5AT-76
Rear Drive Shaft
28.Rear Drive Shaft 2) Using a press, remove the front and rear side
ball bearings, and clutch hub.
A: REMOVAL
1) Remove the transmission assembly from vehi- (B)
(A)
mission Assembly.>
(C)
remove the extension case. <Ref. to 5AT-72, RE-
MOVAL, Extension Case & Intermediate Case.>
3) Pull out the rear drive shaft from center differen-
tial assembly.
AT-00151
(A) Rear ball bearing

(C) Clutch hub
D: ASSEMBLY
NOTE:
AT-01963 • Use new ball bearings and revolution gear.
4) Remove the drive plate and driven plate. • Make sure the clutch hub is oriented in the cor-
rect direction.
B: INSTALLATION
1) Select the appropriate shim. <Ref. to 5AT-74, (B)
2) Install drive plate and driven plate.
3) Insert the rear drive shaft into the center differen-
tial assembly. (A) (C)
4) Combine the extension case, and then install the
rear vehicle speed sensor. <Ref. to 5AT-72, IN-
STALLATION, Extension Case & Intermediate
Case.> (D)
5) Install the transmission assembly into vehicle. AT-00152
Transmission Assembly.> (A) Front side
C: DISASSEMBLY (B) Clutch hub
1) Using a press, remove the revolution gear. (C) Rear side
(D) Revolution gear
(A)
E: INSPECTION
• Check each parts for holes, damages or other
foreign matters.
AT-00149
(A) Revolution gear
5AT-77
29.Reduction Driven Gear C: DISASSEMBLY

1) Remove the ball bearing from reduction driven
A: REMOVAL gear using ST.
1) Remove the transmission assembly from vehi- ST 498077310 REMOVER
mission Assembly.>
(A) ST
separate the extension case and intermediate case
from transmission case. <Ref. to 5AT-72, REMOV-
AL, Extension Case & Intermediate Case.>
3) Remove the center differential carrier. <Ref. to
5) Using the ST1 and ST2, extract the reduction
driven gear. AT-00157
ST1 499737100 PULLER SET
ST2 18680AA000 GEAR HOLDER (A) Ball bearing
2) Remove the ball bearing on reverse side with the

ST2 same procedure in step 1).
ST1 ST
(A)
(A)
AT-01968
(A) Reduction driven gear

AT-01969
B: INSTALLATION 3) Remove the snap ring from reduction driven
1) Set the select lever to “P” range. gear.
2) Use a plastic hammer to install reduction driven
gear assembly. D: ASSEMBLY
3) Select the reduction gear shim. <Ref. to 5AT-79, 1) Install the snap ring to reduction driven gear.
ADJUSTMENT, Reduction Driven Gear.> 2) Install the new ball bearing to reduction driven
4) Connect the transmission case, extension case gear using press.
and intermediate case, and install the rear wheel
speed sensor. <Ref. to 5AT-72, INSTALLATION,
Extension Case & Intermediate Case.>
AT-01970
(A) Ball bearing
5AT-78
3) Install the ball bearing on reverse side with the T: Shim clearance
same procedure in step 2). A: Depth from mating surface of extension case to
ball bearing outer ring end surface
B: Height from mating surface of extension case to
ball bearing inside low part
Reduction gear shim
31288AA030 0.2 (0.008)
31288AA050 0.5 (0.020)
31288AA060 0.3 (0.012)
AT-01971
E: INSPECTION
Make sure the ball bearing and gear are not de-
formed or damaged.
F: ADJUSTMENT
1) Using depth gauge, measure depth “A” from
mating surface of extension case to ball bearing on
rear end of reduction driven gear.
AT-02090
2) Using a depth gauge, measure the height “B”

from mating surface of extension case to ball bear-
ing inside low part of extension case.
AT-02091
Select the ball bearing from the table to adjust
clearances within 0.05 — 0.25 mm (0.0020 —
0.098 in).
T (mm) = A " B + 0.23
[T (in) = A " B + 0.0091]
T (mm) = A " B + 0.03
[T (in) = A " B +0.0011]
5AT-79
30.Center Differential Carrier 4) Install the transmission assembly into vehicle.

A: REMOVAL Transmission Assembly.>
C: DISASSEMBLY
mission Assembly.> 1) Remove the seal ring.
arate the extension case and intermediate case
from transmission case. <Ref. to 5AT-72, REMOV-
AL, Extension Case & Intermediate Case.>
3) Pull out the rear drive shaft. <Ref. to 5AT-77,
4) Pull out the center differential carrier assembly. (A)
AT-02015
(A) Seal ring
2) Using a press and ST, remove the ball bearing.

AT-01972
5) Pull out the shim(s) from transmission case.

B: INSTALLATION
1) Install the center differential assembly with the
shim(s).
NOTE:
Press-fit it to the bottom of bearing shoulder com-
AT-00167
pletely.
3) Remove the snap ring, and pull out the shaft
from center differential assembly.
(B) (A)
AT-01972
2) Insert the rear drive shaft. <Ref. to 5AT-77, IN-

AT-01973
STALLATION, Rear Drive Shaft.>
3) Connect the transmission case, extension case (A) Snap ring
and intermediate case, and install the rear wheel (B) Shaft
speed sensor. <Ref. to 5AT-72, INSTALLATION,
Extension Case & Intermediate Case.>
5AT-80
4) Remove the thrust washers, pinion gears and

washers from center differential assembly.
(A)
AT-00169
(A) Pinion gear
5) Pull out the intermediate shaft and thrust bear-

ing.
D: ASSEMBLY
1) Install the thrust washer onto intermediate shaft.
2) Install the thrust bearing onto intermediate shaft.
3) Install the pinion gears and washers.
4) Insert the shaft into the center differential as-
sembly.
6) Using a press, install a new ball bearing into the
center differential assembly.
(A)
ST
(B)
AT-00170
(A) Plate
7) Apply vaseline onto the seal ring outer surface

and shaft grooves.
8) Install a new seal rings.
E: INSPECTION
• Check each parts for holes, damages or other
foreign matters.
5AT-81
Parking Pawl
31.Parking Pawl 4) Set the ST between parking pawl and parking

support actuator.
A: REMOVAL ST 18679AA000 ADJUSTER
mission Assembly.>
2) Remove the extension case and intermediate
4) Remove the parking support actuator.
ST
AT-02069
5) Tighten the securing bolts while pressing park-

ing support actuator with finger.
Tightening torque:
10%2 N!m (1.0%0.2 kgf-m, 7.4%1.5 ft-lb)
CAUTION:
Press the reduction driven gear and parking
pawl in bottom condition.
AT-02067
5) Remove the parking pawl, parking pawl shaft

and return spring.
ST
AT-02070
6) Using the ST, tighten the bolts which tightened in

step 4) with specified angle.
AT-02068
Tightening angle:
B: INSTALLATION 18&%2&
1) Set the transmission to “N” range. ST 18554AA000 ANGLE GAUGE
2) Install the parking pawl, parking pawl shaft and
return spring.
AT-02068
3) Temporarily secure the parking support actua-

tor.
5AT-82
Parking Pawl
NOTE:
Do not use extension as much as possible.
ST
AT-02071
ST
AT-02072
7) Install the center differential carrier. <Ref. to

5AT-80, INSTALLATION, Center Differential Carri-
er.>
8) Install the extension case and intermediate
case. <Ref. to 5AT-72, INSTALLATION, Extension
C: INSPECTION
Make sure that the tab of parking pawl on reduction
driven gear is not worn or otherwise damaged.
5AT-83
Converter Case
32.Converter Case 3) Install the differential assembly to case. <Ref. to

5AT-94, INSTALLATION, Front Differential.>
A: REMOVAL 4) Install the left and right side retainers. <Ref. to
1) Remove the transmission assembly from vehi- 5AT-97, ADJUSTMENT, Front Differential.>
cle. <Ref. to 5AT-38, REMOVAL, Automatic Trans- 5) Apply proper amount of liquid gasket to the en-
mission Assembly.> tire matching surface of converter case.
2) Remove the torque converter assembly. <Ref. to
Liquid gasket:
5AT-71, REMOVAL, Torque Converter Assembly.>
THREE BOND 1215 (Part No. 004403007)
from stay.
4) Remove the turbine speed sensor 1. <Ref. to
5AT-57, REMOVAL, Turbine speed sensor 1.>
6) Remove the ATF filter inlet and outlet pipes.
<Ref. to 5AT-60, REMOVAL, ATF Filter.>
7) Remove the converter case aligning bolt.
8) Lay along the transmission body, and then re-
move the oil pan. AT-01975
9) Remove the three converter case aligning bolts
(TORX®). 6) Install the converter case assembly without
ST 18676AA020 TORX® WRENCH damaging bushing and oil seal.
Tightening torque:
41 N!m (4.2 kgf-m, 30.4 ft-lb)
7) Install the three converter case aligning bolts
(TORX®).
ST 18676AA020 TORX® WRENCH
Tightening torque:
41 N!m (4.2 kgf-m, 30.4 ft-lb)
AT-01974
10) Separate the converter case by lightly tapping

with plastic hammer.
11) Remove the differential assembly. <Ref. to
5AT-94, REMOVAL, Front Differential.>
12) Remove the oil seal from converter case.
B: INSTALLATION
1) Check the appearance of each component and AT-01974
clean them.
2) Press-fit the oil seal to converter case using ST.
tire oil pan mating surface, and then install it.
ST 499587100 OIL SEAL INSTALLER
Liquid gasket:
ST
AT-01979
5AT-84
Converter Case
Tightening torque:
5 N!m (0.5 kgf-m, 3.7 ft-lb)
AT-01955
9) Install the transmission harness connector to the

stay.
11) Install the ATF filter pipe. <Ref. to 5AT-60, IN-
STALLATION, ATF Filter.>
12) Install the oil charge pipe with O-ring.<Ref. to
13) Install the torque converter assembly. <Ref. to
5AT-71, INSTALLATION, Torque Converter As-
sembly.>
C: INSPECTION
Measure the backlash, and then adjust it within
specification. <Ref. to 5AT-91, ADJUSTMENT,
Drive Pinion Shaft Assembly.>
5AT-85
Oil Pump Cover
33.Oil Pump Cover 6) Install the torque converter assembly. <Ref. to

A: REMOVAL sembly.>
1) Remove the transmission assembly from vehi- 7) Install the transmission assembly into vehicle.
cle. <Ref. to 5AT-38, REMOVAL, Automatic Trans- <Ref. to 5AT-42, INSTALLATION, Automatic
mission Assembly.> Transmission Assembly.>
2) Pull out the torque converter assembly. <Ref. to
C: DISASSEMBLY
3) Remove the transmission harness connector 1. FRONT BRAKE
from stay.
case part. <Ref. to 5AT-84, REMOVAL, Converter
Case.>
7) Remove the oil pump cover aligning bolt, and
then separate it from the AT main case by lightly
tapping with plastic hammer.
AT-01980
2) Remove the retainer plate, drive plate and driven

plate.
3) Remove the snap ring using ST1, ST2 and ST3.
ST1 18762AA000 COMPRESSOR SPECIAL
TOOL
ST2 18765AA000 COMPRESSOR SUPPORT
ST3 18763AA000 COMPRESSOR SHAFT
AT-01976 ST1
B: INSTALLATION
1) Secure the oil pump cover. ST2
Tightening torque:
41 N!m (4.2 kgf-m, 30.4 ft-lb)
ST3
AT-01981
4) Remove the retainer and return spring.

5) Remove the front brake piston by blowing com-
pressed air.
AT-01976

LATION, Torque Converter Assembly.>
3) Install the transmission harness connector to the
stay.
AT-02349
5) Install the oil charge pipe with O-ring. <Ref. to 6) Remove the D-ring from front brake piston.
5AT-86
Oil Pump Cover
2. OIL PUMP ST3 18763AA000 COMPRESSOR SHAFT

1) Take out the oil pump housing.
ST1
ST2
ST3
AT-01981
AT-01982 5) Install the genuine driven plate instead of retain-

er plate, temporarily assemble the drive plate and
2) Take out the oil pump body.
driven plate.
D: ASSEMBLY ST 31536AA290 DRIVEN PLATE
1. FRONT BRAKE
1) Apply ATF to D-ring, and then install it to the
front brake piston.
2) Install the front brake piston to oil pump cover.
NOTE:
Install by aligning the “▲” mark on front brake pis-
ton surface with the oil pump cover rib.
AT-01980
7) Measure the clearance between retainer plate

and snap ring, and then select a suitable retainer
plate from table.
Front brake clearance standard value:
0.7 — 1.1 mm (0.028 — 0.043 in)
AT-01983
AT-02350
Front brake retainer plate
3) Install the retainer and return spring.
31567AB130 3.4 (0.134)
4) Install the front brake piston assembly using
31567AB140 3.6 (0.142)
ST1, ST2 and ST3.
31567AB150 3.8 (0.150)
TOOL 31567AB160 4.0 (0.157)
ST2 18765AA000 COMPRESSOR SUPPORT 8) Remove the snap ring, replace the drive plate
which used in measurement of clearance with re-
tainer plate, and then reassemble.
5AT-87
Oil Pump Cover
2. OIL PUMP Tip clearance:

0.02 — 0.15 mm (0.0008 — 0.0059 in)
1) Apply ATF to oil pump assembly, and then install
it to oil pump housing.
2) Install the O-ring to oil pump cover. (A) (B)
3) Install the oil pump housing to oil pump housing (C)
cover.
Tightening torque:
10 N!m (1.0 kgf-m, 7.4 ft-lb)
AT-01977
(A) Thickness gauge

(B) Inner rotor
(C) Outer rotor
(2) Side clearance

AT-01982
Set a depth gauge to oil pump housing, then
measure the oil pump housing-to-rotor clear-
E: INSPECTION ance.
1. FRONT BRAKE Side clearance:
Check the following items: 0.02 — 0.045 mm (0.0008 — 0.0018 in)
(A)
• Snap ring for wear, return spring for damage,
and retainer for damage
• Piston for damage
• D-ring for damage
2. OIL PUMP
• Oil pump cover and oil seal for breakage or dam- (B)
age (C)
AT-01978
• Oil pump body for scratch or damage
1) Check seal ring and oil seal for breaks or dam- (A) Depth gauge
ages. (B) Inner rotor
2) Check other parts for dents or abnormalities. (C) Outer rotor
3) Selection of oil pump rotor assembly
(1) Tip clearance (3) If the depth and/or side clearance are not
Install the inner rotor and outer rotor to oil pump within the specifications, replace the rotor as-
housing. With rotor gears facing each other, sembly.
measure the crest-to-crest clearance.
Oil pump rotor ASSY
15008AA130 11.37 — 11.38 (0.4476 — 0.4480)
15008AA140 11.38 — 11.39 (0.4480 — 0.4484)
15008AA150 11.39 — 11.40 (0.4484 — 0.4488)
Measure the total end play and adjust it within

specifications. <Ref. to 5AT-106, ADJUST-
MENT, AT Main Case.>
5AT-88
34.Drive Pinion Shaft Assembly 2) Adjust the tooth contact between drive pinion
shaft assembly and front differential side gear.
A: REMOVAL <Ref. to 5AT-91, ADJUSTMENT, Drive Pinion
1) Remove the transmission assembly from vehi- Shaft Assembly.>
cle. <Ref. to 5AT-38, REMOVAL, Automatic Trans- 3) Combine the converter case with transmission
mission Assembly.> case. <Ref. to 5AT-84, INSTALLATION, Converter
2) Pull out the torque converter assembly. <Ref. to Case.>
5AT-71, REMOVAL, Torque Converter Assembly.> 4) Install the transmission harness connector to the
3) Remove the transmission harness connector stay.
from stay. 5) Install the ATF filter pipe. <Ref. to 5AT-60, IN-
4) Disconnect the air breather hose. <Ref. to 5AT- STALLATION, ATF Filter.>
69, REMOVAL, Air Breather Hose.> 6) Install the oil charge pipe with O-ring.
5) Remove the oil charge pipe. <Ref. to 5AT-70, 7) Install the torque converter assembly. <Ref. to
REMOVAL, Oil Charge Pipe.> 5AT-71, INSTALLATION, Torque Converter As-
6) Remove the ATF filter inlet and outlet pipes. sembly.>
<Ref. to 5AT-60, REMOVAL, ATF Filter.> 8) Install the transmission assembly into vehicle.
7) Separate the converter case and transmission <Ref. to 5AT-42, INSTALLATION, Automatic
case part. <Ref. to 5AT-84, REMOVAL, Converter Transmission Assembly.>
Case.>
C: DISASSEMBLY
8) Remove the drive pinion shaft mounting bolt,
and then remove the drive shaft assembly from oil 1) Remove the caulking part of lock nut, and then
pump cover. remove the lock nut with holding rear spline part of
the shaft using ST1 and ST2. Pull out the drive pin-
ion collar.
ST1 18667AA010 HOLDER
ST3
AT-01984 ST2
9) Remove the oil pump cover from AT main case. ST1

<Ref. to 5AT-86, Oil Pump Cover.>
B: INSTALLATION
AT-00197
1) Assemble the drive pinion assembly to oil pump
cover. 2) Remove the O-ring.
NOTE: 3) Separate the rear roller bearing and outer race
Be careful not to bend the shim. from the shaft using press.
Tightening torque:
70 N!m (7.1 kgf-m, 51.6 ft-lb)
(A)
AT-00198
(A) Outer race

AT-01984
4) Separate the front roller bearing from the shaft
using press and ST.
5AT-89
ST 498517000 REPLACER T1: 116 N!m (11.8 kgf-m, 85.3 ft-lb)

L1: ST2 length 0.072 m (2.83 in)
(A) L2: Torque wrench length
ST Example:
m (in) N!m (kgf-m, ft-lb)
0.4 (15.75) 98 (10.0, 72)
0.45 (17.72) 100 (10.2, 73.8)
AT-00199 0.5 (19.69) 101 (10.3, 74.5)
0.55 (21.65) 102 (10.4, 75)
(A) Front roller bearing
ST1 18667AA010 HOLDER
D: ASSEMBLY ST2 499787700 WRENCH
1) Measure the dimension “A” of drive pinion shaft. ST3 499787500 ADAPTER
ST 398643600 GAUGE NOTE:
Install the ST2 to torque wrench as straight as pos-
sible.
ST3
ST2
L1 [m (in)]
A AT-00200 L2 [m (in)]
2) Using a press, press-fit the new roller bearing ST1
into specified position. AT-00202
NOTE: 6) Measure the starting torque of bearing. Make
If excessive force is applied to roller bearing, the sure the starting torque is within the specified
roller bearing will not turn easily. range. If the torque is not within specified range, re-
place the roller bearing.
(A)
Starting torque:
7.6 — 38.1 N (0.776 — 3.88 kgf, 1.7 — 3.88 kg)
(B)
AT-00201

(B) Roller bearing
AT-00203
3) After fitting a new O-ring to the shaft, attach the 7) Stake the caulking of lock nut at two points.
drive pinion collar to shaft.
8) Measure the dimension “B” of drive pinion shaft.
4) Install the lock washer to drive pinion shaft in
proper direction.
5) Tighten new lock nuts using ST1, ST2 and ST3.
Calculate the lock washer and lock nut specifica-
tions using following formula.
T2 = L2/(L1 + L2) ' T1
5AT-90
ST 398643600 GAUGE ST2 499787700 WRENCH
ST1 ST2
B
AT-00204 AT-01985
9) Calculate the thickness “t” (mm) of drive pinion 4) Adjust the backlash between drive pinion and
shim. hypoid driven gear. <Ref. to 5AT-97, ADJUST-
t = 6.5 % 0.0625 " (B " A) MENT, Front Differential.>
10) Select three or less shims from following table. 5) Apply red lead evenly to the surfaces of three or
four teeth on hypoid driven gear. Rotate the drive
Drive pinion shim
pinion in the leftward and rightward for several
Part Number Thickness mm (in) times. Remove the oil pump cover, and check the
31451AA180 0.150 (0.0059) tooth contact pattern.
31451AA190 0.175 (0.0069) If the tooth contact is improper, readjust the back-
31451AA200 0.200 (0.0079) lash or shim thickness. <Ref. to 5AT-97, ADJUST-
31451AA210 0.225 (0.0089) MENT, Front Differential.>
31451AA220 0.250 (0.0098) • Correct tooth contact
31451AA230 0.275 (0.0108) Checking item: Tooth contact pattern is slightly
shifted toward to toe side under no-load
E: INSPECTION rotation. [When loaded, contact pattern moves
• Make sure that all component parts are free of toward heel.]
scratch, hole and other faults.
• Adjust the teeth alignment. <Ref. to 5AT-91, AD-
(A)
JUSTMENT, Drive Pinion Shaft Assembly.>
F: ADJUSTMENT
1) Remove the liquid gasket completely from mat-
ing surfaces.
2) Install the converter case to oil pump cover, and
secure them with tightening four bolts evenly. (B)
NOTE:
Use an old gasket or aluminum washer so as not to AT-00207
damage the mating surface of housing.
(A) Toe side
Tightening torque: (B) Heel side
41 N!m (4.2 kgf-m, 30.4 ft-lb)
3) Rotate the drive pinion several times using ST1 • Face contact
and ST2. Checking item: Backlash is too large.
ST1 18667AA010 HOLDER Contact pattern
AT-00208
5AT-91
Corrective action: Increase thickness of drive pin- Corrective action: Reduce thickness of drive pinion
ion height adjusting shim in order to bring drive pin- height adjusting shim in order to bring drive pinion
ion close to hypoid driven gear. away from hypoid driven gear.
AT-00212 AT-00213
• Flank contact • Heel contact (outside end contact)

Checking item: Backlash is too small. Checking item: Contact areas are too small
Contact pattern Contact pattern
AT-00209 AT-00211
Corrective action: Reduce thickness of drive pinion Corrective action: Increase thickness of drive pin-
height adjusting shim in order to bring drive pinion ion height adjusting shim in order to bring drive pin-
away from hypoid driven gear. ion close to hypoid driven gear.
AT-00213 AT-00212
• Toe contact (inside end contact) 6) If tooth contact is correct, mark the retainer posi-
Checking item: Contact areas are too small tion and loosen it. After fitting a new O-ring and oil
Contact pattern seal, screw in the retainer to the marked position.
Tighten the lock plate with specified torque.
AT-00210
5AT-92
Tightening torque:
25 N!m (2.5 kgf-m, 18.1 ft-lb)
(A)
AT-01986
(A) Lock plate
5AT-93
Front Differential
35.Front Differential Tightening torque:

25 N!m (2.5 kgf-m, 18.1 ft-lb)
A: REMOVAL
cle. <Ref. to 5AT-38, REMOVAL, Automatic Trans- (A)
mission Assembly.>
from stay.
5) Remove the ATF filter inlet and outlet pipes. AT-01988
6) Separate the converter case and transmission (A) Lock plate
6) Install the converter case to transmission case.
Case.>
<Ref. to 5AT-84, INSTALLATION, Converter
7) Remove the differential side retainers using ST. Case.>
NOTE: 7) Install the transmission harness connector to the
Hold the differential case assembly by hand to stay.
avoid damaging the retainer mounting hole of con- 8) Install the ATF filter pipe. <Ref. to 5AT-60, IN-
verter case. STALLATION, ATF Filter.>
ST 18630AA010 WRENCH COMPL RETAIN- 9) Install the oil charge pipe with a O-ring. <Ref. to
ER 5AT-70, INSTALLATION, Oil Charge Pipe.>
8) Remove the differential assembly without dam- 10) Install the torque converter assembly. <Ref. to
aging the installation part of retainer. 5AT-71, INSTALLATION, Torque Converter As-
sembly.>
B: INSTALLATION 11) Install the transmission assembly into vehicle.
1) When installing the differential assembly to <Ref. to 5AT-42, INSTALLATION, Automatic
case, be careful not to damage the inside of case Transmission Assembly.>
(particularly, the differential side retainer mating
surface). C: DISASSEMBLY
(A)
1) Remove the taper roller bearing using ST and
press.
AT-01987
(A) Differential ASSY
2) Install the O-ring to left and right side retainer.

3) Install the side retainers using ST. <Ref. to 5AT- AT-00216
94, REMOVAL, Front Differential.>
ST 18630AA010 WRENCH COMPL RETAIN-
ER
4) Adjust the front differential backlash. <Ref. to
5AT-97, ADJUSTMENT, Front Differential.>
5) Install the lock plate.
5AT-94
Front Differential
2) Secure the case in a vise and remove the hypoid 2) Remove the oil seal.
driven gear tightening bolts, then separate the hy-
poid driven gear case (RH) and case (LH).
(A)
(B)
(C)
AT-00220
3) Remove the split pin, and then remove the claw.

AT-00217
3) Pull out the straight pin and shaft, and then re-
move the differential bevel gear, washer and differ-
ential bevel pinion.
AT-00221
(A) Claw
(B) Split pin
(C) Pin
4) Attach two claws to the outer race, and set the

(A) ST to side retainer.
AT-00218
2. SIDE RETAINER
NOTE:
After adjusting the drive pinion backlash and tooth
contact, remove and install the oil seal and O-ring.
AT-00222
(A) Shaft
(B) Claw
5) Restore the removed claws to original position,

and install the pin and split pin.
6) Hold the shaft of ST to avoid removing from side
retainer, and then remove the bearing outer race.
AT-00219
5AT-95
Front Differential
NOTE: 4) Install the hypoid driven gear and secure by

Replace the bearing inner and outer races as a sin- tightening the bolt.
gle unit. Tightening torque:
62 N!m (6.3 kgf-m, 45.6 ft-lb)
(A)
(B)
(C)
AT-00223
AT-00217
(A) Shaft
(B) Side retainer (A) Hypoid driven gear
D: ASSEMBLY
5) Measurement of backlash (Selection of washer)
1) Install the washer, differential bevel gear and dif- (1) Install the SUBARU genuine axle shaft to
ferential bevel pinion in the differential case (RH). differential case.
Insert the pinion shaft. Parts No. 38415AA070 AXLE SHAFT
2) Install the straight pin in reverse direction. (2) Measure the gear backlash using ST1 and
ST2, and then insert the ST2 from the access
window of case.
NOTE:
• Measure the backlash by applying a pinion tooth
between two bevel gear teeth.
• Fix the bevel pinion gear in place with a screw-
driver or similar tool when measuring.
(A)
AT-00218
Standard value:
0.13 — 0.18 mm (0.0051 — 0.0071 in)
3) Install the washer and differential bevel gear to

differential case (LH). Put the differential case (RH) ST1
on the case, and then combine the both cases.
ST2
AT-00224
(3) If the backlash is not within specifications,

select a washer from the table below.
Washer
803038021 0.95 (0.037)
803038022 1.00 (0.039)
803038023 1.05 (0.041)
5AT-96
Front Differential
6) Using the ST, install the taper roller bearing. ST 18630AA010 WRENCH ASSY
ST 398487700 DRIFT
2. SIDE RETAINER
NOTE: ST
Install the oil seal and O-ring of side retainer after
the adjustment of backlash and tooth contact.
1) Install the bearing outer race to side retainer.
2) Fit a new oil seal using ST.
ST 18675AA000 DIFFERENTIAL SIDE OIL
SEAL INSTALLER AT-00227
NOTE: 2) Remove the oil pump cover.
Apply oil to the oil seal lips. 3) Remove the liquid gasket from the mating sur-
face completely.
ST
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 so as not to
damage the mating surface of housing.
Tightening torque:
41 N!m (4.2 kgf-m, 30.4 ft-lb)
5) Rotate the drive pinion ten times or more using
AT-00226
ST1 and ST2.
3) Install a new O-ring. ST1 18667AA010 HOLDER
ST1 ST2
AT-00219
E: INSPECTION AT-01985
• Check each component for scratches, damage 6) Tighten the retainer LH until contact is felt while
and other faults. rotating the shaft. Then loosen the retainer RH.
• Measure the backlash, and then adjust it within Keep tightening the retainer LH, and loosening the
specification. retainer RH until the pinion shaft cannot be turned.
<Ref. to 5AT-97, ADJUSTMENT, Front Differen- This is the “zero” state.
tial.>
F: ADJUSTMENT
1) Using the ST, screw-in the retainer until light
contact is felt. (A)
NOTE:
Screw-in the RH side slightly deeper than the LH
side.
AT-01986
(A) Retainer
5AT-97
Front Differential
7) After the “zero” state is established, back off the

retainer LH 3 notches and secure it with the lock
plate. Then back off the retainer RH and retighten
until it stops. Rotate the drive pinion few times.
Tighten the retainer RH 1-3/4 notches further. This
sets the preload. Finally, secure the retainer with its
lock plate.
(A)
AT-01988
(A) Lock plate
NOTE:
Turning the retainer by one tooth changes the
backlash about 0.05 mm (0.0020 in).
(A)
AT-01989
(A) 0.05 mm (0.0020 in)
8) Turn the drive pinion several times with ST1 and

check to see if the backlash is within the specified
value with ST2, ST3, ST4 and ST5.
ST5 498255400 PLATE
Backlash:
0.13 — 0.18 mm (0.0051 — 0.0071 in)
9) Adjust the tooth contact between front differen-
tial and drive shaft. <Ref. to 5AT-91, ADJUST-
MENT, Drive Pinion Shaft Assembly.>
5AT-98
AT Main Case
36.AT Main Case 14) Remove the mid carrier assembly.
A: REMOVAL
mission Assembly.>
from stay.
7) Remove the extension case and intermediate
9) Remove the reduction driven gear. <Ref. to 5AT-
78, REMOVAL, Reduction Driven Gear.>
10) Separate the converter case and transmission AT-01992
15) Remove the rear carrier assembly.
Case.>
11) Remove the control valve body. <Ref. to 5AT-
58, REMOVAL, Control Valve Body.>
12) Remove the oil pump cover.
<Ref. to 5AT-86, REMOVAL, Oil Pump Cover.>
NOTE:
The input clutch pack assembly and front sun gear
assembly are also removed together.
AT-01990
13) Remove the needle bearing of the mid carrier

assembly.
AT-01993
AT-01991
5AT-99
AT Main Case
16) Remove the mid & rear sun gear assembly. 19) Remove the direct clutch assembly.
AT-01997
20) Remove the snap ring of reverse brake.
AT-01994
AT-01998
17) Remove the thrust needle bearing of high & low
reverse clutch. 21) Remove the retaining plate.
22) Remove the leaf spring.
(A)
B’ B
AT-01995
18) Remove the high & low reverse clutch assem-

bly.
B’ B
(A)
AT-01999
AT-01996
(A) Leaf spring
23) Take out the drive plate, driven plate and dish
plate.
24) Remove the snap ring of the spring retainer of
reverse brake.
5AT-100
AT Main Case
ST1 18762AA000 COMPRESSOR SPECIAL 28) Apply compressed air.

TOOL
ST1
AT-02004
29) Remove the reverse brake piston.
ST2
ST3
AT-02005
B: INSTALLATION
AT-02000
1) Install the reverse brake piston.
25) Remove the spring retainer. NOTE:
Apply ATF onto the piston sliding surface.
TOOL
2) Install the return spring.
AT-02001
26) Remove the return spring.
AT-02002
3) Install the spring retainer and snap ring.

TOOL
AT-02002
27) Remove the snap ring of reverse brake piston.

TOOL
5AT-101
AT Main Case
ST3 18763AA000 COMPRESSOR SHAFT 8) Install the snap ring of reverse brake.
ST1
AT-01998
9) Perform the clearance check of reverse brake.

ST2 (1) Measure the clearance between retainer
plate and snap ring using thickness gauge.
Standard value:
ST3 0.7 — 1.1 mm (0.028 — 0.043 in)
AT-02000
4) Install the dish plate.

NOTE:
When installing, make sure that the identification
mark is facing the front side of transmission.
AT-02372
5) Install the drive plate and driven plate.
6) Install the leaf spring. (2) If the clearance is out of specification, select
a suitable retainer plate from following table and
assemble it.
(A)
Retainer plate
B’ B 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)
10) Install the direct clutch assembly.

B’ B
(A)
AT-01999 AT-01997
(A) Leaf spring
7) Install the retaining plate.
5AT-102
AT Main Case
11) Install the high & low reverse clutch assembly. 14) Install the rear carrier assembly.
AT-01996
12) Install the thrust needle bearing of high & low

reverse clutch.
AT-01993
AT-01995
15) Install the middle carrier assembly.
13) Install the middle & rear sun gear assembly.
AT-01992
AT-01994
5AT-103
AT Main Case
16) Install the thrust needle bearing of middle carri- (3) Make sure the rear end of drive pinion shaft
er assembly. is engaged to the spline of reduction driven
gear.
AT-01991
(A)
AT-02092
17) Measure the total end play, and select the
bearing. <Ref. to 5AT-106, ADJUSTMENT, AT
Main Case.>
18) Install the impact clutch pack assembly to oil (4) Using a cloth, protect the input clutch shaft
pump cover. and rotate to engage the spline of input clutch
and rear carrier using pliers.
(B)
NOTE:
Work with pressing oil pump cover.
(A)
AT-02006
(A) Impact clutch pack ASSY

(B) Front sun gear ASSY (A)
AT-02046
19) Turn the transmission sideways.
20) Install the oil pump cover. (A) Cloth
(1) Apply ATF to the O-ring of input clutch shaft.
(5) Combine the oil pump cover with transmis-
(2) Install the oil pump cover to AT main case
sion main case.
while supporting the input clutch shaft and oil
pump housing by hand. Tightening torque:
41 N!m (4.2 kgf-m, 30.4 ft-lb)
AT-01990
AT-01976
21) Install the center differential carrier. <Ref. to

5AT-80, INSTALLATION, Center Differential Carri-
er.>
22) Install the reduction driven gear. <Ref. to 5AT-
78, INSTALLATION, Reduction Driven Gear.>
5AT-104
AT Main Case
23) Install the extension case and intermediate 3) Remove the input clutch assembly from rear in-
case. <Ref. to 5AT-72, INSTALLATION, Extension ternal gear.
24) Install the control valve body. <Ref. to 5AT-58,
INSTALLATION, Control Valve Body.>
LATION, Converter Case.>
28) Install the oil charge pipe with O-ring. <Ref. to AT-02009
5AT-70, INSTALLATION, Oil Charge Pipe.> D: ASSEMBLY
5AT-71, INSTALLATION, Torque Converter As- 1. INPUT CLUTCH PACK ASSY
sembly.> 1) Assemble the input clutch assembly to rear inter-
30) Install the transmission assembly into vehicle. nal gear.
C: DISASSEMBLY
1. INPUT CLUTCH PACK ASSY
1) Remove the front sun gear.
AT-02009
2) Install the front carrier, and then install the snap

ring.
AT-02007
2) Remove the snap ring, and then remove the

front carrier.
AT-02008
3) Install the front sun gear.
AT-02008
AT-02007
5AT-105
AT Main Case
E: INSPECTION Standard value:

0.6 — 0.8 mm (0.024 — 0.031 in)
1. FRONT, MIDDLE & REAR PLANETARY
CARRIER ASSY L
Inspect the followings:

• Visually inspect the tooth surface of planetary
gear, and replace with new one if damaged, broken
or excessively worn.
• Inspect the planetary carrier body for damage or
brakeage.
2. INPUT CLUTCH
AT-02011
Check for damage of drive plate, driven plate and
snap ring, and replace them as input clutch assem- 5. REVERSE BRAKE
bly if damaged.
3. HIGH & LOW REVERSE CLUTCH AS- • Drive plate facing for wear and damage
SEMBLY • Snap ring for wear, return spring for breakage,
Check the clearance of high & low reverse clutch. and spring retainer for deformation
Measure the clearance “L” between snap ring and • Lip seal and D-ring for damage
retaining plate using thickness gauge. If the mea- • Piston operation
sured value is out of specification, replace them as F: ADJUSTMENT
high & low reverse clutch assembly. 1) Using the ST, measure the height “A” from AT
Standard value: main case mating surface to convex surface of oil
1.8 — 2.2 mm (0.070 — 0.087 in) pump cover.
ST 499575400 GAUGE
L
ST
AT-02010
AT-02012
4. DIRECT CLUTCH ASSEMBLY 2) Using the ST, measure the depth “B” from the
Check the clearance of direct clutch. convex surface of oil pump cover to thrust bearing
Measure the clearance “L” between snap ring and transferring surface.
retaining plate using thickness gauge. If the mea- ST 499575400 GAUGE
sured value is out of specification, replace them as
direct clutch assembly.
B ST
AT-02013
3) Calculate the measured value on step 1) and 2),

and then set the calculated value as “C”
Calculation formula: C = A " B
5AT-106
AT Main Case
4) Using the ST, measure the depth “D” from AT NOTE:

main case mating surface to thrust bearing trans- Calculation formula for “T” is applied when measur-
ferring surface of front sun gear. ing using ST (499575400 GAUGE). In the calcula-
ST 499575400 GAUGE tion without using ST, insert the thickness of collar
to calculate value “E” on step 5).
ST AT-02014
5) Set the value as “E” which subtract the thickness

of ST GAUGE from measured value on step 4).
Calculation formula: E (mm) = D " 15
[E (in) = D " 0.59]
Select a thrust bearing from the table to adjust
clearance within 0.25 — 0.55 mm (0.0098 — 0.022
in).
T (mm) = E " C + 0.03
[T (in) = E " C + 0.0012]
T (mm) = E " C " 0.27
[T (in) = E " C " 0.012]
T: Thrust bearing clearance

C: Distance from oil pump cover mating surface to
rear end of oil pump cover
E: Depth from mating surface of AT main case to
bearing surface of front sun gear
Example:
When the A is 39.50 mm (1.56 in), B is going to be
16.20 mm (0.64 in), so the C would be 23.30 mm
(0.92 in) by calculation.
When the D is 41.90 mm (1.65 in), subtract the
thickness of ST GAUGE from D, and then the value
E would be 26.90 mm (1.06 in).
Calculation when clearance is 0.25 mm (0.0098 in)
T (mm) = 26.90 " 23.30 + 0.03 = 3.63
[T (in) = 1.059 " 0.917 + 0.0012 = 0.143]
Calculation formula when clearances are 0.55 mm
(0.022 in)
T (mm) = 26.90 " 23.30 " 0.27 = 3.33
[T (in) = 1.059 " 0.917 " 0.012 = 0.131]
According to the calculation, the value “T” would be

3.33 — 3.63 mm (0.131 — 0.143 in), therefore se-
lect the thrust bearing with the thickness of 3.4 mm
(0.134 in) or 3.6 mm (0.142 in) thrust bearing from
the table.
5AT-107
37.Transmission Control Device 10) Remove the detention spring.
A: REMOVAL
mission Assembly.>
3) Lift-up the lever on rear side of transmission har-
ness connector, and then disconnect it from stay.
69, REMOVAL, Air Breather Hose.> AT-00307
5) Wrap vinyl tape around the nipple attached to B: INSTALLATION
the air breather hose. 1) Install the detention spring to transmission case.
6) Remove the pitching stopper bracket.
7) Remove the control valve body assembly. <Ref. Tightening torque:
to 5AT-58, REMOVAL, Control Valve Body.> 6 N!m (0.6 kgf-m, 4.3 ft-lb)
8) Pull out the straight pin of manual plate.
AT-00307
AT-00305
2) Insert the select lever, and then tighten the bolt.
9) Remove the bolts securing select lever, and then
Tightening torque:
remove the select lever, manual plate and parking
6 N!m (0.6 kgf-m, 4.3 ft-lb)
rod.
NOTE:
Be careful not to damage the lips of press-fitted oil
seal in the case.
AT-00308
AT-00306
(A) Bolt
(C) Manual plate
(D) Parking rod
5AT-108
3) Insert the manual plate and parking rod.
AT-00306
(A) Bolt
(C) Manual plate
(D) Parking rod
4) Insert the spring pin to manual plate.
AT-00305
5) Install the oil pan and control valve assembly.

<Ref. to 5AT-58, INSTALLATION, Control Valve
Body.>
6) Install the pitching stopper bracket.
Tightening torque:
41 N!m (4.2 kgf-m, 30.4 ft-lb)
7) Insert the transmission connector to the stay.
8) Install the air breather hose.<Ref. to 5AT-69, IN-
STALLATION, Air Breather Hose.>
sembly.>
C: INSPECTION
Make sure the manual lever and detention spring
are not worn or otherwise damaged.
5AT-109
5AT-110
CONTROL SYSTEMS CS

(DIAGNOSTICS)


approval.

(DIAGNOSTICS)
5AT(diag)
Page
1. Basic Diagnostics Procedure ......................................................................2
2. Check List for Interview...............................................................................4
4. Electrical Component Location ...................................................................7
5. Transmission Control Module (TCM) I/O Signal .......................................12
6. Subaru Select Monitor...............................................................................16
7. Read Diagnostic Trouble Code (DTC) ......................................................19
8. Inspection Mode........................................................................................20
9. Clear Memory Mode..................................................................................21
10. Learning Control........................................................................................22
11. SPORT Indicator Light Display .................................................................23
12. Diagnostic Procedure for Select Monitor Communication.........................26
13. List of Diagnostic Trouble Code (DTC) .....................................................30
14. Diagnostic Procedure with Diagnostic Trouble Code (DTC) .....................34
15. Diagnostic Procedure without Diagnostic Trouble Code (DTC) ..............138
16. General Diagnostic Table........................................................................147
Basic Diagnostics Procedure
1. Basic Diagnostics Procedure

A: PROCEDURE
Step Check Yes No
1 CHECK PRE-INSPECTION. Is the unit that might influence Go to step 2. Repair or replace
1) Ask the customer when and how the trou- the AT problem normal? each item.
ble occurred using the interview checklist.
<Ref. to 5AT(diag)-4, Check List for Interview.>
2) Before performing diagnosis, inspect the
following items which might influence the AT
problems.
• General inspection <Ref. to 5AT(diag)-5,
INSPECTION, General Description.>
• Oil Leakage
• Stall speed test <Ref. to 5AT-31, Stall Test.>
• Line Pressure Test <Ref. to 5AT-34, Line
Pressure Test.>
• Transfer Clutch Pressure Test <Ref. to 5AT-
36, Transfer Clutch Pressure Test.>
• Time Lag Test <Ref. to 5AT-33, Time Lag
Test.>
• Road Test <Ref. to 5AT-30, Road Test.>
• Inhibitor Switch <Ref. to 5AT-51, Inhibitor
Switch.>
After the ignition switch is turned to “ON”, wait light illuminate?
for at least 2 seconds.
1) Turn the ignition switch to OFF. light blink?
2) Check the SPORT indicator light. <Ref. to
5AT(diag)-24, INSPECTION, SPORT Indicator
Light Display.>
3) After the ignition switch is turned to ON,
wait for at least 2 seconds.
4 CHECK DTC. Is DTC displayed? Go to step 6. Go to step 5.
Read the DTC. <Ref. to 5AT(diag)-19, OPERA- NOTE:
TION, Read Diagnostic Trouble Code (DTC).> Record all DTC.
NOTE:
If the communication function of the Subaru Se-
lect Monitor cannot be executed normally,
check the communication circuit. <Ref. to
5AT(diag)-26, COMMUNICATION FOR INI-
TIALIZING IMPOSSIBLE, Diagnostic Proce-
dure for Select Monitor Communication.>
5 PERFORM THE GENERAL DIAGNOSTICS. Is DTC displayed? Go to step 6. Inspect using
1) Inspect using “Diagnostic Procedure with- “General Diagnos-
out Diagnostic Trouble Code (DTC)”. <Ref. to tic Table”. <Ref. to
5AT(diag)-138, Diagnostic Procedure without 5AT(diag)-147,
Diagnostic Trouble Code (DTC).> General Diagnos-
2) Perform clear memory mode. tic Table.>
4) Display DTC.
5AT(diag)-2
Basic Diagnostics Procedure
Step Check Yes No

6 PERFORM THE DIAGNOSIS. Is DTC displayed? Inspect using the Inspect using
1) Inspect using the “Diagnostic Procedure “Diagnostic Proce- “General Diagnos-
with Diagnostic Trouble Code (DTC)”. <Ref. to dure with Diagnos- tic Table”. <Ref. to
5AT(diag)-34, Diagnostic Procedure with Diag- tic Trouble Code 5AT(diag)-147,
nostic Trouble Code (DTC).> (DTC)”. <Ref. to General Diagnos-
NOTE: 5AT(diag)-34, tic Table.>
For DTC table, refer to “List of Diagnostic Trou- Diagnostic Proce-
ble Code (DTC)”. <Ref. to 5AT(diag)-30, List of dure with Diagnos-
Diagnostic Trouble Code (DTC).> tic Trouble Code
2) Repair the trouble cause. (DTC).>
3) Perform clear memory mode.
5) Display DTC.
5AT(diag)-3
Check List for Interview
2. Check List for Interview

A: INSPECTION
Check the following items when problem has occurred.
NOTE:
Use copies of this page for interviewing customers.
Customer’s name
Date of sale
Date of repair
Trans. model TRANSMISSION V.I.N.
Odometer reading km (miles)
Symptom ❏ No up-shift
❏ No down-shift
❏ No kick down
❏ Vehicle does not move (❏ Any position ❏ Particular position)
❏ Lock-up malfunction
❏ Noise or vibration
❏ Shift shock or slip
❏ Select lever does not move
❏ Others
( )
Frequency ❏ Continuous ❏ Intermittent ( times a day)
Weather ❏ Fine ❏ Cloudy ❏ Rainy ❏ Snowy
❏ Others
( )
Place ❏ Highland ❏ Suburbs ❏ Inner city ❏ Uphill ❏ Rough road
❏ Others
( )
Ambient air temperature ❏ Hot ❏ Warm ❏ Cool ❏ Cold
Vehicle speed km/h (MPH)
AT warning light (SPORT indicator ❏ Blinks continuously ❏ Not blink
light)
Select lever position ❏P ❏R ❏N ❏D ❏ Manual mode
Driving condition ❏ Not affected ❏ At starting ❏ While idling
❏ At racing ❏ When accelerating ❏ While cruising
❏ When decelerating ❏ While turning (❏ RH / ❏ LH)
Manual mode ❏ ON ❏ OFF
5AT(diag)-4
General Description
3. General Description 3. ATF LEVEL

A: CAUTION Make sure that ATF level is in the specification.
<Ref. to 5AT-27, INSPECTION, Automatic Trans-
• Supplemental Restraint System
mission Fluid.>
The airbag system wiring harness is routed near
the TCM.
CAUTION: (A)
F
• All airbag system wiring harnesses and con- (C) (B)
HOT
L
nectors are colored yellow. Do not use an elec- (D)
tric test equipment on these circuits.

