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Subaru Impreza 2004 Service Manual

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2004 IMPREZA SERVICE MANUAL
TRANSMISSION SECTION
This service manual has been prepared
to provide SUBARU service personnel
with the necessary information and data
for the correct maintenance and repair
of SUBARU vehicles.
This manual includes the procedures
for maintenance, disassembling, reas-
sembling, inspection and adjustment of
components and diagnostics for guid-
ance of experienced mechanics.
Please peruse and utilize this manual
fully to ensure complete repair work for
satisfying our customers by keeping
their vehicle in optimum condition.
When replacement of parts during
repair work is needed, be sure to use
SUBARU genuine parts.
All information, illustration and specifi-
cations contained in this manual are
based on the latest product information
available at the time of publication
approval.
FUJI HEAVY INDUSTRIES LTD.
QUICK REFERENCE INDEX
CONTROL SYSTEMS
AUTOMATIC TRANSMISSION
AUTOMATIC TRANSMISSION
(DIAGNOSTICS)
MANUAL TRANSMISSION AND
DIFFERENTIAL
MANUAL TRANSMISSION AND
DIFFERENTIAL
MANUAL TRANSMISSION AND
DIFFERENTIAL (DIAGNOSTICS)
CLUTCH SYSTEM
CS
4AT
4AT(diag)
5MT
6MT
6MT(diag)
CL
G1870GE4

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Summary of Contents for Subaru Impreza 2004

  • Page 1 AUTOMATIC TRANSMISSION 4AT(diag) (DIAGNOSTICS) MANUAL TRANSMISSION AND DIFFERENTIAL This service manual has been prepared to provide SUBARU service personnel MANUAL TRANSMISSION AND with the necessary information and data DIFFERENTIAL for the correct maintenance and repair of SUBARU vehicles. MANUAL TRANSMISSION AND...

  • Page 2: Table Of Contents

    AUTOMATIC TRANSMISSION Page General Description ..................2 Automatic Transmission Fluid ..............31 Differential Gear Oil...................33 Road Test....................34 Stall Test ....................35 Time Lag Test ...................37 Line Pressure Test ..................38 Transfer Clutch Pressure Test ..............39 Automatic Transmission Assembly ............41 Transmission Mounting System ..............48 Extension Case Oil Seal ................50 Differential Side Retainer Oil Seal.............51 Inhibitor Switch..................52 Front Vehicle Speed Sensor ..............56...

  • Page 3: General Description

    General Description AUTOMATIC TRANSMISSION 1. General Description 5. PLANETARY GEAR AND PLATE A: SPECIFICATIONS 2.0 L 2.0 L Model 1.6 L Non- 2.5 L Turbo 1. TORQUE CONVERTER CLUTCH turbo Tooth num- 2.0 L ber of front 2.0 L Model 1.6 L Non- 2.5 L...

  • Page 4: Automatic Transmission Fluid

    General Description AUTOMATIC TRANSMISSION 6. SELECTOR POSITION 9. TRANSFER Transmission in neutral, output member immov- 1.6 L and P (Park) able, and engine start possible Model 2.0 L Non- 2.5 L 2.0 L Turbo turbo Transmission in reverse for backing (Reverse) Variable Transfer...

  • Page 5: Differential Gear Oil

    General Description AUTOMATIC TRANSMISSION 10.FINAL REDUCTION Model Except for 1.6 L, 2.0 L Turbo 1.6 L, 2.0 L Turbo Front final gear ratio 4.111 (37/9) 4.444 (40/9) 11.RECOMMENDED GEAR OIL GL-5 ( C) -30 -26 -15 -5 0 25 30 ( F) -22 -15 23 32...
  • Page 6 General Description AUTOMATIC TRANSMISSION B: COMPONENT 1. TORQUE CONVERTER CLUTCH AND CASE (17) (15) (16) (14) (13) (12) (10) (11) AT-02375 Pitching stopper bracket (Turbo Oil drain pipe (16) Converter case model) Input shaft (17) Pitching stopper bracket (Non- O-ring (10) O-ring turbo model)