(C)
F
• Be careful not to damage the airbag system
COLD
(E)
L
(D)
wiring harness when performing diagnostics
and servicing the TCM.
• Measurement
When measuring the voltage and resistance of the AT-01450
ECM, TCM or each sensor, use a tapered pin with

(A) Level gauge
a diameter of less than 0.64 mm (0.025 in) in order
to avoid poor contact. Do not insert a pin more than (B) Check position when “HOT”
0.65 mm (0.026 in) diameter. (C) Upper level
(D) Lower level
B: INSPECTION (E) Check position when “COLD”
1. BATTERY
4. FRONT DIFFERENTIAL OIL LEVEL
Measure battery voltage and specific gravity of
electrolyte. Make sure the front differential oil level is in the
specification. <Ref. to 5AT-29, INSPECTION, Dif-
Standard voltage: 12 V or more ferential Gear Oil.>
Specific gravity: More than 1.260
2. TRANSMISSION GROUND
Make sure that the ground terminal bolt is tightened
securely.
F
(A)
• Chassis side (B)
L
Tightening torque:
13 N!m (1.3 kgf-m, 9.4 ft-lb)
AT-00317
(A) Upper level

(B) Lower level
5. OPERATION OF SHIFT SELECT LEVER

Make sure there is no abnormal noise, dragging or
contact pattern in each select lever range.
AT-01464
WARNING:
Stop the engine while checking operation of the
select lever.
5AT(diag)-5
General Description
• LHD model • RHD model
AT-02048 AT-01465
C: PREPARATION TOOL
1. SPECIAL TOOL
ST24082AA230
ST22771AA030
2. GENERAL TOOL
TOOL NAME REMARKS
Circuit tester Used for measuring resistance, voltage and current.
Oscilloscope Used for measuring sensor.
5AT(diag)-6
4. Electrical Component Location

A: LOCATION
1. CONTROL MODULE
• LHD model
(1)
(3) (4) (2) (5)

AT-02049
light)
• RHD model
(3) (2) (4) (5)
(1)
AT-01467
light)
5AT(diag)-7
• LHD model
(1)
(2)
AT-02051 AT-01470
(4)
(3)
AT-02053 AT-02052
(5)
AT-02054
• RHD model
(1)
(2)
AT-01468 AT-01470
5AT(diag)-8
(4)
(3)
AT-01469 AT-01471
(5)
AT-01472
2. SENSOR
• LHD model
(3) (6),(9) (7)
(5),(8) (1) (2) (4)
AT-02050
5AT(diag)-9
• RHD model
(1) (3) (6),(9) (7)
(5),(8) (2) (4)

AT-01443
(1) Accelerator position sensor (4) Rear vehicle speed sensor (7) Lateral G sensor
(2) Front vehicle speed sensor (5) Turbine speed sensor 1 (8) Turbine speed sensor 2
(3) Inhibitor switch (6) ATF temperature sensor 1 (9) ATF temperature sensor 2
(2)
(1)
AT-00375 AT-01447
(5)
(4)
(3)
AT-01445 AT-01448
5AT(diag)-10
(7)
(6)
AT-01446 AT-01475
(9)
(8)
AT-01759 AT-01760
3. SOLENOID
(3) (2) (4) (7) (8) (6) (5) (1)
(9)
AT-01449
(1) High & low reverse clutch solenoid (4) Input clutch solenoid (7) Transfer solenoid
(2) Direct clutch solenoid (5) Line pressure solenoid (8) Low coast brake solenoid
(3) Front brake solenoid (6) Lock up solenoid (9) Memory box
5AT(diag)-11
5. Transmission Control Module (TCM) I/O Signal

A: ELECTRICAL SPECIFICATION
B54 B55
1 2 3 4 5 6 7 8 9 1 2 3 4 5 6 7 8 9
10 11 12 13 14 15 16 17 18 10 11 12 13 14 15 16 17 18
19 20 21 22 23 24 19 20 21 22 23 24
AT-01451
NOTE:
The measurement should perform after warming up.
Measure the
Ter-
resistance
Connector min
Item Measuring conditions Voltage (V) between termi- Remarks
No. al
nal and chassis
No.
ground.
Engine ON, “P” range,
Approx. 4.0 —
Accelerator OFF, Brake
6.0 V 3 — 9 " (ATF Driving fre-
P/L solenoid output B54 9 ON temperature quency 750 —
Manual mode 1st, Accel- Approx. 2.0 — 20#C (68#F)) 850 Hz
erator OFF, Brake ON 4.0 V
Power supply
8 Ignition switch ON —
voltage
PVIGN power supply B54
Power supply
7 Ignition switch ON —
voltage
The condition
of I/C oil pres-
I/C oil pressure switch
B54 6 — — — sure switch
input
cannot read by
the tester.
Power GND B54 5 Always Approx. 0 V —
CAN communication line
B54 4 — — —
(+)
CAN communication line
B54 3 — — —
($)
2.5 — 2.9 V 4.0 — 5.0 k"
(ATF tempera- (ATF tempera-
ture 20#C ture 20#C
ATF temperature sensor (68#F)) (68#F))
B54 2 Ignition switch ON
1 input 0.8 — 1.0 V 0.7 — 0.9 k"
ture 80#C ture 80#C
(176#F)) (176#F))
5AT(diag)-12
Measure the
Ter-
resistance
Connector min
No. al
nal and chassis
No.
ground.
Power supply
Battery power supply B54 1 Always —
voltage
While driving at 1st — 3rd Approx. 5.5 —
of manual mode 7.5 V 3 — 9 " (ATF Driving fre-
I/C solenoid output B54 18 temperature quency 750 —
While driving at 4th or 5th 20#C (68#F)) 850 Hz
Approx. 0 V
of manual mode
While driving at 2nd of Approx. 5.5 —
manual mode 7.5 V 3 — 9 " (ATF Driving fre-
H&LR/C solenoid output B54 17 temperature quency 750 —
While driving at 3rd — 5th 20#C (68#F)) 850 Hz
Approx. 0 V
of manual mode
Power supply
Control valve power sup- Ignition switch ON
B54 16 voltage —
ply output
Ignition switch OFF Approx. 0 V
While driving at 1st — 2nd Power supply
5 — 17 " (ATF
of manual mode voltage
LC/B solenoid output B54 15 temperature
While driving at 3rd — 5th 25#C (77#F))
Approx. 0 V
of manual mode
Power GND B54 14 Always Approx. 0 V —
Analog GND (Sensor
B54 13 Always Approx. 0 V —
GND)
The condition
of LC/B oil
LC/B oil pressure switch
B54 12 — — — pressure switch
input
cannot read by
the tester.
2.3 — 2.7 V 3.0 — 3.6 k"
ture 20#C ture 20#C
ATF temperature sensor (68#F)) (68#F))
B54 11 Ignition switch ON
2 input 0.6 — 0.8 V 0.4 — 0.6 k"
ture 80#C ture 80#C
(176#F)) (176#F))
PVIGN power supply
B54 10 Ignition switch ON 0 — 1.5 V —
relay output
While driving at other than Approx. 4.5 —
4th of manual mode 6.5 V 3 — 9 " (ATF Driving fre-
Fr/B solenoid output B54 24 temperature quency 750 —
While driving at 4th of 20#C (68#F)) 850 Hz
Approx. 0 V
manual mode
When lock-up
Approx. 3.5 — 3 — 9 " (ATF Driving fre-
L/U solenoid output B54 23 5.5 V temperature quency 750 —
When not lock-up Approx. 0 V 20#C (68#F)) 850 Hz
While driving at 1st or 5th Approx. 5.5 —
of manual mode 7.5 V 3 — 9 " (ATF Driving fre-
D/C solenoid output B54 22 temperature quency 750 —
While driving at 2nd — 4th 20#C (68#F)) 850 Hz
Approx. 0 V
of manual mode
The condition
of D/C oil pres-
D/C oil pressure switch
B54 21 — — — sure switch
input
cannot read by
the tester.
B54 20 — — —
communication line
5AT(diag)-13
Measure the
Ter-
resistance
Connector min
No. al
nal and chassis
No.
ground.
Control GND B54 19 Always Approx. 0 V —
While driving at 2nd of Power supply
H&LR/C oil pressure manual mode voltage
B55 8 —
switch input While driving at 3rd — 5th
Approx. 0 V
of manual mode
While driving at 2nd and
Approx. 140 —
20 km/h (12 MPH) of man-
170 Hz
Front vehicle speed sen- ual mode
B55 7 —
sor input While driving at 4th and 80
Approx. 560 —
km/h (50 MPH) of manual
680 Hz
mode
Lateral G sensor power
B55 6 Ignition switch ON 4.75 — 5.25 V —
supply
Lateral G sensor signal Ignition switch ON, Engine
B55 5 2.0 — 3.0 V —
input ON, Flat value
Ignition switch ON, “P”
4.0 — 5.0 V
range
Inhibitor switch 1 input B55 4 —
Ignition switch ON, “N”
1.5 V or less
range
4.0 — 5.0 V
range
Ignition switch ON, “D”
1.5 V or less
range
Power supply
Accessory switch ON
Accessory power supply B55 2 voltage —
Accessory switch OFF Approx. 0 V
Power supply
Ignition switch ON
Ignition power supply B55 1 voltage —
While driving at 2nd and
Approx. 190 —
20 km/h (12 MPH) of man-
230 Hz
Rear vehicle speed sen- ual mode
B55 18 —
sor input While driving at 4th and 80
Approx. 760 —
km/h (50 MPH) of manual
920 Hz
mode
Ignition switch ON, Engine
ON, While driving at other Approx. 0 V
Fr/B oil pressure switch than 4th
B55 17 —
input
Ignition switch ON, Engine Power supply
ON, While driving at 4th voltage
2nd of manual mode, Tur-
bine speed sensor is Use an oscillo-
Approx. 0 Hz
2,000 rpm (Read from scope.
Turbine speed sensor 1 Subaru Select Monitor)
B55 16 —
input 4th of manual mode, Tur-
bine speed sensor is Approx. 1,900 Use an oscillo-
2,000 rpm (Read from — 2,100 Hz scope.
Subaru Select Monitor)
5AT(diag)-14
Measure the
Ter-
resistance
Connector min
No. al
nal and chassis
No.
ground.
About Power
Ignition switch ON, While
Supply Voltage
stopping at “D” range
Range lock solenoid out- $ 1.2 V
B55 15 7 — 21 "
put Ignition switch ON, Vehicle
speed at least 20 km/h (12 Approx. 0 V
MPH)
Ignition switch ON, “R”
4.0 — 5.0 V
range
1.5 V or less
range
4.0 — 5.0 V
range
1.5 V or less
range
Control valve communi-
B55 12 — — —
cation line
Ignition switch ON, “R” Approx. 90 —
1.5 V
Back-up light relay out- range 110 " (ATF tem-
B55 11
put Ignition switch ON, Other Power supply perature 25#C
than “R” range voltage (77#F))
Power supply
Ignition switch ON
Ignition power supply B55 10 voltage —
Engine ON, “P” range or
“N” range, Accelerator Approx. 0 V
OFF 3 — 9 " (ATF Driving fre-
AWD solenoid output B55 23 temperature quency 750 —
Engine ON, “D” range, 20#C (68#F)) 850 Hz
Approx. 2.0 —
Accelerator OFF, Brake
3.0 V
ON
2nd of manual mode, Tur-
Turbine speed sensor 2 Subaru Select Monitor)
B55 22
input 4th of manual mode, Tur-
—
Subaru Select Monitor)
Control GND B55 21 Always Approx. 0 V —
4.0 — 5.0 V
Inhibitor switch 3 open range
B55 20 —
circuit monitor input Ignition switch ON, “R”
Less than 1.5 V
range
Ignition switch ON, Other ECM should
Power supply
than “P” range or “N” — connected cor-
voltage
PN signal output B55 19 range rectly
0 — 1.0 V —
range or “N” range
5AT(diag)-15
6. Subaru Select Monitor NOTE:

Do not connect scan tools except for Subaru Select
A: OPERATION Monitor.
1. READ DIAGNOSTIC TROUBLE CODE 5) Turn ignition switch to ON (engine OFF) and turn
(DTC) on the Subaru Select Monitor.
1) Prepare the Subaru Select Monitor kit.
(A)
AT-00341
AT-00338 (A) Power switch

2) Connect the diagnosis cable to Subaru Select 6) On the «Main Menu» display screen, select the
Monitor. {Each System Check} and press the [YES] key.
3) Insert the cartridge to Subaru Select Monitor. 7) On the «System Selection Menu» display
<Ref. to 5AT(diag)-6, PREPARATION TOOL, Gen- screen, select the {Transmission} and press the
eral Description.> [YES] key.
screen, select the {Diagnosis Code(s) Display} and
press [YES] key.
NOTE:
• For details concerning operation procedure, re-
fer to the “SUBARU SELECT MONITOR OPERA-
TION MANUAL”.
AT-00339 • For details concerning DTCs, refer to the List of
4) Connect the Subaru Select Monitor to data link Diagnostic Trouble Code (DTC). <Ref. to 5AT(di-
connector. ag)-30, List of Diagnostic Trouble Code (DTC).>
(1) Data link connector is located in the lower 2. READ CURRENT DATA
portion of the instrument panel (on the driver’s
side). 1) On the «Main Menu» display screen, select the
[YES] key.
(1) 3) Press the [YES] key after the information of
screen, select the {Current Data Display & Save}
and press the [YES] key.
AT-01712 screen, select the {Data Display} and press the
[YES] key.
(1) Data link connector 6) Using the scroll key, scroll the display screen up
or down until the desired data is shown.
(2) Connect the diagnosis cable to data link
connector.
5AT(diag)-16
• A list of the support data is shown in the following table.

Engine speed signal Engine speed rpm
Battery voltage Battery Voltage V
Accelerator Position Sensor Acceleration opening angle %
Front vehicle speed sensor signal Front Wheel Speed km/h
Gear position Gear Position —
Turbine speed sensor signal Turbine Revolution Speed rpm
Rear vehicle speed sensor signal Rear Wheel Speed km/h
Lateral G sensor Lateral G sensor V
ATF Temperature Sensor 1 Signal ATF Temp. #C
ATF Temperature Sensor 2 Signal ATF Temp. 2 #C
Turbine speed sensor 1 signal Turbine Revolution Speed 1 rpm
Turbine speed sensor 2 signal Turbine Revolution Speed 2 rpm
High & Low Reverse Clutch Solenoid Indicator Current H&LR/C Solenoid Current A
Direct Clutch Solenoid Indicator Current D/C Solenoid Current A
Front Brake Solenoid Indicator Current F/B Solenoid Current A
Input Clutch Solenoid Indicator Current I/C Solenoid Current A
Line Pressure Solenoid Indicator Current P/L Solenoid Current A
Lock-up Solenoid Indicator Current L/U Solenoid Current A
Transfer Solenoid Indicator Current AWD Solenoid Current A
H&LR/C Solenoid Target Pres-
High & Low Reverse Clutch Solenoid Target Oil Pressure kPa
sure
Direct Clutch Solenoid Target Oil Pressure D/C Solenoid Target Pressure kPa
Front Brake Solenoid Target Oil Pressure F/B Solenoid Target Pressure kPa
Input Clutch Solenoid Target Oil Pressure I/C Solenoid Target Pressure kPa
Line Pressure Solenoid Target Oil Pressure P/L Solenoid Target Pressure kPa
Lock-up Solenoid Target Oil Pressure L/U Solenoid Target Pressure kPa
Transfer Solenoid Target Oil Pressure AWD Solenoid Target Pressure kPa
Ignition switch Ignition SW ON Input or OFF Input
Tip signal Tip Mode SW ON or OFF
Cruise control On signal Cruise Control Signal ON or OFF
Tip Down Shift Signal Down SW ON or OFF
Stop light switch signal Stop Light SW ON or OFF
Tip Up Shift Signal Up SW ON or OFF
Drive range signal D Range ON or OFF
Reverse range signal R Range ON or OFF
Diagnosis Light Output Signal Diagnosis Lamp ON or OFF
Shift lock solenoid signal Shift lock solenoid ON or OFF
Parking range signal P range ON or OFF
P/N Range Output Signal P/N Signal ON or OFF
Neutral range signal N range ON or OFF
Inhibitor Switch 1 Input Signal Inhibitor SW1 High or Low
Inhibitor Switch 3 Monitor Input Signal Inhibitor SW3 Monitor High or Low
Backup light relay output signal Back-up light relay ON or OFF
High & Low Reverse Clutch Oil Pressure Switch Input Signal H&LR/C Oil Pressure SW ON or OFF
Direct Clutch Oil Pressure Switch Input Signal D/C Oil Pressure SW ON or OFF
Front Brake Oil Pressure Switch Input Signal Fr/B Oil Pressure SW ON or OFF
Input Clutch Oil Pressure Switch Input Signal I/C Oil Pressure SW ON or OFF
5AT(diag)-17

Low Coast Brake Oil Pressure Switch Input Signal LC/B Oil Pressure SW ON or OFF
Low Coast Brake Solenoid Input Signal LC B Solenoid ON or OFF
NOTE:
For details concerning operation procedure, refer
to the “SUBARU SELECT MONITOR OPERATION
MANUAL”.
3. CLEAR MEMORY MODE
NOTE:
To clear the previous DTC, use {Clear Memory},
and to clear the learned value, use {Clear Memory
2}.
1) Check that the select lever is in “P” range.
[YES] key.
screen, select the {Clear Memory} and press the
[YES] key.
NOTE:
If {Clear Memory 2} is selected and performed,
DTC may not be cleared.
6) When the ‘Done’ are shown on the display
screen, turn off the Subaru Select Monitor and turn
the ignition switch to OFF. To turn the ignition
switch ON again, wait for more than 10 seconds.
NOTE:
For details concerning operation procedure, refer
to the “SUBARU SELECT MONITOR OPERATION
MANUAL”.
5AT(diag)-18
Read Diagnostic Trouble Code (DTC)
7. Read Diagnostic Trouble

Code (DTC)
A: OPERATION
about how to obtain and understand the DTC.
<Ref. to 5AT(diag)-16, OPERATION, Subaru Se-
lect Monitor.>
NOTE:
DTC can not be read by SPORT indicator light.
5AT(diag)-19
Inspection Mode
8. Inspection Mode
A: PROCEDURE
WARNING:
Observe the traffic law during actual driving.
1) Shift the select lever to “D” range, and then drive
the vehicle with changing the gear from 1st to 5th.
2) When driving the vehicle at 5th speed of “D”
range, set the gear to manual mode and drive the
vehicle with shifting down using “$” of steering
switch or “$” of select lever from 5th % 4th, 4th %
3rd, 3rd % 2nd, 2nd % 1st.
NOTE:
At shifting down, drive the vehicle at least 10 sec-
onds in each speed.
3) Shift the select lever to “R” range and drive the
vehicle for more than 2 seconds.
5AT(diag)-20
Clear Memory Mode
9. Clear Memory Mode

A: OPERATION
Use “Subaru Select Monitor” to clear DTC. <Ref. to
5AT(diag)-18, CLEAR MEMORY MODE, OPERA-
NOTE:
DTC cannot be cleared without using Subaru Se-
lect Monitor.
5AT(diag)-21
Learning Control
10.Learning Control
A: GENERAL DESCRIPTION
Be sure to perform the {Clear Memory 2} only when
the following services are performed. And when the
shifting shock is occurred in total check with vehicle
driving, perform the learning with following proce-
dures. <Ref. to 5AT(diag)-18, CLEAR MEMORY
MODE, OPERATION, Subaru Select Monitor.>
• Replacement of TCM
• Replacement of transmission assembly
• Replacement of TCM and transmission assem-
bly
CAUTION:
When {Clear Memory 2} is executed, DTC may
not be cleared.
B: PROCEDURE
2) Turn the air conditioner switch to OFF.
3) Turn the headlight switch to OFF.
4) Turn the rear defogger switch to OFF.
6) Connect the Subaru Select Monitor to the vehi-
cle.
7) Drive the vehicle for 5 — 10 km (3 — 6 miles) to
warm up ATF temperature more than 70 #C (158
#F).
8) With the throttle opening angle on SUBARU se-
lect monitor indicates between 10%&2%, shift the
gear from 1st % 2nd, 2nd % 3rd, 3rd % 4th, 4th %
5th while driving the vehicle at “D” range. <Ref. to
9) Repeat the step 8) until reducing of shifting
shock was felt.
10) Reducing of shifting shock was not felt though
the procedure was repeated 5 cycle, recheck that
the learning conditions (throttle opening angle, ATF
temperature, etc.) are specified and recheck that
other parts are normal.
5AT(diag)-22
11.SPORT Indicator Light Display

A: OPERATION
When any on-board diagnostics item is malfunctioning, the display on the SPORT indicator light blinks from
the time the malfunction is detected after starting the engine until the ignition switch is turned OFF. The mal-
functioning part or unit can be determined by a DTC during the on-board diagnostics operation. Problems
which occurred previously can also be identified through the memory function. If the SPORT indicator light
does not show a problem (although a problem is occurring), the problem can be determined by checking the
performance characteristics of each sensor using the Subaru Select Monitor. Indicator light signal is as
shown in the figure.
When the SPORT indicator light does not operates normally though the DTC is not stored, perform the
SPORT indicator light inspection. <Ref. to 5AT(diag)-24, INSPECTION, SPORT Indicator Light Display.>
(A)
(1)
(2)
(B)
(1)
(3)
(2)
(4)
(C)
(1)
(3)
(2)
(5)
AT-01750
(A) Ignition switch (Engine OFF) (B) Normal (Engine ON) (C) Faulty (Engine ON)
(1) ON (3) 2 sec. (5) Blink

(2) OFF (4) 0.25 sec.
5AT(diag)-23
B: INSPECTION
DIAGNOSIS:
SPORT indicator light circuit is open or shorted.
TROUBLE SYMPTOM:
When the ignition switch is turned to ON (engine OFF), SPORT indicator light does not illuminate.
WIRING DIAGRAM:
i10
IGNITION
1 2 3 4 5 6 7 8 9 10
SWITCH
11 12 13 14 15 16 17 18 19 20 21 22
SBF-1 SBF-7
i77
No.12
1 2 3 4 5 6 7 8 9 10 11 12
BATTERY
A: i84
3
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
24 25 26 27 28 29 30 31 32 33 34 35
SPORT COMBINATION
E METER
i10 B: B280
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19 20
21
22
21 22 23 24 25 26 27 28 29 30
1
JOINT
CONNECTOR
B54
i77
8
1 2 3 4 5 6 7 8 9
10 11 12 13 14 15 16 17 18
A26
A27
19 20 21 22 23 24
B: B280 A: i84 BODY INTEGRATED UNIT

B20
B30
4
B54 TCM
AT-01452
5AT(diag)-24
Step Check Yes No

1 CHECK SPORT INDICATOR LIGHT. Does the SPORT indicator Go to step 2. Perform the self-
Turn the ignition switch to ON. light illuminate? diagnosis of com-
bination meter.
After the ignition switch is “ON”, wait for at least light illuminate?
2 seconds.
3 CHECK SPORT INDICATOR LIGHT. Does the SPORT indicator Normal. Go back Go to step 7.
Start the engine. light go off? to “Basic Diagno-
sis Procedure”.
<Ref. to 5AT(diag)-
2, Basic Diagnos-
tics Procedure.>
4 CHECK SUBARU SELECT MONITOR COM- Is the communication between Go to step 5. Check the TCM
MUNICATION. Subaru Select Monitor and power supply
Connect the Subaru Select Monitor to data link TCM normal? ground circuit and
connector. Subaru Select
Monitor communi-
cation. <Ref. to
5AT(diag)-26,
Diagnostic Proce-
dure for Select
Monitor Communi-
cation.>
5 CHECK TCM. Is “Diagnosis light” output sig- Go to step 6. Replace the TCM.
Display the current data of TCM using Subaru nal set to “ON”? <Ref. to 5AT-61,
Select Monitor. Transmission Con-
trol Module
(TCM).>
6 CHECK BODY INTEGRATED UNIT. Is “SPORT light” input signal Replace the com- Check DTC of
Display the current data of body integrated unit set to “ON”? bination meter body integrated
using Subaru Select Monitor. <Ref. to assembly. <Ref. to unit. <Ref. to
LAN(diag)-14, OPERATION, Subaru Select IDI-16, Combina- LAN(diag)-14,
Monitor.> tion Meter Assem- OPERATION,
bly.> Subaru Select
Monitor.>
7 CHECK TCM. Is “Diagnosis light” output sig- Replace the TCM. Go to step 8.
1) Start the engine. nal set to “ON”? <Ref. to 5AT-61,
2) Display the current data of TCM using Sub- Transmission Con-
aru Select Monitor. <Ref. to 5AT(diag)-16, trol Module
OPERATION, Subaru Select Monitor.> (TCM).>
8 CHECK BODY INTEGRATED UNIT. Is “SPORT light” input signal Check DTC of Perform the self-
Display the current data of body integrated unit set to “ON”? body integrated diagnosis for com-
using Subaru Select Monitor. <Ref. to unit. Perform the bination meter.
LAN(diag)-14, OPERATION, Subaru Select diagnosis accord- <Ref. to IDI-3,
Monitor.> ing to DTC. <Ref. INSPECTION,
to LAN(diag)-14, Combination
OPERATION, Meter System.>
Subaru Select
Monitor.>
5AT(diag)-25
12.Diagnostic Procedure for Select Monitor Communication

A: COMMUNICATION FOR INITIALIZING IMPOSSIBLE
DIAGNOSIS:
Faulty harness connector
TROUBLE SYMPTOM:
Subaru Select Monitor communication failure
WIRING DIAGRAM:
BATTERY
No.13
SBF-1
E
NO.32
SBF-7
1
2
3
DATA LINK
IGNITION ACCESSORY 10
CONNECTOR
SWITCH SWITCH 12
B40
B357 13
NO.12
NO.31
4
B21
16
E2
B10
A20
A10
B1
B2
A1
A7
A8
A: B54 B: B55 TCM
E
A19
A14
B21
A5
E E TRANSMISSION
B21 B40 A: B54 B: B55
1 2 3 4
1 2 3 4 5 6 7 8 9 1 2 3 4 5 6 7 8 9
5 6 7 8 1 2 3 4 5 6 7 8
10 11 12 13 14 15 16 17 18 10 11 12 13 14 15 16 17 18
9 10 11 12
9 10 11 12 13 14 15 16 19 20 21 22 23 24 19 20 21 22 23 24
13 14 15 16
AT-01453
5AT(diag)-26
Step Check Yes No

1 CHECK SUBARU SELECT MONITOR POW- Is the voltage more than 10 V? Go to step 2. Repair harness
ER SUPPLY CIRCUIT. connector and
Measure the voltage between data link con- connector
nector and chassis ground. between battery
Connector & terminal and data link con-
(B40) No. 1 (+) — Chassis ground ($): nector, and poor
contact in cou-
pling connector.
2 CHECK SUBARU SELECT MONITOR Is the resistance less than 1 Go to step 3. Repair the open
Measure the resistance of harness between between data link
data link connector and chassis ground. connector and
Connector & terminal ground terminal,
(B40) No. 12 — Chassis ground: and poor contact
(B40) No. 13 — Chassis ground: in coupling con-
nector.
3 CHECK COMMUNICATION OF SUBARU SE- Are the name and year of sys- Go to step 8. Go to step 4.
LECT MONITOR. tem displayed on Subaru
1) Turn the ignition switch to ON. Select Monitor?
2) Using the Subaru Select Monitor, check
whether communication to transmission sys-
tems can be executed normally.
4 CHECK COMMUNICATION OF SUBARU SE- Are the name and year of sys- Go to step 6. Go to step 5.
1) Turn the ignition switch to OFF. Select Monitor?
2) Disconnect the TCM connector.
4) Check whether communication to engine
systems can be executed normally.
5 CHECK COMMUNICATION OF SUBARU SE- Are the name and year of sys- Inspect the ECM. Go to step 6.
1) Turn the ignition switch to OFF. Select Monitor?
3) Disconnect the ECM connector.
5) Check whether communication to transmis-
sion systems can be executed normally.
6 CHECK HARNESS CONNECTOR BETWEEN Is the resistance more than 1 Go to step 7. Check harness
EACH CONTROL UNIT AND DATA LINK M"? and connector
CONNECTOR. between each con-
1) Turn the ignition switch to OFF. trol unit and data
2) Disconnect the TCM and ECM connector. link connector.
7 CHECK OUTPUT SIGNAL OF TCM. Is the voltage more than 1 V? Check harness Go to step 8.
1) Turn the ignition switch to ON. and connector
2) Measure the voltage between TCM and between each con-
chassis ground. trol unit and data
Connector & terminal link connector.
8 CHECK HARNESS CONNECTOR BETWEEN Is the resistance less than 1 Go to step 9. Repair the har-
TCM AND DATA LINK CONNECTOR. "? ness and connec-
Measure the resistance between TCM connector between TCM
tor and data link connector. and data link con-
(B54) No. 20 — (B40) No. 10:
5AT(diag)-27
Step Check Yes No

9 CHECK INSTALLATION OF TCM CONNEC- Is TCM connector connected Go to step 10. Connect the TCM
TOR. to TCM? connector to TCM.
Turn the ignition switch to OFF.
10 CHECK INSTALLATION OF TRANSMISSION Is the transmission harness Go to step 11. Connect the bulk-
HARNESS CONNECTOR. connector connected to bulk- head harness con-
head harness connector? nector to
transmission har-
ness connector.
11 CHECK POOR CONTACT IN CONNECTORS. Is there poor contact in control Repair the poor Go to step 12.
unit power supply and data link contact.
connector?
12 CHECK POWER SUPPLY OF TCM. Is the voltage 10 — 13 V? Go to step 15. Go to step 13.
13 CHECK FUSE (No. 32). Is the fuse (No. 32) blown out? Go to step 14. Repair the open
1) Turn the ignition switch to OFF. circuit in harness
2) Remove the fuse (No. 32). between fuse (No.
32) and TCM, or
fuse (No. 32) and
battery, and poor
contact in cou-
pling connector.
14 CHECK HARNESS. Is the resistance less than 10 Replace the fuse Replace the fuse
Measure the resistance between TCM connec- "? (No. 32). If the (No. 32).
tor and chassis ground. replaced fuse (No.
Connector & terminal 32) has blown out
(B54) No. 1 — Chassis ground: easily, repair the
short circuit in har-
ness between fuse
(No. 32) and TCM.
15 CHECK IGNITION POWER SUPPLY CIR- Is the voltage 10 — 13 V? Go to step 17. Go to step 16.
CUIT.
OFF).
2) Measure the ignition power supply voltage
16 CHECK FUSE (No. 12). Is the fuse (No. 12) blown out? Replace the fuse Repair the open
Remove the fuse (No. 12). (No. 12). If the circuit in harness
replaced fuse (No. between fuse (No.
12) has blown out 12) and TCM, or
easily, repair the fuse (No. 12) and
short circuit in har- battery, and poor
ness between fuse contact in cou-
(No. 12) and TCM. pling connector.
5AT(diag)-28
Step Check Yes No

2) Disconnect the connectors from TCM and transmission har-
transmission. ness connector,
3) Measure the resistance of harness and poor contact
between TCM and transmission connector. in coupling con-
18 CHECK POOR CONTACT IN CONNECTORS. Is there poor contact in TCM Repair the con- Replace the TCM.
power supply, ground and data nector. <Ref. to 5AT-61,
link connector? Transmission Con-
trol Module
(TCM).>
5AT(diag)-29
13.List of Diagnostic Trouble Code (DTC)

A: LIST
Transmission Range
Inhibitor switch 1 malfunction, MISSION RANGE SENSOR CIRCUIT (PRNDL
P0705 Sensor Circuit (PRNDL
open or short circuit INPUT), Diagnostic Procedure with Diagnostic
Input)
ATF temperature sensor 1 mal- MISSION FLUID TEMPERATURE SENSOR
function, open input signal circuit CIRCUIT LOW INPUT, Diagnostic Procedure
Low Input
ATF temperature sensor 1 mal- MISSION FLUID TEMPERATURE SENSOR
function, short input signal circuit CIRCUIT HIGH INPUT, Diagnostic Procedure
High Input
<Ref. to 5AT(diag)-45, DTC P0715 INPUT/
Input/Turbine Speed Turbine speed sensor 1 malfunc- TURBINE SPEED SENSOR CIRCUIT, Diag-
P0715
Sensor Circuit tion, short input signal circuit nostic Procedure with Diagnostic Trouble Code
(DTC).>
Brake switch malfunction, open <Ref. to 5AT(diag)-49, DTC P0719 TORQUE
Torque Converter/Brake input signal circuit, body inte- CONVERTER/BRAKE SWITCH “B” CIRCUIT
P0719
Switch “B” Circuit Low grated unit malfunction, CAN LOW, Diagnostic Procedure with Diagnostic
communication malfunction Trouble Code (DTC).>
Front wheel speed sensor is
<Ref. to 5AT(diag)-51, DTC P0720 OUTPUT
Output Speed Sensor faulty or input signal circuit,
P0720 SPEED SENSOR CIRCUIT, Diagnostic Proce-
Circuit ground, power supply is open or
shorted.
Brake switch malfunction, short <Ref. to 5AT(diag)-56, DTC P0724 TORQUE
Torque Converter/Brake circuit of input signal, body inte- CONVERTER/BRAKE SWITCH “B” CIRCUIT
P0724
Switch “B” Circuit High grated unit malfunction, CAN HIGH, Diagnostic Procedure with Diagnostic
communication malfunction Trouble Code (DTC).>
Open or short engine speed out-
<Ref. to 5AT(diag)-58, DTC P0725 ENGINE
Engine Speed Input Cir- put signal circuit, ECM malfunc-
P0725 SPEED INPUT CIRCUIT, Diagnostic Proce-
cuit tion, CAN communication
malfunction
Vehicle sensor, turbine speed <Ref. to 5AT(diag)-58, DTC P0731 GEAR 1
P0731 Gear 1 Incorrect Ratio sensor, control valve malfunction INCORRECT RATIO, Diagnostic Procedure
or shift clutch malfunction with Diagnostic Trouble Code (DTC).>
Vehicle sensor, turbine speed <Ref. to 5AT(diag)-58, DTC P0732 GEAR 2
P0732 Gear 2 Incorrect Ratio sensor, control valve malfunction INCORRECT RATIO, Diagnostic Procedure
or shift clutch malfunction with Diagnostic Trouble Code (DTC).>
<Ref. to 5AT(diag)-58, DTC P0733 GEAR 3
Vehicle sensor, turbine speed
P0733 Gear 3 Incorrect Ratio INCORRECT RATIO, Diagnostic Procedure
sensor, or shift clutch malfunction
<Ref. to 5AT(diag)-59, DTC P0736 REVERSE
P0736 Reverse Incorrect Ratio INCORRECT RATIO, Diagnostic Procedure
Torque Converter Clutch
Lock-up clutch is faulty or valve is CONVERTER CLUTCH CIRCUIT PERFOR-
P0741 Circuit Performance or
stuck. MANCE OR STUCK OFF, Diagnostic Proce-
Stuck Off
5AT(diag)-30

Torque Converter Clutch L/U solenoid circuit malfunction CONVERTER CLUTCH CIRCUIT ELECTRI-
P0743
Circuit Electrical or L/U solenoid body malfunction CAL, Diagnostic Procedure with Diagnostic
<Ref. to 5AT(diag)-63, DTC P0748 PRES-
Line pressure solenoid circuit
Pressure Control Sole- SURE CONTROL SOLENOID “A” ELECTRI-
P0748 malfunction or line pressure sole-
noid “A” Electrical CAL, Diagnostic Procedure with Diagnostic
noid body malfunction
<Ref. to 5AT(diag)-65, DTC P0751 SHIFT
Shift Solenoid “A” Perfor- Shift Solenoid “A” performance SOLENOID “A” PERFORMANCE OR STUCK
P0751
mance or Stuck Off malfunction OFF, Diagnostic Procedure with Diagnostic
Shift Solenoid “A” Elec- Fr/B solenoid circuit malfunction
P0753 SOLENOID “A” ELECTRICAL, Diagnostic Pro-
trical or Fr/B solenoid body malfunction
Shift Solenoid “B” Perfor- Shift Solenoid “B” Performance SOLENOID “B” PERFORMANCE OR STUCK
P0756
mance or Stuck Off malfunction OFF, Diagnostic Procedure with Diagnostic
Shift Solenoid “B” Elec- I/C solenoid circuit malfunction or
P0758 SOLENOID “B” ELECTRICAL, Diagnostic Pro-
trical I/C solenoid body malfunction
Shift Solenoid “C” Perfor- SOLENOID “C” PERFORMANCE OR STUCK
P0761 H&LR/C solenoid malfunction
mance or Stuck Off OFF, Diagnostic Procedure with Diagnostic
H&LR/C solenoid circuit malfunc- <Ref. to 5AT(diag)-82, DTC P0763 SHIFT
Shift Solenoid “C” Elec-
P0763 tion or H&LR/C solenoid body SOLENOID “C” ELECTRICAL, Diagnostic Pro-
trical
malfunction cedure with Diagnostic Trouble Code (DTC).>
Shift Solenoid “D” Perfor- SOLENOID “D” PERFORMANCE OR STUCK
P0766 D/C solenoid malfunction
Shift Solenoid “D” Elec- D/C solenoid circuit malfunction
P0768 SOLENOID “D” ELECTRICAL, Diagnostic Pro-
trical or D/C solenoid body malfunction
Shift Solenoid “E” Perfor- SOLENOID “E” PERFORMANCE OR STUCK
P0771 LC/B solenoid malfunction
• LC/B solenoid circuit malfunc-
tion or LC/B solenoid body mal- <Ref. to 5AT(diag)-94, DTC P0773 SHIFT
Shift Solenoid “E” Elec-
P0773 function SOLENOID “E” ELECTRICAL, Diagnostic Pro-
trical
• OFF malfunction of PVIGN cedure with Diagnostic Trouble Code (DTC).>
relay circuit or relay body
• Shift lock solenoid is faulty or
<Ref. to 5AT(diag)-97, DTC P0801 REVERSE
Reverse Inhibit Control output signal circuit is open or
P0801 INHIBIT CONTROL CIRCUIT, Diagnostic Pro-
Circuit shorted.
• Brown out of TCM+B fuse
• PN signal output circuit is open
or shorted. <Ref. to 5AT(diag)-100, DTC P0817 STARTER
P0817 Starter Disable Circuit • ECM Source Voltage Is Abnor- DISABLE CIRCUIT, Diagnostic Procedure with
mal Diagnostic Trouble Code (DTC).>
• Brown out of TCM+B fuse
PVIGN relay output circuit is <Ref. to 5AT(diag)-102, DTC P0882 TCM
PVIGN Power Supply
P0882 open, shorted or relay malfunc- POWER INPUT SIGNAL LOW, Diagnostic Pro-
Circuit (Low)
tion cedure with Diagnostic Trouble Code (DTC).>
5AT(diag)-31

Back-up relay output circuit is <Ref. to 5AT(diag)-104, DTC P0957 BACKUP
Backup Light Relay Cir-
P0957 open, shorted or relay OFF mal- LIGHT RELAY CIRCUIT LOW, Diagnostic Pro-
cuit Low
function cedure with Diagnostic Trouble Code (DTC).>
Back-up relay output circuit is <Ref. to 5AT(diag)-106, DTC P0958 BACKUP
Backup Light Relay Cir-
P0958 open, shorted or relay ON mal- LIGHT RELAY CIRCUIT HIGH, Diagnostic Pro-
cuit High
function cedure with Diagnostic Trouble Code (DTC).>
<Ref. to 5AT(diag)-108, DTC P1601 TCM
TCM Communication Communication Failure between COMMUNICATION MALFUNCTION, Diagnos-
P1601
Malfunction TCM and Memory Box tic Procedure with Diagnostic Trouble Code
(DTC).>
<Ref. to 5AT(diag)-110, DTC P1706 AT VEHI-
AT Vehicle Speed Sen- Rear wheel speed sensor is faulty
CLE SPEED SENSOR CIRCUIT MALFUNC-
P1706 sor Circuit Malfunction or input circuit, ground, power
TION (REAR WHEEL), Diagnostic Procedure
(Rear Wheel) supply is open or shorted.
<Ref. to 5AT(diag)-114, DTC P1707 AT AWD
AWD solenoid circuit malfunction
AT AWD Solenoid Valve SOLENOID VALVE CIRCUIT MALFUNC-
P1707 or AWD solenoid body malfunc-
Circuit Malfunction TION, Diagnostic Procedure with Diagnostic
tion
Torque Converter Tur- Torque converter sensor 2 mal-
CONVERTER TURBINE 2 SPEED SIGNAL
P1710 bine 2 Speed Signal Cir- function, input circuit, ground,
CIRCUIT 2 MALFUNCTION, Diagnostic Proce-
cuit 2 Malfunction power open, short circuit
<Ref. to 5AT(diag)-120, DTC P1716 ATF
ATF Temp. Sensor 2 Cir- ATF temperature sensor 2 mal- TEMP. SENSOR 2 CIRCUIT LOW, Diagnostic
P1716
cuit Low function, open input signal circuit Procedure with Diagnostic Trouble Code
(DTC).>
<Ref. to 5AT(diag)-123, DTC P1717 ATF
ATF Temp. Sensor 2 Cir- ATF temperature sensor 2 mal- TEMP. SENSOR 2 CIRCUIT HIGH, Diagnostic
P1717
cuit High function, short input signal circuit Procedure with Diagnostic Trouble Code
(DTC).>
CAN communication line bus off
<Ref. to 5AT(diag)-125, DTC P1718 AT CAN
AT CAN Communication is open, EUM short circuit, ABS/
P1718 COMMUNICATION CIRCUIT, Diagnostic Pro-
Circuit VDCCM, integrated CU malfunc-
tion
Lateral Acceleration
ACCELERATION SENSOR PERFORMANCE
P1760 Sensor Performance Lateral G sensor malfunction
PROBLEM, Diagnostic Procedure with Diag-
Problem
Lateral Acceleration Lateral G sensor is faulty or input ACCELERATION SENSOR CIRCUIT LOW,
P1761
Sensor Circuit Low signal circuit is open. Diagnostic Procedure with Diagnostic Trouble
Code (DTC).>
Lateral Acceleration Lateral G sensor is faulty or input ACCELERATION SENSOR CIRCUIT HIGH,
P1762
Sensor Circuit High signal circuit is shorted. Diagnostic Procedure with Diagnostic Trouble
Code (DTC).>
Malfunction of clutch oil pressure <Ref. to 5AT(diag)-133, DTC P1798 GEAR 1
P1798 Gear 1 Engine Brake related to 1st engine brake, sole- ENGINE BRAKE, Diagnostic Procedure with
noid current malfunction Diagnostic Trouble Code (DTC).>
Malfunction of clutch oil pressure <Ref. to 5AT(diag)-134, DTC P1799 INTER-
P1799 Interlock which emit interlock, solenoid LOCK, Diagnostic Procedure with Diagnostic
current malfunction Trouble Code (DTC).>
<Ref. to 5AT(diag)-135, DTC P1817 SPORTS
SPORTS Mode Switch Manual mode switch is open or MODE SWITCH CIRCUIT (MANUAL
P1817
Circuit (Manual Switch) shorted, or switch malfunction SWITCH), Diagnostic Procedure with Diagnos-
tic Trouble Code (DTC).>
5AT(diag)-32

Transmission Fluid Pres- H&LR/C oil pressure switch is
MISSION FLUID PRESSURE SENSOR/
P1840 sure Sensor/Switch A open or shorted, or switch mal-
SWITCH A CIRCUIT, Diagnostic Procedure
Circuit function
Transmission Fluid Pres-
D/C oil pressure switch is open or MISSION FLUID PRESSURE SENSOR/
P1841 sure Sensor/Switch B
shorted, or switch malfunction SWITCH B CIRCUIT, Diagnostic Procedure
Circuit
Fr/B oil pressure switch is open or MISSION FLUID PRESSURE SENSOR/
P1842 sure Sensor/Switch C
shorted, or switch malfunction SWITCH C CIRCUIT, Diagnostic Procedure
Circuit
I/C oil pressure switch is open or MISSION FLUID PRESSURE SENSOR/
P1843 sure Sensor/Switch D
shorted, or switch malfunction SWITCH D CIRCUIT, Diagnostic Procedure
Circuit
LC/B oil pressure switch is open MISSION FLUID PRESSURE SENSOR/
P1844 sure Sensor/Switch E
or shorted, or switch malfunction SWITCH E CIRCUIT, Diagnostic Procedure
Circuit
5AT(diag)-33
14.Diagnostic Procedure with Diagnostic Trouble Code (DTC)

A: DTC P0705 TRANSMISSION RANGE SENSOR CIRCUIT (PRNDL INPUT)
The inhibitor switch is open or short.
TROUBLE SYMPTOM:
• Shift characteristics are erroneous.
• Shift indicator light does not match with select lever.
• Shift indicator light does not illuminate.
• N-D, N-R shock occur.
5AT(diag)-34
WIRING DIAGRAM:
SBF-1 SBF-7 No.12
i10
4
BATTERY
1 2 3 4 5 6 7 8 9 10
11 12 13 14 15 16 17 18 19 20 21 22
COMBINATION
METER P R N D
i10 i77
E 1 2 3 4 5 6 7 8 9 10 11 12
21
22
A: i84
JOINT
7
CONNECTOR 1 2 3 4 5 6 7 8
i77 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
24 25 26 27 28 29 30 31 32 33 34 35
2
8
A27
A26
B: B280
A: i84
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19 20
B20
B30
B: B280
21 22 23 24 25 26 27 28 29 30
A: B54
1 2 3 4 5 6 7 8 9
10 11 12 13 14 15 16 17 18
19 20 21 22 23 24
B: B55
1 2 3 4 5 6 7 8 9
10 11 12 13 14 15 16 17 18
A4
A3
19 20 21 22 23 24
A: B54 B: B55 TCM

B12
B14
B13
B20
B4
B3
1 2 3 4
B12 5 6 7 8
4
3
2
1
8
T3
TRANSMISSION
E
AT-02073
5AT(diag)-35
Step Check Yes No

1 CHECK DTC OF TCM. Is DTC of AT CAN communica- Perform the diag- Go to step 2.
tion circuit displayed? nosis according to
DTC.
Monitor?
3 CHECK INHIBITOR SWITCH. Are all indications High? Go to step 5. Go to step 4.
2) Check input signal of inhibitor SW 1 — 4
and inhibitor SW 3 monitor using Subaru
Select Monitor.
1) Turn the ignition switch to OFF. between TCM con-
2) Disconnect the connectors from TCM and nector and chassis
transmission. ground.
nector and chassis ground about the item
which indicated Low on step 3.
5 CHECK INHIBITOR SWITCH. Are all indications High? Go to step 9. Go to step 6.
2) Check input signal of inhibitor SW 1 — 4
and inhibitor SW 3 monitor using Subaru
Select Monitor.
2) Disconnect the connectors from TCM and nector and trans-
transmission. mission connector.
between TCM and transmission connector
about the item which indicated High on step 5.
(B55) No. 4 — (B12) No. 4:
(B55) No. 3 — (B12) No. 3:
(B55) No. 14 — (B12) No. 2:
(B55) No. 13 — (B12) No. 1:
(B55) No. 20 — (B12) No. 8:
(B55) No. 4 — (B12) No. 4:
(B55) No. 3 — (B12) No. 3:
(B55) No. 14 — (B12) No. 2:
(B55) No. 13 — (B12) No. 1:
(B55) No. 20 — (B12) No. 8:
5AT(diag)-36
Step Check Yes No

Measure the resistance between TCM connec- between TCM con-
tor and chassis ground. nector and chassis
Connector & terminal ground.
9 CHECK INPUT SIGNAL FOR TCM USING Is the voltage 4 — 6 V for the Go to step 11. Go to step 10.
CIRCUIT TESTER. inhibitor SW 1 — 4?
1) Turn the ignition switch to OFF. Is the voltage 3.5 — 5.5 V for
2) Disconnect the transmission connector the inhibitor SW 3 monitor?
(B12).
5) Measure the voltage between TCM termi-
nals.
(B55) No. 4 — (B54) No. 19:
(B55) No. 3 — (B54) No. 19:
(B55) No. 14 — (B54) No. 19:
(B55) No. 13 — (B54) No. 19:
(B55) No. 20 — (B54) No. 19:
10 CHECK TCM I/O SIGNAL. Is TCM I/O signal OK? Replace the TCM. Repair the open or
Check I/O signal of power supply, ground and <Ref. to 5AT-61, short circuit for
PVIGN power supply relay. Transmission Con- power supply and
<Ref. to 5AT(diag)-12, ELECTRICAL SPECIFI- trol Module ground. Perform
CATION, Transmission Control Module (TCM) (TCM).> the diagnosis
I/O Signal.> according to DTC
for PVIGN power
supply relay.
TRANSMISSION AND CONTROL VALVE "? circuit in harness
BODY. between control
1) Turn the ignition switch to OFF. valve body con-
2) Disconnect the connector from transmis- nector and trans-
sion. mission connector.
bracket.
4) Lift-up the vehicle and place it on rigid
racks.
NOTE:
5) Drain the ATF.
CAUTION:
connector from control valve body connector.
sion connector and control valve body connec-
tor.
(T3) No. 4 — (T5) No. 6:
(T3) No. 3 — (T5) No. 5:
(T3) No. 2 — (T5) No. 4:
(T3) No. 1 — (T5) No. 3:
(T3) No. 8 — (T5) No. 2:
5AT(diag)-37
Step Check Yes No

TRANSMISSION AND CONTROL VALVE M"? circuit in harness
Measure the resistance between transmission valve body con-
ground and control valve body connector. nector and trans-
Connector & terminal mission connector.
13 CHECK POOR CONTACT. Is there any poor contact in Repair the poor Replace the con-
inhibitor SW 1 — 4 or inhibitor contact. trol valve body.
SW 3 monitor circuit? <Ref. to 5AT-58,
Control Valve
Body.>
5AT(diag)-38
B: DTC P0712 TRANSMISSION FLUID TEMPERATURE SENSOR CIRCUIT LOW

INPUT
Input signal circuit of TCM to ATF temperature sensor 1 is opened.
TROUBLE SYMPTOM:
Excessive shift shock.
WIRING DIAGRAM:
B54
B54 TCM 1 2 3 4 5 6 7 8 9
10 11 12 13 14 15 16 17 18
19 20 21 22 23 24
13
B11
1 2 3 4
5 6 7 8
9 10 11 12
13 14 15 16
17 18 19 20
B11
12
T4
T5
1 2 3 4 5 6
7 8 9 10 11 12 13 14 15 16
16
T5
1
TRANSMISSION
AT-02037
5AT(diag)-39
Step Check Yes No

2) Disconnect the connectors from TCM and transmission con-
(B54) No. 13 — (B11) No. 12:
(B54) No. 2 — (B11) No. 5:
2 CHECK ATF TEMPERATURE SENSOR. Is the resistance 500 — 1,200 Go to step 3. Go to step 7.
and TCM.
engine.
NOTE:
ating temperature.
sion.
(T4) No. 5 — (T4) No. 12:
(T4) No. 5 — (T4) No. 12:
Monitor?
5 CHECK INPUT SIGNAL FROM TCM. Is the voltage 0.5 — 1.2 V? Even if the SPORT Go to step 8.
1) Connect the connector to transmission. indicator lights
2) Warm-up the transmission until the ATF blinks, the system
temperature is approx. 80#C (176#F). is in normal condi-
NOTE: tion. A temporary
If the ambient temperature is below 0#C (32#F), poor contact of
drive the vehicle until the ATF reaches its oper- connector or har-
ating temperature. ness may be the
3) Measure the voltage between TCM con- cause. Repair the
nector terminals. poor contact of
Connector & terminal harness between
(B54) No. 2 (+) — (B54) No. 13 ($): ATF temperature
sensor and trans-
mission connector.
5AT(diag)-40
Step Check Yes No

SUBARU SELECT MONITOR. gradually decrease? indicator lights
1) Connect the connector. blinks, the system
2) Turn the ignition switch to ON (engine is in normal condi-
OFF). tion. A temporary
3) Read the ATF temperature using Subaru poor contact of
Select Monitor. connector or har-
ness may be the
cause. Repair the
poor contact of
harness between
ATF temperature
sensor and trans-
mission connector.
7 CHECK HARNESS CONNECTOR BETWEEN Is the resistance less than 1 Replace the con- Repair the open
TRANSMISSION AND CONTROL VALVE "? trol valve body. circuit in harness
BODY. <Ref. to 5AT-58, between control
1) Turn the ignition switch to OFF. Control Valve valve body con-
2) Disconnect the connector from transmis- Body.> nector and trans-
bracket.
racks.
NOTE:
5) Drain the ATF.
CAUTION:
tor.
(T4) No. 12 — (T5) No. 1:
(T4) No. 5 — (T5) No. 16:
temperature sensor circuit 1? contact. <Ref. to 5AT-61,
Transmission Con-
trol Module
(TCM).>
5AT(diag)-41
C: DTC P0713 TRANSMISSION FLUID TEMPERATURE SENSOR CIRCUIT HIGH

INPUT
Input signal circuit of TCM to ATF temperature sensor 1 is shorted.
TROUBLE SYMPTOM:
WIRING DIAGRAM:
B54
B54 TCM 1 2 3 4 5 6 7 8 9
10 11 12 13 14 15 16 17 18
19 20 21 22 23 24
13
B11
1 2 3 4
5 6 7 8
9 10 11 12
13 14 15 16
17 18 19 20
B11
12
T4
T5
1 2 3 4 5 6
7 8 9 10 11 12 13 14 15 16
16
T5
1
TRANSMISSION
AT-02037
5AT(diag)-42
Step Check Yes No

2 CHECK ATF TEMPERATURE SENSOR. Is the resistance 500 — 1,200 Go to step 3. Go to step 7.
and TCM.
engine.
NOTE:
ating temperature.
sion.
(T4) No. 5 — (T4) No. 12:
(T4) No. 5 — (T4) No. 12:
Monitor?
5 CHECK INPUT SIGNAL FROM TCM. Is the voltage 0.5 — 1.2 V? Even if the SPORT Go to step 8.
3) Measure the voltage between TCM con- cause. Repair the
nector terminals. poor contact of
Connector & terminal harness between
(B54) No. 2 (+) — (B54) No. 13 ($): ATF temperature
sensor and trans-
mission connector.
5AT(diag)-43
Step Check Yes No

2) Turn the ignition switch to ON (engine is in normal condi-
OFF). tion. A temporary
ness may be the
cause. Repair the
poor contact of
harness between
ATF temperature
sensor and trans-
mission connector.
TRANSMISSION AND CONTROL VALVE M"? trol valve body. circuit in harness
bracket.
racks.
NOTE:
5) Drain the ATF.
CAUTION:
7) Measure the resistance between chassis
ground and control valve body connector.
temperature sensor circuit 1? contact. <Ref. to 5AT-61,
Transmission Con-
trol Module
(TCM).>
5AT(diag)-44
D: DTC P0715 INPUT/TURBINE SPEED SENSOR CIRCUIT

TROUBLE SYMPTOM:
• Excessive shift shock.
• Does not shift to 5th
WIRING DIAGRAM:
A: B54
TCM
1 2 3 4 5 6 7 8 9
A: B54 B: B55 10 11 12 13 14 15 16 17 18
19 20 21 22 23 24
A16
B16
B: B55
1 2 3 4 5 6 7 8 9
10 11 12 13 14 15 16 17 18
19 20 21 22 23 24
B11 B12
B11
7
7
T4 T3
1 2 3 4
5 6 7 8
9 10 11 12
13 14 15 16
17 18 19 20
B12
1 2 3 4
5 6 7 8
AT1
3
2
1
E AT1
TURBINE SPEED SENSOR 1 1 2 3
AT-02074
5AT(diag)-45
Step Check Yes No

(B55) No. 16 — (B12) No. 7:
(B54) No. 16 — (B11) No. 7:
TCM connector and chassis ground. chassis ground.
3 CHECK TCM POWER SUPPLY OUTPUT. Is the voltage 10 — 13 V? Go to step 4. Go to step 5.
1) Connect the TCM connector. (Transmission
connector is disconnected)
OFF)
4 CHECK TURBINE SPEED SENSOR INPUT Is the voltage 4 — 6 V? Go to step 6. Go to step 5.
CIRCUIT OF TCM.
Measure the voltage between TCM connector
terminals.
(B55) No. 16 (+) — (B54) No. 19 ($):
for PVIGN power
supply relay.
6 CHECK HARNESS ASSEMBLY (TURBINE Is the ground connecting har- Go to step 7. If the poor installa-
SPEED SENSOR GROUND). ness connected to transmis- tion of ground
Check the installing condition of ground con- sion body securely? occurs, install it
necting harness of harness assembly (used for And there are no excessive securely. Replace
both of turbine speed sensor 1, rear vehicle damages on harness and ter- the transmission
speed sensor). minal? assembly when
the harness or ter-
minal is damaged.
<Ref. to 5AT-38,
Automatic Trans-
mission Assem-
bly.>
5AT(diag)-46
Step Check Yes No

7 CHECK HARNESS ASSEMBLY. Is the resistance less than 1 Go to step 8. Repair the open
2) Disconnect the connector from transmis- between TCM and
sion. transmission con-
3) Disconnect the connector from turbine nector, and poor
speed sensor 1. contact in cou-
4) Measure the resistance between transmis- pling connector.
sion connector and turbine speed sensor 1
connector.
(T4) No. 7 — (AT1) No. 3:
(T3) No. 7 — (AT1) No. 2:
(AT1) No. 1 — Chassis ground:
8 CHECK HARNESS ASSEMBLY. Is the resistance more than 1 Go to step 9. Repair the short
Measure the resistance between transmission M"? circuit in harness
connector and chassis ground. between TCM and
Connector & terminal transmission con-
(T4) No. 7 — Chassis ground: nector.
Monitor?
11 CHECK INPUT SIGNAL FOR TCM USING Does the value of the turbine Even if the SPORT Replace the tur-
SUBARU SELECT MONITOR. speed sensor 1 change indicator lights bine speed sensor
1) Connect all the connectors. depending on the acceleration, blinks, the system 1. <Ref. to 5AT-57,
2) Lift-up the vehicle and support with rigid deceleration and shifting range is in normal condi- Turbine speed
racks. of the vehicle? tion. sensor 1.>
NOTE: A temporary poor
Raise all wheels off floor. contact of connec-
3) Start the engine, and set the vehicle in 4th tor or harness may
speed driving condition of manual mode. be the cause.
Repair the poor
NOTE:
Turbine speed sensor 1 signal can be mea- contact of har-
sured only on 4th speed. ness between the
ATF temperature
4) Read the current data of turbine speed sen-
sensor and trans-
sor 1 using the Subaru Select Monitor. <Ref. to
mission connector.
5AT(diag)-16, READ CURRENT DATA,
NOTE:
wheels may light the ABS warning light, but this
indicates no malfunction. When AT control di-
agnosis is finished, perform the ABS memory
clearance procedure of on-board diagnostics
system. <Ref. to ABS(diag)-27, Clear Memory
Mode.>
5AT(diag)-47
Step Check Yes No

12 CHECK INPUT SIGNAL FOR TCM USING Is the frequency of measured Even if the SPORT Replace the tur-
OSCILLOSCOPE. waveform (pulse wave) indicator lights bine speed sensor
1) Connect all the connectors. changed depending on the blinks, the system 1. <Ref. to 5AT-57,
2) Lift-up the vehicle and support with rigid acceleration, deceleration and is in normal condi- Turbine speed
racks. shifting range of the vehicle? tion. sensor 1.>
3) Set the oscilloscope to TCM connector ter- tor or harness may
minals. be the cause.
Positive probe; (B55) No. 16: Repair the poor
Ground lead; (B54) No. 19: contact of har-
ness between the
4) Start the engine, and set the vehicle in 4th
ATF temperature
speed driving condition of manual mode.
sensor and trans-
NOTE: mission connector.
Turbine speed sensor 1 signal can be mea-
sured only on 4th speed.
5) Display the pulse signal of turbine speed
sensor 1 to oscilloscope, and measure the fre-
quency.
NOTE:
Mode.>
13 CHECK INPUT SIGNAL FOR TCM USING Does the voltage change Even if the SPORT Replace the tur-
CIRCUIT TESTER. within the range of 2 — 3 V indicator lights bine speed sensor
1) Connect all the connectors. when driving the vehicle with blinks, the system 1. <Ref. to 5AT-57,
2) Lift-up the vehicle and support with rigid 4th of manual mode? Is the is in normal condi- Turbine speed
racks. voltage less than 0.5 V or more tion. sensor 1.>
NOTE: than 4.5 V constantly when the A temporary poor
Raise all wheels off floor. vehicle is parked with “P” contact of connec-
3) Start the engine, and set the vehicle in 4th range? tor or harness may
Repair the poor
NOTE:
Turbine speed sensor 1 signal can be mea- contact of har-
sured only on 4th speed. ness between the
ATF temperature
sensor and trans-
nals.
mission connector.
(B55) No. 16 (+) — (B54) No. 19 ($):
5) Stop the vehicle, and shift the select lever
to “P” range.
nals.
(B55) No. 16 (+) — (B54) No. 19 ($):
NOTE:
Mode.>
5AT(diag)-48
E: DTC P0719 TORQUE CONVERTER/BRAKE SWITCH “B” CIRCUIT LOW

TROUBLE SYMPTOM:
• Brake down control is not operated at SPORT mode.
• No lock-up occurs at braking.
WIRING DIAGRAM:
SBF-1 SBF-3 C: B281
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23 24 25 26 27 28
BATTERY
No.8
B64
1 2
1
E STOP LIGHT
SWITCH
B159
B64
1 2 3 4
2
5 6 7 8 9
JOINT
9
CONNECTOR
B159 B: B280
5
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19 20
C23
BODY INTEGRATED 21 22 23 24 25 26 27 28 29 30
UNIT
B: B280
B54
B20
B30
C: B281
1 2 3 4 5 6 7 8 9
10 11 12 13 14 15 16 17 18
19 20 21 22 23 24
4
B54 TCM
AT-01629
5AT(diag)-49
Step Check Yes No

1 CHECK DTC. Is any of following DTC dis- Perform the diag- Go to step 2.
played? nosis according to
' AT CAN Communication Cir- DTC.
cuit
' Output Speed Sensor Circuit
' AT Vehicle Speed Sensor
Circuit Malfunction (Rear
Wheel)
2 CHECK BODY INTEGRATED UNIT. Is the ON displayed? Go to step 3. Go to step 4.
link connector.
OFF)
ON.
3 CHECK TCM. Is the ON displayed? A temporary poor Replace the TCM
contact.
SIGNAL.
grated unit.
3) Measure the voltage between body inte-
grated unit connector and chassis ground.
BODY INTEGRATED UNIT AND STOP LIGHT "? circuit of harness
1) Turn the ignition switch to OFF. integrated unit and
2) Disconnect the connector from stop light stop light switch.
switch.
between body integrated unit and stop light
switch.
(B281) No. 23 — (B64) No. 2:
BODY INTEGRATED UNIT AND STOP LIGHT M"? circuit of harness
Measure the resistance of harness between integrated unit and
body integrated unit connector and stop light stop light switch.
switch.
5AT(diag)-50
F: DTC P0720 OUTPUT SPEED SENSOR CIRCUIT

• AT vehicle speed signal is abnormal.
• The harness connector between TCM and vehicle speed sensor is in short or open.
TROUBLE SYMPTOM:
• Deterioration of shifting quality.
• Poor driving performance.
WIRING DIAGRAM:
A: B54
A: B54
TCM 1 2 3 4 5 6 7 8 9
B: B55 10 11 12 13 14 15 16 17 18
19 20 21 22 23 24
A16
B7
B: B55
1 2 3 4 5 6 7 8 9
10 11 12 13 14 15 16 17 18
19 20 21 22 23 24
B11
7
B11
1 2 3 4
5 6 7 8
9 10 11 12
13 14 15 16
17 18 19 20
T5
15
14
T5
T7
1 2 3 4 5 6
1
3
2
CONTROL 7 8 9 10 11 12 13 14 15 16
VALVE
FRONT VEHICLE
SPEED SENSOR
T7
TRANSMISSION 3 2 1
AT-02075
5AT(diag)-51
Step Check Yes No

(B54) No. 16 — (B11) No. 7:
(B55) No. 7 — (B11) No. 1:
1) Connect the connector to TCM. (Transmis-
sion connector is disconnected)
OFF)
CIRCUIT OF TCM.
terminals.
(B55) No. 7 (+) — (B54) No. 19 ($):
for PVIGN power
supply relay.
Monitor?
5AT(diag)-52
Step Check Yes No

8 CHECK INPUT SIGNAL FOR TCM USING Does the value of the front Even if the SPORT Go to step 11.
SUBARU SELECT MONITOR. wheel speed depending on the indicator lights
1) Connect all the connectors. acceleration and deceleration blinks, the system
2) Lift-up the vehicle and support with rigid of the vehicle? is in normal condi-
racks. tion.
3) Start the engine, and drive it. tor or harness may
4) Read the current data of front wheel speed be the cause.
using Subaru Select Monitor. <Ref. to Repair the poor
5AT(diag)-16, READ CURRENT DATA, contact of har-
OPERATION, Subaru Select Monitor.> ness between the
ATF temperature
NOTE:
The speed difference between front and rear sensor and trans-
wheels may light the ABS warning light, but this mission connector.
Mode.>
9 CHECK INPUT SIGNAL FOR TCM USING Is the frequency of measured Even if the SPORT Go to step 11.
OSCILLOSCOPE. waveform (pulse wave) indicator lights
1) Connect all the connectors. changed depending on the blinks, the system
2) Lift-up the vehicle and support with rigid acceleration and deceleration is in normal condi-
racks. of the vehicle? tion.
Positive probe; (B55) No. 16: Repair the poor
Ground lead; (B54) No. 19: contact of har-
ness between the
4) Start the engine, and drive it.
ATF temperature
sensor and trans-
mission connector.
quency.
NOTE:
Mode.>
5AT(diag)-53
Step Check Yes No

10 CHECK INPUT SIGNAL FOR TCM USING Does the voltage change Even if the SPORT Go to step 11.
CIRCUIT TESTER. within the range of 2 — 3 V indicator lights
1) Connect all the connectors. when vehicle is driving? Is the blinks, the system
2) Lift-up the vehicle and support with rigid voltage less than 0.5 V or more is in normal condi-
racks. than 4.5 V constantly when the tion.
NOTE: vehicle is parked with “P” A temporary poor
Raise all wheels off floor. range? contact of connec-
3) Start the engine, and drive it. tor or harness may
4) Measure the voltage between TCM termi- be the cause.
nals. Repair the poor
Connector & terminal contact of har-
(B55) No. 7 (+) — (B54) No. 19 ($): ness between the
ATF temperature
sensor and trans-
to “P” range.
mission connector.
nals.
(B55) No. 7 (+) — (B54) No. 19 ($):
NOTE:
Mode.>
bracket.
racks.
NOTE:
5) Drain the ATF.
CAUTION:
tor.
(B11) No. 7 — (T5) No. 15:
(B11) No. 1 — (T5) No. 14:
BODY. between transmis-
Measure the resistance between transmission sion connector
ground and control valve body connector. and transmission
5AT(diag)-54
Step Check Yes No

13 CHECK HARNESS CONNECTOR BETWEEN Is the resistance less than 1 Go to step 14. Replace the con-
CONTROL VALVE BODY AND VEHICLE "? trol valve body.
SPEED SENSOR. <Ref. to 5AT-58,
1) Disconnect the connector from vehicle Control Valve
speed sensor. Body.>
between control valve body connector and
vehicle speed sensor connector.
(T5) No. 15 — (T7) No. 3:
(T5) No. 14 — (T7) No. 2:
14 CHECK HARNESS CONNECTOR BETWEEN Is the resistance more than 1 Replace the vehi- Replace the con-
CONTROL VALVE BODY AND VEHICLE M"? cle speed sensor. trol valve body.
SPEED SENSOR. <Ref. to 5AT-58,
Measure the resistance of harness between Control Valve
control valve body connector and transmission Body.>
ground.
5AT(diag)-55
G: DTC P0724 TORQUE CONVERTER/BRAKE SWITCH “B” CIRCUIT HIGH

TROUBLE SYMPTOM:
Gear is not shifted down when climbing a hill.
WIRING DIAGRAM:
SBF-1 SBF-3 C: B281
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23 24 25 26 27 28
BATTERY
No.8
B64
1 2
1
E STOP LIGHT
SWITCH
B159
B64
1 2 3 4
2
5 6 7 8 9
JOINT
9
CONNECTOR
B159 B: B280
5
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19 20
C23
BODY INTEGRATED 21 22 23 24 25 26 27 28 29 30
UNIT
B: B280
B54
B20
B30
C: B281
1 2 3 4 5 6 7 8 9
10 11 12 13 14 15 16 17 18
19 20 21 22 23 24
4
B54 TCM
AT-01629
5AT(diag)-56
Step Check Yes No

1 CHECK DTC. Is any of following DTC Perform the diag- Go to step 2.
detected? nosis according to
cuit
Wheel)
2 CHECK BODY INTEGRATED UNIT. Is OFF displayed? Go to step 3. Go to step 4.
link connector.
OFF)
ON.
Subaru Select Monitor. <Ref. to 5AT(diag)-16,
3 CHECK TCM. Is OFF displayed? A temporary poor Replace the TCM
contact.
SIGNAL.
grated unit.
2) Measure the voltage between body inte-
grated unit connector and chassis ground.
5 CHECK STOP LIGHT SWITCH. Is the resistance more than 1 Go to step 6. Replace stop light
1) Turn the ignition switch to OFF. M"? switch.
2) Disconnect the connector from stop light
switch.
between stop light switch connectors.
Terminals
No. 1 — No. 2:
6 CHECK HARNESS CONNECTOR BETWEEN Is the voltage less than 1 V? Go to step 7. Repair the short
BODY INTEGRATED UNIT AND STOP LIGHT circuit in harness
SWITCH. between TCM and
1) Turn the ignition switch to ON. stop light switch.
the body integrated unit connector and chassis
ground.
5AT(diag)-57
H: DTC P0725 ENGINE SPEED INPUT CIRCUIT

Information of engine speed is not correctly received from ECM.
TROUBLE SYMPTOM:
No lock-up (after engine warm-up).
Step Check Yes No

1 CHECK DTC OF ECM. Is DTC of AT CAN communica- Perform the diag- Go to step 2.
tion circuit detected? nosis according to
DTC.
2 CHECK DTC OF TCM. Is DTC of AT CAN communica- Perform the diag- Go to step 3.
tion circuit detected? nosis according to
DTC.
3 CHECK DTC OF TCM. Is any of following DTC Perform the diag- Replace the TCM.
detected? nosis according to <Ref. to 5AT-61,
' Output Speed Sensor Circuit DTC. Transmission Con-
' AT Vehicle Speed Sensor trol Module
Circuit Malfunction (Rear (TCM).>
Wheel)
I: DTC P0731 GEAR 1 INCORRECT RATIO

NOTE:
J: DTC P0732 GEAR 2 INCORRECT RATIO
NOTE:
K: DTC P0733 GEAR 3 INCORRECT RATIO
NOTE:
L: DTC P0734 GEAR 4 INCORRECT RATIO
NOTE:
M: DTC P0735 GEAR 5 INCORRECT RATIO
NOTE:
5AT(diag)-58
N: DTC P0736 REVERSE INCORRECT RATIO

Vehicle speed sensor, turbine speed sensor or control valve malfunction
TROUBLE SYMPTOM:
• Gear is not shifted to reverse.
• Gear position is held by fail safe function.
• Vehicle does not run.
Step Check Yes No

1 CHECK DTC OF TCM. Is any of following DTC Perform the diag- Go to step 2.
cuit
' Engine Speed Input Circuit
Range/Performance
' Input/Turbine Speed Sensor
Circuit
' Torque Converter Turbine 2
Speed Signal Circuit 2 Mal-
function
Wheel)
' Transmission Range Sensor
Circuit (PRNDL Input)
' PVIGN Power Supply Cir-
cuit (Low)
Monitor?
3 CHECK ENGINE SPEED. Is the indication of Subaru Go to step 4. Perform the diag-
Compare the meter with Subaru Select Moni- Select Monitor and meter nosis according to
tor indications. matches? DTC P0725.
4 CHECK TURBINE SPEED SENSOR. Is the indication changes Go to step 5. Perform the diag-
Check the indication of Subaru Select Monitor. according to acceleration, nosis according to
braking and shifting? DTC P0715,
P1710.
5 CHECK FRONT AND REAR VEHICLE Is the indication of Subaru Go to step 6. Perform the diag-
SPEED SENSOR. Select Monitor and meter nosis according to
matches? DTC P0720,
P1706.
6 CHECK INHIBITOR SWITCH. Is the indication of Subaru Go to step 7. Perform the diag-
Select Monitor and meter nosis according to
matches? DTC P0705.
7 CHECK AFTER REPAIR. Is DTC displayed? Replace the con- Temporary poor
trol valve body. contact occurs.
<Ref. to 5AT-58,
Control Valve
Body.>
5AT(diag)-59
O: DTC P0741 TORQUE CONVERTER CLUTCH CIRCUIT PERFORMANCE OR

STUCK OFF
• Lock up clutch malfunction
• Locking of bulb
TROUBLE SYMPTOM:
No lock-up occurs. (After engine is warmed-up)
Step Check Yes No

1 CHECK DTC OF TCM. Is any of following DTC Perform the diag- Go to step 2.
' AT CAN Communication Cir- each DTC.
cuit
' Engine Speed Input Circuit
' Input/Turbine Speed Sensor
Circuit
' Torque Converter Turbine 2
Speed Signal Circuit 2 Mal-
function
2 CHECK DTC OF TCM. Is DTC displayed? Perform the diag- Go to step 3.
1) Perform the clear memory mode. <Ref. to nosis according to
5AT(diag)-18, CLEAR MEMORY MODE, DTC.
2) Read DTC.
3 CHECK INHIBITOR SWITCH CIRCUIT. Is there any trouble? Repair or replace Go to step 4.
Diagnose according to DTC P0705 procedure. the inhibitor switch
circuit.
4 CHECK STOP LIGHT SWITCH CIRCUIT. Is there any trouble? Repair or replace Go to step 5.
Diagnose according to DTC P0719 and P0724 the stop light
procedure. switch circuit.
5 CHECK ATF TEMPERATURE SENSOR CIR- Is there any trouble? Repair or replace There are mal-
CUIT. the ATF tempera- functions in TCM,
Diagnose according to DTC P0712, P0713, ture sensor circuit. TCM connector
P1716 and P1717 procedure. poor contact or
transmission
assembly mechan-
ical malfunction.
5AT(diag)-60
P: DTC P0743 TORQUE CONVERTER CLUTCH CIRCUIT ELECTRICAL

The output signal circuit of lock up solenoid is open or shorted.
TROUBLE SYMPTOM:
No lock-up (after engine warm-up).
WIRING DIAGRAM:
B54
TCM
1 2 3 4 5 6 7 8 9
B54 10 11 12 13 14 15 16 17 18
19 20 21 22 23 24
23
14
5
B11
1 2 3 4
5 6 7 8
E 13
9 10
14
11
15
12
16
17 18 19 20
B11
20
T4
T6
1 2 3 4
5 6 7 8 9 10 11 12
T6
6
TRANSMISSION
AT-02076
5AT(diag)-61
Step Check Yes No

(B54) No. 23 — (B11) No. 20:
Measure resistance of harness between TCM between TCM con-
connector and chassis ground. nector and trans-
bracket.
racks.
5) Drain the ATF.
control valve body connector.
tor.
(T4) No. 20 — (T6) No. 6:
Measure the resistance between chassis valve body con-
Connector & terminal mission ground.
5 CHECK LOCK-UP SOLENOID. Is the resistance 3 — 9 "? Go to step 6. Replace the con-
Measure the resistance between transmission trol valve body.
ground and control valve body connector. <Ref. to 5AT-58,
Connector & terminal Control Valve
(T6) No. 6 — Transmission ground: Body.>
6 CHECK POOR CONTACT. Is there any loosing terminal, Repair the poor Go to step 7.
Check that there are no poor contact in TCM entering foreign matter, dam- contact.
connector, transmission connector and control aging connector body?
valve body connector.
7 CHECK AFTER REPAIR. Is DTC displayed? Replace the TCM. Temporary poor
1) Perform the clear memory mode. <Ref. to 5AT-61, contact or open
2) Drive for a while, read the DTC, and verify Transmission Con- circuit occurs.
that there is no faulty. trol Module Recheck that the
(TCM).> harness connec-
tor has no faulty.
5AT(diag)-62
Q: DTC P0748 PRESSURE CONTROL SOLENOID “A” ELECTRICAL

Output signal circuit of line pressure solenoid is open or shorted.
TROUBLE SYMPTOM:
WIRING DIAGRAM:
B54
TCM
1 2 3 4 5 6 7 8 9
B54 10 11 12 13 14 15 16 17 18
19 20 21 22 23 24
14
5
9
B11
1 2 3 4
5 6 7 8
E 9 10 11 12
13 14 15 16
17 18 19 20
B11
19
T4
T6
1 2 3 4
5 6 7 8 9 10 11 12
T6
7
TRANSMISSION
AT-02077
5AT(diag)-63
Step Check Yes No

(B54) No. 9 — (B11) No. 19:
Measure the resistance between TCM connec- between TCM con-
tor and chassis ground. nector and trans-
bracket.
racks.
5) Drain the ATF.
tor.
(T4) No. 19 — (T6) No. 7:
5 CHECK LINE PRESSURE SOLENOID. Is the resistance 3 — 9 "? Go to step 6. Replace the con-
tor has no faulty.
5AT(diag)-64
R: DTC P0751 SHIFT SOLENOID “A” PERFORMANCE OR STUCK OFF

Output signal of front brake solenoid does not match with oil pressure.
TROUBLE SYMPTOM:
Locked to 4th or 5th gear.
WIRING DIAGRAM:
A: B54
1 2 3 4 5 6 7 8 9
TCM 10 11 12 13 14 15 16 17 18
19 20 21 22 23 24
A: B54
B: B55
B: B55
A24
B17
14
5
1 2 3 4 5 6 7 8 9
10 11 12 13 14 15 16 17 18
19 20 21 22 23 24
E B11
B11 1 2 3 4
5 6 7 8
17
3
9 10 11 12
T4
13 14 15 16
17 18 19 20
T5
1 2 3 4 5 6
7 8 9 10 11 12 13 14 15 16
T6
11
T5
10
T6
1 2 3 4
5 6 7 8 9 10 11 12
TRANSMISSION
AT-02078
5AT(diag)-65
Step Check Yes No

(B54) No. 24 — (B11) No. 17:
(B55) No. 17 — (B11) No. 3:
Measure resistance of harness between TCM between TCM and
connector and chassis ground. transmission con-
Monitor?
4 CHECK INPUT SIGNAL FOR TCM USING Is OFF displayed? Go to step 5. Go to step 11.
SUBARU SELECT MONITOR.
OFF)
3) Check input signal of Fr/B oil pressure SW.
5 CHECK INPUT SIGNAL FOR TCM USING Is OFF displayed? Go to step 6. Replace the con-
SUBARU SELECT MONITOR. trol valve body.
2) Turn the ignition switch to ON. (engine ON) Control Valve
3) Shift to 4th speed with checking current Body.>
gear position using Subaru Select Monitor.
4) Check input signal of Fr/B oil pressure SW.
6 CHECK INPUT SIGNAL FOR TCM USING Is the ON displayed? Even if the SPORT Go to step 10.
SUBARU SELECT MONITOR. indicator lights
1) Turn the ignition switch to OFF. blinks, the system
2) Turn the ignition switch to ON. (engine ON) is in normal condi-
3) Shift to 1st speed with checking current tion.
gear position using Subaru Select Monitor. A temporary poor
4) Check input signal of Fr/B oil pressure SW. contact of connec-
tor or harness may
be the cause.
Repair the poor
contact of har-
ness in the sole-
noid output and oil
pressure SW
input.
7 CHECK INPUT SIGNAL FOR TCM USING Is the voltage 10 — 13 V? Go to step 8. Go to step 11.
CIRCUIT TESTER.
OFF)
TCM connector and chassis ground.
5AT(diag)-66
Step Check Yes No

8 CHECK INPUT SIGNAL FOR TCM USING Is the voltage 10 — 13 V? Go to step 9. Replace the con-
CIRCUIT TESTER. trol valve body.
3) Shift to 4th speed of manual mode with Body.>
checking indication of gear position in combi-
nation meter.
NOTE:
Read the value of gear position indication after
the shifting is completed (approx. 2 seconds
later from shifting).
9 CHECK INPUT SIGNAL FOR TCM USING Is the voltage less than 1.5 V? Even if the SPORT Go to step 10.
CIRCUIT TESTER. indicator lights
3) Shift to 1st speed of manual mode with tion.
checking indication of gear position in combi- A temporary poor
nation meter. contact of connec-
NOTE: tor or harness may
Read the value of gear position indication after be the cause.
the shifting is completed (approx. 2 seconds Repair the poor
later from shifting). contact of har-
4) Measure the voltage of harness between ness in the sole-
TCM connector and chassis ground. noid output and oil
Connector & terminal pressure SW
(B55) No. 17 (+) — Chassis ground ($): input.
10 CHECK HARNESS CONNECTOR BETWEEN Is the resistance less than 1 Replace the trans- Repair the open
TRANSMISSION AND CONTROL VALVE "? mission assembly. circuit in harness
1) Turn the ignition switch to OFF. Automatic Trans- valve body con-
2) Disconnect the connector from transmis- mission Assem- nector and trans-
sion. bly.> mission connector.
bracket.
racks.
5) Drain the ATF.
tor.
(B11) No. 17 — (T6) No. 10:
(B11) No. 3 — (T6) No. 11:
5AT(diag)-67
Step Check Yes No

bracket.
racks.
5) Drain the ATF.
sion ground and control valve body connector.
5AT(diag)-68
S: DTC P0753 SHIFT SOLENOID “A” ELECTRICAL

Output signal circuit of front brake solenoid is open or shorted.
TROUBLE SYMPTOM:
Locked to 4th or 5th gear.
WIRING DIAGRAM:
A: B54
1 2 3 4 5 6 7 8 9
TCM 10 11 12 13 14 15 16 17 18
19 20 21 22 23 24
A: B54
B: B55
B: B55
A24
B17
14
5
1 2 3 4 5 6 7 8 9
10 11 12 13 14 15 16 17 18
19 20 21 22 23 24
E B11
B11 1 2 3 4
5 6 7 8
17
3
9 10 11 12
T4
13 14 15 16
17 18 19 20
T5
1 2 3 4 5 6
7 8 9 10 11 12 13 14 15 16
T6
11
T5
10
T6
1 2 3 4
5 6 7 8 9 10 11 12
TRANSMISSION
AT-02078
5AT(diag)-69
Step Check Yes No

(B54) No. 24 — (B11) No. 17:
(B55) No. 17 — (B11) No. 3:
bracket.
racks.
5) Drain the ATF.
tor.
(T4) No. 17 — (T6) No. 9:
(T4) No. 3 — (T5) No. 11:
Measure the resistance between transmission valve body and
ground and control valve body connector. transmission con-
5 CHECK FRONT BRAKE SOLENOID. Is the resistance 3 — 9 "? Go to step 6. Replace the con-
5AT(diag)-70
Step Check Yes No

tor has no faulty.
5AT(diag)-71
T: DTC P0756 SHIFT SOLENOID “B” PERFORMANCE OR STUCK OFF

Output signal value of input clutch solenoid and oil pressure does not match.
TROUBLE SYMPTOM:
Locked to 4th gear.
WIRING DIAGRAM:
B54
TCM
1 2 3 4 5 6 7 8 9
B54 10 11 12 13 14 15 16 17 18
19 20 21 22 23 24
14
18
5
6
B11
1 2 3 4
5 6 7 8
9 10 11 12
E 13 14 15 16
17 18 19 20
B11
11
18
T4
T5
1 2 3 4 5 6
7 8 9 10 11 12 13 14 15 16
T6
1 2 3 4
5 6 7 8 9 10 11 12
T5 T6
8
8
TRANSMISSION
AT-02079
5AT(diag)-72
Step Check Yes No

(B54) No. 18 — (B11) No. 18:
(B54) No. 6 — (B11) No. 11:
OFF)
3) Check input signal of I/C oil pressure SW.
3) Shift to “D” range and brake ON (1st) with Body.>
checking current gear position using Subaru
Select Monitor.
4) Check input signal of I/C oil pressure SW.
3) Drive the vehicle on 4th speed of “D” range tion.
with checking current gear position using Sub- A temporary poor
aru Select Monitor. contact of connec-
4) Check input signal of I/C oil pressure SW. tor or harness may
be the cause.
Repair the poor
contact of har-
ness in the sole-
noid output and oil
pressure SW
input.
5AT(diag)-73
Step Check Yes No

bracket.
racks.
5) Drain the ATF.
tor.
(T4) No. 18 — (T6) No. 8:
(T4) No. 11 — (T5) No. 8:
bracket.
racks.
5) Drain the ATF.
5AT(diag)-74
U: DTC P0758 SHIFT SOLENOID “B” ELECTRICAL

Output signal circuit of input clutch solenoid is open or shorted.
TROUBLE SYMPTOM:
Locked to 4th gear.
WIRING DIAGRAM:
B54
TCM
1 2 3 4 5 6 7 8 9
B54 10 11 12 13 14 15 16 17 18
19 20 21 22 23 24
14
18
5
6
B11
1 2 3 4
5 6 7 8
9 10 11 12
E 13 14 15 16
17 18 19 20
B11
11
18
T4
T5
1 2 3 4 5 6
7 8 9 10 11 12 13 14 15 16
T6
1 2 3 4
5 6 7 8 9 10 11 12
T5 T6
8
8
TRANSMISSION
AT-02079
5AT(diag)-75
Step Check Yes No

(B54) No. 18 — (B11) No. 18:
(B54) No. 6 — (B11) No. 11:
TCM AND BODY HARNESS. M"? circuit in harness
connector and body harness. transmission con-
bracket.
racks.
5) Drain the ATF.
tor.
(T4) No. 18 — (T6) No. 8:
(T4) No. 11 — (T5) No. 8:
5 CHECK INPUT CLUTCH SOLENOID. Is the resistance 3 — 9 "? Go to step 6. Replace the con-
5AT(diag)-76
Step Check Yes No

tor has no faulty.
5AT(diag)-77
V: DTC P0761 SHIFT SOLENOID “C” PERFORMANCE OR STUCK OFF

Output signal value of high & low reverse clutch solenoid and oil pressure does not match.
TROUBLE SYMPTOM:
Locked to 4th gear.
WIRING DIAGRAM:
A: B54
1 2 3 4 5 6 7 8 9
TCM 10 11 12 13 14 15 16 17 18
19 20 21 22 23 24
A: B54
B: B55
B: B55
A17
A14
A5
B8
1 2 3 4 5 6 7 8 9
10 11 12 13 14 15 16 17 18
19 20 21 22 23 24
E B11
B11 1 2 3 4
5 6 7 8
15
4
9 10 11 12
T4
13 14 15 16
17 18 19 20
T5
1 2 3 4 5 6
7 8 9 10 11 12 13 14 15 16
T6
12
T5
12
T6
1 2 3 4
5 6 7 8 9 10 11 12
TRANSMISSION
AT-02080
5AT(diag)-78
Step Check Yes No

(B54) No. 17 — (B11) No. 15:
(B55) No. 8 — (B11) No. 4:
Monitor?
OFF)
3) Check input signal of H&LR/C oil pressure
SW.
3) Drive the vehicle on 2nd speed of “D” range Body.>
with checking current gear position using Sub-
aru Select Monitor.
4) Check input signal of H&LR/C oil pressure
SW.
3) Shift to “D” range and brake ON (1st) with tion.
checking current gear position using Subaru A temporary poor
Select Monitor. contact of connec-
4) Check input signal of H&LR/C oil pressure tor or harness may
SW. be the cause.
Repair the poor
contact of har-
ness in the sole-
noid output and oil
pressure SW
input.
5AT(diag)-79
Step Check Yes No

7 CHECK INPUT SIGNAL FOR TCM USING Is the voltage 10 — 13 V? Go to step 8. Go to step 11.
CIRCUIT TESTER.
OFF)
8 CHECK INPUT SIGNAL FOR TCM USING Is the voltage 10 — 13 V? Go to step 9. Replace the con-
CIRCUIT TESTER. trol valve body.
3) Shift to 2nd speed of manual mode with Body.>
checking indication of gear position in combi-
nation meter.
NOTE:
Read the value of gear position indication after
the shifting is completed (approx. 2 seconds
later from shifting).
9 CHECK INPUT SIGNAL FOR TCM USING Is the voltage less than 1.5 V? Even if the SPORT Go to step 10.
CIRCUIT TESTER. indicator lights
3) Shift to 1st speed of manual mode with tion.
checking indication of gear position in combi- A temporary poor
nation meter. contact of connec-
NOTE: tor or harness may
Read the value of gear position indication after be the cause.
the shifting is completed (approx. 2 seconds Repair the poor
later from shifting). contact of har-
4) Measure the voltage between TCM con- ness in the sole-
nector and chassis ground. noid output and oil
Connector & terminal pressure SW
(B55) No. 8 (+) — Chassis ground ($): input.
bracket.
racks.
5) Drain the ATF.
tor.
(T4) No. 15 — (T6) No. 12:
(T4) No. 4 — (T5) No. 12:
5AT(diag)-80
Step Check Yes No

bracket.
racks.
5) Drain the ATF.
5AT(diag)-81
W: DTC P0763 SHIFT SOLENOID “C” ELECTRICAL

Output signal circuit of high & low reverse clutch solenoid is open or shorted.
TROUBLE SYMPTOM:
Locked to 4th gear.
WIRING DIAGRAM:
A: B54
1 2 3 4 5 6 7 8 9
TCM 10 11 12 13 14 15 16 17 18
19 20 21 22 23 24
A: B54
B: B55
B: B55
A17
A14
A5
B8
1 2 3 4 5 6 7 8 9
10 11 12 13 14 15 16 17 18
19 20 21 22 23 24
E B11
B11 1 2 3 4
5 6 7 8
15
4
9 10 11 12
T4
13 14 15 16
17 18 19 20
T5
1 2 3 4 5 6
7 8 9 10 11 12 13 14 15 16
T6
12
T5
12
T6
1 2 3 4
5 6 7 8 9 10 11 12
TRANSMISSION
AT-02080
5AT(diag)-82
Step Check Yes No

(B54) No. 17 — (B11) No. 15:
(B55) No. 8 — (B11) No. 4:
bracket.
racks.
5) Drain the ATF.
tor.
(T4) No. 15 — (T6) No. 12:
(T4) No. 4 — (T5) No. 12:
4 CHECK HARNESS CONNECTOR BETWEEN Is the resistance more than 1 Go to step 5. Repair the open
Measure the resistance of harness connector valve body con-
between control valve body connector and nector and trans-
chassis ground. mission ground.
5 CHECK HIGH & LOW REVERSE CLUTCH Is the resistance 3 — 9 "? Go to step 6. Replace the con-
SOLENOID. trol valve body.
Measure the resistance between transmission <Ref. to 5AT-58,
ground and control valve body connector. Control Valve
Connector & terminal Body.>
5AT(diag)-83
Step Check Yes No

tor has no faulty.
5AT(diag)-84
X: DTC P0766 SHIFT SOLENOID “D” PERFORMANCE OR STUCK OFF

Output signal value of direct clutch solenoid and oil pressure does not match.
TROUBLE SYMPTOM:
Locked to 4th gear.
WIRING DIAGRAM:
B54
TCM
1 2 3 4 5 6 7 8 9
B54 10 11 12 13 14 15 16 17 18
19 20 21 22 23 24
14
21
22
B11
1 2 3 4
5 6 7 8
9 10 11 12
E 13 14 15 16
17 18 19 20
B11
10
16
T4
T6
1 2 3 4
5 6 7 8 9 10 11 12
T5 T6
11
9
TRANSMISSION
AT-02081
5AT(diag)-85
Step Check Yes No

(B54) No. 22 — (B11) No. 16:
(B54) No. 21 — (B11) No. 10:
connector and body harness. transmission con-
OFF)
3) Check input signal of D/C oil pressure SW.
3) Shift to “D” range and brake ON (1st) with Body.>
checking current gear position using Subaru
Select Monitor.
4) Check input signal of D/C oil pressure SW.
3) Shift to 2nd speed of manual mode and tion.
brake ON with checking current gear position A temporary poor
using Subaru Select Monitor. contact of connec-
4) Check input signal of D/C oil pressure SW. tor or harness may
be the cause.
Repair the poor
contact of har-
ness in the sole-
noid output and oil
pressure SW
input.
5AT(diag)-86
Step Check Yes No

bracket.
racks.
5) Drain the ATF.
tor.
(T4) No. 16 — (T6) No. 10:
(T4) No. 10 — (T5) No. 9:
bracket.
racks.
5) Drain the ATF.
5AT(diag)-87
Y: DTC P0768 SHIFT SOLENOID “D” ELECTRICAL

The output signal circuit of direct clutch solenoid is open or shorted.
TROUBLE SYMPTOM:
Locked to 4th gear.
WIRING DIAGRAM:
B54
TCM
1 2 3 4 5 6 7 8 9
B54 10 11 12 13 14 15 16 17 18
19 20 21 22 23 24
14
21
22
B11
1 2 3 4
5 6 7 8
9 10 11 12
E 13 14 15 16
17 18 19 20
B11
10
16
T4
T6
1 2 3 4
5 6 7 8 9 10 11 12
T5 T6
11
9
TRANSMISSION
AT-02081
5AT(diag)-88
Step Check Yes No

(B54) No. 22 — (B11) No. 16:
(B54) No. 21 — (B11) No. 10:
bracket.
racks.
5) Drain the ATF.
tor.
(T4) No. 16 — (T6) No. 10:
(T4) No. 10 — (T5) No. 9:
5 CHECK DIRECT CLUTCH SOLENOID. Is the resistance 3 — 9 "? Go to step 6. Replace the con-
Measure the resistance of harness connector trol valve body.
between control valve body connector and <Ref. to 5AT-58,
transmission ground. Control Valve
5AT(diag)-89
Step Check Yes No

tor has no faulty.
5AT(diag)-90
Z: DTC P0771 SHIFT SOLENOID “E” PERFORMANCE OR STUCK OFF

Output signal value of low coast brake solenoid and oil pressure does not match.
TROUBLE SYMPTOM:
• Locked to 2nd gear.
• Engine brake does not function at 1st or 2nd of manual mode.
WIRING DIAGRAM:
B54
TCM
1 2 3 4 5 6 7 8 9
B54 10 11 12 13 14 15 16 17 18
19 20 21 22 23 24
14
15
12
B11
1 2 3 4
5 6 7 8
9 10 11 12
E 13 14 15 16
17 18 19 20
B11
13
9
T4
T6
1 2 3 4
5 6 7 8 9 10 11 12
T5 T6
10
13
TRANSMISSION
AT-02082
5AT(diag)-91
Step Check Yes No

(B54) No. 15 — (B11) No. 13:
(B54) No. 12 — (B11) No. 9:
Measure the resistance between TCM connec- between TCM and
tor and chassis ground. transmission con-
OFF)
3) Check input signal of LC/B oil pressure SW.
3) Shift to 3rd speed with checking current Body.>
gear position using Subaru Select Monitor.
4) Check input signal of LC/B oil pressure SW.
3) Drive the vehicle on 2nd speed of manual tion.
mode 15 km/h (9 MPH) with checking current A temporary poor
gear position using Subaru Select Monitor. contact of connec-
4) Check input signal of LC/B oil pressure SW. tor or harness may
be the cause.
Repair the poor
contact of har-
ness in the sole-
noid output and oil
pressure SW
input.
5AT(diag)-92
Step Check Yes No

bracket.
racks.
5) Drain the ATF.
tor.
(T4) No. 13 — (T6) No. 13:
(T4) No. 9 — (T5) No. 10:
bracket.
racks.
5) Drain the ATF.
5AT(diag)-93
AA:DTC P0773 SHIFT SOLENOID “E” ELECTRICAL

Output signal circuit of low coast brake solenoid is open or shorted.
TROUBLE SYMPTOM:
• Locked to 2nd gear.
• Engine brake does not function at 1st or 2nd of manual mode.
WIRING DIAGRAM:
B54
TCM
1 2 3 4 5 6 7 8 9
B54 10 11 12 13 14 15 16 17 18
19 20 21 22 23 24
14
15
12
B11
1 2 3 4
5 6 7 8
9 10 11 12
E 13 14 15 16
17 18 19 20
B11
13
9
T4
T6
1 2 3 4
5 6 7 8 9 10 11 12
T5 T6
10
13
TRANSMISSION
AT-02082
5AT(diag)-94
Step Check Yes No

(B54) No. 15 — (B11) No. 13:
(B54) No. 12 — (B11) No. 9:
connector and body harness. nector and trans-
bracket.
racks.
5) Drain the ATF.
tor.
(T4) No. 13 — (T6) No. 13:
(T4) No. 9 — (T5) No. 10:
5 CHECK LOW COAST BRAKE SOLENOID. Is the resistance between 5 — Go to step 6. Replace the con-
Measure the resistance of harness connector 17 "? trol valve body.
between control valve body connector and <Ref. to 5AT-58,
transmission ground. Control Valve
5AT(diag)-95
Step Check Yes No

tor has no faulty.
5AT(diag)-96
AB:DTC P0801 REVERSE INHIBIT CONTROL CIRCUIT

Shift lock solenoid malfunction, open or short reverse inhibitor control circuit
TROUBLE SYMPTOM:
• Gear is shifted from “N” range to “R” range during driving at 20 km/h 12 MPH) or more.
• Gear can not be shifted from “N” range to “R” range though the vehicle is parked.
WIRING DIAGRAM:
B55
TCM 1 2 3 4 5 6 7 8 9
10 11 12 13 14 15 16 17 18
19 20 21 22 23 24
B55
15
B116
1 2 3 4
5 6 7 8 9 10
SHIFT LOCK
SOLENOID
B116
3
4
AT-01536
5AT(diag)-97
Step Check Yes No