  • Page 7: Oil Pump

    General Description AUTOMATIC TRANSMISSION 2. OIL PUMP AT-00003 Oil pump rotor (11) Gasket (21) Lock nut Oil pump cover (12) O-ring Seal ring (13) Test plug Tightening torque: N·m (kgf-m, ft-lb) Thrust needle bearing (14) Stud bolt T1: 7 (0.7, 5.1) Drive pinion shaft (15) O-ring...
  • Page 8 General Description AUTOMATIC TRANSMISSION 3. TRANSMISSION CASE AND CONTROL DEVICE (38) (43) (41) (40) (37) (10) (35) (36) (11) (42) (39) (34) (33) (13) (32) (12) (30) (31) (29) (20) (17) (18) (14) (27) (26) (28) (25) (19) (23) (24) (22) (16) (21)
  • Page 9 General Description AUTOMATIC TRANSMISSION ATF level gauge (20) Oil filter stud bolt (39) Nipple Oil charge pipe (21) Drain plug (40) Air breather hose O-ring (22) Gasket (41) Transmission case Transfer valve plate (23) Oil pan (42) Plate ASSY Transfer valve ASSY (24) Magnet (43)
  • Page 10 General Description AUTOMATIC TRANSMISSION 4. CONTROL VALVE AND HARNESS ROUTING (10) (11) (12) (14) (15) (13) (16) (17) (19) (18) (20) (24) (21) (22) (25) (28) (26) (23) (27) AT-01277 Stay (12) Accumulator spring (24) Line pressure duty solenoid Transmission harness (13) Side plate (25)
  • Page 11 General Description AUTOMATIC TRANSMISSION 5. HIGH CLUTCH AND REVERSE CLUTCH AT-00006 High clutch drum Spring retainer (15) Dish plate Lip seal Cover (16) Driven plate (Reverse clutch) D-ring (10) Snap ring (17) Drive plate (Reverse clutch) Reverse clutch piston (11) Driven plate (High clutch) (18) Retaining plate (Reverse clutch)
  • Page 12 General Description AUTOMATIC TRANSMISSION 6. PLANETARY GEAR AND 2-4 BRAKE (13) (12) (11) (10) (19) (18) (16) (17) (16) (17) (16) (15) (14) (24) (26) (25) (23) (22) (21) (20) AT-00007 Thrust needle bearing (10) Washer (19) Snap ring Front sun gear (11) Thrust needle bearing (20)
  • Page 13 General Description AUTOMATIC TRANSMISSION 7. LOW CLUTCH AND LOW & REVERSE BRAKE (10) (11) (16) (15) (14) (13) (12) (21) (23) (22) (20) (19) (18) (30) (17) (29) (28) (27) (28) (27) (25) (26) (24) AT-01278 Snap ring (12) Low clutch drum (23) Return spring Retaining plate...
  • Page 14 General Description AUTOMATIC TRANSMISSION 8. REDUCTION GEAR WITH MPT (11) (10) (13) (12) (11) (10) AT-02376 (A) AWD (B) FWD Seal ring Ball bearing (13) Ball bearing Ball bearing Snap ring Reduction drive gear Reduction driven gear Tightening torque: N·m (kgf-m, ft-lb) Reduction drive shaft (10) Washer...
  • Page 15 General Description AUTOMATIC TRANSMISSION 9. REDUCTION GEAR WITH VTD (11) (10) (23) (22) (21) (19) (20) (19) (17) (18) (16) (15) (14) (13) (12) (32) (31) (29) (30) (27) (27) (28) (27) (26) (25) (24) AT-02203 Ball bearing (13) Rear drive shaft (25) Snap ring Reduction drive gear...
  • Page 16 General Description AUTOMATIC TRANSMISSION 10.DIFFERENTIAL GEAR (12) (13) (11) (12) (11) (13) (10) (10) AT-00011 Crown gear Oil seal (13) Differential bevel gear Pinion shaft O-ring Differential case (RH) Differential side retainer Tightening torque: N·m (kgf-m, ft-lb) Straight pin (10) Lock plate T1: 25 (2.5, 18.1) Differential case (LH)
  • Page 17 General Description AUTOMATIC TRANSMISSION 11.TRANSFER AND EXTENSION CASE WITH MPT (14) (13) (12) (20) (19) (11) (18) (10) (21) (15) (22) (23) (17) (16) AT-00012 Thrust needle bearing (10) Return spring (19) Oil seal Needle bearing (11) Transfer clutch piston (20) Dust cover Snap ring...
  • Page 18 General Description AUTOMATIC TRANSMISSION 12.TRANSFER AND EXTENSION CASE WITH VTD (20) (19) (21) (12) (18) (17) (16) (15) (22) (14) (11) (13) (10) AT-02377 Driven plate (Thick) (10) Multi-plate clutch (LSD) piston (19) O-ring Driven plate (11) D-ring (20) Rear wheel sensor Driven plate (Thin) (12) Gasket...
  • Page 19 General Description AUTOMATIC TRANSMISSION 13.TRANSMISSION MOUNTING AT-01276 Pitching stopper Rear cushion rubber (AWD model) Tightening torque: N·m (kgf-m, ft-lb) Rear bracket (FWD model) Crossmember T1: 35 (3.6, 26) Rear cushion rubber (FWD model) Stopper T2: 39 (4.0, 29) T3: 50 (5.1, 37) T4: 58 (5.9, 43) T5: 70 (7.1, 51) T6: 123 (12.5, 90)
  • Page 20 General Description AUTOMATIC TRANSMISSION C: CAUTION • Be sure to tighten fasteners including bolts and nuts to the specified torque. • Wear working clothing, including a cap, protec- • Place shop jacks or rigid racks at the specified tive goggles and protective shoes during operation. points.
  • Page 21 General Description AUTOMATIC TRANSMISSION ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 498897700 ADAPTER SET Used for measuring transfer clutch pressure. ST-498897700 498545400 FILTER WRENCH Used for removing and installing ATF filter. ST-498545400 498277200 STOPPER SET Used for removing and installing automatic trans- mission assembly to engine.
  • Page 22 General Description AUTOMATIC TRANSMISSION ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 41099AA020 ENGINE SUPPORT • Used for supporting engine. • Used with ENGINE SUPPORT BRACKET (41099AA010). ST41099AA020 398527700 PULLER ASSY • Used for removing extension case roller bear- ing. • Used for removing extension oil seal. •...
  • Page 23 General Description AUTOMATIC TRANSMISSION ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 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...
  • Page 24 General Description AUTOMATIC TRANSMISSION ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 398487700 INSTALLER Used for installing taper roller bearing of front dif- ferential. ST-398487700 398673600 COMPRESSOR Used for removing and installing clutch spring. ST-398673600 498255400 PLATE Used for measuring backlash of hypoid gear. ST-498255400 399893600 PLIERS...
  • Page 25 General Description AUTOMATIC TRANSMISSION ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 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...
  • Page 26 General Description AUTOMATIC TRANSMISSION ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 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.
  • Page 27 General Description AUTOMATIC TRANSMISSION ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 498627100 SEAT Used for holding low clutch piston retainer spring when installing snap ring. ST-498627100 499577000 GAUGE • Used for measuring the transmission case mating surface to the reduction gear end sur- face.
  • Page 28 General Description AUTOMATIC TRANSMISSION ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 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...
  • Page 29 General Description AUTOMATIC TRANSMISSION ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 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 the ball bearing for transfer clutch.
  • Page 30 General Description AUTOMATIC TRANSMISSION ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 28399SA010 OIL SEAL PROTEC- Used for installing front drive shaft. ST28399SA010 398497701 SEAT Used for installing needle bearing. ST-398497701 899524100 PULLER SET • Using the bolt only. (1) Bolt • Used with PULLER SET (499737100). •...
  • Page 31 General Description AUTOMATIC TRANSMISSION ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 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 PURPOSE TOOLS...
  • Page 32 4) Replace with a new gasket, and then tighten the ATF drain plug. gine to raise ATF temperature to 70 — 80°C (158 — 176°F) on SUBARU Select Monitor. <Ref. to Tightening torque: 4AT(diag)-21, READ CURRENT DATA, OPERA- 25 N·m (2.5 kgf-m, 18.1 ft-lb) TION, Subaru Select Monitor.>...
  • Page 33 Automatic Transmission Fluid AUTOMATIC TRANSMISSION 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.
  • Page 34 Differential Gear Oil AUTOMATIC TRANSMISSION 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 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.