1 CHECK FUSE (No. 32). Is the fuse (No. 32) blown out? Replace the fuse Go to step 2.
1) Turn the ignition switch to OFF. (No. 32). If the
2) Remove the fuse (No. 32). replaced fuse has
blown out easily,
repair the short cir-
cuit in harness
between fuse (No.
32) and TCM.
2 CHECK OUTPUT SIGNAL OF TCM. Is the voltage more than 10.5 Go to step 3. Replace the TCM.
1) Turn the ignition switch to ON. V? <Ref. to 5AT-61,
2) With the brake pedal depressed, shift the Transmission Con-
select lever to “D” range. trol Module
3) Measure the voltage between TCM and (TCM).>
chassis ground.
TCM AND SHIFT LOCK SOLENOID. "? circuit in harness
2) Disconnect the connector from TCM and shift lock solenoid
shift lock solenoid. connector.
between TCM and shift lock solenoid connec-
tor.
(B55) No. 15 — (B116) No. 3:
TCM AND SHIFT LOCK SOLENOID. M"? circuit in harness
Measure the voltage of harness between TCM between TCM and
and chassis ground. shift lock solenoid
5 CHECK HARNESS BETWEEN SHIFT LOCK Is the resistance less than 1 Go to step 6. Repair the open
SOLENOID AND CHASSIS GROUND TERMI- "? circuit in harness
NAL. between chassis
Measure the resistance of harness between ground and shift
shift lock solenoid and chassis ground. lock solenoid con-
terminals.
(B116) No. 3 — No. 4:
5AT(diag)-98
Step Check Yes No

7 CHECK OUTPUT SIGNAL OF TCM. Is the voltage less than 1 V? Even if the SPORT Go to step 8.
1) Lift-up the vehicle and support with rigid indicator lights up,
racks. the circuit has
NOTE: returned to nor-
Raise all wheels off floor. mal condition at
2) Start the engine. this time. A tempo-
3) Shift the select lever to “D” range and rary poor contact
slowly increase vehicle speed to 20 km/h (12 of connector or
MPH). harness may be
the cause. Repair
NOTE:
The speed difference between front and rear harness or con-
wheels may light the ABS warning light, but this nector in reverse
indicates no malfunction. When AT control di- inhibitor control
agnosis is finished, perform the ABS memory circuit.
Mode.>
chassis ground.
8 CHECK POOR CONTACT. Is there poor contact in the Repair the poor Replace the TCM.
reverse inhibitor control circuit? contact. <Ref. to 5AT-61,
Transmission Con-
trol Module
(TCM).>
5AT(diag)-99
AC:DTC P0817 STARTER DISABLE CIRCUIT

Open or short in P/N signal output circuit
TROUBLE SYMPTOM:
• Engine can be started on other than “P” or “N” range
• Engine can not be started on “P” or “N” range
WIRING DIAGRAM:
B55
ECM
1 2 3 4 5 6 7 8 9
B137 10 11 12 13 14 15 16 17 18
19 20 21 22 23 24
9
B137
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23 24 25
26 27 28 29 30 31
19
B55
TCM
AT-01632
5AT(diag)-100
Step Check Yes No

1 CHECK DTC OF TCM. Is DTC of Transmission Range Perform the diag- Go to step 2.
Sensor Circuit (PRNDL Input) nosis according to
circuit detected? DTC.
2 CHECK ECM. Is the communication between Go to step 3. Perform the diag-
Subaru Select Monitor and nosis according to
ECM normal? DTC concerning
ECM.
3 CHECK FUSE (No. 32). Is the fuse (No. 32) blown out? Replace the fuse Go to step 4.
1) Turn the ignition switch to OFF. (No. 32). If the
2) Remove the fuse. replaced fuse (No.
32) has blown out
easily, repair the
ness between fuse
(No. 32) and TCM.
TCM AND ECM. "? circuit in harness
transmission. nector, and poor
between TCM and transmission connector. pling connector.
(B55) No. 19 — (B137) No. 9:
TCM AND ECM. M"? circuit in harness
Measure the resistance of harness between between transmis-
TCM connector and chassis ground. sion connector
Connector & terminal and chassis
(B55) No. 19 — Chassis ground: ground.
6 CHECK TCM OUTPUT SIGNAL. Is the voltage more than 10 V? Go to step 7. Replace the TCM.
1) Connect the TCM and ECM connector. <Ref. to 5AT-61,
2) Turn the ignition switch to ON. (engine Transmission Con-
OFF) trol Module
3) Shift the select lever to “P” range. (TCM).>
7 CHECK TCM OUTPUT SIGNAL. Is the voltage less than 1 V? Go to step 8. Replace the TCM.
1) Shift the select lever to “D” range. <Ref. to 5AT-61,
2) Measure the voltage between TCM con- Transmission Con-
nector and chassis ground. trol Module
Connector & terminal (TCM).>
8 CHECK POOR CONTACT. Is there any open or poor con- Repair the poor Check neutral cir-
tact of connector (loosing ter- contact. cuit inside the
minal, entering foreign matter, ECM.
damaging connector body)?
5AT(diag)-101
AD:DTC P0882 TCM POWER INPUT SIGNAL LOW

Malfunction of PVIGN power supply relay or open, short circuit of PVIGN power supply circuit.
TROUBLE SYMPTOM:
Gear is not changed.
WIRING DIAGRAM:
IGNITION
SWITCH
SBF-1 SBF-9
B54
1 2 3 4 5 6 7 8 9
No.12
10 11 12 13 14 15 16 17 18
19 20 21 22 23 24
BATTERY
B357
1 2
3
2
4
E
B357
1
4
10
8
7
B54 TCM
AT-01630
5AT(diag)-102
Step Check Yes No

1 CHECK FUSE. Is the fuse blown out? Replace the fuse. Go to step 2.
1) Turn the ignition switch to OFF. If the replaced
2) Remove the SBF 1, SBF 2 and fuse (No. fuse has blown out
12), and then check those are not blown out. easily, repair the
ness of each fuse.
2 CHECK INPUT VOLTAGE FOR PVIGN RE- Is the voltage 10 — 13 V? Go to step 3. Check open cir-
LAY. cuit in harness
Measure the voltage between PVIGN relay and between fuse (No.
chassis ground. 12) and PVIGN
Connector & terminal relay.
3 CHECK HARNESS BETWEEN PVIGN RE- Is the resistance less than 1 Go to step 4. Repair the open
LAY OF TCM. "? circuit of harness.
Measure the resistance between TCM connec-
tor and PVIGN relay connector.
(B54) No. 10 — (B357) No. 1:
(B54) No. 7 — (B357) No. 4:
(B54) No. 8 — (B357) No. 4:
4 CHECK PVIGN POWER SUPPLY CIRCUIT. Is the voltage 10 — 13 V? Temporary poor Go to step 5.
1) Turn the ignition switch to ON. (engine contact. Recheck
OFF) the harness
2) Measure the voltage between TCM con- between TCM and
nector and chassis ground. relay. (Lightly
Connector & terminal move the harness
(B54) No. 7 (+) — Chassis ground ($): and check that the
(B54) No. 8 (+) — Chassis ground ($): open or short cir-
cuit is not
occurred.)
5 CHECK PVIGN RELAY OUTPUT OF TCM. Is the voltage less than 1.5 V? Replace the Replace the TCM.
Measure the voltage between TCM connector PVIGN relay. <Ref. to 5AT-61,
and chassis ground. Transmission Con-
(B55) No. 11 (+) — Chassis ground ($): (TCM).>
5AT(diag)-103
AE:DTC P0957 BACKUP LIGHT RELAY CIRCUIT LOW

Short circuit of back-up light relay output circuit
TROUBLE SYMPTOM:
Back-up light does not illuminate in “R” range.
WIRING DIAGRAM:
IGNITION
RELAY
SBF-1 SBF-9
B55
1 2 3 4 5 6 7 8 9
No.18
10 11 12 13 14 15 16 17 18
19 20 21 22 23 24
BATTERY
B356
1 2
3
2
4
E
B356
1
BACKUP LIGHT CIRCUIT

11
B55 TCM
AT-01631
5AT(diag)-104
Step Check Yes No

TCM AND BACK-UP LIGHT RELAY. "? circuit in harness
backup light relay. nector, and poor
between TCM and backup light relay connec- pling connector.
tor.
(B55) No. 11 — (B356) No. 1:
1) Turn the ignition switch to ON. (engine <Ref. to 5AT-61,
OFF) Transmission Con-
2) Shift the select lever to “P” range. trol Module
(TCM).>
Shift the select lever to “R” range. <Ref. to 5AT-61,
Transmission Con-
trol Module
(TCM).>
6 CHECK INPUT VOLTAGE FOR BACKUP Is the voltage 10 — 13 V? Replace the back- Check open or
LIGHT RELAY. up light relay. short circuit in har-
Measure the voltage between back-up light ness between fuse
relay and chassis ground. (No. 18) and
backup light relay.
5AT(diag)-105
AF:DTC P0958 BACKUP LIGHT RELAY CIRCUIT HIGH

Back-up light relay malfunction, or open/short circuit in back-up light relay output circuit
TROUBLE SYMPTOM:
• Back-up light does not illuminate in “R” range.
• Back-up light always illuminate in other than “R” range.
WIRING DIAGRAM:
IGNITION
RELAY
SBF-1 SBF-9
B55
1 2 3 4 5 6 7 8 9
No.18
10 11 12 13 14 15 16 17 18
19 20 21 22 23 24
BATTERY
B356
1 2
3
2
4
E
B356
1
BACKUP LIGHT CIRCUIT

11
B55 TCM
AT-01631
5AT(diag)-106
Step Check Yes No

TCM AND BACK-UP LIGHT RELAY. "? circuit in harness
back-up light relay. nector, and poor
between TCM and back-up light relay connec- pling connector.
tor.
(B55) No. 11 — (B356) No. 1:
1) Turn the ignition switch to ON. (engine <Ref. to 5AT-61,
OFF) Transmission Con-
2) Shift the select lever to “P” range. trol Module
(TCM).>
Shift the select lever to “R” range. <Ref. to 5AT-61,
Transmission Con-
trol Module
(TCM).>
6 CHECK INPUT VOLTAGE FOR BACK-UP Is the voltage 10 — 13 V? Replace the back- Check open or
LIGHT RELAY. up light relay. short circuit in har-
Measure the voltage between back-up light ness between fuse
relay and chassis ground. (No. 18) and
backup light relay.
5AT(diag)-107
AG:DTC P1601 TCM COMMUNICATION MALFUNCTION

Communication does not complete between control valve memory box.
TROUBLE SYMPTOM:
Shifting quality malfunction
WIRING DIAGRAM:
B54
B54 TCM 1 2 3 4 5 6 7 8 9
10 11 12 13 14 15 16 17 18
19 20 21 22 23 24
21
12
B11
1 2 3 4
5 6 7 8
9 10 11 12
13 14 15 16
17 18 19 20
10
11
B11
9
T5
1 2 3 4 5 6
7 8 9 10 11 12 13 14 15 16
10
T5
9
8
TRANSMISSION
AT-01800
Step Check Yes No

1 CHECK POOR CONTACT OF TRANSMIS- Is there poor contact on con- Go to step 2. Connect it
SION CONNECTOR. nector? securely.
Check loose connection on TCM connector
(B54).
2 CHECK DTC OF TCM. Is DTC of oil pressure switch Perform the diag- Go to step 3.
DTC.
5AT(diag)-108
Step Check Yes No

3 CHECK TCM OUTPUT SIGNAL. Is the voltage 10 — 13 V? Go to step 4. Go to step 5.
OFF)
transmission. nector, and poor
between TCM and transmission connector. pling connector.
(B54) No. 12 — (B11) No. 9:
(B54) No. 21 — (B11) No. 10:
(B54) No. 6 — (B11) No. 11:
TRANSMISSION CONNECTOR AND CON- "? circuit in harness
TROL VALVE BODY CONNECTOR. between control
connector and control valve body connector. nector and trans-
(B54) No. 9 — (T5) No. 10:
(B54) No. 10 — (T5) No. 9:
(B54) No. 11 — (T5) No. 8:
TRANSMISSION CONNECTOR AND CON- M"? circuit in harness
TROL VALVE BODY CONNECTOR. between control
8 CHECK POOR CONTACT. Is there any open or poor con- Repair the poor Replace the trans-
NOTE: tact of connector (loosing ter- contact. mission assembly.
Data communication malfunction is detected minal, entering foreign matter, <Ref. to 5AT-38,
when the malfunction occurred on inspection damaging connector body)? Automatic Trans-
area above while transmission assembly is re- mission Assem-
placing or “Clear Memory 2” is performing. bly.>
When the repair is performed with following di-
agnosis above, perform the “Clear Memory 2”,
and then recheck that the DTC of TCM data
communication malfunction is not detected.
5AT(diag)-109
AH:DTC P1706 AT VEHICLE SPEED SENSOR CIRCUIT MALFUNCTION (REAR

WHEEL)
TROUBLE SYMPTOM:
• Shifting quality malfunction
WIRING DIAGRAM:
A: B54
TCM
1 2 3 4 5 6 7 8 9
A: B54 B: B55 10 11 12 13 14 15 16 17 18
19 20 21 22 23 24
A16
B18
B: B55
1 2 3 4 5 6 7 8 9
10 11 12 13 14 15 16 17 18
19 20 21 22 23 24
A: B11
B5
A7
A: B11
B: B12
1 2 3 4
5 6 7 8
9 10 11 12
13 14 15 16
17 18 19 20
B: B12
1 2 3 4
5 6 7 8
REAR VEHICLE
SPEED SENSOR
AT-01537
5AT(diag)-110
Step Check Yes No

(B54) No. 16 — (B11) No. 7:
(B55) No. 18 — (B12) No. 5:
OFF)
CIRCUIT OF TCM.
terminals.
(B55) No. 18 (+) — (B54) No. 19 ($):
Check TCM I/O signal of power supply, ground <Ref. to 5AT-61, short circuit for
and PVIGN power supply relay. Transmission Con- power supply and
for PVIGN power
supply relay.
6 CHECK HARNESS ASSEMBLY (TURBINE Is the ground connecting har- Go to step 7. When the poor
SPEED SENSOR GROUND). ness installed to transmission installation of
Check the installing condition of ground con- body correctly, or the harness ground connect-
necting harness (used for both of turbine and connector terminals not ing harness, install
speed sensor 1, rear vehicle speed sensor). damaged? it securely.
Replace the trans-
mission assembly
when the harness
is damaged. <Ref.
to 5AT-38, Auto-
matic Transmis-
sion Assembly.>
Monitor?
5AT(diag)-111
Step Check Yes No

9 CHECK INPUT SIGNAL FOR TCM USING Does the value of the front Even if the SPORT Replace the trans-
SUBARU SELECT MONITOR. wheel speed depending on the indicator lights mission harness.
1) Connect all the connectors. acceleration and deceleration blinks, the system
2) Lift-up the vehicle and support with rigid of the vehicle? is in normal condi-
racks. tion.
3) Start the engine, and drive the vehicle. tor or harness may
4) Read the current data of front wheel speed be the cause.
using Subaru Select Monitor. Repair harness or
<Ref. to 5AT(diag)-16, OPERATION, Subaru contact in the ATF
Select Monitor.> temperature sen-
sor and transmis-
NOTE:
The speed difference between front and rear sion connector.
Mode.>
10 CHECK INPUT SIGNAL FOR TCM USING Is the frequency of measured Even if the SPORT Replace the trans-
OSCILLOSCOPE. waveform (pulse wave) indicator lights mission harness.
Connector & terminal Repair harness or
Positive probe; (B55) No. 18: contact in the ATF
Ground lead; (B54) No. 19: temperature sen-
sor and transmis-
4) Start the engine, and drive the vehicle.
sion connector.
quency.
NOTE:
Mode.>
5AT(diag)-112
Step Check Yes No

11 CHECK INPUT SIGNAL FOR TCM USING Does the voltage change Even if the SPORT Replace the trans-
CIRCUIT TESTER. within the range of 2 — 3 V indicator lights mission harness.
3) Start the engine, and drive the vehicle. tor or harness may
4) Measure the voltage between TCM termi- be the cause.
nals. Repair harness or
Connector & terminal contact in the ATF
(B55) No. 7 (+) — (B54) No. 19 ($): temperature sen-
sor and transmis-
sion connector.
to “P” range.
nals.
(B55) No. 7 (+) — (B54) No. 19 ($):
NOTE:
Mode.>
5AT(diag)-113
AI: DTC P1707 AT AWD SOLENOID VALVE CIRCUIT MALFUNCTION

Output signal circuit of transfer solenoid is open or shorted.
TROUBLE SYMPTOM:
• Drivability getting worse.
WIRING DIAGRAM:
TCM A: B54
A: B54
1 2 3 4 5 6 7 8 9
B: B55 10 11 12 13 14 15 16 17 18
19 20 21 22 23 24
A14
B23
A5
B: B55
1 2 3 4 5 6 7 8 9
E 10 11 12 13 14 15 16 17 18
19 20 21 22 23 24
B11
8
T4
B11
1 2 3 4
5 6 7 8
9 10 11 12
13 14 15 16
17 18 19 20
T6
11
T6
1 2 3 4
5 6 7 8 9 10 11 12
TRANSMISSION
AT-02083
5AT(diag)-114
Step Check Yes No

(B55) No. 23 — (B11) No. 8:
bracket.
racks.
5) Drain the ATF.
tor.
(T4) No. 8 — (T6) No. 11:
5 AWD SOLENOID CURRENT. Is the resistance 3 — 9 "? Go to step 6. Replace the con-
tor has no faulty.
5AT(diag)-115
AJ:DTC P1710 TORQUE CONVERTER TURBINE 2 SPEED SIGNAL CIRCUIT 2

MALFUNCTION
TROUBLE SYMPTOM:
• Does not shift to 5th
WIRING DIAGRAM:
A: B54
1 2 3 4 5 6 7 8 9
10 11 12 13 14 15 16 17 18
TCM 19 20 21 22 23 24
A: B54 B: B55
B: B55
A16
B22
1 2 3 4 5 6 7 8 9
10 11 12 13 14 15 16 17 18
19 20 21 22 23 24
B11
B11 B12
1 2 3 4
6
7
5 6 7 8
T4 T3
9 10 11 12
13 14 15 16
17 18 19 20
B12
15
T5 T6
3
1 2 3 4
5 6 7 8
T5
1 2 3 4 5 6
E 7 8 9 10 11 12 13 14 15 16
TURBINE SPEED SENSOR 2

T6
TRANSMISSION
1 2 3 4
5 6 7 8 9 10 11 12
AT-02084
5AT(diag)-116
Step Check Yes No

(B55) No. 22 — (B12) No. 6:
(B54) No. 16 — (B11) No. 7:
OFF)
(B54) No. 16 (+) — (B54) No. 19 ($):
CIRCUIT OF TCM.
terminals.
(B55) No. 22 (+) — (B54) No. 19 ($):
5 CHECK TCM I/O SIGNAL. Is I/O signal OK? Replace the TCM. Repair the open or
Check TCM I/O signal of power supply, ground <Ref. to 5AT-61, short circuit for
and PVIGN power supply relay. Transmission Con- power supply and
for PVIGN power
supply relay.
Monitor?
5AT(diag)-117
Step Check Yes No

8 CHECK INPUT SIGNAL FOR TCM USING Does the value of the turbine Even if the SPORT Go to step 11.
SUBARU SELECT MONITOR. speed sensor 2 change indicator lights
1) Connect all the connectors. depending on the acceleration, blinks, the system
2) Lift-up the vehicle and support with rigid deceleration and shifting gear is in normal condi-
3) Start the engine, and set the vehicle in 1st tor or harness may
4) Read the current data of torque converter Repair the poor
turbine speed 2 using the Subaru Select Moni- contact in harness
tor. of turbine speed
<Ref. to 5AT(diag)-16, OPERATION, Subaru sensor 2 and
Select Monitor.> transmission con-
nector.
NOTE:
Mode.>
9 CHECK INPUT SIGNAL FOR TCM USING Is the frequency of measured Even if the SPORT Go to step 11.
OSCILLOSCOPE. waveform (pulse wave) indicator lights
Connector & terminal Repair the poor
Positive probe; (B55) No. 22: contact in harness
Ground lead; (B54) No. 19: of turbine speed
sensor 2 and
4) Start the engine, and set the vehicle in 1st
transmission con-
speed driving condition of manual mode.
nector.
quency.
NOTE:
Mode.>
5AT(diag)-118
Step Check Yes No

10 CHECK INPUT SIGNAL FOR TCM USING Does the voltage change Even if the SPORT Go to step 11.
CIRCUIT TESTER. within the range of 2 — 3 V indicator lights
3) Start the engine, and set the vehicle in 1st tor or harness may
4) Measure the voltage between TCM termi- Repair the poor
nals. contact in harness
Connector & terminal of turbine speed
(B55) No. 22 (+) — (B54) No. 19 ($): sensor 2 and
transmission con-
nector.
to “P” range.
nals.
(B55) No. 22 (+) — (B54) No. 19 ($):
NOTE:
Mode.>
bracket.
racks.
NOTE:
5) Drain the ATF.
CAUTION:
tor.
(T3) No. 6 — (T6) No. 3:
(T4) No. 7 — (T5) No. 15:
BODY. <Ref. to 5AT-58, between transmis-
Measure the resistance between transmission Control Valve sion connector
ground and control valve body connector. Body.> and transmission
5AT(diag)-119
AK:DTC P1716 ATF TEMP. SENSOR 2 CIRCUIT LOW

Input signal circuit of TCM to ATF temperature sensor 2 is open or shorted.
TROUBLE SYMPTOM:
WIRING DIAGRAM:
B54
B54 TCM 1 2 3 4 5 6 7 8 9
10 11 12 13 14 15 16 17 18
19 20 21 22 23 24
11
13
B11
1 2 3 4
5 6 7 8
9 10 11 12
13 14 15 16
17 18 19 20
B11
12
T4
T5
1 2 3 4
5 6 7 8 9 10 11 12
T6
1 2 3 4 5 6
T5 T6 7 8 9 10 11 12 13 14 15 16
2
1
TRANSMISSION
AT-01628
5AT(diag)-120
Step Check Yes No

(B54) No. 13 — (B11) No. 12:
(B54) No. 11 — (B11) No. 6:
and TCM.
engine.
NOTE:
ating temperature.
sion.
(T4) No. 6 — (T4) No. 12:
(T4) No. 6 — (T4) No. 12:
Monitor?
5 CHECK INPUT SIGNAL FOR TCM. Is the voltage 0.4 — 0.9 V? Even if the SPORT Go to step 8.
3) Measure the voltage between TCM con- cause. Repair har-
nector terminals. ness or contact in
Connector & terminal the ATF tempera-
(B54) No. 11 (+) — (B54) No. 13 ($): ture sensor and
transmission con-
nector.
5AT(diag)-121
Step Check Yes No

2) Turn the ignition switch to ON. (engine is in normal condi-
OFF) tion. A temporary
ness may be the
cause. Repair har-
ness or contact in
the ATF tempera-
ture sensor and
transmission con-
nector.
7 CHECK HARNESS CONNECTOR BETWEEN Is the resistance less than 1 Replace the con- Repair the open
TRANSMISSION AND CONTROL VALVE "? trol valve body. circuit in harness
bracket.
racks.
NOTE:
5) Drain the ATF.
CAUTION:
tor.
(T4) No. 12 — (T5) No. 1:
(T4) No. 6 — (T6) No. 2:
8 CHECK POOR CONTACT. Is there poor contact? Repair the poor Replace the TCM.
Check poor contact of ATF temperature sensor contact. <Ref. to 5AT-61,
1 circuit. Transmission Con-
trol Module
(TCM).>
5AT(diag)-122
AL:DTC P1717 ATF TEMP. SENSOR 2 CIRCUIT HIGH

Input signal circuit of TCM to ATF temperature sensor 2 is open or shorted.
TROUBLE SYMPTOM:
WIRING DIAGRAM:
B54
B54 TCM 1 2 3 4 5 6 7 8 9
10 11 12 13 14 15 16 17 18
19 20 21 22 23 24
11
13
B11
1 2 3 4
5 6 7 8
9 10 11 12
13 14 15 16
17 18 19 20
B11
12
T4
T5
1 2 3 4
5 6 7 8 9 10 11 12
T6
1 2 3 4 5 6
T5 T6 7 8 9 10 11 12 13 14 15 16
2
1
TRANSMISSION
AT-01628
5AT(diag)-123
Step Check Yes No

(B54) No. 13 — (B11) No. 12:
(B54) No. 11 — (B11) No. 6:
and TCM.
engine.
NOTE:
ating temperature.
sion.
(T4) No. 6 — (T4) No. 12:
(T4) No. 6 — (T4) No. 12:
Monitor?
5 CHECK INPUT SIGNAL FOR TCM. Is the voltage 0.4 — 0.9 V? Even if the SPORT Go to step 8.
3) Measure the voltage between TCM con- cause. Repair har-
nector terminals. ness or contact in
Connector & terminal the ATF tempera-
(B54) No. 11 (+) — (B54) No. 13 ($): ture sensor and
transmission con-
nector.
5AT(diag)-124
Step Check Yes No

2) Turn the ignition switch to ON. (engine is in normal condi-
OFF) tion. A temporary
ness may be the
cause. Repair har-
ness or contact in
the ATF tempera-
ture sensor and
transmission con-
nector.
bracket.
racks.
NOTE:
5) Drain the ATF.
CAUTION:
8 CHECK POOR CONTACT. Is there poor contact? Repair the poor Replace the TCM.
Check poor contact of ATF temperature sensor contact. <Ref. to 5AT-61,
1 circuit. Transmission Con-
trol Module
(TCM).>
AM:DTC P1718 AT CAN COMMUNICATION CIRCUIT

NOTE:
For DTC P1718 AT CAN Communication circuit, Refer to “LAN System”. <Ref. to LAN(diag)-14, READ DI-
AGNOSTIC TROUBLE CODE (DTC), OPERATION, Subaru Select Monitor.>
5AT(diag)-125
AN:DTC P1760 LATERAL ACCELERATION SENSOR PERFORMANCE PROB-

LEM
WIRING DIAGRAM:
A: B54
A: B54 1 2 3 4 5 6 7 8 9
TCM
10 11 12 13 14 15 16 17 18
B: B55 19 20 21 22 23 24
A13
B5
B6
B: B55
1 2 3 4 5 6 7 8 9
10 11 12 13 14 15 16 17 18
19 20 21 22 23 24
B359
1 2 3
2
B359
G SENSOR
AT-01634
5AT(diag)-126
Step Check Yes No

USING SUBARU SELECT MONITOR. play 2.3 — 2.7 V when the
1) Select {Current Data Display & Save} in vehicle is on a level?
1) Turn the ignition switch to OFF. G sensor is inclined to the right <Ref. to 5AT-63,
2) Remove the console box. to 90#? Lateral G Sensor.>
5) Select {Current Data Display & Save} in
Read the Subaru Select Monitor display.
G sensor is inclined to the left <Ref. to 5AT-63,
to 90#? Lateral G Sensor.>
lateral G sensor?
5 CHECK ABSCM&H/U. Is the same DTC displayed? Replace the TCM. Go to step 6.
6 CHECK OTHER DTC DETECTION. Is any other DTC displayed? Perform the diag- Temporary poor
DTC.
nector terminals.
(B54) No. 13 — (B55) No. 6:
4) Connect the connector to ABSCM&H/U.
(B359) No. 3 (+) — No. 2 ($):
(B359) No. 3 (+) — No. 2 ($):
(B359) No. 3 (+) — No. 2 ($):
5AT(diag)-127
Step Check Yes No

5) Read the DTC.
DTC.
5AT(diag)-128
AO:DTC P1761 LATERAL ACCELERATION SENSOR CIRCUIT LOW

WIRING DIAGRAM:
A: B54
A: B54 1 2 3 4 5 6 7 8 9
TCM
10 11 12 13 14 15 16 17 18
B: B55 19 20 21 22 23 24
A13
B5
B6
B: B55
1 2 3 4 5 6 7 8 9
10 11 12 13 14 15 16 17 18
19 20 21 22 23 24
B359
1 2 3
2
B359
G SENSOR
AT-01634
Step Check Yes No

lateral G sensor?
5AT(diag)-129
Step Check Yes No

DTC.
nector terminals.
(B54) No. 13 — (B55) No. 6:
6 CHECK GROUND SHORT OF HARNESS. Is the resistance more than 1 Go to step 7. Repair the har-
Measure the resistance between TCM connec- M"? ness between lat-
tor and chassis ground. eral G sensor and
Connector & terminal TCM.
(B54) No. 13 — Chassis ground: Replace the TCM.
<Ref. to 5AT-61,
Transmission Con-
trol Module
(TCM).>
4) Connect the connector to the TCM.
(B359) No. 3 (+) — No. 2 ($):
(B359) No. 3 (+) — No. 2 ($):
(B359) No. 3 (+) — No. 2 ($):
10 CHECK TCM. Is the same DTC displayed? Replace the TCM. Go to step 11.
5) Read the DTC.
DTC.
5AT(diag)-130
AP:DTC P1762 LATERAL ACCELERATION SENSOR CIRCUIT HIGH

WIRING DIAGRAM:
A: B54
A: B54 1 2 3 4 5 6 7 8 9
TCM
10 11 12 13 14 15 16 17 18
B: B55 19 20 21 22 23 24
A13
B5
B6
B: B55
1 2 3 4 5 6 7 8 9
10 11 12 13 14 15 16 17 18
19 20 21 22 23 24
B359
1 2 3
2
B359
G SENSOR
AT-01634
5AT(diag)-131
Step Check Yes No

nector between TCM and the nector.
lateral G sensor?
DTC.
5 CHECK CONDITIONAL INFORMATION Is the reading indicated on Go to step 6. Go to step 12.
WHEN FAULTY. monitor display 4.65 V or
Read the lateral G sensor output on the Sub- more?
aru Select Monitor display.
1) Turn the ignition switch to OFF. sensor and
2) Disconnect the connector from TCM. ABSCM&H/U.
nector terminals.
(B55) No. 5 — No. 1:
1) Turn the ignition switch to OFF. ness between lat-
2) Remove the console box. eral G sensor and
3) Disconnect the connector from lateral G TCM.
sensor.
1) Turn the ignition switch to ON. ness between lat-
2) Measure the voltage between TCM con- eral G sensor and
nector and chassis ground. TCM.
nector between TCM and the nector.
lateral G sensor?
10 CHECK TCM. Is the same DTC displayed? Replace the TCM. Go to step 11.
DTC.
5AT(diag)-132
Step Check Yes No

12 CHECK INPUT VOLTAGE OF LATERAL G Is the voltage 4.75 — 5.25 V? Go to step 13. Repair the har-
SENSOR. ness connector
1) Turn the ignition switch to OFF. between lateral G
2) Remove the console box. sensor and TCM.
(B359) No. 1 (+) — No. 2 ($):
nector terminals.
(B55) No. 5 — No. 6:
1) Connect the connector to lateral G sensor. when the lateral G sensor is eral G sensor.
2) Connect the connector to the TCM. horizontal? <Ref. to 5AT-63,
3) Turn the ignition switch to ON. Lateral G Sensor.>
(B359) No. 3 (+) — No. 2 ($):
(B359) No. 3 (+) — No. 2 ($):
(B359) No. 3 (+) — No. 2 ($):
lateral G sensor?
DTC.
AQ:DTC P1798 GEAR 1 ENGINE BRAKE

NOTE:
Refer to DTC P0773 for diagnostic procedure. <Ref. to 5AT(diag)-94, DTC P0773 SHIFT SOLENOID “E”
ELECTRICAL, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
5AT(diag)-133
AR:DTC P1799 INTERLOCK

Perform the interlock judgment when the oil pressure switch pattern detect the specified interlock patterns for
more than 2 seconds other than shifting.
TROUBLE SYMPTOM:
Locked to 2nd, 4th or 5th gear.
Step Check Yes No

1 CHECK DTC OF TCM. Is DTC of oil pressure switch Perform the diag- Go to step 2.
DTC.
2 CHECK DTC OF TCM. Is the DTC related to solenoid Perform the diag- Go to step 3.
function or solenoid circuit nosis according to
detected? DTC.
3 CHECK POOR CONTACT. Is there any open or poor con- Repair the poor Replace the TCM.
tact of connector (loosing ter- contact. <Ref. to 5AT-61,
minal, entering foreign matter, Transmission Con-
damaging connector body)? trol Module
(TCM).>
5AT(diag)-134
AS:DTC P1817 SPORTS MODE SWITCH CIRCUIT (MANUAL SWITCH)

TROUBLE SYMPTOM:
• Can not set to manual mode.
• “SPORT” light illuminates when shifting to “N” % “D” range.
WIRING DIAGRAM:
i10
IGNITION
SWITCH 1 2 3 4 5 6 7 8 9 10
11 12 13 14 15 16 17 18 19 20 21 22
SBF-1 SBF-7
i77
No.12
1 2 3 4 5 6 7 8 9 10 11 12
BATTERY
A: i84
1 2 3 4 5 6 7 8
3
9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
24 25 26 27 28 29 30 31 32 33 34 35
SPORT COMBINATION
E METER
B: B280
i10
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19 20
21
22
21 22 23 24 25 26 27 28 29 30
1
JOINT B54
CONNECTOR
i77 1 2 3 4 5 6 7 8 9
2
10 11 12 13 14 15 16 17 18
19 20 21 22 23 24
A26
A27
B116
A: i84 B: B280
BODY INTEGRATED UNIT 1 2 3 4
C: B281 5 6 7 8 9 10
C26
B20
B30
C: B281
1 2 3 4 5 6 7
7
8 9 10 11 12 13 14 15 16 17 18 19
SELECT 20 21 22 23 24 25 26 27 28
SPORT
LEVER
SHIFT MODE
SWITCH B116
8
4
E
B54 TCM
AT-01539
5AT(diag)-135
Step Check Yes No

1 CHECK BODY INTEGRATED UNIT. Is DTC displayed? Perform the diag- Go to step 2.
1) Connect the Subaru Select Monitor to data nosis according to
link connector. DTC.
OFF)
3) Read the DTC of body integrated unit using
2 CHECK BODY INTEGRATED UNIT INPUT Is OFF displayed? Go to step 3. Go to step 7.
SIGNAL.
2) Read the TIP mode SW data of body inte-
grated unit using Subaru Select Monitor. <Ref.
to LAN(diag)-14, OPERATION, Subaru Select
Monitor.>
3 CHECK BODY INTEGRATED UNIT INPUT Is the indication on each range Go to step 4. Replace the select
SIGNAL. OFF? lever assembly.
1) Shift the select lever from “P” to “D” range. <Ref. to CS-7,
2) Read the TIP mode SW data of body inte- Select Lever.>
Monitor.>
4 CHECK BODY INTEGRATED UNIT INPUT Is OFF displayed? Go to step 5. Replace the select
SIGNAL. lever assembly.
1) Shift the select lever to manual mode. <Ref. to CS-7,
2) Shift the select lever to other than “D” Select Lever.>
range.
3) Read the TIP mode SW data of body inte-
Monitor.>
and AT CAN communication each DTC.
circuit displayed?
6 CHECK TCM INPUT SIGNAL. Is the indication on each range Even if the SPORT Replace the TCM.
1) Shift the select lever from “P” to “D” range. OFF? indicator lights <Ref. to 5AT-61,
2) Read the TIP mode SW data of TCM using blinks, the circuit is Transmission Con-
Subaru Select Monitor. <Ref. to 5AT(diag)-16, in normal condi- trol Module
OPERATION, Subaru Select Monitor.> tion. A temporary (TCM).>
poor contact of
connector or har-
ness may be the
cause.
7 CHECK HARNESS BETWEEN BODY INTE- Is the resistance more than 1 Go to step 8. Repair the short
GRATED UNIT AND SPORT SHIFT SWITCH. M"? circuit of harness
1) Turn the ignition switch to OFF. between the body
2) Disconnect harness connector from body integrated unit and
integrated unit and select lever. SPORT shift
3) Measure the harness resistance between switch.
the body integrated unit and chassis ground.
8 CHECK SPORT SHIFT SWITCH. Is the resistance more than 1 Check the body Replace the select
1) Shift the select lever to “P” range. M"? integrated unit. lever assembly.
2) Measure the resistance between harness <Ref. to CS-7,
connector terminals of SPORT shift switch. Select Lever.>
Terminals
(B116) No. 7 — No. 8:
5AT(diag)-136
AT:DTC P1840 TRANSMISSION FLUID PRESSURE SENSOR/SWITCH A CIR-

CUIT
Front brake oil pressure switch malfunction.
TROUBLE SYMPTOM:
NOTE:
Refer to DTC P0751 for diagnostic procedure. <Ref. to 5AT(diag)-65, DTC P0751 SHIFT SOLENOID “A”
PERFORMANCE OR STUCK OFF, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
AU:DTC P1841 TRANSMISSION FLUID PRESSURE SENSOR/SWITCH B CIR-
CUIT
Low coast brake oil pressure switch malfunction.
TROUBLE SYMPTOM:
NOTE:
Refer to DTC P0771 for diagnostic procedure. <Ref. to 5AT(diag)-91, DTC P0771 SHIFT SOLENOID “E”
AV:DTC P1842 TRANSMISSION FLUID PRESSURE SENSOR/SWITCH C CIR-
CUIT
Input clutch oil pressure switch malfunction.
TROUBLE SYMPTOM:
NOTE:
Refer to DTC P0756 for diagnostic procedure. <Ref. to 5AT(diag)-72, DTC P0756 SHIFT SOLENOID “B”
AW:DTC P1843 TRANSMISSION FLUID PRESSURE SENSOR/SWITCH D CIR-
CUIT
Direct clutch oil pressure switch malfunction.
TROUBLE SYMPTOM:
NOTE:
Refer to DTC P0766 for diagnostic procedure. <Ref. to 5AT(diag)-85, DTC P0766 SHIFT SOLENOID “D”
AX:DTC P1844 TRANSMISSION FLUID PRESSURE SENSOR/SWITCH E CIR-
CUIT
High & low reverse clutch oil pressure switch malfunction.
TROUBLE SYMPTOM:
NOTE:
Refer to DTC P0761 for diagnostic procedure. <Ref. to 5AT(diag)-78, DTC P0761 SHIFT SOLENOID “C”
5AT(diag)-137
15.Diagnostic Procedure without Diagnostic Trouble Code (DTC)

A: CHECK SPORT SHIFT SWITCH
DIAGNOSIS:
TROUBLE SYMPTOM:
Does not shift on manual mode.
WIRING DIAGRAM:
A: B280
B: B281 B15
B25
A20
A30
TB
TB
B68
2
7
8
E
5
9
AT SELECT
LEVER
B116
ROLL CONNECTOR
10
6
ST3
4
2
3
4
3
TCM E
B54
LH RH
STEERING SHIFT SWITCH
B54 A: B280 B: B281 B116
1 2 3 4 5 6 7 1 2 3 4 5 6 7 1 2 3 4
1 2 3 4 5 6 7 8 9
8 9 10 11 12 13 14 15 16 17 18 19 20 8 9 10 11 12 13 14 15 16 17 18 19 5 6 7 8 9 10
10 11 12 13 14 15 16 17 18
19 20 21 22 23 24 21 22 23 24 25 26 27 28 29 30 20 21 22 23 24 25 26 27 28
ST3 B68
1 2 3 4 5 1 2 3
6 7 8 9 10 4 5 6 7 8
AT-01545
5AT(diag)-138
Step Check Yes No

1 CHECK BODY INTEGRATED UNIT. Both ON/OFF can be detected Go to step 2. Go to step 7.
1) Perform the ON/OFF operation on SPORT normally?
shift switch.
2) Read the data of SPORT shift switch signal
2 CHECK DTC OF BODY INTEGRATED UNIT. Is DTC of CAN detected? Perform the diag- Go to step 3.
nosis according to
DTC.
3 CHECK TCM. Both ON/OFF can be detected Go to step 4. Go to step 5.
1) Perform the ON/OFF operation on SPORT normally?
shift switch.
2) Read the data of SPORT shift switch signal
4 CHECK TIP INDICATOR ON COMBINATION Is the TIP indicator OK? Go to step 6. Replace the com-
METER. bination meter
assembly. <Ref. to
IDI-16, Combina-
tion Meter Assem-
bly.>
5 CHECK DTC OF TCM. Is DTC of CAN detected? Perform the diag- Replace the TCM.
nosis according to <Ref. to 5AT-61,
DTC. Transmission Con-
trol Module
(TCM).>
6 CHECK DTC OF METER. Is DTC of CAN detected? Perform the diag- Replace the meter.
nosis according to
DTC.
chassis ground.
Measure the resistance between the SPORT M"? plate assembly.
(B116) No. 6 — No. 5:
1) Shift the select lever to manual mode. "? plate assembly.
2) Measure the resistance between the
SPORT shift switch terminals.
(B116) No. 6 — No. 5:
between the body integrated unit and SPORT contact in cou-
shift switch connector. pling connector.
(B116) No. 5 — (B281) No. 15:
5AT(diag)-139
Step Check Yes No

BODY INTEGRATED UNIT AND SPORT M"? circuit in harness
2) Measure the resistance of harness connector.
chassis ground.
12 CHECK INPUT SIGNAL FOR TCM. Is the voltage more than 9 V? Go to step 13. Replace the body
1) Connect all the connectors. integrated unit.
2) Turn the ignition switch to ON (engine <Ref. to SL-46,
OFF). Body Integrated
3) Measure the signal voltage for TCM. Unit.>
13 CHECK INPUT SIGNAL FOR TCM. Is the voltage less than 1 V? Go to step 26. Replace the body
1) Shift and hold the select lever to up side. integrated unit.
2) Measure the signal voltage for TCM. <Ref. to SL-46,
Connector & terminal Body Integrated
(B281) No. 15 (+) — Chassis ground ($): Unit.>
chassis ground.
Measure the resistance between the SPORT M"? plate assembly.
(B116) No. 10 — No. 9:
1) Shift the select lever to manual mode. "? plate assembly.
2) Measure the resistance between the
SPORT shift switch terminals.
(B116) No. 10 — No. 9:
grated unit. nector and body
2) Measure the resistance of harness integrated unit
between the body integrated unit and SPORT connector, or poor
shift switch connector. contact in cou-
Connector & terminal pling connector.
(B116) No. 9 — (B281) No. 25:
5AT(diag)-140
Step Check Yes No

BODY INTEGRATED UNIT AND SPORT M"? circuit of harness
SHIFT SWITCH. between the
1) Disconnect the steering roll connector. SPORT shift
2) Measure the resistance of harness switch connector
between SPORT shift switch connector and and body inte-
chassis ground. grated unit con-
19 CHECK THE INPUT SIGNAL TO BODY INTE- Is the voltage more than 9 V? Go to step 20. Replace the body
1) Connect all the connectors. <Ref. to SL-46,
2) Turn the ignition switch to ON (engine Body Integrated
OFF). Unit.>
grated unit.
20 CHECK THE INPUT SIGNAL TO BODY INTE- Is the voltage less than 1 V? Go to step 26. Replace the body
1) Shift and hold the select lever to up side. <Ref. to SL-46,
2) Check the signal voltage for body inte- Body Integrated
grated unit. Unit.>
21 CHECK STEERING SHIFT SWITCH Is the resistance less than 1 Go to step 22. Repair the open
1) Turn the ignition switch to OFF. between steering
2) Disconnect the connector from steering roll roll connector and
connector. chassis ground.
between steering roll connector and chassis
ground.
(ST3) No. 3 — Chassis ground:
22 CHECK STEERING SHIFT SWITCH. Is the resistance more than 1 Go to step 23. Replace the steer-
Measure the resistance between steering roll M"? ing roll connector
connector terminals. or steering shift
Connector & terminal switch. Or repair
(ST3) No. 1 — No. 3: the poor contact in
connector.
23 CHECK STEERING SHIFT SWITCH. Is the resistance less than 1 Go to step 24. Replace the steer-
1) Press and hold the steering shift switch to + "? ing roll connector
side. or steering shift
2) Measure the resistance between the steer- switch. Or repair
ing shift switch terminals. the poor contact in
(ST3) No. 1 — No. 3:
BODY INTEGRATED UNIT AND STEERING "? circuit in harness
ROLL CONNECTOR. between body inte-
1) Disconnect the connector from body integrated unit con-
grated unit. nector and
2) Measure the resistance of harness steering roll con-
between the body integrated unit connector nector, or poor
and steering roll connector. contact in connec-
(B281) No. 15 — (B68) No. 2:
5AT(diag)-141
Step Check Yes No

BODY INTEGRATED UNIT AND STEERING "? circuit in harness
ROLL CONNECTOR. between body inte-
1) Disconnect the connector from body integrated unit con-
grated unit. nector and
2) Measure the resistance of harness steering roll con-
between the body integrated unit connector nector, or poor
and steering roll connector. contact in connec-
(B281) No. 25 — (B68) No. 6:
26 CHECK POOR CONTACT. Is there poor contact in SPORT Repair the poor A temporary poor
shift switch circuit? contact. contact of SPORT
shift switch con-
nector or harness
5AT(diag)-142
B: CHECK SPORT SHIFT INDICATOR LIGHT

DIAGNOSIS:
Output signal circuit of SPORT shift indicator light is open or shorted.
TROUBLE SYMPTOM:
• SPORT shift indicator light does not illuminate or remains illuminated.
• SPORT shift indicator light display does not change.
WIRING DIAGRAM:
i10
3
1 2 3 4 5 6 7 8 9 10
No.12
SPORT SHIFT 11 12 13 14 15 16 17 18 19 20 21 22
INDICATOR
COMBINATION
METER
IGNITION
SWITCH
i77
i10
1 2 3 4 5 6 7 8 9 10 11 12
21
22
SBF-7
A: i84
JOINT
1
1 2 3 4 5 6 7 8
CONNECTOR
9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
SBF-1
i77 24 25 26 27 28 29 30 31 32 33 34 35
2
B: B280
A27
A26
BODY INTEGRATED
BATTERY
UNIT 1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19 20
A: i84
21 22 23 24 25 26 27 28 29 30
B: B280
B20
B30
B54
E
1 2 3 4 5 6 7 8 9
10 11 12 13 14 15 16 17 18
19 20 21 22 23 24
4
B54 TCM
AT-01626
5AT(diag)-143
Step Check Yes No

1 CHECK BODY INTEGRATED UNIT. Is DTC of AT CAN communica- Perform the diag- Go to step 2.
Check DTC of body integrated unit. tion circuit displayed? nosis according to
DTC.
2 CHECK TCM. Is DTC of AT CAN communica- Perform the diag- Go to step 3.
Check DTC of TCM. tion circuit displayed? nosis according to
DTC.
3 CHECK TCM. Is gear position 1 and “▲” dis- Go to step 4. Replace the TCM.
1) Turn the ignition switch to OFF. played? <Ref. to 5AT-61,
3) Turn the ignition switch to ON. (engine (TCM).>
OFF)
ON.
5) Shift the select lever to manual mode side,
and then shift down the select lever.
6) Read the indicator.
4 CHECK TCM. Is gear position 2 and “▼” dis- Go to step 5. Replace the TCM.
1) Shift up the select lever. played? <Ref. to 5AT-61,
2) Read the indicator. Transmission Con-
trol Module
(TCM).>
5 CHECK BODY INTEGRATED UNIT. Is SPORT shift gear position Refer to “General Check the body
Read the data of gear position using Subaru 2? Diagnostic Table”. integrated unit.
Select Monitor. <Ref. to 5AT(diag)- <Ref. to SL-46,
147, General Diag- Body Integrated
nostic Table.> Unit.>
6 CHECK COMBINATION METER. Is the SPORT shift indicator Refer to “General Replace the com-
OK? Diagnostic Table”. bination meter
<Ref. to 5AT(diag)- assembly. <Ref. to
147, General Diag- IDI-16, Combina-
nostic Table.> tion Meter Assem-
bly.>
5AT(diag)-144
C: CHECK BUZZER
DIAGNOSIS:
Output signal circuit of buzzer is open or shorted.
TROUBLE SYMPTOM:
Buzzer remains beeping.
WIRING DIAGRAM:
IGNITION
SWITCH
SBF-1 SBF-7
No.12
i10
1 2 3 4 5 6 7 8 9 10
11 12 13 14 15 16 17 18 19 20 21 22
BATTERY
i77
SPORT
SHIFT COMBINATION
BUZZER 1 2 3 4 5 6 7 8 9 10 11 12
METER
E i10
A: i84
21
22
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
24 25 26 27 28 29 30 31 32 33 34 35
JOINT
1
CONNECTOR
B: B280
i77
2
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19 20
21 22 23 24 25 26 27 28 29 30
A26
A27
A: i84
BODY INTEGRATED UNIT B54
B: B280
1 2 3 4 5 6 7 8 9
B20
B30
10 11 12 13 14 15 16 17 18
19 20 21 22 23 24
4
B54 TCM
AT-01627
5AT(diag)-145
Step Check Yes No

DTC.
2 CHECK TCM. Is DTC of CAN communication Perform the diag- Go to step 5.
Check DTC of TCM. displayed? nosis according to
DTC.
3 CHECK BUZZER STOP. Does the buzzer stop? Replace the TCM. Go to step 4.
Disconnect the connector (B54). <Ref. to 5AT-61,
Transmission Con-
trol Module
(TCM).>
4 CHECK BODY INTEGRATED UNIT. Is the SPORT shift buzzer dis- Replace the body Replace the com-
1) Turn the ignition switch to OFF. play “ON”? integrated unit. bination meter
2) Connect the Subaru Select Monitor to data <Ref. to SL-46, assembly. <Ref. to
link connector. Body Integrated IDI-16, Combina-
3) Turn the ignition switch to ON. (engine Unit.> tion Meter Assem-
OFF) bly.>
ON.
5) Read the data of SPORT shift buzzer using
5 CHECK COMBINATION METER. Is the buzzer OK? Refer to “General Replace the com-
Diagnostic Table”. bination meter
<Ref. to 5AT(diag)- assembly. <Ref. to
147, General Diag- IDI-16, Combina-
nostic Table.> tion Meter Assem-
bly.>
5AT(diag)-146
16.General Diagnostic Table

A: INSPECTION
• Vehicle speed sensor 1 and Vehicle speed sensor 2
Shifting vehicle speed is low on “D” range. • Throttle position sensor
• CAN communication signal
Shifting vehicle speed is high on “D” range. • CAN communication signal
• Brake switch signal
• Lateral G sensor
• Engine idle speed
• Control cable adjustment
Excessive shock. (“N” % “D” range) • ATF temperature sensor
• Oil pressure switch 1 and Front brake solenoid valve
• Fluid level and condition
• TCM power supply
• PVIGN relay
• Oil pressure switch 4 and Direct clutch solenoid valve
Excessive shift shock on 1st of “D” range % 2nd of “D” range or
“1st of manual mode” % “2nd of manual mode”.
• Turbine speed sensor
• Oil pressure switch 5 and High & low reverse clutch solenoid
Excessive shift shock on 2nd of “D” range % 3rd of “D” range or valve
“2nd of manual mode” % “3rd of manual mode”. • CAN communication signal
• Oil pressure switch 3 and Input clutch solenoid valve
Excessive shift shock on 3rd of “D” range % 4th of “D” range or
“3rd of manual mode” % “4th of manual mode”.
5AT(diag)-147

Excessive shift shock on 4th of “D” range % 5th of “D” range or
“4th of manual mode” % “5th of manual mode”.
Excessive shock at kick down.
Excessive shock at shift up.
Excessive shock at lock up. • CAN communication signal
• Lock up solenoid valve
Excessive shock at engine brake. • CAN communication signal
• Line pressure
• Low coast brake solenoid valve
Judder is occurred at lock up.
• ATF temperature sensor 1 and 2
Noise at “R”, “N” and “D” range. • Engine speed signal
• Direct clutch solenoid valve
Hold at “D” range or 1st on manual mode. • Line pressure
• Up switch signal
5AT(diag)-148

• Line pressure
Hold at “D” range or 2nd on manual mode.
• Down switch signal
• Line pressure
Hold at “D” range or 3rd on manual mode. • Up switch signal
valve
Hold at “D” range or 4th on manual mode. • Front brake solenoid valve
• Line pressure
• PVIGN relay
Hold at “D” range or 5th on manual mode. • Line pressure
Gear does not shift 1st of “D” range % 2nd of “D” range or “1st
• Line pressure
of manual mode” % “2nd of manual mode”.
• Up switch
Gear does not shift 2nd of “D” range % 3rd of “D” range or “2nd valve
of manual mode” % “3rd of manual mode”. • Line pressure
Gear does not shift 3rd of “D” range % 4th of “D” range or “3rd • Oil pressure switch 1 and Front brake solenoid valve
of manual mode” % “4th of manual mode”. • Line pressure
5AT(diag)-149

Gear does not shift 4th of “D” range % 5th of “D” range or “4th • Turbine speed sensor
of manual mode” % “5th of manual mode”. • ATF temperature sensor
• Line pressure
Gear does not shift down to 4th on “D” range or manual mode.
• Line pressure
• Line pressure
Gear does not shift down to 3rd on “D” range or manual mode.
• PVIGN relay
Gear does not shift down to 2nd on “D” range or manual mode. • Line pressure
Gear does not shift down to 1st on “D” range or manual mode. • Line pressure
• Line pressure
No lock-up occurs.
• Brake switch signal
• Range signal
No shift shock occurred when shifting 1st of “D” range % 2nd of • Vehicle speed sensor 1 and Vehicle speed sensor 2
“D” range or “1st of manual mode” % “2nd of manual mode”. Or • Oil pressure switch 4 and Direct clutch solenoid valve
clutch slipping occurred. • Line pressure
5AT(diag)-150

No shift shock occurred when shifting 2nd of “D” range % 3rd of
“D” range or “2nd of manual mode” % “3rd of manual mode”. Or
valve
clutch slipping occurred.
• Line pressure
No shift shock occurred when shifting 3rd of “D” range % 4th of
“D” range or “3rd of manual mode” % “4th of manual mode”. Or
clutch slipping occurred.
• Line pressure
No shift shock occurred when shifting 4th of “D” range % 5th of • Oil pressure switch 1 and Front brake solenoid valve
“D” range or “4th of manual mode” % “5th of manual mode”. Or • Oil pressure switch 4 and Direct clutch solenoid valve
clutch slipping occurred. • Line pressure
Engine skids when shifting 5th of “D” range % 4th of “D” range • Oil pressure switch 1 and Front brake solenoid valve
or “5th of manual mode” % “4th of manual mode”. Or slipping • Oil pressure switch 4 and Direct clutch solenoid valve
occurred. • Line pressure
Engine skids when shifting 4th of “D” range % 3rd of “D” range • Oil pressure switch 3 and Input clutch solenoid valve
or “4th of manual mode” % “3rd of manual mode”. Or slipping • Oil pressure switch 1 and Front brake solenoid valve
occurred. • Line pressure
Engine skids when shifting 3rd of “D” range % 2nd of “D” range
valve
or “3rd of manual mode” % “2nd of manual mode”. Or slipping
occurred.
• Line pressure
Engine skids when shifting 2nd of “D” range % 1st of “D” range
or “2nd of manual mode” % “1st of manual mode”. Or slipping
• Line pressure
occurred.
Engine brake does not function at 5th % 4th of manual mode.
• Manual mode switch
• Oil pressure switch 1
Engine brake does not function at 4th % 3rd of manual mode.
• Oil pressure switch 1 and Oil pressure switch 3
5AT(diag)-151

Engine brake does not function at 3rd % 2nd of manual mode.
Engine brake does not function at 2nd % 1st of manual mode.
• Line pressure
Excessive acceleration failure on “D” range.
• Vehicle speed sensor 1, 2
• Line pressure
Excessive acceleration failure on “R” range.
valve
• Vehicle speed sensor 1, 2
• Line pressure
Engine skids when start driving (1st) the vehicle. Or slipping
occurred.
• Line pressure
Engine skids when driving at 2nd. Or slipping occurred.
• Line pressure
Engine skids when driving at 3rd. Or slipping occurred. • Throttle position sensor
valve
• Line pressure
Engine skids when driving at 4th. Or slipping occurred.
5AT(diag)-152

• Line pressure
5Engine skids when driving 5th. Or slipping occurred.
• Line pressure
Slip at lock up.
• Line pressure
Maximum vehicle speed is low. • Throttle position sensor
• Direct clutch solenoid valve
• Vehicle speed sensor 1 and 2
There is completely no creep. • CAN communication signal
• Line pressure
Excessive large creep. • CAN communication signal
Vehicle cannot be parking condition on “P” range. Parking con- • Inhibitor switch
dition is not released though shifting to other ranges. • Control cable adjustment
Vehicle can drive on “P” range.
• Line pressure
Vehicle can drive on “N” range.
• Line pressure
• Line pressure
Vehicle cannot drive at any range.
• Loosing or damaging of propeller shaft.
• Loosing or damaging of drive shaft.
• Line pressure
Vehicle cannot drive on “D” range.
• Line pressure
Vehicle cannot drive on “R” range.
5AT(diag)-153

• Key switch and Starter
Engine cannot start on “P” or “N” range • Inhibitor switch
• CAN communication line
• TCM
• Key switch and Starter
Engine start other than “P” or “N” range
• TCM
Engine stalls. • Turbine speed sensor
• Line pressure
Engine stalls when shifting to “N” % “D” and “R” range. • Turbine speed sensor
• Line pressure
5AT(diag)-154
CONTROL SYSTEMS CS

(DIAGNOSTICS)


approval.

MANUAL TRANSMISSION
AND DIFFERENTIAL
5MT
Page
2. Transmission Gear Oil ..............................................................................30
3. Manual Transmission Assembly ...............................................................31
5. Oil Seal......................................................................................................39
7. Switches and Harness ..............................................................................41
8. Preparation for Overhaul...........................................................................43
9. Transfer Case and Extension Case Assembly..........................................44
10. Transfer Drive Gear ..................................................................................48
11. Transfer Driven Gear ................................................................................50
12. Center Differential .....................................................................................52
13. Reverse Check Sleeve..............................................................................53
14. Transmission Case ...................................................................................56
15. Main Shaft Assembly for Single-Range ....................................................62
16. Main Shaft Assembly for Dual-Range .......................................................67
17. Input Shaft Assembly ................................................................................73
19. Front Differential Assembly .......................................................................85
20. Reverse Idler Gear....................................................................................92
21. Shifter Fork and Rod .................................................................................94
22. Counter Gear ............................................................................................97
General Description
MANUAL TRANSMISSION AND DIFFERENTIAL
A: SPECIFICATION
1. MANUAL TRANSMISSION AND DIFFERENTIAL
Option code★1 EC, K4, EK KS EC, K4, EK KA

2.0 L 2.5 L
Model Except Except Except
OUT- OUT-
for OUT- OUTBACK for OUT- for OUT-
BACK BACK
BACK BACK BACK
5-forward speeds and 1-reverse
Type
(5 ! 2-forward speeds and 1 ! 2-reverse)★2
1st 3.454 3.454
2nd 1.947 2.062 2.062
3rd 1.366 1.448 1.448
Transmission gear ratio
4th 0.972 1.088 1.088
5th 0.738 0.78 0.825 0.825 0.78 0.825
Reverse 3.333
Auxiliary transmission gear High 1.000
ratio★2 Low 1.447 1.196
Front reduction Type of gear Hypoid
Final
gear Gear ratio 4.111 3.700 3.900 4.111
Type of gear Helical
Transfer
Rear reduction Gear ratio 1.000
gear Type of gear Hypoid
Final
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)
Straight bevel gear
Center differential Type and number of gear
(Bevel pinion: 2, Bevel gear: 2 and viscous coupling)
Transmission gear oil GL-5
Single-range
3.5 2 (3.7 US qt, 3.1 Imp qt)
model
Transmission gear oil capacity
Dual-range
4.0 2 (4.2 US qt, 3.5 Imp qt)
model
★1: For option code, refer to ID section. <Ref. to ID-5, MODEL NUMBER PLATE, IDENTIFICATION, Identification.>
★2:
Dual-range model only
5MT-2
General Description
2. TRANSMISSION GEAR OIL 4. DRIVE PINION ASSEMBLY

Recommended oil: Preload adjustment of thrust bearing
(1) Starting torque:
(2) 0.3 — 0.8 N"m(0.03 — 0.08 kgf-m, 0.2 — 0.6 ft-
(3)
lb)
GL-5
(4)
( C) -30 -26 -15 -5 0 15 25 30
Adjusting washer No. 1
( F) -22 -15 5 23 32 59 77 86 Part Number Thickness mm (in)
90 803025051 3.925 (0.1545)
85W
80W 803025052 3.950 (0.1555)
75W -90 803025053 3.975 (0.1565)
MT-00001
803025054 4.000 (0.1575)
803025055 4.025 (0.1585)
(1) Item 803025056 4.050 (0.1594)
(2) Transmission gear oil 803025057 4.075 (0.1604)
(3) API classification
(4) SAE viscosity No. and applicable temperature Adjusting washer No. 2
3. TRANSMISSION CASE ASSEMBLY 803025059 3.850 (0.1516)
Drive pinion shim adjustment 803025054 4.000 (0.1575)
803025058 4.150 (0.1634)
Hypoid gear backlash:
0.13 — 0.18 mm (0.0051 — 0.0071 in) 5. INPUT SHAFT ASSEMBLY
Drive pinion shim Snap ring (Outer-28) to ball bearing clearance:
Part Number
Thickness
Part Number
Thickness 0 — 0.12 mm (0 — 0.0047 in)
mm (in) mm (in)
0.150 0.250 Snap ring (Outer-28)
32295AA031 32295AA071 Part Number Thickness mm (in)
(0.0059) (0.0098)
0.175 0.275 805028050 2.48 (0.0976)
32295AA041 32295AA081
(0.0069) (0.0108) 805028060 2.56 (0.1008)
0.200 0.300 805028070 2.64 (0.1039)
32295AA051 32295AA091
(0.0079) (0.0118)
0.225 0.500 Snap ring (Inner-68) to ball bearing clearance:
32295AA061 32295AA101
(0.0089) (0.0197) 0 — 0.12 mm (0 — 0.0047 in)
Selection of main shaft rear plate Snap ring (Inner-68)
Main shaft rear plate
805168020 1.84 (0.0724)
Dimension “A” mm (in) Part Number Marking
805168030 1.92 (0.0756)
4.00 — 4.13
32294AA041 1 805168040 2.00 (0.0787)
(0.1575 — 0.1626)
3.87 — 3.99
(0.1524 — 0.1571)
32294AA051 2 6. MAIN SHAFT
Snap ring (Outer-25) to synchronizer hub clear-
Input shaft holder adjustment
ance:
Dimension “D” mm (in) Shim Number 0.060 — 0.100 mm (0.0024 — 0.0039 in)
52.50 — 53.11
— Snap ring (Outer-25)
(2.0669 — 2.0909)
52.00 — 52.49 Thickness Thickness
1 Part Number Part Number
(2.0472 — 2.0665) mm (in) mm (in)
51.26 — 51.99 805025051 2.42 (0.0953) 805025055 2.62 (0.1031)
2 805025052 2.47 (0.0972) 805025056 2.67 (0.1051)
(2.0181 — 2.0468)
805025053 2.52 (0.0992) 805025057 2.72 (0.1071)
805025054 2.57 (0.1012) 805025058 2.37 (0.0933)
5MT-3
General Description
7. REVERSE IDLER GEAR 5th shifter fork

Adjustment of reverse idler gear position Part Number Marking Remarks
Reverse idler gear to transmission case (LH) Approach to 5th gear
32812AA201 4
by 0.2 mm (0.008 in).
wall clearance:
6.0 — 7.5 mm (0.236 — 0.295 in) 32812AA211 5 Standard
Become distant from
Reverse shifter lever 32812AA221 6 5th gear by 0.2 mm
Part Number Marking Remarks (0.008 in).
32820AA070 7 Further from case wall
32820AA080 8 Standard
9. TRANSFER CASE OR REAR CASE
32820AA090 9 Closer to the case wall Neutral position adjustment
After installing a suitable reverse shifter lever, ad- Adjusting shim
just the clearance using washer. Part Number Thickness mm (in)
32190AA000 0.15 (0.0059)
Reverse idler gear to transmission case wall
32190AA010 0.30 (0.0118)
clearance:
0 — 0.5 mm (0 — 0.020 in)
Reverse accent shaft
Washer (20.5 ! 26 ! t) Part No. Mark Remarks
Thickness Thickness Neutral position is
Part Number Part Number 32188AA090 3
mm (in) mm (in) closer to 1st.
803020151 0.4 (0.016) 803020154 1.9 (0.075) 32188AA100 0 Standard
803020152 1.1 (0.043) 803020155 2.3 (0.091) Neutral position is
32188AA110 1
803020153 1.5 (0.059) — — closer to reverse gear.
8. SHIFTER FORK AND ROD Reverse check plate adjustment

Select suitable shifter forks so that both the cou- Reverse check plate
pling sleeve and reverse driven gear are positioned Mark- Angle
Part Number Remarks
in the center of their synchromesh mechanisms. ing #
Arm stops closer to
Rod end clearance: 32189AA000 0 28$
5th gear.
A: 3rd-4th — 5th Arm stops closer to
0.5 — 1.3 mm (0.020 — 0.051 in) 32189AA010 1 31$
5th gear.
B: 1st-2nd — 3rd-4th Arm stops in the cen-
0.4 — 1.4 mm (0.016 — 0.055 in) 33189AA020 2 34$
ter.
Arm stops closer to
1st-2nd shifter fork 32189AA030 3 37$
reverse gear.
Part Number Marking Remarks
Arm stops closer to
Approach to 1st gear 32189AA040 4 40$
32804AA060 1 reverse gear.
by 0.2 mm (0.008 in).
32804AA070 No mark Standard
Approach to 2nd gear
32804AA080 3
by 0.2 mm (0.008 in)
3rd-4th shifter fork

Approach to 4th gear
32810AA061 1
by 0.2 mm (0.008 in).
32810AA071 No mark Standard
Approach to 3rd gear
32810AA101 3
by 0.2 mm (0.008 in)
5MT-4
General Description
10.EXTENSION ASSEMBLY 11.FRONT DIFFERENTIAL

Thrust washer (50 ! 61 ! t) to taper roller bear- Bevel gear to pinion backlash:
ing table outer race side preload: 0.13 — 0.18 mm (0.0051 — 0.0071 in)
0.2 — 0.3 mm (0.0008 — 0.012 in)
Washer (38.1 ! 50 ! t)
NOTE: Thickness Thickness
Be sure that it is within the standard preload. Part Number Part Number
mm (in) mm (in)
Thrust washer (50 ! 61 ! t) 0.925 — 1.025 —
0.950 1.050
Part Number Thickness mm (in) 803038021 803038023
(0.0364 — (0.0404 —
803050060 0.50 (0.0197) 0.0374) 0.0413)
803050061 0.55 (0.0217) 0.975 —
803050062 0.60 (0.0236) 1.000
803038022 — —
803050063 0.65 (0.0256) (0.0384 —
803050064 0.70 (0.0276) 0.0394)
803050065 0.75 (0.0295)
803050066 0.80 (0.0315)
12.TRANSFER DRIVE GEAR
803050067 0.85 (0.0335) Snap ring (Outer-30) to ball bearing clearance:
803050068 0.90 (0.0354) 0.01 — 0.15 mm (0.0004 — 0.0059 in)
803050069 0.95 (0.0374)
Snap ring (Outer-30)
803050070 1.00 (0.0394)
803050071 1.05 (0.0413)
805030041 1.53 (0.0602)
803050072 1.10 (0.0433)
805030042 1.65 (0.0650)
803050073 1.15 (0.0453)
805030043 1.77 (0.0697)
803050074 1.20 (0.0472)
803050075 1.25 (0.0492)
803050076 1.30 (0.0512)
803050077 1.35 (0.0531)
803050078 1.40 (0.0551)
803050079 1.45 (0.0571)
Thrust washer to center differential side clear-

ance:
0.15 — 0.35 mm (0.0059 — 0.0138 in)
Thrust washer
803036050 0.9 (0.035)
803036054 1.0 (0.039)
803036051 1.1 (0.043)
803036055 1.2 (0.047)
803036052 1.3 (0.051)
803036056 1.4 (0.055)
803036053 1.5 (0.059)
803036057 1.6 (0.063)
803036058 1.7 (0.067)
5MT-5
General Description
B: COMPONENT
1. TRANSMISSION CASE
(13)
(10)
(12)
(6)
(9) T2
(7) (5)
(8)
(11)
(4)
(1)
(2)
(3) T1
MT-01008
5MT-6
General Description
(1) Transmission case ASSY (Single- (8) Gasket (13) High-low cable bracket B (Dual-
range) (9) Plug range)
(2) Gasket (10) Oil seal (Dual-range)
(3) Drain plug (11) Transmission case ASSY (Dual- Tightening torque: N"m (kgf-m, ft-lb)
(4) Harness bracket range) T1: 70 (7.1, 51)
(5) Clamp (12) High-low cable bracket A (Dual- T2: 60 (6.1, 43.7)
(6) Pitching stopper bracket range)
(7) Oil level gauge
• Transmission case tightening torque
Bolt size Tightening torque: N"m (kgf-m,

Bolt No.
(9) (16) mm ft-lb)
(5) (7)
(17)
(13) (11)
(1) (5) — (15) 8 25 (2.5, 18.4)
(3)
(15) (2)
(4)
(1) — (4)
(14) 10 39 (4.0, 28.9)
(10) (6) (8) (12) (16) — (17)
MT-00003
5MT-7
General Description
2. DRIVE PINION ASSEMBLY
(4) (5)
(3)
(2)
(1)
(11) (18)
(8) (17)
(7) (16)
(15)
(14)
(13)
(12)
(10)
(9)
(6) (29) T3
(28)
(27)
T1
(26)
(25)
(24)
(23)
(35) T2
(34)
(22) (33)
(21) (32)
(20)
(30)
(19)
(31)
(30)
MT-00351
(1) Drive pinion shaft (15) Baulk ring (29) Lock nut
(2) Roller bearing (16) 1st-2nd synchronizer hub (30) Washer
(3) Washer (17) Insert key (31) Thrust bearing
(4) Thrust bearing (18) Reverse driven gear (32) Differential bevel gear sleeve
(5) Needle bearing (19) Outer baulk ring (33) Washer
(6) Driven shaft (20) Synchro cone (34) Lock washer
(7) Key (21) Inner baulk ring (35) Lock nut
(8) Woodruff key (22) 2nd driven gear
(9) Drive pinion collar (23) 2nd driven gear bushing Tightening torque: N"m (kgf-m, ft-lb)
(10) Needle bearing (24) 3rd-4th driven gear T1: 30 (3.1, 22.4)
(11) Snap ring (KS and K4 model) (25) Driven pinion shim T2: 120 (12.2, 88.2)
(12) Washer (KS and K4 model) (26) Roller bearing T3: 260 (26.5, 191.7)
(13) Sub gear (KS and K4 model) (27) 5th driven gear
(14) 1st driven gear (28) Lock washer
5MT-8
General Description
3. MAIN SHAFT ASSEMBLY FOR SINGLE-RANGE
(3)
(17)
(2) (16)
(1) (15)
(14)
(13)
(12)
(11)
(10)
(9)
(8)
(7)
(6)
(5)
(4)
(33) T
(32)
(24) (31)
(30)
(29)
(28)
(27)
(26)
(25)
(23) (37)
(22)
(36)
(21)
(34)
(20)
(18) (19) (35)
MT-01018
5MT-9
General Description
(1) Oil seal (15) Needle bearing (29) Ball bearing

(2) Needle bearing (16) 4th gear thrust washer (30) Synchro cone stopper
(3) Transmission main shaft (17) Ball bearing (31) Snap ring
(4) Needle bearing (18) 5th gear thrust washer (32) Lock washer
(5) 3rd drive gear (19) 5th needle bearing race (33) Lock nut
(6) Inner baulk ring (20) Needle bearing (34) Reverse idler gear shaft
(7) 3rd synchro cone (21) Main shaft rear plate (35) Straight pin
(8) Outer baulk ring (22) 5th drive gear (36) Reverse idler gear
(9) 3rd-4th coupling sleeve (23) 5th baulk ring (37) Washer
(10) 3rd-4th synchronizer hub (24) 5th-Rev shifting insert key
(11) 3rd-4th shifting insert key (25) 5th-Rev synchronizer hub Tightening torque: N"m (kgf-m, ft-lb)
(12) 4th baulk ring (26) 5th-Rev coupling sleeve T: 120 (12.2, 88.5)
(13) 4th drive gear (27) Reverse baulk ring
(14) 4th needle bearing race (28) Reverse synchro cone
5MT-10
General Description
4. MAIN SHAFT ASSEMBLY FOR DUAL-RANGE
(6)
(7)
(6)
(5) (8)
(4)
(4)
(20)
(2)
(1) (16) (19)

(14)
(3)
(10)
(18)
(17)
(9)
(15)
(13)
(33)
(12)
(11)
T2 (32)
(26) (31)
(30)
(29)
(28)
(68) (22)
(71) T3 (27)
(24)
(72) (25)
(69) (73) (24)
(23)
(70) (74) (21) (47)
(77) (46)
(78) T1 (45)
(79) (44)
(43)
(76) (42)
(75) (41)
(40)
(39)
(38)
(37)
(36)
(35)
(34)
(63) T4
(62)
(54) (61)
(60)
(59)
(58)
(57)
(56)
(55)
(53) (67)
(52) (66)
(51) (64)
(50)
(48) (49) (65)
MT-01019
5MT-11
General Description
(1) O-ring (30) Needle bearing (59) Ball bearing

(2) High-low counter shaft (31) Input low gear spacer (60) Synchro cone stopper
(3) Knock pin (32) Ball (61) Snap ring
(4) High-low counter washer (33) Main shaft (62) Lock washer
(5) Counter gear (34) Needle bearing (63) Lock nut
(6) Needle bearing (35) 3rd drive gear (64) Reverse idler gear shaft
(7) Counter gear collar (36) Inner baulk ring (65) Straight pin
(8) Snap ring (Outer-19) (37) Synchro cone (66) Reverse idler gear
(9) Input shaft holder (38) Outer baulk ring (67) Washer
(10) Input shaft shim (39) 3rd-4th coupling sleeve (68) Straight pin
(11) Oil seal (40) 3rd-4th synchronizer hub (69) High-low shifter lever
(12) O-ring (41) 3rd-4th shifting insert key (70) High-low shifter shaft
(13) Snap ring (Outer-28) (42) 4th baulk ring (71) Low switch
(14) Oil squeeze (43) 4th drive gear (72) Gasket
(15) Straight pin (44) 4th needle bearing race (73) Straight pin
(16) Snap ring (Outer-28) (45) Needle bearing (74) High-low shifter fork
(17) Ball bearing (46) 4th gear thrust washer (75) High-low shifter piece
(18) Snap ring (Inner-68) (47) Ball bearing (76) Ball
(19) Input shaft (48) 5th gear thrust washer (77) Spring
(20) Needle bearing (49) 5th needle bearing race (78) Gasket
(21) Snap ring (Outer-25) (50) Needle bearing (79) Plug
(22) High-low baulk ring (51) Main shaft rear plate
(23) High-low coupling sleeve (52) 5th drive gear Tightening torque: N"m (kgf-m, ft-lb)
(24) High-low synchronizer spring (53) 5th baulk ring T1: 10 (1.0, 7.4)
(25) High-low synchronizer hub (54) 5th-Rev shifting insert key T2: 20 (2.0, 14.5)
(26) Shifting insert key (55) 5th-Rev synchronizer hub T3: 25 (2.5, 18.1)
(27) High-low baulk ring (56) 5th-Rev coupling sleeve T4: 120 (12.2, 88.5)
(28) Friction damper (57) Rev baulk ring
(29) Input low gear (58) Rev synchro cone
5MT-12
General Description
5. SHIFTER FORK AND SHIFTER ROD
(1)
(2)
(8)
(7)
(4)
(6)
(5) T
(3)
(12)
(18)
(9)
(10)
(10)
(6)
(7)
(5) T
(17)
(16)
(8)
(10)
(11)
(3)
(6)
(15) (5) T
(14)
(8)
(7)
(3) (13)
MT-00007
(1) Shifter arm (8) Ball (15) Spring

(2) 5th shifter fork (9) 3rd-4th fork rod (16) Snap ring (Outer)
(3) Straight pin (10) Interlock plunger (17) Reverse fork rod arm
(4) Reverse fork rod (11) 1st-2nd fork rod (18) Reverse shifter lever
(5) Checking ball plug (12) 3rd-4th shifter fork
(6) Gasket (13) 1st-2nd shifter fork Tightening torque: N"m (kgf-m, ft-lb)
(7) Checking ball spring (14) Ball T: 19.5 (2.0, 14.4)
5MT-13
General Description
6. TRANSFER CASE AND EXTENSION

(5)
T3 (4) (7) T2
(3)
(6)
(2)
(8)
T3
(20)
(1)
T1 (21) T3
(23) T3
(22)
(12)
(14)
(9)
(17)
(10) (11) (19)
(15) T1
(13) (35)
(18)
(16) (34)
(36)
T5 T3
(26) (27)
(25)
(24)
(31) T5
(30)
(37) (33)
(29)
(32)
(28)
T4
MT-00008
(1) Oil guide (16) Return spring (31) Transfer drive gear
(2) Gasket (17) O-ring (32) Ball bearing
(3) Transfer case (18) Adjusting select shim (33) Extension case
(4) Ball (19) Reverse check sleeve (34) Oil seal
(5) Reverse accent spring (20) Gasket (35) Dust cover
(6) Gasket (21) Neutral position switch (36) Shift bracket
(7) Plug (22) Gasket (37) Snap ring
(8) Oil seal (23) Back-up light switch
(9) Snap ring (Inner) (24) Roller bearing Tightening torque: N"m (kgf-m, ft-lb)
(10) Reverse check plate (25) Transfer driven gear T1: 6.4 (0.65, 4.7)
(11) Reverse check spring (26) Roller bearing T2: 10 (1.0, 7.4)
(12) Reverse return spring (27) Adjusting washer T3: 25 (2.5, 18.4)
(13) Reverse check cam (28) Ball bearing T4: 26 (2.7, 20)
(14) Reverse accent shaft (29) Center differential T5: 40 (4.1, 29.7)
(15) Return spring cap (30) Adjusting washer
5MT-14
General Description
7. FRONT DIFFERENTIAL
(7)
(5)
(1)
(6)
(5)
(8) (2)
(7)
(3)
(4)
T2
(8)
(11)
(10) (10)
(12)
(12)
(9)
(11) (13)
T1
T1 (13)
MT-01031
(1) Drive pinion shaft (7) Differential bevel pinion (13) Retainer lock plate
(2) Hypoid driven gear (8) Roller bearing
(3) Pinion shaft (9) Differential case Tightening torque: N"m (kgf-m, ft-lb)
(4) Straight pin (10) Oil seal T1: 25 (2.5, 18.1)
(5) Washer (11) Differential side retainer T2: 62 (6.3, 45.6)
(6) Differential bevel gear (12) O-ring
5MT-15
General Description
8. TRANSMISSION MOUNTING
(6)
(4)
(3) (5)
T4
(2)
T3 T1
T2
(10)
(1)
(8)
(3)
(9)
(2)
(7) (3)
T2
T5
T5
T6
MT-00998
(1) Pitching stopper (8) Center crossmember Tightening torque: N"m (kgf-m, ft-lb)
(2) Spacer (9) Front crossmember T1: 70 (7.1, 51)
(3) Cushion rubber (10) Cushion (crossmember) T2: 35 (3.6, 26)
(4) Front plate T3: 50 (5.1, 37)
(5) Rear cushion rubber T4: 58 (5.9, 43)
(6) Rear crossmember T5: 70 (7.1, 51)
(7) Cushion D T6: 140 (14.3, 103)
5MT-16
General Description
C: CAUTION • Be sure to tighten fasteners including bolts and

• Wear work clothing, including a cap, protective nuts to the specified torque.
goggles and protective shoes, during operation. • Place shop jacks or rigid racks at the specified
• Remove contamination including dirt and corro- points.
sion before removal, installation or disassembly. • Apply gear oil onto sliding or revolution surfaces
• Keep the disassembled parts in order and pro- before installation.
tect them from dust and dirt. • Replace deformed or damaged snap rings with
• Before removal, installation or disassembly, be new ones.
sure to clarify the failure. Avoid unnecessary re- • Before installing O-rings or oil seals, apply suffi-
moval, installation, disassembly and replacement. cient amount of gear oil to avoid damage and defor-
• When disassembling the case and other light al- mation.
loy parts, use a plastic hammer to force it apart. Do • Be careful not to incorrectly install or fail to install
not pry it apart with a screwdriver or other tool. O-rings, snap rings and other such parts.
• Be careful not to burn yourself, because each • Before securing a part on a vice, place cushion-
part on the vehicle is hot after running. ing material such as wood blocks, aluminum plate
• Use SUBARU genuine gear oil, grease etc. or or cloth between the part and the vice.
equivalent. Do not mix gear oil, grease etc. with • Avoid damaging the mating surface of the case.
that of another grade or from other manufacturers. • Before applying sealant, completely remove the
old seal.
D: PREPARATION TOOL
1. SPECIAL TOOL
399411700 ACCENT BALL Used for installing reverse shifter rail arm.
INSTALLER
ST-399411700
899524100 PULLER SET Used for removing and installing roller bearing
(Differential).
(1) Puller
(2) Cap
ST-899524100
5MT-17
General Description

399780104 WEIGHT Used for measuring preload on roller bearing.
ST-399780104
498077000 REMOVER Used for removing roller bearing of drive pinion
shaft.
ST-498077000
498077300 CENTER DIFFER- Used for removing the center differential cover
ENTIAL BEARING ball bearing.
REMOVER
ST-498077300
498147000 DEPTH GAUGE Used for adjusting main shaft axial end play.
ST-498147000
5MT-18
General Description

498247001 MAGNET BASE • Used for measuring backlash between side
gear and pinion, and hypoid gear.
ST-498247001
498247100 DIAL GAUGE • Used for measuring backlash between side
gear and pinion, and hypoid gear.
ST-498247100
498427100 STOPPER Used for securing drive pinion shaft assembly
and driven gear assembly when removing lock
nut of drive pinion shaft assembly.
ST-498427100
498787100 MAIN SHAFT Used for removing and installing lock nut of
STOPPER transmission main shaft.
ST-498787100
5MT-19
General Description

498937000 TRANSMISSION Used for removing and installing transmission
HOLDER main shaft lock nut.
ST-498937000
499277100 BUSHING 1-2 • Used for installing 1st driven gear thrust plate
INSTALLER and 1st-2nd driven gear bushing.
• Used for installing roller bearing outer races to
differential case.
ST-499277100
499277200 INSTALLER Used for press-fitting 2nd driven gear, roller
bearings, and 5th driven gear onto driven shaft.
ST-499277200
499757002 INSTALLER • Used for installing snap ring (OUT 25), and
ball bearing (25 ! 26 ! 17).
• Used for installing bearing cone of transfer
driven gear (extension core side).
ST-499757002
5MT-20
General Description

499787000 WRENCH ASSY Used for removing and installing differential side
retainer.
ST-499787000
499827000 PRESS Used for installing speedometer oil seal when

installing speedometer cable to transmission.
ST-499827000
499857000 5TH DRIVEN GEAR Used for removing 5th driven gear.
REMOVER
ST-499857000
499877000 RACE 4-5 • Used for installing 4th needle bearing race and
INSTALLER ball bearing onto transmission main shaft.
• Used with REMOVER (899714110).
ST-499877000
5MT-21
General Description

499917500 DRIVE PINION Used for adjusting drive pinion shim.
GAUGE ASSY
ST-499917500
499927100 HANDLE Used for fitting transmission main shaft.
ST-499927100
499937100 TRANSMISSION Stand used for transmission disassembly and
STAND SET assembly.
ST-499937100
499987003 SOCKET WRENCH Used for removing and installing driven pinion
(35) lock nut and main shaft lock nut.
ST-499987003
5MT-22
General Description

499987300 SOCKET WRENCH Used for removing and installing driven gear
(50) assembly lock nut.
ST-499987300
899714110 REMOVER Used for installing transmission main shaft drive
pinion and rear drive shaft.
ST-899714110
899864100 REMOVER Used for removing parts on transmission main

shaft and drive pinion.
ST-899864100
899884100 HOLDER Used for tightening lock nut on sleeve.
ST-899884100
5MT-23
General Description

899904100 REMOVER Used for removing and installing straight pin.
ST-899904100
899988608 SOCKET WRENCH Used for removing and installing drive pinion lock
(27) nut.
ST-899988608
398497701 ADAPTER • Used for installing roller bearing onto differen-

tial case.
• Used with INSTALLER (499277100).
ST-398497701
499587000 INSTALLER Used for installing driven gears to driven shaft.
ST-499587000
5MT-24
General Description

(35) nut.
ST-499987100
(35) nut.
ST-899984103
ST-498057300
498255400 PLATE Used for measuring backlash.
ST-498255400
5MT-25
General Description

498077400 SYNCHRONIZER • Used for removing synchronizer cone of main
CONE REMOVER shaft.
• Used for removing 5th driven gear of drive pin-
ion shaft.
ST-498077400
41099AA000 ENGINE SUPPORT Used for supporting engine.
BRACKET (1) ENGINE SUPPORT BRACKET
(41099AA010)
(1) (2) ENGINE SUPPORT (41099AA020)
(2)
ST41099AA000
398527700 PULLER ASSY Used for removing extension case roller bearing.
ST-398527700
ST-398643600
5MT-26
General Description

398177700 INSTALLER • Used for installing bearing cone of transfer
driven gear (transfer case side).
• Used for installing ball bearing of transfer drive
gear.
ST-398177700
28399SA010 FRONT DRIVE Used for protecting oil seal from damage when
SHAFT OIL SEAL inserting front drive shaft.
PROTECTOR
ST28399SA010
18675AA000 DIFFERENTIAL Used for installing differential side retainer oil

SIDE OIL SEAL seal.
INSTALLER
ST18675AA000
398507703 DUMMY COLLAR • Used for installing input shaft holder oil seal.
• For dual-range model.
ST-398507703
5MT-27
General Description

398663600 PLIERS • Used for removing and installing input shaft
snap ring.
ST-398663600
499757001 SNAP RING GUIDE • Used for installing snap ring (OUT 25).
ST-499757001
899858600 RETAINER • Used for removing ball bearing.

ST-899858600
899474100 EXPANDER • Used for removing and installing snap ring.

ST-899474100
5MT-28
General Description

899580100 INSTALLER • Used for pressing ball bearings into input
shaft.
ST-899580100
399513600 INSTALLER • Used for pressing ball bearings into input

shaft.
ST-399513600
2. GENERAL TOOL
TOOL NAME REMARKS
Circuit tester Used for measuring resistance, voltage and ampere.
5MT-29
Transmission Gear Oil
2. Transmission Gear Oil Tightening torque:

70 N"m (7.1 kgf-m, 51 ft-lb)
A: INSPECTION
2) Turn the ignition switch to OFF, and wait until the
engine cools.
proper direction. (B)
5) Pull out the oil level gauge again, and check the
oil level. If it is below the lower level, add oil through (A)
the oil level gauge hole to bring the level up to the MT-00061
upper level.
(A) Drain plug
(B) Gasket
(A)
5) Pour gear oil through the gauge hole.
(B)
Recommended gear oil:
(C)
GL-5 (75W-90) or equivalent
Gear oil capacity:
Single-range model
PM-00030 3.5 2 (3.7 US qt, 3.1 Imp qt)
Dual-range model
(A) Oil level gauge 4.0 2 (4.2 US qt, 3.5 Imp qt)
(B) Upper level 6) Check the level of transmission gear oil.
(C) Lower level
CAUTION:
B: REPLACEMENT The level should be within the specified range
marked on the gauge.
1) Pull out the oil level gauge.
3) Drain transmission gear oil completely.
CAUTION:
Immediately after the engine running, the trans-
mission gear oil is very hot. Be careful not to
burn yourself.
NOTE:
• Tighten the transmission gear oil drain plug after
draining transmission gear oil.
• Use a new gasket.
5MT-30
Manual Transmission Assembly
3. Manual Transmission As- 8) Remove the drive select cable on transmission

side. (Dual-range model)
sembly
A: REMOVAL
1) Open the front hood fully, and support with stay.
2) Disconnect the ground cable from battery. (A)
3) Drain transmission gear oil completely.
4) Remove the air intake chamber and air cleaner
case. <Ref. to IN(H4SO 2.0)-8, REMOVAL, Air In-
take Chamber.> <Ref. to IN(H4SO 2.0)-6, REMOV- (C)
AL, Air Cleaner Case.> (B)
5) Remove the air intake chamber stay. MT-00066
(A) Snap pin

(B) Clevis pin
(C) Drive select cable
9) Remove the starter. <Ref. to SC(H4SO 2.0)-6,

REMOVAL, Starter.>
10) Remove the operating cylinder from transmis-
sion.
MT-00062
6) Disconnect the following connectors:

(1) Neutral position switch connector
(2) Back-up light switch connector
(3) High-low switch connector (Dual-range
model)
CL-00253
MT-00063
7) Remove the snap pin and clevis pin from drive

select cable. (Dual-range model)
MT-00069
5MT-31
12) Set the ST. (1) Disconnect the stay from transmission.
ST 41099AA000 ENGINE SUPPORT ASSY (2) Remove the rod from transmission.
ST
(A)
(B)
(B)
MT-00070 MT-00075
13) Remove the bolts which hold upper side of

(A) Stay
(B) Rod
21) Remove the stabilizer link from front arm.
MT-00073

15) Remove the front and center exhaust pipes. MT-00988
<Ref. to EX(H4SO 2.0)-7, REMOVAL, Front Ex- 22) Remove the bolt securing ball joint of front arm
haust Pipe.> to housing.
haust Pipe.> <Ref. to EX(H4SO 2.0)-13, REMOV- (B)
AL, Muffler.>
CAUTION:
When removing the exhaust pipes, be careful
each exhaust pipe does not drop out.
17) Remove the heat shield cover. (if equipped) (C)
18) Remove the hanger bracket from the right side
(A)
of transmission. MT-00987
(A) Front arm

(B) Ball joint
(C) Stabilizer link
MT-00074

20) Remove the gear shift rod and the stay from
transmission.
5MT-32
23) Using the lever, remove the left and right front 26) Remove the transmission rear crossmember
drive shaft from transmission. from vehicle.
(A)
MT-01017 MT-00079
27) Remove the transmission.

(A) Lever
NOTE:
24) Remove the nuts which hold lower side of Move the transmission jack toward rear until main
transmission to engine. shaft is withdrawn from clutch disc.
28) Separate the transmission assembly from rear
cushion rubber.
B: INSTALLATION
1) Install the rear cushion rubber to transmission
assembly.
Tightening torque:
35 N"m (3.57 kgf-m, 25.8 ft-lb)
MT-00077 (1) Gradually raise the transmission with trans-
mission jack.
25) Place the transmission jack under transmis-
sion. (2) Engage them at splines.
CAUTION: NOTE:
Always support transmission case with a trans- Be careful not to strike the main shaft against clutch
mission jack. housing cover.
3) Install the transmission rear crossmember.
Tightening torque:
T1: 70 N"m (7.1 kgf-m, 51 ft-lb)
T2: 140 N"m (14.3 kgf-m, 103 ft-lb)
T1 T1
MT-00078 T2 T2
MT-00081
4) Take out the transmission jack.
5MT-33
5) Tighten the nuts which hold lower side of trans- 8) Install the pitching stopper.
mission to engine.
Tightening torque:
Tightening torque: T1: 50 N"m (5.1 kgf-m, 37 ft-lb)
50 N"m (5.1 kgf-m, 36.9 ft-lb) T2: 58 N"m (5.9 kgf-m, 43 ft-lb)
T1
T2
MT-00077 MT-00085
6) Connect the transmission to engine. 9) Lift-up the vehicle.

(1) Install the starter. 10) Install the front drive shaft into transmission.
<Ref. to SC(H4SO 2.0)-6, INSTALLATION, 11) Replace the differential side retainer oil seal.
Starter.> <Ref. to 5MT-40, REPLACEMENT, Differential
(2) Tighten the bolts that hold upper side of Side Retainer Oil Seal.>
transmission to engine. ST 186755AA000 DIFFERENTIAL SIDE OIL
SEAL INSTALLER
Tightening torque:
50 N"m (5.1 kgf-m, 36.9 ft-lb) NOTE:
Be sure to replace the differential side retainer oil
seal after the procedure of removing the front drive
shaft.
ST
MT-00073
7) Remove the ST.

MT-00103
ST
12) Install the front drive shaft into transmission.
ST 28399SA010 FRONT DRIVE SHAFT OIL
SEAL PROTECTOR
MT-00070
ST
AT-00110
5MT-34
13) Install the ball joint of lower arm. 18) Install the hanger bracket on the right side of
transmission.
Tightening torque:
49 N"m (5.0 kgf-m, 36 ft-lb)
(B)
(C)
MT-00074
(A)
MT-00987
19) Install the front, center and rear exhaust pipe,
(A) Front arm TION, Front Exhaust Pipe.> <Ref. to EX(H4SO
(B) Ball joint 2.0)-11, INSTALLATION, Rear Exhaust Pipe.>
(C) Stabilizer link <Ref. to EX(H4SO 2.0)-13, INSTALLATION, Muf-
fler.>
14) Install the stabilizer link into front arm. 20) Install the operating cylinder.
45 N"m (4.6 kgf-m, 33.2 ft-lb) 37 N"m (3.8 kgf-m, 27.5 ft-lb)
MT-00988 CL-00253
15) Install the gear shift rod and the stay. 21) Install the drive select cable on transmission
(1) Install the gear shift rod into transmission. side. (Dual-range model)
(A)
(A)
(B)
(B)
(C)
(B)
MT-00089 MT-00066
(A) Stay (A) Snap pin

(B) Rod (B) Clevis pin
(C) Drive select cable
(2) Install the stay onto transmission.
16) Install the propeller shaft. <Ref. to DS-11, IN- 22) Connect the following connectors:
STALLATION, Propeller Shaft.> (1) Transmission ground cable
17) Install the heat shield cover. (if equipped) Tightening torque:
13 N"m (1.3 kgf-m, 9.4 ft-lb)
5MT-35
(2) Neutral position switch connector

(3) Back-up light switch connector
(4) High-low switch connector (Dual-range
model)
23) Fill transmission gear oil through the transmis-
sion level gauge hole.
24) Install the air intake chamber stay.
Tightening torque:
16 N"m (1.6 kgf-m, 11.6 ft-lb)
25) Install the air intake chamber and air cleaner
case. <Ref. to IN(H4SO 2.0)-7, INSTALLATION,
Air Cleaner Case.> <Ref. to IN(H4SO 2.0)-8, IN-
STALLATION, Air Intake Chamber.>
27) Take off the vehicle from lift arms.
5MT-36
4. Transmission Mounting Sys- B: INSTALLATION

tem 1. PITCHING STOPPER
A: REMOVAL 1) Install the pitching stopper.
1. PITCHING STOPPER Tightening torque:
T1: 50 N"m (5.1 kgf-m, 37 ft-lb)
1) Disconnect the ground cable from battery. T2: 58 N"m (5.9 kgf-m, 43 ft-lb)
3) Remove the air cleaner case. <Ref. to IN(H4SO
2.0)-6, REMOVAL, Air Cleaner Case.>
T1
T2
MT-00085
2) Install the air intake chamber and cleaner case.