  • Page 35: Road Test

    Road Test AUTOMATIC TRANSMISSION 4. Road Test 10.TRANSFER CLUTCH Check if the tight corner braking occurs when the A: INSPECTION vehicle is started with steering wheel held at fully turned position. (MPT model) 1. GENERAL PRECAUTION Road tests should be conducted to properly diag- 11.OIL LEAKS nose the condition of the automatic transmission.

  • Page 36: Stall Test

    Stall Test AUTOMATIC TRANSMISSION 5. Stall Test 13) Perform the stall tests with the select lever in “D” range. Turn hold switch OFF. A: INSPECTION NOTE: NOTE: • Do not continue the stall test for MORE THAN 5 The stall test is of extreme importance in diagnos- SECONDS at a time (from closed throttle, fully ing the condition of the automatic transmission and open throttle to stall speed reading).
  • Page 37 Stall Test AUTOMATIC TRANSMISSION Stall speed (at sea level) Position Cause • Throttle valve not fully open Less than specifications 2 (HOLD switch ON), R • Erroneous engine operation • Torque converter clutch’s one-way clutch slipping • Line pressure too low •...

  • Page 38: Time Lag Test

    Time Lag Test AUTOMATIC TRANSMISSION 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 &...

  • Page 39: Line Pressure Test

    “N” or “P”.) 6) Check for duty ratio changes by opening and 3) Temporarily attach the ST to a suitable place in closing the throttle valve using SUBARU Select the driver’s compartment, remove the blind plug lo- Monitor.