<Ref. to IN(H4SO 2.0)-7, INSTALLATION, Air
Cleaner Case.> <Ref. to IN(H4SO 2.0)-8, INSTAL-
MT-00069 LATION, Air Intake Chamber.>
2. CROSSMEMBER AND CUSHION RUB-
BER 2. CROSSMEMBER AND CUSHION RUB-
BER
2) Jack-up the vehicle and support it with rigid 1) Install the rear cushion rubber.
racks. Tightening torque:
3) Remove the front, center and rear exhaust pipe, 35 N"m (3.6 kgf-m, 26 ft-lb)
and muffler. <Ref. to EX(H4SO 2.0)-7, REMOVAL,
2) Install the rear crossmember.
Front Exhaust Pipe.> <Ref. to EX(H4SO 2.0)-11,
REMOVAL, Rear Exhaust Pipe.> <Ref. to Tightening torque:
EX(H4SO 2.0)-13, REMOVAL, Muffler.> T1: 70 N"m (7.1 kgf-m, 51 ft-lb)
4) Remove the heat shield cover. (If equipped) T2: 140 N"m (14.3 kgf-m, 103 ft-lb)
5) Set the transmission jack under transmission
body.
T1 T1
CAUTION:
Always support the transmission case with a
transmission jack.
6) Remove the rear crossmember. T2 T2
MT-00081

4) Install the heat shield cover. (If equipped)
5) Install the front, center and rear exhaust pipe,
TION, Front Exhaust Pipe.> <Ref. to EX(H4SO
MT-00079 2.0)-11, INSTALLATION, Rear Exhaust Pipe.>
7) Remove the rear cushion rubber. <Ref. to EX(H4SO 2.0)-13, INSTALLATION, Muf-
fler.>
5MT-37
C: INSPECTION
Perform the following inspection procedures and
repair or replace defective parts.
1. PITCHING STOPPER
Check pitching stopper for bends or damage.
Check that the rubber is not stiff, cracked, or other-
wise damaged.
2. CROSSMEMBER AND CUSHION RUB-
BER
Check crossmember for bends or damage. Check
that the cushion rubber is not stiff, cracked, or oth-
erwise damaged.
5MT-38
Oil Seal
5. Oil Seal 7) Using the ST, install the oil seal.

A: INSPECTION
Check leakage of gear oil from the oil seal part. If
there is oil leakage, replace with a new oil seal.
B: REPLACEMENT
2) Drain gear oil completely.
NOTE:
Tighten the drain plug after draining gear oil.
Tightening torque: MT-00099
70 N"m (7.1 kgf-m, 51 ft-lb)
9) Install the heat shield cover. (If equipped)
10) Install the rear exhaust pipe and muffler.
11) Pour gear oil and check the oil level. <Ref. to
5MT-30, REPLACEMENT, Transmission Gear
Oil.>
MT-00097

AL, Muffler.>
4) Remove the heat shield cover. (If equipped)
5) Remove the propeller shaft. <Ref. to DS-10, RE-
6) Using the ST, remove the oil seal.
(A) ST
MT-00098
(A) Oil seal
5MT-39
6. Differential Side Retainer Oil 7) Using the ST, install the differential side retainer
by slightly tapping with a plastic hammer.
Seal ST 18675AA000 DIFFERENTIAL SIDE OIL
A: INSPECTION SEAL INSTALLER
Check leakage of gear oil from the differential side NOTE:
retainer oil seal part. If there is oil leakage, replace Apply oil to the oil seal lips.
with a new oil seal.
B: REPLACEMENT
ST
2) Drain gear oil from differential oil drain plug.
MT-00103
8) Install the front drive shaft. <Ref. to DS-22, IN-

STALLATION, Front Drive Shaft.>
ST 28399SA010 FRONT DRIVE SHAFT OIL
(A) SEAL PROTECTOR
MT-00339
9) Install the front and center exhaust pipe.
(A) Differential oil drain plug <Ref. to EX(H4SO 2.0)-8, INSTALLATION, Front
Exhaust Pipe.>
3) Replace with a new gasket and tighten the differ-
ential oil drain plug.
11) Pour gear oil through the gauge hole. <Ref. to
Tightening torque: 5MT-30, REPLACEMENT, Transmission Gear
70 N"m (7.1 kgf-m, 51 ft-lb) Oil.>
(A)
MT-00339
(A) Differential oil drain plug
4) Remove the front and center exhaust pipe.

haust Pipe.>
6) Remove the differential side retainer oil seal.
NOTE:
• Be sure to replace the differential side retainer oil
seal after the procedure of removing the front drive
shaft from transmission.
• When prying to remove the part using flat tip
screwdriver, be careful not to scratch the differen-
tial side retainer. ST 398527700 puller assembly
may be used for this operation procedure.
5MT-40
Switches and Harness
7. Switches and Harness 3) Disconnect the connector of high-low switch.
A: REMOVAL
1. BACK-UP LIGHT SWITCH AND NEU-
TRAL POSITION SWITCH (A)

2) Remove the air intake chamber and cleaner
case. <Ref. to IN(H4SO 2.0)-6, REMOVAL, Air (B)
Cleaner Case.> <Ref. to IN(H4SO 2.0)-8, REMOV-
AL, Air Intake Chamber.>
3) Disconnect the connectors of back-up light (C) MT-00107
switch and neutral position switch.
(A) Neutral switch (Brown)
(B) Back-up light switch (Gray)
(C) High-low switch (Black)
(A)
4) Remove the high-low switch cable from clamp.
5) Remove the high-low switch.
(B) (A)
(B)
MT-00104
(A) Neutral position switch connector (Brown)

(B) Back-up light switch connector (Gray)

5) Remove the back-up light switch and neutral po- MT-00108
sition switch with harness.
(A) Clamp
(B) High-low switch
(A)
B: INSTALLATION
1. BACK-UP LIGHT SWITCH AND NEU-
TRAL POSITION SWITCH
1) Install the back-up light switch and neutral posi-
tion switch with harness.
(B) Tightening torque:
MT-00106
25 N"m (2.5 kgf-m, 18.4 ft-lb)
(A) Neutral position switch (Brown)
(B) Back-up light switch (Gray)
(A)
2. HIGH-LOW SWITCH (DUAL-RANGE

MODEL)
2) Remove the air intake chamber and cleaner
case. <Ref. to IN(H4SO 2.0)-6, REMOVAL, Air
Cleaner Case.> <Ref. to IN(H4SO 2.0)-8, REMOV- (B)
AL, Air Intake Chamber.> MT-00106
(A) Neutral position switch

(B) Back-up light switch
5MT-41
Switches and Harness
2) Connect the connectors of back-up light switch

and neutral position switch.
LATION, Air Intake Chamber.>
2. HIGH-LOW SWITCH (DUAL-RANGE
MODEL)
1) Install the high-low switch.
Tightening torque:
25 N"m (2.5 kgf-m, 18.4 ft-lb)
2) Install the high-low switch cable to clamp.
3) Connect the connector of high-low switch.
LATION, Air Intake Chamber.>
C: INSPECTION
1. BACK-UP LIGHT SWITCH
Inspect the back-up light switch. <Ref. to LI-7, IN-
SPECTION, Back-up Light System.>
2. NEUTRAL POSITION SWITCH
2) Disconnect the connector of neutral position
switch.
3) Measure the resistance between neutral posi-
tion switch terminals.
2 1
MT-00110
Gear shift position Terminal No. Specified resistance

Neutral position More than 1 M%
1 and 2
Other positions Less than 1 %
4) Replace the faulty parts.
5MT-42
Preparation for Overhaul
8. Preparation for Overhaul

A: PROCEDURE
1) Clean oil, grease, dirt and dust from transmis-
sion.
2) Remove the drain plug to drain oil. Tighten the
engine oil drain plug after draining.
NOTE:
Use a new gasket.
Tightening torque:
70 N"m (7.1 kgf-m, 51 ft-lb)
MT-00097
3) Attach the transmission to ST.

ST 499937100 TRANSMISSION STAND
ST
MT-00115
4) Rotating parts should be coated with oil prior to

assembly.
5) All disassembled parts, if to be reused, should
be reinstalled in the original positions and direc-
tions.
6) Always use new ones for gaskets, lock washers
and lock nut.
7) Liquid gasket should be used where specified to
prevent leakage.
5MT-43
Transfer Case and Extension Case Assembly
9. Transfer Case and Extension 2) Remove the bearing outer race from extension
case.
Case Assembly
(B)
A: REMOVAL
1) Remove the manual transmission assembly
from vehicle. <Ref. to 5MT-31, REMOVAL, Manual (A)
2) Remove the back-up light switch and neutral po-
sition switch. <Ref. to 5MT-41, REMOVAL, Switch-
es and Harness.>
3) Remove the transfer case with extension case
assembly. MT-00119
(A) Bearing outer race

(B) Extension case
3) While pressing the bearing outer race horizontal-

ly, turn the driven shaft ten rotations.
4) Measure the height “W” between transfer case
and taper roller bearing on the transfer driven gear.
MT-00116
4) Remove the shifter arm.

5) Remove the extension case assembly.
MT-00120
5) Measure the depth “X” on bearing insertion part

of extension case.
NOTE:
Measure with bearing outer race and thrust washer
MT-00117
removed.
B: INSTALLATION
1) Install the center differential and transfer driven
gear into transfer case.
MT-00121
6) Calculate the tight “t” using following equation.

t = X & W + 0.2 to 0.3 mm (0.008 to 0.012 in)
MT-00118
7) Select the washer of nearest value in the follow-
ing table:
Standard preload between thrust washer and
taper roller bearing:
0.2 — 0.3 mm (0.008 — 0.012 in)
5MT-44
NOTE: 11) Measure the height “T” between extension

Be sure that the preload is within standard value. case and transfer drive gear.
ST 398643600 GAUGE
Thrust washer (50 ! 61 ! t)
803050060 0.50 (0.0197)
ST
803050061 0.55 (0.0217)
803050062 0.60 (0.0236)
803050063 0.65 (0.0256)
803050064 0.70 (0.0276)
T
803050065 0.75 (0.0295)
803050066 0.80 (0.0315)
803050067 0.85 (0.0335) MT-00123
803050068 0.90 (0.0354)
12) Calculate the thrust washer “U” using following
803050069 0.95 (0.0374)
equation.
803050070 1.00 (0.0394)
U = {15 mm (1.18 in) & T} & {S & 15 mm (1.18 in)} &
803050071 1.05 (0.0413) 0.15 to 0.35 mm (0.0059 to 0.0138 in)
803050072 1.10 (0.0433)
803050073 1.15 (0.0453) U Thickness of transfer drive gear
mm (in) thrust washer
803050074 1.20 (0.0472)
T Height from end of ST to transfer
803050075 1.25 (0.0492)
mm (in) drive gear
803050076 1.30 (0.0512)
S Depth from end of transmission
803050077 1.35 (0.0531) mm (in) case to the end of ST
803050078 1.40 (0.0551) 0.15 — 0.35 mm Standard clearance between thrust
803050079 1.45 (0.0571) (0.0059 — 0.0138 in) washer and transfer drive gear.
15 mm (1.18 in) Thickness of ST
8) Fit the thrust washers on transfer drive shaft.
9) Install the bearing outer race into extension 13) Select a suitable washer in the following table:
case.
10) Measure the depth “S” between transfer case Standard clearance:
and center differential. 0.15 — 0.35 mm (0.0059 — 0.0138 in)
ST 398643600 GAUGE Thrust washer
ST
803036050 0.9 (0.035)
803036054 1.0 (0.039)
803036051 1.1 (0.043)
803036055 1.2 (0.047)
S
803036052 1.3 (0.051)
803036056 1.4 (0.055)
803036053 1.5 (0.059)
803036057 1.6 (0.063)
MT-00122 803036058 1.7 (0.067)
14) Fit the thrust washer on center differential.
5MT-45
15) Apply proper amount of liquid gasket to the 18) Hang the shifter arm on 3rd-4th fork rod.
transfer case mating surface.
(A)
Liquid gasket
THREE BOND 1215 (Part No. 004403007) or
equivalent
(B) MT-00127
(A) Shifter arm

(B) 3rd-4th fork rod
MT-00124 19) Install the transfer case with extension case as-
16) Install the extension assembly into transfer sembly to transmission case.
case. Tightening torque:
Tightening torque: 25 N"m (2.5 kgf-m, 18.4 ft-lb)
40 N"m (4.1 kgf-m, 29.7 ft-lb)
MT-00116
MT-00117 C: DISASSEMBLY
17) Install the shifter arm to transfer case. 1. TRANSFER CASE
1) Remove the reverse check assembly. <Ref. to
5MT-53, REMOVAL, Reverse Check Sleeve.>
2) Remove the oil guide.
MT-00126
MT-00129
2. EXTENSION CASE
1) Remove the transfer drive gear assembly. <Ref.
to 5MT-48, REMOVAL, Transfer Drive Gear.>
5MT-46
2) Remove the shift bracket. 2) Install the reverse check sleeve assembly to
transfer case. <Ref. to 5MT-53, INSTALLATION,
Reverse Check Sleeve.>
MT-00130
3) Remove the oil seal from extension case. <Ref.

to 5MT-39, Oil Seal.>
D: ASSEMBLY
1. EXTENSION CASE
1) Using the ST, install the oil seal to extension
case. <Ref. to 5MT-39, Oil Seal.>
NOTE:
Use a new oil seal.
2) Install the shift bracket to extension case.
Tightening torque:
25 N"m (2.5 kgf-m, 18.4 ft-lb)
MT-00130
3) Install the transfer drive gear to extension case.

<Ref. to 5MT-48, INSTALLATION, Transfer Drive
Gear.>
2. TRANSFER CASE
1) Install the oil guide to transfer case.
Tightening torque:
6.4 N"m (0.65 kgf-m, 4.7 ft-lb)
MT-00129
5MT-47
Transfer Drive Gear
10.Transfer Drive Gear C: DISASSEMBLY

A: REMOVAL
from vehicle. <Ref. to 5MT-31, REMOVAL, Manual
es and Harness.>
assembly. <Ref. to 5MT-44, REMOVAL, Transfer
Case and Extension Case Assembly.>
4) Remove the extension case assembly. MT-00135
5) Remove the transfer driven gear. 2) Remove the ball bearing.
6) Remove the transfer drive gear.
MT-00136
MT-00133
D: ASSEMBLY
B: INSTALLATION 1) Set the ST applying to the inner race of bearing
1) Install the transfer drive gear. to install the drive shaft.
Tightening torque: ST 398177700 INSTALLER
26 N"m (2.7 kgf-m, 20 ft-lb) NOTE:
Do not apply pressure in excess of 10 kN (1 ton, 1.1
US ton, 1.0 Imp ton).
ST
MT-00133
2) Install the transfer driven gear.

3) Install the extension case assembly. MT-00137
4) Install the transfer case and extension case as- 2) Install the snap ring on transfer drive shaft.
sembly. <Ref. to 5MT-44, INSTALLATION, Trans- 3) Inspect the clearance between snap ring and
fer Case and Extension Case Assembly.> ball bearing. <Ref. to 5MT-48, INSPECTION,
5) Install the back-up light switch and neutral posi- Transfer Drive Gear.>
tion switch. <Ref. to 5MT-41, INSTALLATION,
Switches and Harness.> E: INSPECTION
6) Install the manual transmission assembly into 1) Bearings
vehicle. <Ref. to 5MT-33, INSTALLATION, Manual Replace the bearing in following cases:
Transmission Assembly.> • In case of broken or rusty bearings
• In case of worn or damaged bearings
• When the bearings fail to turn smoothly or emit
noise in rotation after gear oil lubrication.
5MT-48
Transfer Drive Gear
2) Drive gear
Replace the drive gear when their tooth surface
and shaft are excessively broken or damaged.
3) Measure the clearance between snap ring and
inner race of ball bearing with a thickness gauge.
Clearance:
0.01 — 0.15 mm (0.0004 — 0.0059 in)
MT-00138
If the measurement is not within specification, se-

lect a suitable snap ring and replace it.
Snap ring (Outer-30)
805030041 1.53 (0.0602)
805030042 1.65 (0.0650)
805030043 1.77 (0.0697)
5MT-49
Transfer Driven Gear
11.Transfer Driven Gear B: INSTALLATION

1) Install the bearing outer races to the extension
A: REMOVAL case and transfer case.
from vehicle. <Ref. to 5MT-31, REMOVAL, Manual (C)
(A)
es and Harness.>
4) Remove the extension case assembly.
5) Remove the transfer driven gear.
(B) (D)
MT-00118
MT-00141
6) Remove the bearing outer races from the exten-
sion case and transfer case. (A) Bearing outer race
(B) Bearing outer race
(C) Transfer case
(D) Extension case
(A)
2) Install the transfer driven gear.
(B)
MT-00118
3) Install the transfer case and extension case as-

sembly. <Ref. to 5MT-44, INSTALLATION, Trans-
fer Case and Extension Case Assembly.>
MT-00140 Switches and Harness.>
5) Install the manual transmission assembly into
(A) Bearing outer race (Transfer case side) vehicle. <Ref. to 5MT-33, INSTALLATION, Manual
(B) Bearing outer race (Extension case side) Transmission Assembly.>
5MT-50
Transfer Driven Gear
C: DISASSEMBLY 2) Using the ST, install the roller bearing (transfer

1) Using the ST, remove the roller bearing (exten- case side).
sion case side). ST 499757002 INSTALLER
ST 498077000 REMOVER NOTE:
ST
(A) ST
(A)
MT-00143
(A) Roller bearing

MT-00146
2) Using the ST1 and ST2, remove the roller bear-

(A) Roller bearing
ing (transfer case side).
ST1 498077000 REMOVER E: INSPECTION
ST2 899864100 REMOVER
1) Bearings
Replace the bearing in following cases:
• In case of broken or rusty bearings
ST2 • In case of worn or damaged bearings
(A)
ST1
2) Driven gear
Replace the drive gear when their tooth surface
and shaft are excessively broken or damaged.
MT-00144
(A) Roller bearing
D: ASSEMBLY
1) Using the ST, install the roller bearing (extension
case side).
NOTE:
ST2
(A) ST1
MT-00145
(A) Roller bearing
5MT-51
CONTROL SYSTEMS CS

(DIAGNOSTICS)


approval.

MANUAL TRANSMISSION
AND DIFFERENTIAL
5MT
Page
2. Transmission Gear Oil ..............................................................................30
3. Manual Transmission Assembly ...............................................................31
5. Oil Seal......................................................................................................39
7. Switches and Harness ..............................................................................41
8. Preparation for Overhaul...........................................................................43
9. Transfer Case and Extension Case Assembly..........................................44
10. Transfer Drive Gear ..................................................................................48
11. Transfer Driven Gear ................................................................................50
12. Center Differential .....................................................................................52
13. Reverse Check Sleeve..............................................................................53
14. Transmission Case ...................................................................................56
15. Main Shaft Assembly for Single-Range ....................................................62
16. Main Shaft Assembly for Dual-Range .......................................................67
17. Input Shaft Assembly ................................................................................73
19. Front Differential Assembly .......................................................................85
20. Reverse Idler Gear....................................................................................92
21. Shifter Fork and Rod .................................................................................94
22. Counter Gear ............................................................................................97
Center Differential
12.Center Differential D: ASSEMBLY

Install the ball bearing into center differential as-
A: REMOVAL sembly.
from vehicle. <Ref. to 5MT-31, REMOVAL, Manual NOTE:
Transmission Assembly.> Do not apply pressure in excess of 10 kN (1 ton, 1.1
2) Remove the transfer case with extension case US ton, 1.0 Imp ton).
3) Remove the extension case assembly. <Ref. to
5MT-44, REMOVAL, Transfer Case and Extension
Case Assembly.>
4) Remove the transfer driven gear. <Ref. to 5MT-
50, REMOVAL, Transfer Driven Gear.>
5) Remove the center differential.
B: INSTALLATION (A)
1) Install the center differential into transfer case. MT-00148

2) Install the transfer driven gear. <Ref. to 5MT-50,
INSTALLATION, Transfer Driven Gear.> (A) Ball bearing
3) Install the extension case assembly. <Ref. to
5MT-44, INSTALLATION, Transfer Case and Ex- E: INSPECTION
tension Case Assembly.> 1) Bearings
4) Install the transfer case with extension case as- Replace the bearing in following cases:
sembly. <Ref. to 5MT-44, INSTALLATION, Trans- • In case of broken or rusty bearings
fer Case and Extension Case Assembly.> • In case of worn or damaged bearings
5) Install the back-up light switch and neutral posi- • When the bearings fail to turn smoothly or emit
tion switch. <Ref. to 5MT-41, INSTALLATION, noise in rotation after gear oil lubrication.
Switches and Harness.> • When bearings have other defects.
6) Install the manual transmission assembly into 2) Center differential
vehicle. <Ref. to 5MT-33, INSTALLATION, Manual Replace the center differential case assembly if
Transmission Assembly.> worn or damaged.
C: DISASSEMBLY
NOTE:
Center differential is a non-disassembled part
which should not be disassembled.
Remove the ball bearing using ST.
NOTE:
Do not reuse the ball bearing.
ST 498077300 CENTER DIFFERENTIAL
BEARING REMOVER
ST
MT-00147
5MT-52
Reverse Check Sleeve
13.Reverse Check Sleeve 2) Install the ball, spring, washer and plug to trans-
fer case.
10 N!m (1.0 kgf-m, 7.4 ft-lb)
3) Remove the shifter arm.
4) Remove the plug, spring, washer and reverse
check ball.
MT-00149
3) Install the shifter arm to transfer case assembly.

4) Install the transfer case with extension case as-
vehicle. <Ref. to 5MT-33, INSTALLATION, Manual
MT-00149 Transmission Assembly.>
5) Remove the reverse check sleeve. C: DISASSEMBLY
1) Cover the reverse check sleeve with a rag, and
remove the snap ring using a screwdriver.
NOTE:
Replace the snap ring with a new one if it is de-
formed or reactive force is weakened.
(A)
MT-00150
B: INSTALLATION
1) Install the reverse check sleeve.
Tightening torque:
6.4 N!m (0.65 kgf-m, 4.7 ft-lb)
MT-00153
(A) Snap ring
MT-00150
5MT-53
2) Remove the reverse check plate, reverse check D: ASSEMBLY

spring, reverse check cam, return spring (5th-Rev), 1) Install the return spring (1st-2nd), return spring
reverse accent shaft, return spring cap and return cap, reverse accent shaft, check cam, return spring
spring (1st-2nd). (5th-Rev.) and reverse check spring onto reverse
check sleeve.
(A) NOTE:
(C) Be sure to position the bent section of reverse
check spring in the groove in check cam.
(B) (E)
(D) (G)
(A)
(F)
(C)
(B) (E)
MT-00154 (D) (G)
(A) Reverse check plate (F)

(B) Reverse check spring
(C) Return spring (5th-Rev)
(D) Reverse check cam MT-00154
(E) Reverse accent shaft

(A) Reverse check plate
(F) Return spring cap
(B) Reverse check spring
(G) Return spring (1st-2nd)
(C) Return spring (5th-Rev)
3) Remove the O-ring. (D) Reverse check cam
(E) Reverse accent shaft
NOTE:
• Visually check the O-ring. Replace if defective. (F) Return spring cap
• Be careful not to break adjustment shim placed (G) Return spring (1st-2nd)
between reverse check sleeve assembly and case. 2) Hook the bent section of reverse check spring
over reverse check plate.
3) Rotate the cam so that the protrusion of reverse
check cam is at the opening in plate.
4) With cam held in that position, install the reverse
check plate onto reverse check sleeve and hold
with snap ring.
5) Position the O-ring in the groove in sleeve.
5MT-54
E: INSPECTION • If the shims alone cannot adjust the clearance,

• Make sure the cutout of reverse accent shaft is replace the reverse accent shaft and re-adjust.
aligned with the opening in reverse check sleeve. Adjusting shim
• Check the cam for smooth rotation by turning Part Number Thickness mm (in)
with hand.
32190AA000 0.15 (0.0059)
• Make sure the cam and shaft move all the way
32190AA010 0.30 (0.0118)
toward plate and release.
If the cam does not return properly, replace the re-
verse check spring. If the shaft does not return, Reverse accent shaft
check for scratches on the inner surface of sleeve. Part No. Mark Remarks
If the sleeve is in good order, replace the spring. 32188AA090 3
Neutral position is
closer to 1st.
(D) Neutral position is
(C)
32188AA110 1
closer to reverse gear.
2. REVERSE CHECK PLATE ADJUST-

MENT
1) Shift the shifter arm to “5th” and then to reverse
(A) to see if reverse check mechanism operates prop-
(B) erly.
MT-00156
2) Also check to see if the arm returns to neutral
(A) Snap ring when released from the reverse position. If the arm
does not return properly, replace the reverse check
(B) Reverse check plate
plate.
(C) Checking spring
(D) Check cam Reverse check plate
(A): Angle
• Select a suitable reverse accent shaft and re- Part Number Remarks
No. "
verse check plate. <Ref. to 5MT-55, ADJUST- Arm stops closer to
MENT, Reverse Check Sleeve.> 32189AA000 0 28#
5th gear.
F: ADJUSTMENT 32189AA010 1 31#
Arm stops closer to
5th gear.
1. NEUTRAL POSITION ADJUSTMENT Arm stops in the cen-
32189AA020 2 34#
1) Shift the gear into 3rd gear position. ter.
2) Shifter arm turns lightly toward the 1st/2nd gear Arm stops closer to
32189AA030 3 37#
reverse gear.
side but heavily toward the reverse gear side be-
cause of the function of return spring, until arm con- Arm stops closer to
32189AA040 4 40#
reverse gear.
tacts the stopper.
3) Make adjustment so that the heavy stroke (re-
verse side) is a little more than the light stroke (1st/
2nd side).
4) To adjust, remove the bolts holding reverse
check sleeve assembly to the case, move the
sleeve assembly outward, and place the adjust-
ment shim between sleeve assembly and case to
adjust the clearance.
CAUTION:
Be careful not to break O-ring when placing (A)
shim(s). MT-00157
NOTE:
• When the shim is removed, the neutral position
will move closer to reverse; when the shim is add-
ed, the neutral position will move closer to 1st gear.
5MT-55
Transmission Case
14.Transmission Case 7) Remove the drive pinion shaft assembly from

the left side of transmission case.
A: REMOVAL NOTE:
1. SINGLE-RANGE MODEL Use a hammer handle, etc. to remove if too tight.
1) Remove the manual transmission assembly (A)
from vehicle. <Ref. to 5MT-31, REMOVAL, Manual (B)
2) Remove the clutch release lever. <Ref. to CL-
18, REMOVAL, Release Bearing and Lever.>
4) Remove the bearing mounting bolts.
MT-00161
(A) Main shaft ASSY for single-range

(B) Drive pinion shaft ASSY
8) Remove the main shaft assembly for single-

range.
9) Remove the differential assembly.
NOTE:
• Be careful not to confuse right and left roller
MT-00158
bearing outer races.
5) Remove the main shaft rear plate. • Be careful not to damage the oil seal of retainer.
(A)
MT-00159
MT-00162
(A) Main shaft rear plate 2. DUAL-RANGE MODEL

6) Separate the transmission case into the right 1) Remove the manual transmission assembly
and left cases by loosening coupling bolts and nuts. from vehicle. <Ref. to 5MT-31, REMOVAL, Manual
2) Remove the clutch release lever. <Ref. to CL-
18, REMOVAL, Release Bearing and Lever.>
MT-00160
5MT-56
Transmission Case
4) Remove the input shaft holder. 8) Separate the transmission case into right and
left cases by loosening the seventeen coupling
bolts and nuts.
(A)
(B)
MT-00163
(A) Input shaft holder MT-00160

(B) Input shaft
9) Remove the drive pinion shaft assembly from
5) Remove the high-low switch. <Ref. to 5MT-41, transmission case LH.
REMOVAL, Switches and Harness.> NOTE:
6) Using the ST, drive out the straight pin, and re- Use a hammer handle, etc. to remove if too tight.
move the high-low shifter lever.
ST 398791700 STRAIGHT PIN REMOVER 2 (B)
(A)
NOTE:
When driving out the straight pin, remove it in the
direction that it does not hit against transmission
case.
(A)
(B)
MT-00161
ST
(A) Main shaft ASSY for dual-range
10) Removing high-low shifter fork:

Raise the main shaft assembly slightly, and remove
MT-00164
the high-low shifter fork together with high-low
shifter shaft and washer.
(A) Straight pin
(B) High-low shifter lever NOTE:
Be careful not to drop the two high-low shifter piec-
7) Remove the main shaft rear plate. es.
(A)
MT-00165 (B) (A) MT-00169
(A) Main shaft rear plate (A) High-low shifter fork

(B) Input shaft ASSY
11) Remove the main shaft assembly and input

shaft assembly.
5MT-57
Transmission Case
NOTE: NOTE:
Be careful not to drop the input shaft and main shaft • Insert the bolts from the bottom and tighten nuts
as they are separable. on the top.
• Put the cases together being careful that the
(A) drive pinion shim and input shaft holder shim are
not caught up in between.
Tightening torque:
8 mm bolt
25 N!m (2.5 kgf-m, 18.1 ft-lb)
★ 10 mm bolt
39 N!m (4.0 kgf-m, 28.9 ft-lb)
(B) (16)
MT-00170 (17)
(9) (5) (7)
(A) Main shaft ASSY (11)

(13)
(B) Input shaft ASSY
(1) (3)
12) Remove the differential assembly. (2)
(15)
NOTE:
• Be careful not to confuse the right and left roller (4)
(14)
bearing outer races. (10) (6)
(8) (12)
MT-00172
• Be careful not to damage the retainer oil seal.
7) Tighten the ball bearing mounting bolts.
Tightening torque:
29 N!m (3.0 kgf-m, 21.7 ft-lb)
MT-00162
B: INSTALLATION
1. SINGLE-RANGE MODEL MT-00158
1) Wipe off grease, oil and dust on the mating sur- 8) Backlash adjustment of hypoid gear and preload
faces of transmission cases with white gasoline. adjustment of roller bearing:
2) Install the front differential assembly.
3) Install the main shaft assembly for single-range. NOTE:
Set the ST on drive pinion assembly.
Install the transmission case knock pin into needle
bearing knock pin hole. ST 498427100 STOPPER
4) Install the drive pinion shaft assembly.
Install the transmission case knock pin into roller
bearing knock pin hole.
5) Apply liquid gasket, and then put the case RH
and LH together.
Liquid gasket
THREE BOND 1215 (Part No. 004403007) or
equivalent
6) Tighten seventeen bolts with bracket, clip, etc. ST
as shown in the figure. MT-00174
9) Place the transmission with the left side of case

facing downward, and put ST1 on bearing cup.
5MT-58
Transmission Case
10) Screw the retainer assembly into left case from 15) Turn the transmission main shaft several times
the bottom with ST2. Fit the ST3 on transmission while tapping around retainer lightly with plastic
main shaft. Shift the gear into 4th or 5th and turn hammer.
the shaft several times. Screw in the retainer while 16) Inspect and adjust the backlash and tooth con-
turning ST3 until a slight resistance is felt on ST2. tact of hypoid gear. <Ref. to 5MT-88, INSPEC-
This is the contact point of hypoid gear and drive TION, Front Differential Assembly.>
pinion shaft. Repeat the above sequence several 17) After checking the tooth contact of hypoid
times to ensure the contact point. gears, remove the lock plate. Then loosen the re-
ST1 399780104 WEIGHT tainer until the O-ring groove appears. Fit O-ring
ST2 499787000 WRENCH ASSY into the groove and tighten the retainer into the po-
ST3 499927100 HANDLE sition where retainer has been tightened in.
Tighten the lock plate.
ST1 NOTE:
ST2 ST3 Carry out this job on both upper and lower retain-
ers.
Tightening torque:
T: 25 N!m (2.5 kgf-m, 18.4 ft-lb)
MT-00175
11) Remove the weight, and screw in the retainer

without O-ring on the upper side and stop at the
point where slight resistance is felt.
NOTE: T
At this condition, the backlash between hypoid gear
and drive pinion shaft is zero. MT-00177
ST 499787000 WRENCH ASSY 18) Selecting of main shaft rear plate: <Ref. to
5MT-66, ADJUSTMENT, Main Shaft Assembly for
ST Single-Range.>
19) Install the clutch release lever and bearing.
<Ref. to CL-18, INSTALLATION, Release Bearing
and Lever.>
MT-00176
12) Install the lock plate. Loosen the retainer on the
lower side by 1-1/2 notches from lock plate, and 2. DUAL-RANGE MODEL
turn the retainer on the upper side by the same 1) Wipe off grease, oil and dust on the mating sur-
amount in order to obtain the backlash. faces of transmission cases with white gasoline.
NOTE: 2) Install the front differential assembly.
The notch on the lock plate moves by 1/2 notch if 3) Install the main shaft assembly for dual-range
the plate is turned upside down. and the input shaft assembly.
13) Turn in the retainer on the upper side addition- Connect the main shaft assembly for dual-range
ally by 1 notch in order to apply preload on taper with the input shaft assembly, and install the trans-
roller bearing. mission case knock pin into needle bearing knock
14) Tighten temporarily both the upper and lower pin hole.
lock plates and mark both holder and lock plate for 4) Install the drive pinion shaft assembly.
later readjustment. Install the transmission case knock pin into roller
bearing knock pin hole.
5MT-59
Transmission Case
5) Apply liquid gasket, and then put the case right 8) Tighten the input shaft holder attaching bolts.
side and left side together.
Tightening torque:
Liquid gasket: 20 N!m (2.0 kgf-m, 14.5 ft-lb)
THREE BOND (Part No. 004403007) 1215 or
equivalent
6) Tighten the seventeen bolts with bracket, clip, (A)
etc. as shown in the figure.

NOTE:
• Insert the bolts from the bottom and tighten the (B)
nuts at the top.
• Put the cases together being careful that the
drive pinion shim and input shaft holder shim are
not caught up in between.
MT-00163
Tightening torque:
8 mm bolt (A) Input shaft holder
25 N!m (2.5 kgf-m, 18.1 ft-lb) (B) Input shaft
★ 10 mm bolt
9) Backlash adjustment of hypoid gear and preload
39 N!m (4.0 kgf-m, 28.9 ft-lb)
adjustment of roller bearing
(16) NOTE:
(9) (5) (7)
(17)
Set the ST to drive pinion assembly.
(13) (11) ST 498427100 STOPPER
(1)
(3)
(15) (2)
(4)
(14)
(10)
(6) (8) (12) MT-00178
7) Tighten the ball bearing mounting bolts.

Tightening torque: ST
29 N!m (3.0 kgf-m, 21.7 ft-lb) MT-00174
10) Place the transmission with the left side of case

facing downward, and put ST1 on bearing cup.
11) Screw the retainer assembly into left case from
the bottom using ST2. Fit the ST3 on transmission
main shaft. Shift the gear into 4th or 5th and turn
the shaft several times. Screw in the retainer while
turning ST3 until a slight resistance is felt on ST2.
This is the contact point of hypoid gear and drive
pinion shaft. Repeat the above sequence several
times to ensure the contact point.
MT-00158
5MT-60
Transmission Case
ST1 399780104 WEIGHT 18) After checking the tooth contact of hypoid
ST2 499787000 WRENCH ASSY gears, remove the lock plate. Then loosen the re-
ST3 499927100 HANDLE tainer until the O-ring groove appears. Fit the O-
ring into groove and tighten the retainer into the po-
ST1
sition where retainer has been tightened in.
Tighten the lock plate.
ST2 ST3
NOTE:
Carry out this job on both upper and lower retain-
ers.
Tightening torque:
T: 25 N!m (2.5 kgf-m, 18.4 ft-lb)
MT-00175
12) Remove the weight, and screw in the retainer

without O-ring on upper side and stop at the point
where slight resistance is felt.
NOTE:
In this condition, the backlash between hypoid gear
and drive pinion shaft is zero. T
MT-00177
ST 19) Selection of main shaft rear plate: <Ref. to

5MT-66, ADJUSTMENT, Main Shaft Assembly
for Single-Range.>
21) Install the clutch release lever and bearing.
<Ref. to CL-18, INSTALLATION, Release Bearing
MT-00176
and Lever.>
13) Fit the lock plate. Loosen the retainer on the vehicle. <Ref. to 5MT-33, INSTALLATION, Manual
lower side by 1-1/2 notches of lock plate and turn in Transmission Assembly.>
the retainer on upper side by the same amount in
order to obtain the backlash. C: INSPECTION
Check the transmission case for cracks, damage,
NOTE:
or oil leaks.
The notch on the lock plate moves by 1/2 notch if
the plate is turned upside down.
14) Turn in the retainer on the upper side addition-
ally by 1 notch in order to apply preload on taper
roller bearing.
15) Tighten temporarily both the upper and lower
lock plates and mark both holder and lock plate for
later readjustment.
16) Turn the transmission main shaft several times
while tapping around the retainer lightly with plastic
hammer.
17) Inspect and adjust the backlash and tooth con-
tact of hypoid gear. <Ref. to 5MT-88, INSPEC-
TION, Front Differential Assembly.>
5MT-61
Main Shaft Assembly for Single-Range
15.Main Shaft Assembly for Sin- C: DISASSEMBLY

gle-Range 1) Put the vinyl tape around main shaft splines to
protect oil seal from damage. Then pull out the oil
A: REMOVAL seal and needle bearing by hand.
1) Remove the manual transmission assembly 2) Remove the lock nut from transmission main
from vehicle. <Ref. to 5MT-31, REMOVAL, Manual shaft assembly for single range.
Transmission Assembly.> NOTE:
2) Remove the transfer case with extension case Unlock the caulking before removing lock nut.
assembly. <Ref. to 5MT-44, REMOVAL, Transfer ST1 498937000 TRANSMISSION HOLDER
ST2 499987003 SOCKET WRENCH (35)
3) Remove the transmission case. <Ref. to 5MT-
56, REMOVAL, Transmission Case.>
4) Remove the drive pinion shaft assembly. <Ref.
to 5MT-77, REMOVAL, Drive Pinion Shaft Assem-
bly.>
5) Remove the main shaft assembly for single
range.
B: INSTALLATION
1) Install the needle bearing and oil seal onto the
front of transmission main shaft assembly for single ST2 ST1
range. MT-00186
NOTE: 3) Remove the 5th-Rev sleeve & hub assembly,

• Wrap the clutch splined section with vinyl tape to baulk ring, 5th drive gear & needle bearing.
prevent damage to oil seal.
(C)
• Apply grease (UNILUBE #2 or equivalent) to the (B)
sealing lip of oil seal. (A)
• Use a new oil seal.
2) Install the transmission case knock pin into nee-
dle bearing outer race knock pin hole.
NOTE:
Align the end face of seal with surface (A) when in-
stalling oil seal.
MT-00187
(A) 5th-Rev sleeve & hub ASSY

(B) Baulk ring
(C) 5th drive gear
4) Remove the snap ring and synchro cone stopper

from 5th-Rev sleeve & hub assembly.
(A) (B)
MT-00185
(A)
3) Install the drive pinion assembly. <Ref. to 5MT-
77, INSTALLATION, Drive Pinion Shaft Assem-
bly.>
4) Install the transmission case. <Ref. to 5MT-58,
INSTALLATION, Transmission Case.>
sembly. <Ref. to 5MT-44, INSTALLATION, Trans- MT-00188
6) Install the manual transmission assembly into (A) Synchro cone stopper
vehicle. <Ref. to 5MT-33, INSTALLATION, Manual (B) Snap ring
5MT-62
5) Using the ST1, ST2 and a press, remove the ball ST1 899864100 REMOVER
bearing, synchro cone and baulk ring (Rev). ST2 899714110 REMOVER
NOTE:
(A)
• When replacing the sleeve & hub with new ones,
replace them as a set.
• Do not disassemble the sleeve & hub, because
the aligning position is specified.
• If it is necessary to disassemble, mark the en- ST1
gaging points on the splines beforehand.
• Do not reuse the ball bearing.
ST2 498077400 SYNCHRO CONE REMOV-
ER
ST1
(B) ST2
ST2
(A)
(C)
MT-00189 MT-00190
(A) Ball bearing (A) Push

(B) Synchro cone
(C) Baulk ring
D: ASSEMBLY
1) When the sleeve & hub assemblies have been
6) Using the ST1 and ST2, remove the rest of disassembled, reassemble with aligning each en-
parts. gaging point.
NOTE:
• When replacing the sleeve & hub with new ones,
replace them as a set.
• Do not disassemble the sleeve & hub, because
the aligning position is specified.
• If it is necessary to disassemble, mark the en-
5MT-63
NOTE: NOTE:
Position open ends of spring 120# apart. Align the groove in baulk ring with shifting insert.
4) Install the 4th needle bearing race onto trans-
mission main shaft using ST1, ST2 and a press.
(A)
NOTE:
ST2 499877000 RACE 4-5 INSTALLER
ST2
(B)
(A)
(C) ST1
MT-00192
(A) 4th needle bearing race

(D)
MT-00191
5) Install the baulk ring, needle bearing, 4th drive
gear and 4th gear thrust washer to transmission
(A) 3rd-4th hub ASSY main shaft.
(B) 3rd gear side NOTE:
(C) 5th-Rev hub ASSY Align the baulk ring and gear & hub assembly with
(D) 5th gear side key groove.
2) Install the 3rd drive gear, baulk ring, sleeve &
hub assembly for 3rd needle bearing, on the trans-
mission main shaft. (2.0 L model)
3) Install the 3rd drive gear, outer baulk ring, syn-
chro cone, inner baulk ring, sleeve & hub assembly
for 3rd needle bearing, on the transmission main
shaft. (2.5 L model) (A)
(A) (D) (E) (B)
MT-00193
(A) Groove
(B) 4th gear side
6) Press the ball bearing into the rear section of

transmission main shaft using ST1, ST2 and a
press.
(B) (C) (F)
MT-00200
NOTE:
(A) 3rd needle bearing
(B) 3rd drive gear
(C) Inner baulk ring
(D) Synchro cone
(E) Outer baulk ring
(F) Sleeve & hub ASSY
5MT-64
ST1 899714110 REMOVER ST 499757002 INSTALLER

ST
ST2
(A) (B) (C)
ST1
MT-00196
MT-00194
(A) Baulk ring
7) Using the ST1 and ST2, install the 5th gear
(B) Synchro cone
thrust washer and 5th needle bearing race onto the
rear section of transmission main shaft. (C) Ball bearing
NOTE: 10) Install the synchro cone stopper and snap ring
• Do not apply pressure in excess of 10 kN (1 ton, to 5th-Rev sleeve & hub assembly.
1.1 US ton, 1.0 Imp ton).
(B)
• Face the thrust washer in the correct direction.
(A)
(A)
MT-00188
(A) Synchro cone stopper

(B) Snap ring
MT-00195 11) Install the rest of parts to the rear section of
transmission main shaft.
(A) Face this surface to 5th gear side.
NOTE:
8) Install the bearing onto synchro cone. Align the groove in baulk ring with shifting insert.
9) Install the baulk ring and synchro cone onto 5th-
Rev sleeve & hub assembly using ST and a press. (A) (B) (C) (D)
NOTE:
• Do not apply pressure in excess of 10 kN (1 ton,
• Use new ball bearing. (E)
• Make sure the synchro cone rotates smoothly af- (F)
ter press-fitting.
MT-00198
(A) Needle bearing

(B) 5th drive gear
(C) Baulk ring
(D) 5th-Rev sleeve & hub ASSY
(E) Lock washer
(F) Lock nuts
5MT-65
12) Tighten the lock nuts to the specified torque us- 6) Oil seal
ing ST1 and ST2. Replace the oil seal if the lip is deformed, hard-
NOTE: ened, worn or defective in any way.
Caulk the lock nuts in two places after tightening. 7) O-ring
Replace the O-ring if the sealing face is deformed,
ST1 499987003 SOCKET WRENCH
hardened, damaged, worn or defective in any way.
ST2 498937000 TRANSMISSION HOLDER
8) Gearshift mechanism
Tightening torque: Repair or replace the gearshift mechanism if ex-
120 N!m (12.2 kgf-m, 88.5 ft-lb) cessively worn, bent or defective in any way.
E: INSPECTION F: ADJUSTMENT
Disassembled parts should be washed with un- Selection of main shaft rear plate:
leaded gasoline first and then inspected carefully. Using the ST, measure the amount (A) of ball bear-
1) Bearings ing protrusion from transmission main case sur-
Replace the bearing in following cases: face, and select a suitable plate in the following
• When the bearing balls, outer races and inner table.
races are broken or rusty. NOTE:
• When the bearing is worn. Before measuring, tap the end of main shaft with a
• When the bearings fail to turn smoothly or emit plastic hammer lightly in order to make the clear-
noise in rotation after gear oil lubrication. ance zero between the main case surface and
• When bearings have other defects. moving flange of bearing.
2) Bushing (each gear) ST 498147000 DEPTH GAUGE
Replace the bushings in following cases:
• When the sliding surface is damaged or abnor- Dimension (A)
Part Number Marking
mally worn. mm (in)
• When the inner wall is abnormally worn. 4.00 — 4.13
3) Gears (0.1575 — 32294AA041 1
0.1626)
• Replace gears with new ones if their tooth sur-
faces are broken, damaged or excessively worn. 3.87 — 3.99
(0.1524 — 32294AA051 2
• Correct or replace if the cone that contacts the
0.1571)
baulk ring is rough or damaged.
• Correct or replace if the inner surface or end face
(A)
is damaged.
4) Baulk ring
Replace the ring in following cases:
• When the inner surface and end face is dam-
aged.
• When the ring inner surface is abnormally or par-
tially worn.
• When contact surfaces of the synchronizer ring
insert have cracks or abnormally worn.
5) Shifting insert key MT-00209
Replace the insert key if deformed, excessively

worn or defective in any way.
(A)
MT-00989
(A) Insert key
5MT-66
Main Shaft Assembly for Dual-Range
16.Main Shaft Assembly for ST1 498937000 TRANSMISSION HOLDER

ST2 499987003 SOCKET WRENCH (35)
Dual-Range
A: REMOVAL
56, REMOVAL, Transmission Case.> ST2 ST1
MT-00186
to 5MT-77, REMOVAL, Drive Pinion Shaft Assem- 3) Remove the 5th-Rev sleeve & hub assembly,
bly.> baulk ring, 5th drive gear and needle bearing.
5) Remove the main shaft assembly and input shaft
assembly. (C)
(B)
(A)
B: INSTALLATION
1) Install the needle bearing onto the front of trans-
mission main shaft assembly.
2) Connect the main shaft assembly and input shaft
assembly.
4) Install the drive pinion assembly. <Ref. to 5MT- MT-00187
bly.> (A) 5th-Rev sleeve & hub ASSY
5) Install the transmission case. <Ref. to 5MT-58, (B) Baulk ring
INSTALLATION, Transmission Case.> (C) 5th drive gear
sembly. <Ref. to 5MT-44, INSTALLATION, Trans- 4) Remove the snap ring and synchro cone stopper
fer Case and Extension Case Assembly.> from 5th-Rev sleeve & hub assembly.
7) Install the manual transmission assembly to ve- (B)
hicle. <Ref. to 5MT-33, INSTALLATION, Manual
Transmission Assembly.> (A)
C: DISASSEMBLY
1) Put a vinyl tape around the main shaft splines to
protect oil seal from damage. Then pull out the oil
seal and needle bearing by hand.
2) Remove the lock nut from transmission main
shaft assembly.
MT-00188
NOTE:
Straighten the caulking before taking off lock nut. (A) Synchro cone stopper
(B) Snap ring
5) Using the ST1, ST2 and a press, remove the ball

bearing, synchro cone and baulk ring (Rev).
NOTE:
• When replacing the sleeve and hub with new
ones, replace them as a set.
• Do not disassemble the sleeve and hub, be-
cause the aligning position is specified.
5MT-67
• Do not reuse the ball bearing. 7) Remove the snap ring from main shaft.
ST1 499757002 INSTALLER ST 899474100 EXPANDER
ST2 498077400 SYNCHRO CONE REMOV-
ER
ST1
(B) ST2
(A)
(C) ST (A)
MT-00215
MT-00189
(A) Snap ring
8) Remove rest of the parts.