  • Page 40: Transfer Clutch Pressure Test

    Transfer Clutch Pressure Test AUTOMATIC TRANSMISSION 8. Transfer Clutch Pressure ST 498575400 OIL PRESSURE GAUGE ASSY Test A: INSPECTION • MPT MODEL Check the transfer clutch pressure in accordance with the following chart in the same manner as with line pressure. <Ref. to 4AT-38, Line Pressure Test.>...
  • Page 41 Transfer Clutch Pressure Test AUTOMATIC TRANSMISSION STANDARD TRANSFER CLUTCH PRESSURE: AWD mode FWD mode Range posi- ON Duty Transfer clutch pressure Transfer clutch pressure Acceleration opening angle (%) tion ratio (%) (kPa (kg/cm , psi)) (kPa (kg/cm , psi)) 910 — 1,070 —...

  • Page 42: Automatic Transmission Assembly

    Automatic Transmission Assembly AUTOMATIC TRANSMISSION 9. Automatic Transmission As- 10) Remove the pitching stopper. sembly A: REMOVAL 1) Set the vehicle on a lift. 2) Open the front hood fully, and support it with stay. 3) Disconnect the battery ground cable. 4) Remove the air intake duct.
  • Page 43 Automatic Transmission Assembly AUTOMATIC TRANSMISSION 20) Remove the center and rear exhaust pipes, NOTE: and muffler. (Turbo model) Plug the opening to prevent an entry of foreign par- <Ref. to EX(H4DOTC)-9, REMOVAL, Center Ex- ticles into transmission fluid. haust Pipe.>, <Ref. to EX(H4DOTC)-14, REMOV- Rear Exhaust Pipe.>...
  • Page 44 Automatic Transmission Assembly AUTOMATIC TRANSMISSION • WAGON MODEL NOTE: Make sure that the support plates of transmission jack don’t touch the oil pan. 32) Remove the transmission rear crossmember from vehicle. AT-00684 • SEDAN MODEL AT-00024 33) While gradually lowering the transmission jack, fully contract the engine support and tilt the engine rearward.
  • Page 45 Automatic Transmission Assembly AUTOMATIC TRANSMISSION 3) Install the ST to converter case. Tightening torque: ST 498277200 STOPPER SET 50 N·m (5.1 kgf-m, 36.9 ft-lb) AT-00103 AT-00108 4) Install the transmission onto engine. 8) Tighten the bolt of clutch housing cover. (1) Gradually raise the transmission with trans- 9) Lower the vehicle.
  • Page 46 Automatic Transmission Assembly AUTOMATIC TRANSMISSION Tightening torque: ST 28399SA010 OIL SEAL PROTECTOR 25 N·m (2.5 kgf-m, 18.1 ft-lb) AT-00110 AT-00102 19) Align the spline of front differential shaft to that of differential bevel gear for insertion, and remove (3) Clog the plug onto service hole. them using ST.
  • Page 47 Automatic Transmission Assembly AUTOMATIC TRANSMISSION 23) Tighten the installing bolts. (Sedan model) 28) Install the heat shield cover. (If equipped) Tightening torque: 50 N·m (5.1 kgf-m, 36.9 ft-lb) AT-00682 29) Install the rear exhaust pipe and muffler as- sembly. AT-00809 Non-turbo model 24) Install the stabilizer link to transverse link.
  • Page 48 Automatic Transmission Assembly AUTOMATIC TRANSMISSION 38) Install the air intake duct. (Non-turbo model) <Ref. to IN(H4SO)-6, INSTALLATION, Air Intake Duct.> 39) Install the intercooler. (Turbo model) <Ref. to IN(H4DOTC)-10, INSTALLATION, Inter- cooler.> 40) Connect the battery ground cable. 41) Fill ATF up to the middle of the “COLD” side on level gauge by using the oil charge pipe.

  • Page 49: Transmission Mounting System

    Transmission Mounting System AUTOMATIC TRANSMISSION 10.Transmission Mounting Sys- 7) Remove the transmission rear crossmember. A: REMOVAL 1. PITCHING STOPPER 1) Disconnect the ground cable from battery. 2) Remove the air cleaner case. (2.0 L Non-turbo model) <Ref. to IN(H4SO)-5, REMOVAL, Air Cleaner Case.>...
  • Page 50 Transmission Mounting System AUTOMATIC TRANSMISSION 2. TRANSMISSION REAR CROSSMEMBER AND REAR CUSHION RUBBER 1) Install the rear cushion rubber. Tightening torque: 39 N·m (4.0 kgf-m, 29 ft-lb) 2) Install the 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-00026 3) Remove the transmission jack.

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