(A) Ball bearing
(B) Synchro cone
(C) Baulk ring
6) Using the ST1 and ST2, remove rest of the

parts. (G)
NOTE: (B) (F)
(E)
• When replacing the sleeve and hub with new (D)
(C)
ones, replace them as a set. (B)
• Do not disassemble the sleeve and hub, be-
cause the aligning position is specified. (A)
MT-00216
gaging points on the splines beforehand. (A) Sleeve & hub ASSY
ST1 899864100 REMOVER (B) High-low baulk ring
ST2 899714110 REMOVER (C) Friction damper
(D) Low input gear
(A) (E) Needle bearing
(F) Input low gear spacer
(G) Ball
ST1 D: ASSEMBLY
1) Assemble with aligning the matching mark if the
sleeve & hub assembly have been disassembled.
ST2
MT-00190
(A) Press
5MT-68
NOTE: NOTE:
Position the open ends of spring 120# apart. Align the groove in baulk ring with shifting insert.
4) Install the 4th needle bearing race onto trans-
(C) (B) (A) (F) (E) (I) (H) mission main shaft using ST1, ST2 and a press.
(G) (J) ST1 899714110 REMOVER
(D)
ST2
(A)
(K) (L) (M) (N) (O) (P) ST1

MT-00217
(A) High-low coupling sleeve

(B) Shifting insert
(C) High-low synchronizer spring MT-00201
(D) High-low synchronizer hub
(E) Sleeve (A) 4th needle bearing race
(F) Insert key 5) Install the baulk ring, needle bearing, 4th drive
(G) 3rd-4th synchronizer hub gear and 4th gear thrust washer to transmission
(H) Sleeve main shaft.
(I) Insert key
NOTE:
(J) 5th-Rev synchronizer hub
Face the thrust washer in correct direction.
(K) High side
(L) Low side
(M) 3rd side
(N) 4th side
(O) 5th side
(P) Rev side
2) Install the 3rd drive gear, baulk ring, sleeve & (A)
hub assembly for 3rd-4th needle bearing on trans-
mission main shaft. (2.0 L model) (B)
3) Install the 3rd drive gear, outer baulk ring, syn- MT-00193
chro cone, inner baulk ring, sleeve & hub assembly
for 3rd needle bearing, on the transmission main (A) Groove
shaft. (2.5 L model) (B) 4th gear side
(A) (D) (E) 6) Press-fit the ball bearing into the rear section of
transmission main shaft using ST1, ST2 and a
press.
NOTE:
(B) (C) (F)

MT-00200
(A) 3rd needle bearing

(B) 3rd drive gear
(C) Inner baulk ring
(D) Synchro cone
(E) Outer baulk ring
(F) Sleeve & hub ASSY
5MT-69
ST1 899714110 REMOVER ST 499757002 INSTALLER

ST
ST2
(A) (B) (C)
ST1
MT-00196
MT-00194
(A) Baulk ring
7) Using the ST1 and ST2, install the 5th gear
(B) Synchro cone
thrust washer and 5th needle bearing race onto the
rear section of transmission main shaft. (C) Ball bearing
NOTE: 10) Install the synchro cone stopper and snap ring
• Do not apply pressure in excess of 10 kN (1 ton, to 5th-Rev sleeve & hub assembly.
(B)
• Face the thrust washer in correct direction.
(A)
(A)
MT-00188
(A) Synchro cone stopper

(B) Snap ring
MT-00195 11) Install rest of the parts to the rear section of
transmission main shaft.
(A) Face this surface to 5th gear side.
NOTE:
8) Install the bearing onto synchro cone. Align the groove in baulk ring with shifting insert.
9) Install the baulk ring and synchro cone onto 5th-
Rev sleeve & hub assembly using ST and a press. (A) (B) (C) (D)
NOTE:
• Use a new ball bearing. (E)
• After press-fitting, make sure the synchro cone (F)
rotates freely.
MT-00198
(A) Needle bearing

(B) 5th drive gear
(C) Baulk ring
(D) 5th-Rev sleeve & hub ASSY
(E) Lock washer
(F) Lock nuts
5MT-70
12) Tighten the lock nuts to the specified torque us-

Snap ring
ing ST1 and ST2.
NOTE: 805025051 2.42 (0.0953)
Stake the caulking of lock nuts in two places after 805025052 2.47 (0.0972)
tightening.
805025053 2.52 (0.0992)
ST1 499987003 SOCKET WRENCH 805025054 2.57 (0.1012)
ST2 498937000 TRANSMISSION HOLDER 805025055 2.62 (0.1031)
Tightening torque: 805025056 2.67 (0.1051)
120 N!m (12.2 kgf-m, 88.5 ft-lb) 805025057 2.72 (0.1071)
13) Install the needle bearing on main shaft. 805025058 2.37 (0.0933)
14) Install rest of the parts to the front section of
transmission main shaft. E: INSPECTION
Disassembled parts should be washed with un-
NOTE:
leaded gasoline first and then inspected carefully.
• Be careful not to damage the graded section of
1) Bearings
transmission main shaft when installing the needle
bearing. Replace the bearings in following cases:
• Face the grooved side toward input gear. • Bearings balls, outer races and inner races are
broken or rusty.
• Align the high-low baulk ring’s groove with shift-
ing insert. • Worn bearings
• Bearings fail to turn smoothly or emit noise in ro-
tation after gear oil lubrication.
• Bearings having other defects
2) Bushing (each gear)
Replace the bushing in following cases:
(A) • When the sliding surface is damaged or abnor-
(F) (B) mally worn.
(C)
(D) • When the inner wall is abnormally worn.
(E)
(F) 3) Gears
• Replace the gears with new ones if their tooth
(G)
MT-00225 surfaces are broken, damaged or excessively
worn.
(A) Ball • Correct or replace if the cone that contacts the
(B) Input low gear spacer baulk ring is rough or damaged.
(C) Needle bearing • Correct or replace if the inner surface or end face
(D) Input low gear is damaged.
(E) Friction damper 4) Baulk ring
(F) High-low baulk ring
(G) Sleeve & hub ASSY
• When the inner surface and end face are dam-
aged.
15) Install a new snap ring to the rod section of • When the ring inner surface is abnormally or par-
transmission main shaft using ST1 and ST2. tially worn down.
NOTE: • When the contact surface of the synchronizer
Select a suitable outer snap ring so that axial clear- ring insert is scored or abnormally worn down.
ance between snap ring and hub is held within 5) Shifting insert key
0.060 to 0.100 mm (0.0024 to 0.0039 in). Replace the insert key if deformed, excessively
worn or defective in any way.
6) Oil seal
ST2 499757001 SNAP RING GUIDE
Replace the oil seal if the lip is deformed, hard-
ened, worn or defective in any way.
7) O-ring
hardened, damaged, worn or defective in any way.
Repair or replace the gearshift mechanism if ex-
cessively worn, bent or defective in any way.
5MT-71
F: ADJUSTMENT
Select a suitable main shaft rear plate. <Ref. to
5MT-66, ADJUSTMENT, Main Shaft Assembly
for Single-Range.>
5MT-72
Input Shaft Assembly
17.Input Shaft Assembly 2) Put a vinyl tape around the input shaft splines to
protect oil seal from damage.
A: REMOVAL 3) Remove the inner snap ring.
1) Remove the manual transmission assembly ST 398663600 PLIERS
to 5MT-77, REMOVAL, Drive Pinion Shaft Assem- ST
bly.>
5) Remove the main shaft assembly and input shaft MT-00227
assembly. 4) Hold the input shaft holder stationary and re-
B: INSTALLATION move the input shaft by tapping its end with a plas-
1) Install the needle bearing onto the front of trans- tic hammer.
mission main shaft assembly.
2) Connect the main shaft assembly and input shaft
assembly.
bly.>
INSTALLATION, Transmission Case.> (B) (A)
MT-00228
sembly. <Ref. to 5MT-44, INSTALLATION, Trans- (A) Input shaft holder
fer Case and Extension Case Assembly.> (B) Input shaft
7) Install the manual transmission assembly on the
vehicle. <Ref. to 5MT-33, INSTALLATION, Manual 5) Remove the outer snap ring. Then remove the
Transmission Assembly.> oil squeeze plate and straight pin.
C: DISASSEMBLY
1) Remove the O-ring from input shaft holder. Also,
remove the input shaft holder shim.
NOTE:
• Use a new O-ring. (A)
• Number of shims used varies from zero to two.
(B)
(B)
(A)
MT-00229
(A) Snap ring

(B) Oil squeeze plate
(C)
MT-00226
(A) Input shaft holder

(B) O-ring
(C) Input shaft holder shim
5MT-73
6) Remove the snap ring. 2) Install the snap ring on input shaft.
(A) (A)
MT-00230 MT-00230
(A) Snap ring (A) Snap ring
7) Using a press and ST, remove the ball bearing. 3) Inspect the clearance between ball bearing and
NOTE: snap ring. <Ref. to 5MT-75, INSPECTION, Input
Remove the inner snap ring before pressing. Shaft Assembly.>
4) Install the straight pin and oil squeeze plate to in-
ST 498077000 REMOVER put shaft.
ST
(A)
(B)
MT-00231
MT-00234
8) Remove the oil seal from input shaft holder.
(A) Straight pin
D: ASSEMBLY (B) Oil squeeze plate
1) Install the ball bearing onto input shaft.
NOTE: 5) Install the snap ring.
Place the snap ring between input shaft gear and 6) Install the oil seal into input shaft holder.
ball bearing beforehand. Use the table at 8) as a NOTE:
guide in selecting a suitable snap ring. Apply a coat of grease to sealing lips before install-
ST1 899580100 INSTALLER ing oil seal.
ST2 399513600 INSTALLER ST 398507703 DUMMY COLLAR
ST1
ST
ST2
MT-00232 MT-00235
5MT-74
7) Wind a vinyl tape around the shaft splines and E: INSPECTION

insert the input shaft into holder by lightly tapping it Disassembled parts should be washed clean first
by hand. with unleaded gasoline and then inspected careful-
ly.
1) Bearings
Replace the bearings in following cases:
(B)
• Bearing balls, outer races and inner races are
broken or rusty.
• Worn bearings
• Bearings fail to turn smoothly or emit noise in ro-
tation after gear oil lubrication.
(A)
• Bearings having other defects
MT-00236
Replace the bushing in following cases:
(A) Vinyl tape • When the sliding surface is damaged or abnor-
(B) Input shaft mally worn.
• When the inner wall is abnormally worn.
8) Install the snap ring to input shaft holder. 3) Gears
NOTE: • Replace the gears with new ones if their tooth
Select a suitable snap ring so that clearance be- surfaces are broken, damaged or excessively
tween snap ring and bearing is held within 0 to 0.12 worn.
mm (0 to 0.0047 in). • Correct or replace if the cone that contacts the
ST 398663600 PLIERS baulk ring is rough or damaged.
is damaged.
4) Baulk ring
• When the inner surface and end face are dam-
aged.
• When the ring inner surface is abnormally or par-
tially worn down.
ST • When the contact surface of the synchronizer
ring insert is scored or abnormally worn down.
MT-00227 5) Shifting insert key
Snap ring worn or defective in any way.
Part No. Thickness mm (in) 6) Oil seal
805168020 1.84 (0.0724) Replace the oil seal if the lip is deformed, hard-
805168030 1.92 (0.0756) ened, worn or defective in any way.
805168040 2.00 (0.0787) 7) O-ring
9) Install the O-ring to input shaft holder. hardened, damaged, worn or defective in any way.
(A)
cessively worn, bent or defective in any way.
9) Measure the clearance between snap ring and
ball bearing using thickness gauge.
(B)
MT-00238
(A) O-ring
(B) Input shaft holder
5MT-75
Clearance:
0 — 0.12 mm (0 — 0.0047 in)
(A)
MT-00239
(A) Snap ring

lect a suitable snap ring.
Snap ring
805028050 2.48 (0.0976)
805028060 2.56 (0.1008)
805028070 2.64 (0.1039)
5MT-76
18.Drive Pinion Shaft Assembly NOTE:

• Loosen the two bolts and adjust so that the scale
A: REMOVAL indicates 0.5 correctly when the plate end and the
1) Remove the manual transmission assembly scale end are on the same level.
from vehicle. <Ref. to 5MT-31, REMOVAL, Manual • Tighten the two bolts.
Transmission Assembly.> ST 499917500 DRIVE PINION GAUGE
2) Remove the transfer case with extension case ASSY
Case and Extension Case Assembly.> (A)
4) Remove the drive pinion shaft assembly.
NOTE:
Use a hammer handle, etc. to remove if too tight.
(A)
(B)
ST (B)
MT-00242
(A) Plate
(B) Scale
5) Position the ST by inserting the knock pin of ST

into the knock hole in the transmission case.
ST 499917500 DRIVE PINION GAUGE
MT-00161
ASSY
(A) Main shaft ASSY
6) Slide the drive pinion gauge scale with finger tip
and read the value at the point where it matches
with the end face of drive pinion.
B: INSTALLATION ST 499917500 DRIVE PINION GAUGE
ASSY
1) Remove the differential assembly.
2) Alignment marks/numbers on hypoid gear set:
Use hypoid driven gear of its match number corre- ST
(A)
sponding with upper one on the drive pinion (A).
The figure (B) shows a number for shim adjust-
ment. If no number is shown, the value is zero.
(A)
MT-00243
+0
.1
(A) Adjust clearance to zero without shim.
(B) 7) The thickness of shim shall be determined by

(A) adding the value indicated on drive pinion to the
MT-00990 value indicated on the ST. (Add if the number on
drive pinion is prefixed by +, and subtract if the
(A) Match number number is prefixed by $.)
(B) Number for shim adjustment ST 499917500 DRIVE PINION GAUGE
ASSY
3) Place the drive pinion shaft assembly on the
transmission main case RH without shim and tight-
en the bearing mounting bolts.
4) Inspection and adjustment of ST:
5MT-77
8) Select one to three shims in the next table for the 2) Draw out the drive pinion from driven shaft.
value determined as described above, and take the Remove the differential bevel gear sleeve, adjust-
shim(s) which thickness is closest to the said value. ing washer No. 1, adjusting washer No. 2, thrust
bearing, needle bearing and drive pinion collar.
Drive pinion shim
Part Number Thickness mm (in) (F)
(E)
32295AA031 0.150 (0.0059) (G)
(H)
32295AA041 0.175 (0.0069)
32295AA051 0.200 (0.0079)
32295AA061 0.225 (0.0089)
32295AA071 0.250 (0.0098)
32295AA081 0.275 (0.0108)
(A)
32295AA091 0.300 (0.0118) (B)
32295AA101 0.500 (0.0197) (C)
(D) MT-00245
9) Install the differential assembly. <Ref. to 5MT-
85, INSTALLATION, Front Differential Assembly.> (A) Differential bevel gear sleeve
10) Set the transmission main shaft assembly and (B) Washer No. 1 (25 % 37.5 % t)
drive pinion assembly in position. (So there is no (C) Thrust bearing (25 % 37.5 % 3)
clearance between these two when moved all the (D) Washer No. 2 (25 % 37.5 % 4)
way to the front). Inspect the suitable 1st — 2nd, (E) Needle bearing (25 % 30 % 20)
3rd — 4th and 5th shifter fork so that the coupling (F) Drive pinion collar
sleeve and reverse driven gear are positioned in (G) Needle bearing (30 % 37 % 23)
the center of their synchronizing mechanisms. (H) Thrust bearing (33 % 50 % 3)
<Ref. to 5MT-82, INSPECTION, Drive Pinion Shaft
Assembly.> 3) Remove the roller bearing and washer using ST
11) Install the transmission case. <Ref. to 5MT-58, and press.
INSTALLATION, Transmission Case.> NOTE:
12) Install the transfer case with extension case as- Do not reuse the roller bearing.
fer Case and Extension Case Assembly.> ST 498077000 REMOVER
13) Install the manual transmission assembly to ve-
hicle. <Ref. to 5MT-31, Manual Transmission As-
sembly.>
C: DISASSEMBLY
NOTE:
Attach a cloth to the end of driven shaft (on the fric-
tional side of thrust needle bearing) to prevent
damage during disassembly or reassembly. ST
1) Unlock the caulking of lock nut. Remove the lock MT-00246

nut using ST1, ST2 and ST3.
ST1 899884100 HOLDER 4) Unlock the caulking of lock nut. Remove the lock
ST2 498427100 STOPPER nut using ST1 and ST2.
ST3 899988608 SOCKET WRENCH (27) ST1 499987300 SOCKET WRENCH (50)
ST2 899884100 HOLDER
ST1
ST2 ST1
ST2
ST3
MT-00244
MT-00247
5MT-78
5) Remove the 5th driven gear using ST. 10) Remove the 1st driven gear, 2nd gear bushing,
ST 499857000 5TH DRIVEN GEAR REMOV- gear and hub using ST1 and ST2.
ER
(A) (B) (C)
ST
(D)
MT-00991
MT-00248
(A) 1st driven gear
6) Remove the woodruff key.
(B) Inner baulk ring
7) Remove the roller bearing and 3rd-4th driven
(C) Hub
gear using ST1 and ST2.
ST1 499757002 INSTALLER (D) 2nd gear bushing
NOTE:
Replace the gear and hub if necessary. Do not dis-
assemble because they must engage at a specified
ST1 point. If they have to be disassembled, mark the
engaging point on the spline beforehand.
ST2 ST1 499757002 INSTALLER
ST1
MT-00249
8) Remove the key.

9) Remove the 2nd driven gear, inner baulk ring,
synchro cone and outer baulk ring. ST2
(D) (A)
MT-00251
D: ASSEMBLY
1) Install the sleeve and hub assembly by matching
alignment marks.
(C) (B)
MT-00997
(A) 2nd driven gear

(C) Synchro cone
(D) Outer baulk ring
5MT-79
NOTE: • When press-fitting, align the oil holes of shaft and

Use the new gear and hub assembly, when replac- bushing.
ing the gear or hub. ST1 499277200 INSTALLER
(A) (B)
(C) ST1
(D)
ST2
MT-00252
MT-00253
(A) 1st gear side
6) Install the 2nd driven gear, inner baulk ring, syn-
(B) 2nd gear side chro cone and outer baulk ring, and insert onto driv-
(C) Flush surface en shaft.
(D) Stepped surface
(D) (A)
2) Install the washer to 1st driven gear. (EC, EK
and KA model)
3) Install the washer, snap ring and sub gear onto
1st driven gear. (Except for EC, EK and KA model)
4) Install the 1st driven gear, 1st baulk ring, gear
and hub assembly onto driven shaft.
(A) (B) (C)

(C) (B)
MT-00997
(A) 2nd driven gear

(C) Synchro cone
(D) Outer baulk ring
(D) 7) After installing the key on driven shaft, install the

MT-00991 3rd-4th driven gear using ST and press.
(A) 1st driven gear NOTE:
(B) 1st baulk ring • Do not apply pressure in excess of 10 kN (1 ton,
(C) Gear and hub ASSY
• Align the groove in baulk ring with insert.
(D) 2nd gear bushing
NOTE:
• Take care to install the gear and hub assembly in
proper direction.
• Align the baulk ring and gear and hub assembly
with key groove.
ST
5) Install the 2nd driven gear bushing onto driven
shaft using ST1, ST2 and a press.
NOTE:
1.1 US ton, 1.0 Imp ton). MT-00255
• Attach a cloth to the end of driven shaft to pre-
8) Install a set of roller bearings onto the driven
vent damage.
shaft using ST and press.
5MT-80
NOTE: • Using a spring balancer, check that starting

Do not apply pressure in excess of 10 kN (1 ton, 1.1 torque of roller bearing is 0.1 to 1.5 N (0.01 to 0.15
US ton, 1.0 Imp ton). kgf, 0.02 to 0.33 ft).
ST
MT-00259
MT-00256 11) Install the roller bearing onto drive pinion.

9) Position the woodruff key in groove on the rear NOTE:
of driven shaft. Install the 5th driven gear onto driv- When installing roller bearing, note its directions
en shaft using ST and press. (front and rear) because the knock pin hole in outer
NOTE: race is offset.
US ton, 1.0 Imp ton). (A)
ST
(B) MT-00260
(A) Roller bearing

MT-00257
(B) Knock pin hole
10) Install the lock washer. Install the lock nut and 12) Install the washer using ST1, ST2 and a press.
tighten to the specified torque using ST. NOTE:
ST 499987300 SOCKET WRENCH (50) Do not apply pressure in excess of 10 kN (1 ton, 1.1
Tightening torque: US ton, 1.0 Imp ton).
260 N!m (26.5 kgf-m, 191.7 ft-lb) ST1 499277100 BUSHING 1-2 INSTALLER
ST
ST2
ST1
(A)
MT-00258
MT-00261
NOTE:
• Stake the caulking of lock nut at two points. (A) Washer
5MT-81
13) Install the thrust bearing and needle bearing. • The ball bearing on the rear side of the drive pin-
Install the driven shaft assembly. ion shaft should be checked for smooth rotation be-
fore the drive pinion assembly is disassembled. In
this case, because a preload is working on the
bearing, its rotation feels like it is slightly dragging
unlike other bearings.
(A)
MT-00262
14) Install the drive pinion collar, needle bearing,

adjusting washer No. 2, thrust bearing, adjusting (B)
washer No. 1 and differential bevel gear sleeve in
MT-00264
this order.
NOTE: (A) Drive pinion shaft
Be careful because the spacer must be installed in (B) Ball bearing
proper direction.
• When bearings have other defects:
(A) (B)
Replace the bushings in following cases:
• When the sliding surface is damaged or abnor-
mally worn.
• When the inner wall is abnormally worn.
3) Gears
• Replace gears with new ones if their tooth sur-
faces are broken, damaged, or excessively worn.
(C) (D) (E) (F) (G) (H) • Correct or replace if the cone that contacts the
MT-00263 baulk ring is rough or damaged.
(A) Driven shaft is damaged.
(B) Drive shaft 4) Baulk ring
(C) Drive pinion collar Replace the ring in following cases:
(D) Needle bearing (25 % 30 % 20) • When the inner surface and end face are dam-
(E) Washer No. 2 (25 % 36 % 4) aged.
(F) Thrust bearing (25 % 37.5 % 3) • When the ring inner surface is abnormally or par-
(G) Washer No. 1 (25 % 36 % t) tially worn.
(H) Differential bevel gear sleeve • If the gap between the end faces of ring and the
gear splined part is excessively small, check the
15) Adjust the thrust bearing preload. <Ref. to clearance (A) while pressing the ring against the
5MT-83, THRUST BEARING PRELOAD, AD- cone.
JUSTMENT, Drive Pinion Shaft Assembly.>
E: INSPECTION
Disassembled parts should be washed with un-
leaded gasoline first and then inspected carefully.
1) Bearings
Replace the bearing in following cases:
• When the bearing balls, outer races and inner
races are broken or rusty.
• When the bearing is worn.
5MT-82
Clearance (A): F: ADJUSTMENT

0.5 — 1.0 mm (0.020 — 0.040 in)
1. THRUST BEARING PRELOAD
(A) 1) Select a suitable adjusting washer No. 1 to ad-
just dimension (H) to zero through visual check.
Position the washer (18.3 % 30 % 4) and lock washer
(18 % 30 % 2) and install the lock nut (18 % 13.5).
MT-00265
• When the contact surface of synchronizer ring in-

sert is scratched or abnormally worn.
5) Shifting insert key
worn, or defective in any way.
(A)
(H)
MT-00989 MT-00267
(A) Insert key 2) Using the ST1, ST2 and ST3, tighten new lock
nut to the specified torque.
6) Oil seal ST1 899884100 HOLDER
Replace the oil seal if the lip is deformed, hard- ST2 498427100 STOPPER
ened, worn, or defective in any way. ST3 899988608 SOCKET WRENCH (27)
7) O-ring
Replace the O-ring if the sealing face is deformed, Tightening torque:
hardened, damaged, worn, or defective in any way. 120 N!m (12.2 kgf-m, 88.5 ft-lb)
ST1
ST2
ST3
MT-00268
5MT-83
3) After removing the ST2, measure the starting 5) When the specified starting torque cannot be ob-
torque using torque driver. tained by the adjusting washer No. 1, select the ad-
ST1 899884100 HOLDER justing washer No. 2 from following table. Repeat
ST3 899988608 SOCKET WRENCH (27) steps 1) through 4) to adjust starting torque.
Starting torque:
0.3 — 0.8 N!m (0.03 — 0.08 kgf-m, 0.2 — 0.6 ft-
lb)
ST1
ST3
(A)
(B)
MT-00270
(A) Adjusting washer No. 1

(B) Adjusting washer No. 2
MT-00269
4) If the starting torque is not within specified limit, Starting torque Dimension H Washer No. 2
select new adjusting washer No. 1 and recheck Low Small Select thicker one.
starting torque. High Large Select thinner one.

803025059 3.850 (0.1516)
803025054 4.000 (0.1575)
803025058 4.150 (0.1634)
6) Recheck that the starting torque is within speci-

(A) fied range, then clinch the lock nut at four positions.
(B)
MT-00270
(A) Adjusting washer No. 1

(B) Adjusting washer No. 2

803025051 3.925 (0.1545)
803025052 3.950 (0.1555)
803025053 3.975 (0.1565)
803025054 4.000 (0.1575)
803025055 4.025 (0.1585)
803025056 4.050 (0.1594)
803025057 4.075 (0.1604)
5MT-84
19.Front Differential Assembly 3) Install the differential assembly.

NOTE:
A: REMOVAL Be careful not to fold the sealing lip of oil seal.
4) Removes the drive pinion shaft assembly. <Ref.
bly.> MT-00162
5) Remove the main shaft assembly.
• Single-range model 4) Install the main shaft assembly.
<Ref. to 5MT-62, REMOVAL, Main Shaft Assembly • Single-range model
for Single-Range.> <Ref. to 5MT-62, INSTALLATION, Main Shaft As-
• Dual-range model sembly for Single-Range.>
<Ref. to 5MT-67, REMOVAL, Main Shaft Assembly • Dual-range model
for Dual-Range.> <Ref. to 5MT-67, INSTALLATION, Main Shaft As-
6) Remove the differential assembly. sembly for Dual-Range.>
NOTE: 77, INSTALLATION, Drive Pinion Shaft Assem-
• Be careful not to confuse right and left roller bly.>
bearing outer races. 6) Install the transmission case. <Ref. to 5MT-58,
• Be careful not to damage the oil seal of retainer. INSTALLATION, Transmission Case.>
MT-00162
7) Remove the differential side retainers using ST.

ST
MT-00176
B: INSTALLATION
1) Install the differential side retainers using ST.
2) Install the bearing outer race on transmission
case.
5MT-85
C: DISASSEMBLY 3) Pull out the pinion shaft, and remove the differ-
ential bevel pinion, bevel gear and washer.
(B)
(D)
1) Loosen the twelve bolts and remove hypoid driv- (C)
en gear. (A) (C) (D)
(B)
(A)
MT-00277
(A) Pinion shaft

(B) Bevel pinion
(C) Bevel gear
(D) Washer
4) Using the ST, remove the roller bearing.

ST 899524100 PULLER SET
MT-00275
ST
2) Drive out the straight pin from differential assem- MT-00278

bly toward hypoid driven gear side.
ST 899904100 REMOVER 2. SIDE RETAINER
ST
MT-00276
MT-00279
5MT-86
2) Remove the oil seal. Standard backlash

NOTE: 0.13 — 0.18 mm (0.0051 — 0.0071 in)
Do not reuse the oil seal. Replace with a new oil
seal.
ST2
ST1
MT-00285
3) Align the pinion shaft and differential case at

MT-00363 their holes, and drive the straight pin into holes
from the hypoid driven gear side, using ST.
D: ASSEMBLY
NOTE:
1. DIFFERENTIAL CASE ASSEMBLY Lock the straight pin after installing.
1) Install the bevel gear and bevel pinion together ST 899904100 REMOVER
with washers, and insert the pinion shaft.
NOTE:
Face the chamfered side of washer toward gear. (A)
(C)
(B) (B)
MT-00286
(A)
(A) Pinion shaft

(C) (B) Differential case
MT-00284
(C) Straight pin
(A) Bevel pinion 4) Install the roller bearing to differential case.
(B) Bevel gear
NOTE:
(C) Pinion shaft
2) Measure the backlash between bevel gear and 1.1 US ton, 1.0 Imp ton).
pinion. If it is not within specifications, install a suit- • Be careful because the roller bearing outer races
able washer to adjust. <Ref. to 5MT-89, ADJUST- are used as a set.
MENT, Front Differential Assembly.> ST1 499277100 BUSHING 1-2 INSTALLER
NOTE: ST2 398497701 ADAPTER
Be sure the pinion gear teeth contacts adjacent
gear teeth during measurement.
ST1
ST2
MT-00287
5MT-87
5) Install the hypoid driven gear to differential case E: INSPECTION

using twelve bolts. Repair or replace the differential gear in following
Tightening torque: cases:
T: 62 N!m (6.3 kgf-m, 45.6 ft-lb) • When the hypoid drive gear and drive pinion
shaft tooth surface are damaged, excessively worn
or seized.
(A)
• When the roller bearing on the drive pinion shaft
is worn or damaged.
• When there is damage, wear or seizure of the dif-
ferential bevel pinion, differential bevel gear, wash-
er, pinion shaft and straight pin.
• When the differential case sliding surfaces is
worn or damaged.
T
(B)
MT-00993
(A)
(B) Differential case
(G)
2. SIDE RETAINER (E)
(F)
1) Install a new oil seal. (F)
ST 18675AA000 DIFFERENTIAL SIDE OIL (E)
SEAL INSTALLER (H) (B) (C)
(G)
(D)
ST
MT-00289 (I) (H)

MT-00291
NOTE:
• For press-fitting of oil seal to retainer, make tap- (A) Drive pinion shaft
ping with plastic hammer etc. (B) Hypoid driven gear
• Do not use press. (C) Pinion shaft
2) Install a new O-ring. (D) Straight pin
NOTE: (E) Washer
Do not stretch or damage the O-ring. (F) Differential bevel gear
(G) Differential bevel pinion
(H) Roller bearing
(I) Differential case
1. BEVEL PINION GEAR BACKLASH

Measure the backlash between bevel gear and pin-
ion. If it is not within specifications, install a suitable
washer to adjust.
NOTE:
MT-00279 Be sure the pinion gear teeth contacts adjacent
gear teeth during measurement.
5MT-88
Standard backlash 3. TOOTH CONTACT OF HYPOID GEAR

0.13 — 0.18 mm (0.0051 — 0.0071 in)
Check tooth contact of hypoid gear as follows: Ap-
ply a uniform thin coat of red lead on both tooth sur-
faces of 3 or 4 teeth of the hypoid gear. Move the
hypoid gear back and forth by turning the transmis-
ST2
sion main shaft until a definite contact pattern is de-
veloped on hypoid gear, and judge whether face
contact is correct. If it is inaccurate, make adjust-
ment. <Ref. to 5MT-89, ADJUSTMENT, Front Dif-
ferential Assembly.>
ST1
• Tooth contact is correct.
MT-00285
(A)
2. HYPOID GEAR BACKLASH
1) Set the ST1, ST2 and ST3. Insert the needle
through transmission oil drain plug hole so that the
needle comes in contact with the tooth surface on
the right corner and check the backlash.
(D) (C) (B)
ST3 498255400 PLATE MT-00294
2) Install the SUBARU genuine axle shafts to both
side, rotate in the inversion direction so that the (A) Toe
gauge contact with the tooth surface and read the (B) Coast side
dial gauge. (C) Heel
Part No. 38415AA100 AXLE SHAFT (D) Drive side
Backlash
0.13 — 0.18 mm (0.0051 — 0.0071 in)
F: ADJUSTMENT
1. BEVEL PINION GEAR BACKLASH
1) Disassemble the front differential. <Ref. to 5MT-
85, REMOVAL, Front Differential Assembly.>
ST3 ST2 2) Select a different washer from the table and in-
stall.
Washer
0.925 — 0.950
803038021
ST1 (0.0364 — 0.0374)
MT-00293 0.975 — 1.000
803038022
NOTE: (0.0384 — 0.0394)
If the backlash is outside the specified range, ad- 1.025 — 1.050
803038023
just it by turning the side retainer in right side case. (0.0404 — 0.0413)
3) Adjust until the standard value is obtained.

Backlash:
Standard
0.13 — 0.18 mm (0.0051 — 0.0071 in)
5MT-89
2. HYPOID GEAR BACKLASH • Face contact

Checking item: Backlash is too large.
Adjust the backlash by turning holder in the right
side case. Contact pattern
ST
AT-00208
MT-00176 Corrective action: Reduce thickness of pinion

NOTE: ion closer to driven gear.
Each time the side retainer rotates one notch,
backlash changes by 0.05 mm (0.020 in).
0.05mm(0.0020 in)
AT-00212
MT-00296
• Flank contact
Checking item: Backlash is too small.
3. TOOTH CONTACT OF HYPOID GEAR Contact pattern
1) Adjust until correct teeth contact is obtained.
2) Check tooth contact as follows.
• Tooth contact
Checking item: Tooth contact pattern is slightly
shifted to toe side under no-load rotation.
[When loaded, contact pattern moves toward
heel.]
(A)
AT-00209

(B)
AT-00207
(A) Toe side

(B) Heel side
AT-00213
5MT-90
• Toe contact (inside end contact)

Contact pattern
AT-00210

ion closer to driven gear.
AT-00213
• Heel contact (outside end contact)

Contact pattern
AT-00211

AT-00212
5MT-91
Reverse Idler Gear
20.Reverse Idler Gear B: INSTALLATION

1) Install the reverse shifter lever, reverse idler
A: REMOVAL gear and reverse idler gear shaft, and secure them
1) Remove the manual transmission assembly with straight pin.
2) Remove the back-up light switch and neutral po- Be sure to install the reverse idler shaft from rear
sition switch. <Ref. to 5MT-41, REMOVAL, Switch- side.
es and Harness.>
Case and Extension Case Assembly.> (A)
(D) (B)
77, REMOVAL, Drive Pinion Shaft Assembly.>
bly.> (C)
6) Remove the main shaft assembly.
MT-00304
• Single-range model
<Ref. to 5MT-62, REMOVAL, Main Shaft Assembly (A) Reverse shifter lever
for Single-Range.> (B) Reverse idler gear
• Dual-range model
(C) Reverse idler gear shaft
<Ref. to 5MT-67, REMOVAL, Main Shaft Assembly
(D) Straight pin
for Dual-Range.>
7) Remove the differential assembly. <Ref. to 5MT- 2) Inspect and adjust the clearance between re-
85, REMOVAL, Front Differential Assembly.> verse idler gear and transmission case wall. <Ref.
8) Remove the shifter forks and rods. <Ref. to 5MT- to 5MT-92, INSTALLATION, Reverse Idler Gear.>
94, REMOVAL, Shifter Fork and Rod.> <Ref. to 5MT-93, ADJUSTMENT, Reverse Idler
9) Pull out the straight pin, and remove the idler Gear.>
gear shaft, reverse idler gear and washer. 3) Install the shifter forks and rods. <Ref. to 5MT-
94, INSTALLATION, Shifter Fork and Rod.>
4) Install the differential assembly. <Ref. to 5MT-
(B) 85, INSTALLATION, Front Differential Assembly.>
5) Install the main shaft assembly.
(A) (C) • Single-range model
<Ref. to 5MT-62, INSTALLATION, Main Shaft As-
sembly for Single-Range.>
(D) • Dual-range model
<Ref. to 5MT-67, INSTALLATION, Main Shaft As-
sembly for Dual-Range.>
MT-00303
6) Install the drive pinion shaft assembly. <Ref. to
(A) Straight pin
5MT-77, INSTALLATION, Drive Pinion Shaft As-
sembly.>
(B) Reverse idler gear shaft
(C) Reverse idler gear
INSTALLATION, Transmission Case.>
(D) Washer
10) Remove the reverse shifter lever. sembly. <Ref. to 5MT-44, INSTALLATION, Trans-
Switches and Harness.>
5MT-92
Reverse Idler Gear
C: INSPECTION Clearance A:
1) Move the reverse shifter rod toward reverse 6.0 — 7.5 mm (0.236 — 0.295 in)
side. Inspect the clearance between reverse idler
gear and transmission case wall.
If out of specification, select an appropriate reverse
shifter lever and adjust.
Clearance A:
6.0 — 7.5 mm (0.236 — 0.295 in)
A
MT-00305
Reverse shifter lever

A 32820AA070 7 Further from case wall
32820AA090 9 Closer to case wall
MT-00305
2) After installing a suitable reverse shifter lever, 2) Select an appropriate washer from the table be-
shift into neutral. Inspect the clearance between re- low, and adjust until the gap between the reverse
verse idler gear and transmission case wall. idler gear and transmission case wall is within
If out of specification, select an appropriate washer specification.
and adjust. Clearance:
Clearance: 0 — 0.5 mm (0 — 0.020 in)
0 — 0.5 mm (0 — 0.020 in)
MT-00306
MT-00306
Washer
3) Check the reverse idler gear and shaft for dam- Part Number Thickness mm (in)
age. Replace if it is damaged. 803020151 0.4 (0.016)
D: ADJUSTMENT 803020152 1.1 (0.043)
1) Select an appropriate reverse shifter lever from 803020153 1.5 (0.059)
the table below, and adjust until the gap between 803020154 1.9 (0.075)
reverse idler gear and transmission case wall is 803020155 2.3 (0.091)
within specification.
5MT-93
Shifter Fork and Rod
21.Shifter Fork and Rod ST 398791700 STRAIGHT PIN REMOVER
A: REMOVAL (C)
es and Harness.>
Case and Extension Case Assembly.> (A) (B) MT-00994
4) Remove transmission case. <Ref. to 5MT-56,
REMOVAL, Transmission Case.> (A) Straight pin
5) Removes the drive pinion shaft assembly. <Ref. (B) 3-4 fork rod
to 5MT-77, REMOVAL, Drive Pinion Shaft Assem- (C) Shifter fork
bly.>
11) Drive out the straight pin tapping by ST, and
6) Remove the main shaft assembly. pull out the 1-2 fork rod and shifter fork.
• Single-range model ST 398791700 STRAIGHT PIN REMOVER
<Ref. to 5MT-62, REMOVAL, Main Shaft Assembly 12) Remove the outer snap ring, and pull out re-
for Single-Range.> verse fork rod from reverse shifter rod arm. Then
• Dual-range model take out the ball, spring and interlock plunger from
<Ref. to 5MT-67, REMOVAL, Main Shaft Assembly rod.
for Dual-Range.> And then remove the rod.
7) Remove the differential assembly. <Ref. to 5MT-
85, REMOVAL, Front Differential Assembly.> NOTE:
8) Drive out the straight pin tapping by ST, and pull When pulling out reverse shifter rod arm, be careful
out the 5th shifter fork. not to let ball pop out of arm.
ST 398791700 STRAIGHT PIN REMOVER 13) Remove the reverse shifter lever.
B: INSTALLATION
1) Install the reverse arm fork spring, ball and inter-
lock plunger to reverse fork rod arm. Insert the re-
verse fork rod into the hole in reverse fork rod arm,
and hold it with outer snap ring using ST.
NOTE:
Apply a coat of grease to plunger to prevent it from
falling.
(B)
ST 399411700 ACCENT BALL INSTALLER
(A) MT-00309 2) Position the ball, spring and new gasket in the
reverse shifter rod hole on the left side of transmis-
(A) Straight pin sion case, and tighten the checking ball plug.
(B) 5th shifter fork 3) Install the 1-2 fork rod into 1-2 shifter fork
9) Remove the plugs, springs and checking balls. through the hole on the rear of transmission case.
10) Drive out the straight pin tapping by ST, and 4) Align the holes in rod and fork, and drive new
pull out the 3-4 fork rod and shifter fork. straight pin into these holes using ST.
NOTE: NOTE:
When removing a rod, keep other rods in neutral. • Set other rods to neutral.
Also, when pulling out the straight pin, remove it to- • Make sure the interlock plunger is on the 3-4 fork
ward the inside of case so that it does not hit rod side.
against the case. ST 398791700 STRAIGHT PIN REMOVER
5) Install the interlock plunger onto 3-4 fork rod.
NOTE:
Apply a coat of grease to plunger to prevent it from
falling.
5MT-94
6) Install the 3-4 fork rod into 3-4 shifter fork 13) Install the transmission case. <Ref. to 5MT-58,
through the hole on the rear of transmission case. INSTALLATION, Transmission Case.>
7) Align the holes in rod and fork, and drive new 14) Install the transfer case with extension case as-
straight pin into these holes. sembly. <Ref. to 5MT-44, INSTALLATION, Trans-
NOTE: fer Case and Extension Case Assembly.>
• Set the reverse fork rod to neutral. 15) Install the back-up light switch and neutral po-
• Make sure the interlock plunger (before installa- sition switch. <Ref. to 5MT-41, INSTALLATION,
tion) is on the reverse fork rod side. Switches and Harness.>
ST 398791700 STRAIGHT PIN REMOVER vehicle. <Ref. to 5MT-33, INSTALLATION, Manual
8) Install the 5th shifter fork onto the rear of reverse Transmission Assembly.>
fork rod. Align the holes in the two parts and drive
new straight pin into the specified place. C: INSPECTION
ST 398791700 STRAIGHT PIN REMOVER 1) Inspect the fork and rod for damage. Replace if it
is damaged.
(B)
cessively worn, bent, or defective in any way.
3) Inspect the clearance between 1st, 2nd driven
gear and reverse driven gear. If any clearance is
not within specifications, replace the shifter fork as
required.
Clearance (a) and (b):
(A) (C) MT-00311
9.5 mm (0.374 in)
(A) 5th shifter fork (a) (b)

(A) (B) (C)
(B) Reverse fork rod
(C) Straight pin
9) Position the balls, checking ball springs and new

gaskets into 3-4 and 1-2 rod holes, and install
plugs.
MT-00999
(A) 1st driven gear

(B) Reverse driven gear
(C) 2nd driven gear
1st-2nd shifter fork

MT-00366
Approach to 1st gear
32804AA060 1
10) Install the differential assembly. <Ref. to 5MT- by 0.2 mm (0.008 in).
85, INSTALLATION, Front Differential Assembly.> 32804AA070 — Standard
11) Install the main shaft assembly. Become distant from
• Single-range model 32804AA080 3 2nd gear by 0.2 mm
<Ref. to 5MT-62, INSTALLATION, Main Shaft As- (0.008 in).
sembly for Single-Range.>
• Dual-range model 4) Inspect the clearance between 3rd, 4th drive
<Ref. to 5MT-67, INSTALLATION, Main Shaft As- gear and coupling sleeve. If any clearance is not
sembly for Dual-Range.> within specifications, replace the shifter fork as re-
quired.
12) Install the drive pinion shaft assembly. <Ref. to
5MT-77, INSTALLATION, Drive Pinion Shaft As-
sembly.>
5MT-95
Clearance (a) and (b): 6) Inspect the rod end clearances (A) and (B). If
7.3 mm (0.287 in) any clearance is not within specifications, replace
the rod or fork as required.
(a) (b) Clearance (A):
(A) (B) (C)
3rd-4th — 5th:
0.5 — 1.3 mm (0.020 — 0.051 in)
Clearance (B):
1st-2nd — 3rd-4th
0.4 — 1.4 mm (0.016 — 0.055 in)
MT-00940 (A)
(B)
(A) 3rd drive gear

(B) Coupling sleeve
(C) 4th drive gear
3rd-4th shifter fork

Approach to 4th gear MT-00316
32810AA061 1
by 0.2 mm (0.008 in).
32810AA071 — Standard
Become distant from
32810AA101 3 3rd gear by 0.2 mm
(0.008 in).
5) Inspect the clearance between 5th drive gear

and coupling sleeve. If any clearance is not within
specifications, replace the shifter fork as required.
Clearance (a):
9.3 mm (0.366 in)
(A) (a) (B)
MT-00315
(A) 5th drive gear

(B) Coupling sleeve
5th shifter fork

Approach to 5th gear
32812AA201 4
by 0.2 mm (0.008 in).
Become distant from
32812AA221 6 5th gear by 0.2 mm
(0.008 in).
5MT-96
Counter Gear
22.Counter Gear • Be careful not to drop the two needle bearings

and collar contained in counter gear.
A: REMOVAL
1) Remove the manual transmission assembly (A)
Transmission Assembly.> (C)
56, REMOVAL, Transmission Case.> (B)
4) Move the counter gear shaft until it touches
transmission case, and remove the snap ring with a MT-00319
suitable tool.
(A) Counter shaft
(B) Counter gear
(A)
(C) Washers
B: INSTALLATION
1) Install the O-ring and straight pin onto counter
gear shaft.
2) Install the following parts in main case (Right-
side), and push the shaft perfectly into case.
• Counter gear shaft
MT-00317 • Two counter gear washers
• Two needle bearings
(A) Snap ring
• Counter gear collar
5) Slide the washer to the rear of high-low counter • Counter gear
shaft, and remove the straight pin from counter • Straight pin
shaft. • Snap ring
(B) INSTALLATION, Transmission Case.>
5) Install the manual transmission assembly on ve-
hicle. <Ref. to 5MT-33, INSTALLATION, Manual
NOTE:
(A)
• Make sure that the cut-out end surface of counter
MT-00318
gear shaft does not protrude above the end surface
of the case.
(A) Straight pin
• Position the cut-out portion of counter gear shaft.
(B) Counter gear
C: INSPECTION
6) Remove the counter shaft from transmission 1) After installing the snap ring, measure the clear-
case, taking care not to drop the counter gear and ance between snap ring and counter washer.
two washers.
Clearance:
NOTE:
0.05 — 0.35 mm (0.0020 — 0.0138 in)
• Be careful not to damage the O-ring.
• Be careful not to drop the straight pin on front 2) If the clearance is out of specified value, select a
side. snap ring and install to put clearance within speci-
fied value. <Ref. to 5MT-98, ADJUSTMENT,
Counter Gear.>
5MT-97
Counter Gear
D: ADJUSTMENT
Selection of snap ring:
lect a suitable snap ring.
Snap ring
031319000 1.50 (0.0591)
805019010 1.72 (0.0677)
5MT-98

A: INSPECTION
1. MANUAL TRANSMISSION
1. Gears are difficult to intermesh. (a) Worn, damaged or burred chamfer of Replace.
NOTE: internal spline of sleeve and reverse
The cause for difficulty in shifting gears driven gear
can be classified into two kinds: one is de- (b) Worn, damaged or burred chamfer of Replace.
fective gear shift system and the other is spline of gears
defective transmission. However, if the
(c) Worn or scratched bushings Replace.
operation is heavy and engagement of the
gears is difficult, defective clutch disen- (d) Incorrect contact between synchro- Rectify or replace.
gagement may also be responsible. nizer ring and gear cone, or wear
Check whether the clutch is correctly
functioning, before checking the gear shift
system and transmission.
2. Gear slip-out (a) Defective pitching stopper adjustment Adjust.
• Gear slips out when coasting on rough (b) Loose engine mounting bolts Tighten or replace.
road. (c) Worn fork shifter, broken shifter fork Replace.
• Gear slips out during acceleration. rail spring
(d) Worn or damaged ball bearing Replace.
(e) Excessive clearance between splines Replace.
of synchronizer hub and synchronizer
sleeve
(f) Worn tooth step of synchronizer hub Replace.
(caused by slip-out of 3rd gear)
(g) Worn 1st driven gear and driven shaft Replace.
(h) Worn 2nd driven gear and bushing Replace.
(i) Worn 3rd drive gear and needle bear- Replace.
ing
(j) Worn 3rd drive gear and needle bear- Replace.
ing
(k) Worn reverse idler gear and bushing Replace.
3. Noise emit from transmission. (a) Insufficient or improper lubrication Lubricate with specified oil or replace.
NOTE: (b) Worn or damaged gears and bearings Replace.
If a noise is heard when the vehicle is NOTE:
parked with its engine idling and if a noise If the trouble is only wear of the tooth sur-
ceases when the clutch is disengaged, it faces, merely a high roaring noise will oc-
may be considered that the noise comes cur at high speeds, but if any part is
from the transmission. broken, rhythmical knocking sound will be
heard even at low speeds.
5MT-99
2. DIFFERENTIAL
1. Broken differential (case, gear, bear- (a) Insufficient or improper oil Disassemble differential and replace bro-
ing, etc.) ken components. At the same time check
NOTE: other components for any trouble, and
Noise will be developed and finally it will replace if necessary.
become impossible to continue to run due (b) Use of vehicle under severe condi- Readjust bearing preload and backlash
to broken pieces obstructing the gear rev- tions such as excessive load and and face contact of gears.
olution. improper use of clutch
(c) Improper adjustment of taper roller Adjustment.
bearing
(d) Improper adjustment of drive pinion Adjustment.
and hypoid driven gear
(e) Excessive backlash due to worn dif- Add recommended oil to the specified
ferential side gear, washer or differential level. Do not use vehicle under severe
pinion under severe operating conditions operating conditions.
of the vehicle.
(f) Loose hypoid driven gear tightening Tighten.
bolts
2. Differential and hypoid gear noises (a) Insufficient oil Lubricate.
Troubles of the differential and hypoid (b) Improper adjustment of hypoid driven Check tooth contact.
gear always appear as noise problems. gear and drive pinion
Therefore noise is the first indication of (c) Worn teeth of hypoid driven gear and Replace as a set.
trouble. However noises from the engine, drive pinion Readjust bearing preload.
muffler, tire, exhaust gas, bearing, body,
(d) Loose roller bearing Readjust hypoid driven gear to drive pin-
etc. are easily mistaken for the differential
ion backlash and check tooth contact.
noise. Pay special attention to the hypoid
gear noise because it is easily confused (e) Distorted hypoid driven gear or differ- Replace.
with other gear noises. There are the fol- ential case
lowing four kinds of noises. (f) Worn washer and differential pinion Replace.
• Gear noise when driving: shaft
If noise increases as the vehicle speed
increases it may be due to insufficient
gear oil, incorrect gear engagement,
damaged gears, etc.
• Gear noise when coasting:
Damaged gears due to maladjusted bear-
ings and incorrect shim adjustment.
• Bearing noise when driving or coast-
ing:
Cracked, broken or rusty bearings
• Noise mainly when turning:
Noise occurs form differential side gear,
differential pinion or differential pinion
shaft, etc.
5MT-100
CONTROL SYSTEMS CS

(DIAGNOSTICS)


approval.

CLUTCH SYSTEM
CL
Page
2. Clutch Disc and Cover ..............................................................................12
3. Flywheel ....................................................................................................16
4. Release Bearing and Lever.......................................................................18
5. Operating Cylinder ....................................................................................20
6. Master Cylinder .........................................................................................21
7. Clutch Pipe and Hose ...............................................................................23
8. Clutch Fluid ...............................................................................................24
9. Clutch Fluid Air Bleeding...........................................................................25
10. Clutch Pedal..............................................................................................26
11. Clutch Switch ............................................................................................32
General Description
CLUTCH SYSTEM
A: SPECIFICATION
Option code★1 EC, EK, KA KS, K4
Model 2.0 L 2.5 L 2.0 L 2.5 L
Clutch cover Diaphragm set load kgf (lb) 550 (1,213) 450 (992) 580 (1,279)
Facing material Woven
Outer diameter ! Inner 228.6 ! 155 ! 2.95 225 ! 150 ! 3.5
mm (in)
diameter ! Thickness (9.00 ! 6.10 ! 0.1161) (8.86 ! 5.91 ! 0.138)
Spline outer diameter mm (in) 25.2 (0.992)
Clutch disc
Standard 1.3 — 1.9 (0.051 — 0.075)
Depth of rivet head
mm (in) Limit of 0.3 (0.012)
sinking
Limit for deflection mm (in) 1.0 (0.039) at R = 110 (4.33)
Clutch release lever ratio 1.6
Release bearing Grease-packed self-aligning
Full stroke mm (in) 130 — 135 (5.12 — 5.31)
Clutch pedal
Free play mm (in) 4 — 13 (0.16 — 0.51)
Flywheel Type Dual mass Flexible
★1:
For option code, refer to “ID” section. <Ref. to ID-5, MODEL NUMBER PLATE, IDENTIFICATION, Identification.>
CL-2
General Description
CLUTCH SYSTEM
B: COMPONENT
1. CLUTCH ASSEMBLY
• EC, EK and KA model
(1)
(2)
(4)
(5)
(6)
T1
(3)
(9)
(5)
T1
(7)
(8)
T2
CL-00286
(1) Dust cover (6) Release bearing Tightening torque: N"m (kgf-m, ft-lb)
(2) Lever spring (7) Clutch cover T1: 16 (1.6, 11.8)
(3) Pivot (8) Clutch disc T2: 72 (7.3, 52.8)
(4) Release lever (9) Dual mass flywheel
(5) Clip
CL-3
General Description
CLUTCH SYSTEM
• KS and K4 model
(1)
(4)
(2)
(5)
(6) (3) T1
T2 (5)
T2
(7)
(8)
(9)
CL-00287
(1) Dust cover (6) Release bearing Tightening torque: N"m (kgf-m, ft-lb)
(2) Lever spring (7) Clutch cover T1: 16 (1.6, 11.8)
(3) Pivot (8) Clutch disc T2: 72 (7.3, 52.8)
(4) Release lever (9) Flexible flywheel
(5) Clip
CL-4
General Description
CLUTCH SYSTEM
2. CLUTCH PIPE AND HOSE

• LHD model
T2 (1)
(4)
T5
(5) (2)
(3)
T3 T3
T4
(6) (8)
T1
(7)
CL-00288
(1) Master cylinder ASSY (7) Operating cylinder Tightening torque: N"m (kgf-m, ft-lb)
(2) Clutch pipe (8) Clip T1: 8 (0.8, 5.8)
(3) Clamp T2: 15 (1.5, 10.8)
(4) Bracket T3: 18 (1.8, 13.0)
(5) Clutch hose T4: 37 (3.8, 27.5)
(6) Washer T5: 25 (2.5, 18.4)
CL-5
General Description
CLUTCH SYSTEM
• RHD model
(9)
(7)
(6)
(8)
T3
T2 (5)
T3
(3)
T2
(11)
T4
T5
(2)
(1) (4)
T1 (10)
CL-00289
(1) Operating cylinder (7) Clevis pin Tightening torque: N"m (kgf-m, ft-lb)
(2) Washer (8) Snap pin T1: 8 (0.8, 5.8)
(3) Clutch hose (9) Pedal T2: 15 (1.5, 10.8)
(4) Clamp (10) Clip T3: 18 (1.8, 13.0)
(5) Clutch pipe (11) Bracket T4: 25 (2.5, 18.4)
(6) Master cylinder ASSY T5: 37 (3.8, 27.5)
CL-6
General Description
CLUTCH SYSTEM
3. MASTER CYLINDER
T
(1) (10)
(9)
(2)
(8)
(3)
(7)
(4) (6)
(5)
CL-00151
(1) Reservoir cap (6) Return spring Tightening torque: N"m (kgf-m, ft-lb)
(2) Reservoir tank (7) Piston T: 10 (1.0, 7)
(3) Oil seal (8) Push rod ASSY
(4) Straight pin (9) Piston stop ring
(5) Master cylinder (10) Cylinder boot
CL-7
General Description
CLUTCH SYSTEM
4. CLUTCH PEDAL
• LHD model
(24) (4)
(3)
T2 (23)
T1 (2) (10)
T2 (7)
(22)
(21)
T2
(10) T1
(25)
T1
(20)
(13) (1) (19) (2)
(12)
(13)
T1
(18) (17) (1)
(11)
(16)(15) (4)
(14) (2)
(11)
(10) (2)
(1)
(7)
(5)
(8) (6)
(9)
CL-00290
(1) Stopper (11) Clutch clevis pin (21) Stop light switch
(2) Bushing (12) Assist rod A (22) Pedal bracket
(3) Spring pin (13) Clip (23) Clutch master cylinder bracket
(4) Snap pin (14) Assist spring (24) Lever
(5) Brake pedal pad (15) Assist bushing (25) Clutch switch
(6) Brake pedal (16) Assist rod B
(7) Clevis pin (17) Spring A (EC and 2.5 L model) Tightening torque: N"m (kgf-m, ft-lb)
(8) Clutch pedal pad (18) Rod (EC and 2.5 L model) T1: 8 (0.8, 5.8)
(9) Clutch pedal (19) Bushing B (EC and 2.5 L model) T2: 18 (1.8, 13.0)
(10) Bushing C (20) Clip (EC and 2.5 L model)
CL-8
General Description
CLUTCH SYSTEM
• RHD model
(10) (9)
(8)
(5)
(7) (6)
(4)
(18)
T2
(15)
T3
(14)
(1) (13) (16)
(20) T2
(19)
T2
T1 (17)
(4)
(11) (17) (1)
(12)
(2)
(4)
(3)
CL-00291
(1) Stopper (10) Assist rod B (19) Clutch pedal catcher

(2) Clutch pedal pad (11) Spring A (20) Bracket (Clutch pedal catcher)
(3) Clutch pedal (12) Rod S
(4) Bushing C (13) Bushing B Tightening torque: N"m (kgf-m, ft-lb)
(5) Clutch clevis pin (14) Clip T1: 8 (0.8, 5.8)
(6) Assist rod A (15) Clutch switch T2: 18 (1.8, 13.0)
(7) Clip (16) Spacer T3: 30 (3.1, 22.4)
(8) Assist spring (17) Bushing
(9) Assist bushing (18) Clutch pedal bracket
CL-9
General Description
CLUTCH SYSTEM
C: CAUTION • Be sure to tighten fasteners including bolts and

• Wear work clothing, including a cap, protective nuts to the specified torque.
goggles and protective shoes during operation. • Place shop jacks or rigid racks at the specified
• Remove contamination including dirt and corro- points.
sion before removal, installation or disassembly. • Apply grease onto sliding or revolution surfaces
• Keep the disassembled parts in order and pro- before installation.
tect them from dust and dirt. • Before installing O-rings or snap rings, apply suf-
• Before removal, installation or disassembly, be ficient amount of fluid to avoid damage and defor-
sure to clarify the failure. Avoid unnecessary re- mation.
moval, installation, disassembly and replacement. • Before securing a part on a vice, place cushion-
• Be careful not to burn yourself, because each ing material such as wood blocks, aluminum plate
part on the vehicle is hot after running. or cloth between the part and the vice.
• Use SUBARU genuine fluid, grease etc. or • Keep fluid away from the vehicle body. If any flu-
equivalent. Do not mix fluid, grease, etc. with that of id contacts the vehicle body, immediately flush the
another grade or from other manufacturers. area with water.
D: PREPARATION TOOL
1. SPECIAL TOOL
498497100 CRANKSHAFT Used for stopping rotation of flywheel when loos-
STOPPER ening/tightening bolt, etc.
ST-498497100
499747100 CLUTCH DISC Used for installing clutch disc to flywheel.

GUIDE
ST-499747100
CL-10
General Description
CLUTCH SYSTEM

499057000 ®
TORX PLUS Used for removing flywheel (dual mass flywheel
type).
ST-499057000
2. GENERAL TOOL
TOOL NAME REMARKS
Circuit tester Used for measuring resistance, voltage and ampere.
Dial gauge Used for measuring clutch disk run-out.
CL-11
Clutch Disc and Cover
CLUTCH SYSTEM
2. Clutch Disc and Cover ST 499747100 CRANKSHAFT STOPPER
A: REMOVAL (A)
1. EC, EK AND KA MODEL

cle. <Ref. to 5MT-31, REMOVAL, Manual Trans-
mission Assembly.>
2) Insert the ST on flywheel.
ST 499747100 CLUTCH DISC GUIDE ST
(A)
CL-00011
(A) Clutch cover
3) Remove the clutch cover and clutch disc.

NOTE:
• Take care not to allow oil on the clutch disc fac-
ing.
ST • Do not disassemble the clutch cover or clutch
CL-00112 disc.
(A) Dual mass flywheel

B: INSTALLATION
3) Remove the clutch cover and clutch disc.
NOTE: 1) Insert the ST into clutch disc and install on the
flywheel by inserting the ST end into pilot bearing.
• Take care not to allow oil on the clutch disc sur-
face. NOTE:
• Do not disassemble the clutch cover or clutch When installing the clutch disc, be careful of its di-
disc. rection.
• Be sure to mark alignment marks on the flywheel ST 499747100 CLUTCH DISC GUIDE
and clutch cover before removing the clutch cover.
(A)
(A)
ST
CL-00282
CL-00113
(A) Flywheel side
2. KS AND K4 MODEL
2) Place the clutch cover on flywheel and tighten
1) Remove the transmission assembly from vehicle the bolts to specified torque.
body. <Ref. to 5MT-33, INSTALLATION, Manual
2) Install the ST on flywheel. • When reinstalling, align the alignment marks.
• When installing a new clutch cover and flywheel,
position the clutch cover in order to make the gap
between “0” marks of flywheel and clutch cover
120# or more.
• Note the front and rear of the clutch disc when in-
stalling.
CL-12
CLUTCH SYSTEM
• Tighten the clutch cover installing bolts gradual- • Temporarily tighten the bolts by hand. Each bolt
ly. Each bolt should be tightened to the specified should be tightened to the specified torque in a
torque in a crisscross order. crisscross order.
16 N"m (1.6 kgf-m, 11.8 ft-lb) 16 N"m (1.6 kgf-m, 11.8 ft-lb)
(1)
(3)
(6)
(5)
(4)
(2)
CL-00115
(A)
3) Remove the ST.
ST 499747100 CLUTCH DISC GUIDE
4) Install the transmission assembly. <Ref. to 5MT-
33, INSTALLATION, Manual Transmission Assem- (3) (1)
bly.>
2. KS AND K4 MODEL
(5)
1) Insert the ST into clutch disc and install them on (6)
the flywheel by inserting the ST end into pilot bear-
ing. (2) (4) ST
NOTE: CL-00013
When installing the clutch disc, be careful to its di-

(A) “0” marks
rection.
ST 499747100 CLUTCH DISC GUIDE 3) Remove the ST.
33, INSTALLATION, Manual Transmission Assem-
bly.>
(A) C: INSPECTION
ST
1. CLUTCH DISC
1) Facing wear:
Measure the depth from the surface of facing to riv-
CL-00208 et head. Replace if the facings are worn locally or
worn down to less than the specified value.
(A) Flywheel side
Depth of rivet head:
2) Install the clutch cover on flywheel and tighten Limit of sinking
the bolts to specified torque. 0.3 mm (0.012 in)
NOTE: NOTE:
• When installing the clutch cover on flywheel, po- Do not wash the clutch disc with any cleaning fluid.
sition the clutch cover so that there is a gap of 120#
or more between “0” marks on the flywheel and
clutch cover. (“0” marks indicate the directions of
residual unbalance.)
• Note the front and rear of the clutch disc when in-
stalling.
CL-13
CLUTCH SYSTEM
• EC, EK and KA model • KS and K4 model

(A)
CL-00116 CL-00015
• KS and K4 model
(A) Clutch facing
4) Deflection on facing:
If deflection exceeds the specified value at the out-
er circumference of facing, replace the clutch disc.
Limit for deflection:
1.0 mm (0.039 in) at R = 110 mm (4.33 in)
CL-00014
2) Hardened facing: ST
Replace the clutch disc.
3) Oil leakage on facing:
Replace the clutch disc and inspect the transmis-
sion front oil seal, transmission case mating sur-
face, engine rear oil seal and other points for oil
leakage.
CL-00118
• KS and K4 model
(A)
ST
CL-00117
(A) Clutch facing CL-00016
5) If the spline wears, rivets loosen and damper

spring is failure, replace the clutch disc.
CL-14
CLUTCH SYSTEM
• EC, EK and KA model • KS and K4 model
(A) (A)
(B)
(B)
CL-00119 CL-00018
(A) Spline (A) Thrust rivet

(B) Rivet (B) Diaphragm spring
• KS and K4 model 3) Damaged or worn disc contact surface of pres-

sure plate
4) Loose strap plate installation area
5) Worn diaphragm sliding area
(A) (B)
CL-00017
(A) Spline
(B) Rivet
(C) Damper spring CL-00176
2. CLUTCH COVER (A) Pressure plate

(B) Strap plate
NOTE:
Visually check the following items without disas- • KS and K4 model
sembling, and replace or repair if defective.
1) Loose thrust rivet
2) Damaged or worn bearing contact area at the (A)
center of diaphragm spring

(A)
(B)
CL-00177
(A) Pressure plate

(B) Strap plate
(B)
CL-00120
(A) Thrust rivet

(B) Diaphragm spring
CL-15
Flywheel
CLUTCH SYSTEM
3. Flywheel ST 498497100 CRANKSHAFT STOPPER
A: REMOVAL
1) Remove the transmission assembly. <Ref. to
5MT-31, REMOVAL, Manual Transmission As-
sembly.>
2) Remove the clutch cover and clutch disc. <Ref.
to CL-12, REMOVAL, Clutch Disc and Cover.>
3) Using ST1 and ST2, remove the flywheel. ST
ST1 498497100 CRANKSHAFT STOPPER CL-00122
ST2 499057000 TORX® PLUS 2) Tighten the flywheel mounting bolts to specified
torque.
(A) ST 499057000 TORX® PLUS
NOTE:
Tighten the flywheel installing bolts gradually. Each
bolt should be tightened to the specified torque in a
crisscross order.
Tightening torque:
ST2
ST1 72 N"m (7.3 kgf-m, 52.8 ft-lb)
CL-00121
(A) Flywheel
(5) (1)
2. KS AND K4 MODEL (7)

(3)
1) Remove the transmission assembly. <Ref. to (4)
(8)
5MT-31, REMOVAL, Manual Transmission As- (2) (6)
sembly.>
2) Remove the clutch cover and clutch disc. <Ref.
to CL-12, REMOVAL, Clutch Disc and Cover.> CL-00123
3) Using the ST, remove the flywheel. 3) Install the clutch disc and cover. <Ref. to CL-12,
ST 498497100 CRANKSHAFT STOPPER INSTALLATION, Clutch Disc and Cover.>
bly.>
2. KS AND K4 MODEL
1) Install the flywheel and ST.
ST 498497100 CRANKSHAFT STOPPER
(A)
ST
CL-00019
(A) Flywheel
B: INSTALLATION
1) Set the flywheel and ST. ST
CL-00020
2) Tighten the flywheel attaching bolts to specified

torque.
CL-16
Flywheel
CLUTCH SYSTEM
NOTE: • KS and K4 model

Tighten the flywheel installing bolts gradually. Each
bolt should be tightened to the specified torque in a (B)
crisscross order.
Tightening torque:
72 N"m (7.3 kgf-m, 52.8 ft-lb)
(5) (1) (A)

(7) CL-00022
(3)
(4) (A) Flywheel

(8)
(B) Ring gear
(2) (6)
2) Smoothness of rotation
CL-00021 Rotate the ball bearing while applying pressure in
thrust direction.
3) Install the clutch disc and cover. <Ref. to CL-13,
3) If noise or excessive play is noted, replace the
KS AND K4 MODEL, INSTALLATION, Clutch
flywheel.
Disc and Cover.>
bly.>
C: INSPECTION
CAUTION:
Since this bearing is grease-sealed and non-lu-
brication type, do not wash it with gasoline or
any solvent.
1) Damage on sliding surface of facing and ring
gear:
If defective, replace the flywheel.
(B)
(A)
CL-00124
(A) Flywheel
(B) Ring gear
CL-17
Release Bearing and Lever
CLUTCH SYSTEM
4. Release Bearing and Lever NOTE:

• Apply grease (SUNLIGHT 2: Part No.
A: REMOVAL 003602010) to the contact point of release lever
1) Remove the transmission assembly from vehicle and operating cylinder.
body. • Observing from main case hole, check that the
<Ref. to 5MT-31, REMOVAL, Manual Transmis- lever spring is installed securely.
sion Assembly.>
2) Remove the two clips from clutch release lever (A)
and remove the release bearing.
CAUTION:
Be careful not to deform the clips.
3) Remove the dust cover.
CL-00026
(A)
(A) Release lever
2) Place the release bearing and fasten it with two

(B) clips.
3) Install the dust cover.
CL-00023
(A) Clutch release lever

(B) Dust cover
4) Remove the lever spring from pivot with a screw- (A)

driver by accessing it through the clutch housing re-
lease lever hole. Then remove the release lever.
(B)
(B)
CL-00023
(A) Release lever

(B) Dust cover
4) Check smooth movement of bearing with operat-

(A) ing release lever.
5) Install the transmission assembly.
CL-00024 <Ref. to 5MT-33, INSTALLATION, Manual Trans-
mission Assembly.>
(B) Screwdriver C: INSPECTION
B: INSTALLATION 1. RELEASE BEARING
NOTE: NOTE:
Before or during installation, lubricate the following Since this bearing is grease-sealed and non-lubri-
points with a light coat of grease. cation type, do not wash with gasoline or any sol-
• Contact surface of lever and pivot vent when servicing the clutch.
• Contact surface of lever and bearing
• Transmission main shaft spline (Use grease con-
taining molybdenum disulphide.)
1) While pushing the release lever to pivot and
twisting it to both sides, fit the lever spring onto the
constricted portion of pivot.
CL-18
Release Bearing and Lever
CLUTCH SYSTEM
1) Check the bearing for smooth movement by ap-

plying force to the bearing in radial direction.
Radial direction stroke:
1.6 mm (0.063 in)
(A)
CL-00032
(A) Bearing case
2) Check the bearing for smooth rotation by apply-

ing force to the bearing in thrust direction.
(A)
CL-00160
(A) Bearing case
3) Check wear and damage of bearing case sur-

face contacting with lever.
2. RELEASE LEVER
Check the lever pivot portion and contact point with
release bearing case for wear.
(A)
(B)
(C)
CL-00034

(B) Pivot
(C) Clutch release bearing
CL-19
Operating Cylinder
CLUTCH SYSTEM
5. Operating Cylinder Tightening torque:

T1: 18 N"m (1.8 kgf-m, 13.0 ft-lb)
A: REMOVAL T2: 37 N"m (3.8 kgf-m, 27.5 ft-lb)
IN(H4SO 2.0)-8, REMOVAL, Air Intake Chamber.> T2
2) Disconnect the clutch hose from operating cylin-
der.
T1
CAUTION:
Cover the hose joint to prevent clutch fluid from
flowing out.
(A)
T2
CL-00254
2) After bleeding air from the operating cylinder,

ensure that clutch operates properly.
<Ref. to CL-25, Clutch Fluid Air Bleeding.>
C: INSPECTION
(B) 1) Check the operating cylinder for damage. If op-
CL-00252
erating cylinder is damaged, replace it.
2) Check the operating cylinder for fluid leakage or
(A) Clutch hose damage on boot. If any leakage or damage is
(B) Operating cylinder found, replace the operating cylinder.
3) Remove the operating cylinder from transmis-

sion.
CL-00253
B: INSTALLATION
NOTE:
Before installing the operating cylinder, apply
grease (SUNLIGHT 2: Part No. 003602010) to the
contact point of the release lever and operating cyl-
inder.
CL-20
Master Cylinder
CLUTCH SYSTEM
6. Master Cylinder Tightening torque:

T1: 15 N"m (1.5 kgf-m, 10.8 ft-lb)
A: REMOVAL T2: 18 N"m (1.8 kgf-m, 13.0 ft-lb)
1) Thoroughly drain the brake fluid from reservoir
tank.
2) Remove the snap pin and clevis pin, and then
separate the push rod of master cylinder from
clutch pedal.
(A)
T2
(B) T1
(D)
CL-00153
(C) 2) Connect the push rod of master cylinder to

clutch pedal, and install the clevis pin and snap pin.
NOTE:
CL-00042 Apply grease to the clevis pin.
(A) Clevis pin (A)

(B) Snap pin
(C) Push rod
(B)
(D) Lock nut

IN(H4SO 2.0)-8, REMOVAL, Air Intake Chamber.> (C)
4) Disconnect the clutch pipes from master cylin-

der.
5) Remove the master cylinder and reservoir tank CL-00045
as a unit.
CAUTION: (A) Clevis pin
Be careful not to spill the brake fluid. Brake flu- (B) Snap pin
id spilt on the vehicle body will harm the paint (C) Push rod
surface; wipe it off quickly if spilt.
3) After bleeding air from the clutch system, ensure
(A)
that clutch operates properly. <Ref. to CL-25,
Clutch Fluid Air Bleeding.>
(B)
C: DISASSEMBLY
1) Remove the straight pin and reservoir tank.
CL-00152
(A) Master cylinder ASSY

(B) Clutch pipe (A)
B: INSTALLATION
1) Install the master cylinder to the vehicle, and (B)
connect the clutch pipe to master cylinder. CL-00178
NOTE:
(A) Reservoir tank
Check that the pipe is routed properly.
(B) Straight pin
CL-21
Master Cylinder
CLUTCH SYSTEM
2) Remove the oil seal. Tightening torque:

10 N"m (1.0 kgf-m, 7 ft-lb)
(A) E: INSPECTION
If any damage, deformation, wear, swelling, rust or
other faults are found on the cylinder, piston, push
rod, fluid reservoir, return spring, gasket, clutch
damper cylinder boot or hose, replace the faulty
part.
(C)
(B)
(A) (B)
CL-00179
(A) Oil seal

(F)
(B) Master cylinder (D)
3) Pull the cylinder boot backward.
(A) (E)
CL-00157
(A) Master cylinder body

(B) Return spring
(C) Piston
(D) Stop ring
(E) Push rod ASSY
(B)
(F) Cylinder boot
CL-00048
(A) Cylinder boot

(B) Master cylinder

CAUTION:
Be careful to prevent the rod, washer, piston
and return spring from flying out when remov-
ing the snap ring.
D: ASSEMBLY
1) Apply a coat of grease to the contacting surfaces
of the push rod and piston before installation.
Grease:
SILICONE GREASE G40M (Part No.
004404003)
CL-00156
CL-22
Clutch Pipe and Hose
CLUTCH SYSTEM
7. Clutch Pipe and Hose B: INSTALLATION

A: REMOVAL
1) Remove the air intake chamber. <Ref. to NOTE:
IN(H4SO 2.0)-8, REMOVAL, Air Intake Chamber.> Bleed the air of clutch fluid. <Ref. to CL-25, Clutch
2) Drain the clutch fluid. <Ref. to CL-24, Clutch Flu- Fluid Air Bleeding.>
id.> Tightening torque:
3) Disconnect the clutch pipe from the clutch hose T1: 15 N"m (1.5 kgf-m, 10.8 ft-lb)
and master cylinder. T2: 18 N"m (1.8 kgf-m, 13.0 ft-lb)
4) Pull out the clamp, then remove the clutch hose T3: 25 N"m (2.5 kgf-m, 18.4 ft-lb)
from bracket.
T1
T1
(A)
(A)
T3 (B)
(B) T1
(C)
CL-00057
(D)
(A) Clamp
(C) T1
(B) Clutch hose
T3
T2
5) Disconnect the hose from operating cylinder.
6) Remove the bracket. (C)
(B)
CL-00283
(A) Clutch pipe (LHD model)

(B) Clip
(C) Clutch hose
(D) Clutch pipe (RHD model)
C: INSPECTION
Check pipes and hoses for cracks, breakage or
damage. Check joints for fluid leakage. If any
crack, breakage, damage or leakage is found, re-
pair or replace the defective pipe or hose.
CL-23
Clutch Fluid
CLUTCH SYSTEM
8. Clutch Fluid NOTE:

Refill the brake fluid before reservoir tank becomes
A: INSPECTION empty.
2) Inspect the fluid level using the scale on the out-
side of reservoir tank. If the level is below “MIN”,
add fluid to bring it up to “MAX”, and also inspect for
leakage.
(A)
(B)
M AX
MIN
(C)
CL-00183
(A) Reservoir tank

(B) MAX. level
(C) MIN. level
B: REPLACEMENT
CAUTION:
• The FMVSS No. 116, fresh DOT3 or 4 brake
fluid must be used.
• When loosening bleeder screw, cover the
bleeder with cloth to prevent brake fluid from
being splashed over surrounding parts.
• Avoid mixing different brands of brake fluid
to prevent the quality of fluid from degrading.
• Be careful not to allow dirt or dust to get into
the reservoir tank.
NOTE:
• During bleeding operation, keep the clutch reser-
voir tank filled with brake fluid to eliminate the entry
of air.
• Clutch pedal operating must be very slow.
• For convenience and safety, it is advisable to
have two people working.
• The amount of brake fluid required is approx. 70
m2 (2.4 US fl oz, 2.5 Imp fl oz) for total clutch sys-
tem.
2) Drain the brake fluid from reservoir tank.
3) Refill the reservoir tank with recommended
brake fluid.
Recommended brake fluid:
FMVSS No. 116, fresh DOT3 or 4 brake fluid
4) Drain all contaminated fluid in the same method
as air bleeding.
CL-24
Clutch Fluid Air Bleeding
CLUTCH SYSTEM
9. Clutch Fluid Air Bleeding Tightening torque:

T: 8 N"m (0.8 kgf-m, 5.8 ft-lb)
A: PROCEDURE
NOTE:
Bleed air from the oil line with help of a co-worker.
2) Fit one end of a vinyl tube into the air bleeder of T
operating cylinder and put the other end into a
brake fluid container.
(A)
CL-00261
6) After depressing the clutch pedal, make sure

that there are no leaks evident in the entire clutch
system.
7) After bleeding air from the clutch system, ensure
that clutch operates properly.
(B)
CL-00259
(A) Clutch hose

(B) Air bleeder
3) Slowly depress the clutch pedal and keep it de-

pressed. Then open the air bleeder to discharge air
together with the fluid.
Release the air bleeder for 1 or 2 seconds. Next,
with the bleeder closed, slowly release the clutch
pedal.
CAUTION:
When loosening bleeder screw, cover the
bleeder with cloth to prevent brake fluid from
being splashed over surrounding parts.
(B)
(A)
CL-00260
(A) Operating cylinder

(B) Vinyl tube
4) Repeat the procedure 3), until there are no more

air bubbles in the vinyl tube.
5) Tighten the air bleeder.
CL-25
Clutch Pedal
CLUTCH SYSTEM
10.Clutch Pedal 3) Remove the clutch pedal catcher from bracket

(clutch pedal catcher).
A: REMOVAL
1. LHD MODEL
2) Remove the steering column. <Ref. to PS-23, (A)
REMOVAL, Tilt Steering Column.>
3) Disconnect the connectors from the stop light (D)
(B)
and clutch switches. (C)
4) Remove the snap pins which secure lever to
push rod and operating rod.
5) Remove the clevis pins which secure lever to CL-00274
push rod and operating rod.
(A) Bracket (Clutch pedal catcher)
(B) Clutch pedal catcher
(C) Clutch pedal
(D)
(D) Steering support beam
(A) 4) Remove the clutch switch connector from clutch

(D)
pedal.
(C)
5) Remove the snap pin and clevis pin which join
(C) the push rod and clutch pedal.
(B)
6) Remove the master cylinder mounting nuts.
CL-00292
(A) Operating rod

(B) Push rod
(C) Snap pin
(A)
(D) Clevis pin
6) Remove the nut which secures clutch master

cylinder.
CL-00216
(A) Master cylinder
7) Remove the clutch pedal and bracket as a unit.
CL-00093
(A)
7) Remove the bolts and nuts which secure brake
pedal and clutch pedal, and remove the pedal as-
sembly.
(B)
2. RHD MODEL CL-00126
2) Remove the instrument panel lower cover. (A) Clutch pedal bracket
(B) Clutch pedal
CL-26
Clutch Pedal
CLUTCH SYSTEM
B: INSTALLATION 3) Remove the spring pin and lever.

(A)
Tightening torque:
T: 18 N"m (1.8 kgf-m, 13.0 ft-lb)
• Clutch pedal catcher
(B)
(A)
CL-00095
(D)
T (B) (A) Pin
(C)
(B) Lever
CL-00275
4) Remove the clutch pedal and bushings.
(B)
(A) Bracket (Clutch pedal catcher)
(B) Clutch pedal catcher
(C) Clutch pedal
(B)
(D) Steering support beam
CAUTION:
Always use a new clevis pin.
(A)
2) Adjust the clutch pedal after installation. <Ref. to
CL-29, ADJUSTMENT, Clutch Pedal.> CL-00096
C: DISASSEMBLY
(A) Clutch pedal
1. LHD MODEL (B) Bushing
1) Remove the clutch switches. 5) Remove the stopper, clip and rod S, and then re-
2) Remove the clips, assist spring, rod and bush- move the spring and bushing S.
ing.
(D) (B)
(A)
(A)
(E)
(E)
(C)
(D)
(B) (D)
(E)
(C) (D) (C)
CL-00097
CL-00094
(A) Clip
(A) Clip
(B) Bushing S
(B) Assist spring
(C) Spring S
(C) Assist rod
(D) Rod S
(D) Bushing
(E) Stopper
(E) Clevis pin
6) Remove the stoppers from clutch pedal.
7) Remove the clutch pedal pad.
CL-27
Clutch Pedal
CLUTCH SYSTEM
2. RHD MODEL 6) Remove the spacer, bushing and pedal pad from
clutch pedal.
1) Remove the clutch switch.
2) Remove the clip, and then pull out the clevis pin. (A)
(B)
(F)
(C)
(B)
(F) (D)
(E)
CL-00130
(A)
CL-00127 (A) Spacer
(B) Bushing
(A) Clevis pin
(C) Bushing
3) Remove the assist rod, spring and bushing. (D) Pedal pad
4) Remove the clutch pedal from clutch pedal (E) Clutch pedal
bracket. (F) Bushing C
D: ASSEMBLY
1. LHD MODEL
(A)
1) Attach the clutch switch, etc. to pedal bracket
temporarily.
2) Clean the inside of bores of clutch pedal and
brake pedal, and apply grease, and set bushings
(B) into bores.
3) Align the bores of pedal bracket, clutch pedal
CL-00128 and brake pedal, and then attach the brake pedal
return spring, assist rods, spring and bushing.
(A) Clutch pedal bracket
(B) Clutch pedal NOTE:
Clean up the inside of bushings and apply grease
5) Remove the following parts (B to G) from clutch before installing spacer.
pedal bracket (A) as shown in the figure.
2. RHD MODEL
(B)
1) Clean and apply grease to the hole of sliding
(A)
portion between clutch pedal and bushing.
2) Install the pad, stopper, bushing C, spacer and
bushing to clutch pedal.
3) Install the rod S, spring S, bushing S, clip, bush-
(C) ing, clutch switch and bushing C to clutch pedal
(G)
bracket.
(D)
(F)
(E) CL-00184

(B) Bushing C
(C) Clip
(D) Bushing S
(E) Spring S
(F) Rod S
(G) Bushing
CL-28
Clutch Pedal
CLUTCH SYSTEM
4) Install the clutch pedal assembly, stopper, ad- • RHD model

justing rod, bushing and spring to clutch pedal
bracket.
Tightening torque:
T: 30 N"m (3.1 kgf-m, 22.4 ft-lb)
(A) (B)
(A)
CL-00077
T
(A) Clutch pedal
(B) (B) Brake pedal
CL-00276 F: ADJUSTMENT
1) Measure the full stroke amount of clutch pedal.
(B) Clutch pedal NOTE:
• Measure the length between the seat cushion
5) Install the assist rod, bushing and assist spring front end and center portion of clutch pedal.
to clutch pedal and pedal bracket. • Slide the seat at seventh notch from first notch.
E: INSPECTION Specified clutch pedal full stroke A:
130 — 135 mm (5.12 — 5.31 in)
1. CLUTCH PEDAL
Move the clutch pedal pads in the lateral direction
with a force of approximately 10 N (1 kgf, 2 lb) to
ensure the pedal deflection is in specified range.
If excessive deflection is noted, replace the bush-
ings with new ones.
Deflection of clutch pedal:
Service limit (C)
5.0 mm (0.197 in) or less A
(A) (B)
• LHD model CL-00078
(A) Clutch pedal (Full stroke condition)

(B) Scale
(C) Seat
(A) (B)
2) If the clutch pedal stroke is out of specification,
loosen the clutch stopper nut and adjust it.
Tightening torque (Clutch stopper nut):
8 N"m (0.8 kgf-m, 5.8 ft-lb)
CL-00098
(A) Clutch pedal

(B) Brake pedal
CL-29
Clutch Pedal
CLUTCH SYSTEM
3) Loosen the push rod lock nut. 5) Turn the push rod counterclockwise to shorten
until clearance is made at clutch switch.
(A)
(B)
(D)
(C)
(C)
(A)
(B)
CL-00042
CL-00132
(A) Clevis pin
(B) Snap pin (A) Clutch switch
(C) Push rod (B) Stopper
(D) Push rod lock nut (C) Clearance
4) Turn the push rod to adjust. 6) Turn the push rod clockwise to lengthen until
(1) Ensure that the clutch pedal contacts clutch clutch pedal contacts to clutch switch.
switch, when releasing the clutch pedal. 7) Turn the push rod further 270° counterclockwise
(2) Ensure that the clutch pedal contacts clutch to shorten (arrow direction as shown in the figure).
pedal bracket stopper, when fully depressing • LHD model
the clutch pedal.
(B)
(A)
(A)
(B)
(C) (F)
(E)
CL-00101
(D)
CL-00080
(A) Accelerator pedal
(A) Clevis hole (B) Clevis
(B) Push rod lock nut
• RHD model
(C) Shortening direction
(D) Lengthening direction
(E) Push rod
(F) U shaped bracket
(A) (B)
CL-00085
(A) Clutch pedal

(B) Brake pedal
8) Move the clevis pin in lateral direction to ensure

it moves smoothly.
CL-30
Clutch Pedal
CLUTCH SYSTEM
9) Tighten the push rod lock nut. 14) Push the release lever until operating cylinder
push rod retracts. Check that the clutch fluid level in
Tightening torque:
reservoir tank increases.
10 N"m (1.0 kgf-m, 7.2 ft-lb)
10) Depress and release the clutch pedal two or
three times to ensure that clutch pedal and release (2)
fork operates smoothly. If the clutch pedal and re- (1)
lease fork do not operate smoothly, bleed air from
the clutch hydraulic system. <Ref. to CL-25,
Clutch Fluid Air Bleeding.>
11) Measure the clutch pedal full stroke length
again to ensure that it is within specifications. If it is
not, repeat adjustment procedures again from the
beginning. (3) CL-00227
Specified clutch pedal full stroke:

(1) Push rod
130 — 135 mm (5.12 — 5.31 in)
(2) Release lever
12) Move the clevis pin to the left and then to the
(3) Operating cylinder
right. It should move without resistance while it is
rattling. If resistance is felt, repeat adjustment pro- 15) If the clutch fluid level increases, hydraulic
cedures again from the beginning. clutch play is correct.
13) Push the release lever until operating cylinder 16) If the clutch fluid level does not increase or
push rod retracts. Ensure that clutch fluid level in push rod does not retract, clutch pedal must be re-
reservoir tank increases. If the clutch fluid level in- adjusted.
creases, hydraulic clutch is properly adjusted; if flu- 17) Check the fluid level on the outside of the res-
id level does not increase or push rod does not ervoir tank. If the level is below “MIN”, add clutch
retract, replace the master cylinder with a new one. fluid to bring it up to “MAX”.
<Ref. to CL-21, Master Cylinder.>
Recommended clutch fluid:
FMVSS No. 116, fresh DOT 3 or DOT 4 brake
(2)
fluid
(1)
(C)
(A)
(3) CL-00227 (B)
(1) Push rod

(2) Release lever CL-00214
(3) Operating cylinder
(A) Max. level
(B) Min. level
(C) Reservoir tank
CL-31
Clutch Switch
CLUTCH SYSTEM
11.Clutch Switch C: INSPECTION

Check the clutch switch continuity. If continuity is
A: REMOVAL not as specified, replace the switch.
1) Disconnect the ground cable from battery. (1) Disconnect the clutch switch connector.
2) Remove the instrument panel lower cover. (2) Measure the resistance between terminal 1
3) Disconnect the connector from clutch switch. and 2 of switch.
4) Remove the clutch switch.
Terminal / Specified resistance
B: INSTALLATION When clutch pedal depressed:
1) Install the clutch switch and clutch pedal stopper 1 — 2/More than 1 M$
so that the gap between them is 0 mm (0 in).
Terminal / Specified resistance
Tightening torque: When clutch pedal not depressed:
8 N"m (0.8 kgf-m, 5.8 ft-lb) 1 — 2/Less than 1$
2 1
(C)
(A)
(B)
CL-00133 CL-00084
(A) Clutch switch D: ADJUSTMENT

(B) Stopper Refer to “ADJUSTMENT” for clutch pedal. <Ref. to
(C) 0 mm (0 in) CL-29, ADJUSTMENT, Clutch Pedal.>
2) Measure the stroke of clutch pedal.

Specified clutch pedal full stroke A:
130 — 135 mm (5.12 — 5.31 in)
(C)
A
(A) (B)
CL-00078
(A) Clutch pedal (Full stroke condition)

(B) Scale
(C) Seat
3) If the clutch pedal stroke is out of specification,

adjust the stroke. <Ref. to CL-29, ADJUSTMENT,
Clutch Pedal.>
4) Connect the clutch switch connector.
CL-32
CLUTCH SYSTEM

A: INSPECTION
1. CLUTCH
1. Clutch slippage (a) Clutch facing smeared by oil Replace.
It is hard to perceive clutch slippage in (b) Worn clutch facing Replace.
the early stage, but pay attention to the (c) Deteriorated diaphragm spring Replace.
following symptoms.
(d) Distorted pressure plate or flywheel Rectify or replace.
• Engine speeds up when shifting.
• High-speed driving is impossible; espe- (e) Defective release bearing holder Rectify or replace.
cially rapid acceleration is impossible and
vehicle speed does not increase in pro-
portion to the increase in engine speed.
• Power falls, particularly when ascend-
ing a slope, and there is a smell of burn-
ing of the clutch facing.
• Method of testing: Put the vehicle in a
stationary condition with parking brake
fully applied. Disengage the clutch and
shift the transmission gear into the 1st.
Gradually allow the clutch to engage
while gradually increasing the engine
speed. The clutch function is satisfactory
if the engine stalls. However, the clutch is
slipping if the vehicle does not start off
and the engine does not stall.
2. Clutch drags. (a) Worn or rusty clutch disc hub spline Replace clutch disc.
As a symptom of this trouble, a harsh (b) Excessive deflection of clutch disc Rectify or replace.
scratching noise develops and control facing
becomes quite difficult when shifting (c) Stick of crankshaft pilot needle bear- Replace.
gears. The symptom becomes more ing
apparent when shifting into the 1st gear.
(d) Cracked clutch disc facing Replace.
However, because much trouble of this
sort is due to defective synchronization (e) Stuck clutch disc (smeared by oil or Replace.
mechanism, carry out the following tests. water)
• Method of testing: <Ref. to CL-34,
DIAGNOSTIC DIAGRAM OF CLUTCH
DRAG, INSPECTION, General Diagnos-
tic Table.>
It may be judged as insufficient disen-
gagement of clutch if any noise occurs
during this test.
3. Clutch chatters. (a) Adhesion of oil on the facing Replace clutch disc.
Clutch chattering is an unpleasant vibra- (b) Weak or broken damper spring Replace clutch disc.
tion to the whole body when the vehicle is (c) Defective facing contact or excessive Replace the defective clutch disc.
just started with clutch partially engaged. disc
(d) Warped pressure plate or flywheel Rectify or replace.
(e) Loose disc rivets Replace clutch disc.
(f) Loose engine mounting Retighten or replace mounting.
(g) Improper adjustment of pitching stop- Adjustment.
per
4. Noisy clutch (a) Broken, worn or unlubricated release Replace the release bearing.
Examine whether the noise is generated bearing
when the clutch is disengaged, engaged, (b) Insufficient lubrication of pilot bearing Replace the pilot bearing.
or partially engaged. (c) Loose clutch disc hub Replace clutch disc.
(d) Loose damper spring retainer Replace clutch disc.
(e) Deteriorated or broken damper spring Replace clutch disc.
CL-33
CLUTCH SYSTEM

5. Clutch grabs. (a) Grease or oil on facing Replace clutch disc.
When starting the vehicle with the clutch (b) Deteriorated cushioning spring Replace clutch disc.
partially engaged, the clutch grabs sud- (c) Worn or rusted spline of clutch disc or Take off rust, apply grease or replace
denly and the vehicle jumps instead of main shaft clutch disc or main shaft.
making a smooth start.
(d) Deteriorated or broken damper spring Replace clutch disc.
(e) Loose engine mounting Retighten or replace mounting.
(f) Deteriorated diaphragm spring Replace.
2. CLUTCH PEDAL
Trouble Corrective action
Insufficient pedal play Adjust pedal free play.
Insufficient clutch pedal free play Adjust pedal free play.
Excessively worn and damaged pedal shaft and/or bushing Replace the bushing and/or shaft with a new one.
3. DIAGNOSTIC DIAGRAM OF CLUTCH DRAG
Step Check Yes No

1 CHECK GEAR NOISE. Is there any abnormal noise Go to step 2. Clutch is normal.
1) Start the engine. from the transmission gear?
2) Disengage the clutch and shift quickly from
neutral to reverse in idling condition.
2 CHECK GEAR NOISE. Is there any abnormal noise Go to step 3. For defective
Disengage the clutch at idle and shift from neu- from the transmission gear? transmission or
tral to reverse within 0.5 — 1.0 seconds. excessive clutch
drag torque;
inspect the pilot
bearing, clutch
disc, transmission
and clutch disc
hub spline.
3 CHECK GEAR NOISE. Is there any abnormal noise Defect in clutch Clutch and fly-
1) Disengage the clutch at idle and shift from from the transmission gear? disengaging. wheel seizure.
neutral to reverse within 0.5 — 1.0 seconds. Inspect clutch disc, Inspect clutch disc,
2) With the clutch disengaged, shift from neu- clutch cover, clutch spline of clutch
tral to reverse, reverse to neutral several times. release, and clutch disc hub.
pedal free play.
CL-34

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2004 LEGACY SERVICE MANUAL QUICK REFERENCE INDEX

AUTOMATIC TRANSMISSION 4AT

AUTOMATIC TRANSMISSION 4AT(diag)

AUTOMATIC TRANSMISSION 5AT

All information, illustration and specifi-

FUJI HEAVY INDUSTRIES LTD. G2320GE5

2. 5MT GEAR SHIFT LEVER

(1) Gear shift knob (11) O-ring (21) Washer

3. DRIVE SELECT LEVER

2. Select Lever 8) Raise the pawl of clamp to remove cable.

haust Pipe.> <Ref. to EX(H4SO 2.0)-13, REMOV-

• DOHC non-turbo model

12) Disconnect the connectors, and then remove

Tightening torque: NOTE:

CS-00372 2) Remove the grip.

4) Remove the indicator cover. 8) Remove the bracket.

5) Remove the blind. 9) Remove the detent spring.

13) Use a flat-tip screwdriver with thin tip to discon-

14) Remove the grommet.

• Insert the link (D) of shift lock release into the

• Connect the switch and solenoid terminal to con-

(A) Shift lock solenoid (Color code: Blue and Red)

4) After completion of installation, shift the select

3. Select Cable • 4AT

(A) Range select lever

(A) Select cable

(A) Select cable (A) Select cable

10) Disconnect the cable from arm assembly. • 5AT

(A) Adjusting nut (A) Select cable

• 5AT 8) Install the heat shield cover.

9) Install the front, center and rear exhaust pipes

D: ADJUSTMENT 5) Turn the adjusting nut B until it lightly touches

6) Set a spanner wrench to adjusting nut B so that

4) Loosen the adjusting nuts on both sides.

4. AT Steering Shift Switch

7) Remove the steering shift switch.

Step Check Yes No

(A) Detent spring

10) Raise the connector pawl.

6) Remove the blind.

11) Use a flat-tip screwdriver with thin tip to discon-

8) Remove the connector from the plate assembly

(A) Shift lock solenoid terminal

• Insert the protrusion (B) of guide plate into the

• Connect the switch and solenoid terminal to con-

(A) Shift lock solenoid (Color code: Blue and Red)

6. MT Gear Shift Lever 9) Lift-up the vehicle.

6) Remove the boot and insulator assembly.

12) Remove the stay from transmission bracket.

13) Remove the rod from joint.

8) Remove the plate assembly from vehicle body.

(C) (B) (B)

(D) (A) CS-00051

14) Remove the cushion rubber from vehicle body. NOTE:

(A) Stay CS-00315

16) Lower the vehicle. (A) Stay

5) Using new self-locking nuts, connect the rod to

6) Using new self-locking nuts, connect the stay to

Tightening torque: (5) Tighten the bolts (C) and (D).

7) Install the heat shield cover.

12) Install the console box. <Ref. to EI-53, INSTAL-

(B) (A) (B) (A) (C)

8) Remove the boss from the joint.