Subaru 2004 LEGACY Service Manual
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Subaru 2004 LEGACY Service Manual

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2004 LEGACY 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)
AUTOMATIC TRANSMISSION
AUTOMATIC TRANSMISSION
(DIAGNOSTICS)
MANUAL TRANSMISSION AND
DIFFERENTIAL
CLUTCH SYSTEM
CS
4AT
4AT(diag)
5AT
5AT(diag)
5MT
CL
G2320GE5

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Summary of Contents for Subaru 2004 LEGACY

  • Page 1 2004 LEGACY SERVICE MANUAL QUICK REFERENCE INDEX TRANSMISSION SECTION CONTROL SYSTEMS AUTOMATIC TRANSMISSION AUTOMATIC TRANSMISSION 4AT(diag) (DIAGNOSTICS) AUTOMATIC TRANSMISSION 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.

  • Page 2: Table Of Contents

    CONTROL SYSTEMS Page General Description ..................2 Select Lever ....................7 Select Cable....................12 AT Steering Shift Switch ................16 Shift Lock Solenoid ...................18 MT Gear Shift Lever..................21 MT Drive Select Lever................28 Drive Select Cable ..................30 General Diagnostic Table................32...

  • Page 3: General Description

    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 (11) (12) (13) (10) (14) (24) (10) (23) (22) (21) (20) (16)
  • Page 4 General Description CONTROL SYSTEMS Ring indicator (15) Shift lock solenoid UNIT (29) Connector pin Front cover (16) Plate (30) Snap pin Grip (17) Grommet (31) Washer Indicator cover ASSY (18) Plate nut (32) Select cable Blind (19) Detent spring (33) Nut A Guide plate (20)

  • Page 5: General Description

    General Description CONTROL SYSTEMS 2. 5MT GEAR SHIFT LEVER (16) (26) (17) (19) (24) (26) (19) (26) (18) (19) (12) (10) (11) (13) (14) (20) (15) (25) (21) (23) (22) (26) CS-00267 Gear shift knob (11) O-ring (21) Washer Front cover ASSY (12) Spring pin (22)
  • Page 6 General Description CONTROL SYSTEMS 3. DRIVE SELECT LEVER (10) (11) (12) CS-00371 ⋅ Cover Plate ASSY Tightening torque: N m (kgf-m, ft-lb) Knob Bushing T1: 4.5 (0.46, 3.3) Lever ASSY Clevis pin T2: 12 (1.2, 8.9) Bushing (10) Snap pin T3: 27.5 (2.80, 20.3) Spacer (11)
  • Page 7 • 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.

  • Page 8: Select Lever

    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.
  • Page 9 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.> (1) Engine starts when the select lever is in “P” and “N”...

  • Page 10: Indicator Cover

    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.
  • Page 11 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. 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.
  • Page 12 Select Lever CONTROL SYSTEMS • Insert the link (D) of shift lock release into the link (C) of shift lock solenoid assembly. CS-00384 • Connect the switch and solenoid terminal to con- nector. 9 10 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)

  • Page 13: Select Cable

    Select Cable CONTROL SYSTEMS 3. Select Cable • 4AT A: REMOVAL 1) Set the vehicle on a lift. 2) Shift the select lever to “N” range. 3) Disconnect the ground cable from battery. 4) Lift-up the vehicle. 5) Remove the front, center and rear exhaust pipes and muffler.
  • Page 14 Select Cable CONTROL SYSTEMS • 5AT • 4AT CS-00328 CS-00039 (A) Select cable (A) Select cable (B) Plate ASSY (B) Plate ASSY 10) Disconnect the cable from arm assembly. • 5AT 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...

  • Page 15: Lever

    Select Cable CONTROL SYSTEMS • 5AT 8) Install the heat shield cover. CS-00327 AT-01331 9) Install the front, center and rear exhaust pipes (A) Range select lever and muffler. (SOHC and DOHC non-turbo model) (B) Snap pin • SOHC model (C) Select lever <Ref.
  • Page 16 Select Cable CONTROL SYSTEMS D: ADJUSTMENT 5) Turn the adjusting nut B until it lightly touches the connector. 1) Shift the select lever to “N” range. 2) Remove the rear exhaust pipe and muffler. • SOHC model <Ref. to EX(H4SO 2.0)-11, REMOVAL, Rear Ex- haust Pipe.>...

  • Page 17: At Steering Shift Switch

    AT Steering Shift Switch CONTROL SYSTEMS 4. AT Steering Shift Switch A: REMOVAL 1) Disconnect the ground cable from battery. 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”...
  • Page 18 AT Steering Shift Switch CONTROL SYSTEMS C: INSPECTION 2 3 4 CS-00387 Step Check SHIFT-UP SWITCH CONTINUITY CHECK. Is the resistance less than 10 Go to step 2. Replace the steer- Ω? 1) Press the shift-up switch. ing shift switch. 2) Measure the resistance between shift switch connector terminals.

  • Page 19: Shift Lock Solenoid

    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- MOVAL, Console Box.> 2) Disconnect the connector.
  • Page 20 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. CS-00384 •...

  • Page 21: Shift Lock Solenoid

    Shift Lock Solenoid CONTROL SYSTEMS C: INSPECTION Step Check Is the resistance 7 — 18 Ω? CHECK SHIFT LOCK SOLENOID. Go to step 2. Replace the shift Measure the resistance of shift lock solenoid lock solenoid. connector terminals. Terminals No. 4 — No. 3: CHECK SHIFT LOCK SOLENOID.

  • Page 22: Mt Gear Shift Lever

    MT Gear Shift Lever CONTROL SYSTEMS 6. MT Gear Shift Lever 9) Lift-up the vehicle. 10) Remove the rear exhaust pipe and muffler. 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.
  • Page 23 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. CS-00052 (A) Stay CS-00315 (B) Cushion rubber 3) Lift-up the vehicle. 15) Extract the spring pin and remove the joint.
  • Page 24 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) CS-00314 10) Install the harness clamp to plate. CS-00050 11) Install the boot and insulator assembly, and se- (A) Stay cure them with clamp.
  • Page 25 MT Gear Shift Lever CONTROL SYSTEMS 2) Remove the rod from lever. 6) Remove the boot, bushing and snap ring from gear shift lever. CS-00317 CS-00320 (A) Rod (A) O-ring (B) Lever (B) Bushing (C) Stay (C) Snap ring 3) Separate the rod and inner boot. 7) Remove the spring pin, and then remove the 4) Remove the snap ring from the stay.
  • Page 26 MT Gear Shift Lever CONTROL SYSTEMS 9) Remove the bushing and spacer from boss. 2) Install the bushing and spacer to boss. CS-00238 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.
  • Page 27 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) CS-00320 CS-00317 (A) O-ring (A) Rod (B) Bushing (B) Lever (C) Snap ring (C) Stay...
  • Page 28 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- age and wear. If necessary, repair or replace faulty parts.

  • Page 29: Mt Drive Select Lever

    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.
  • Page 30 MT Drive Select Lever CONTROL SYSTEMS 3) Remove the bushing and spacer from plate as- sembly. CS-00399 (A) Bushing (B) Spacer 4) Remove the bushing from plate assembly. CS-00400 D: ASSEMBLY 1) Assemble in the reverse order of disassembly. Tightening torque: ⋅...

  • Page 31: Drive Select Cable

    Drive Select Cable CONTROL SYSTEMS 8. Drive Select Cable 8) Remove the clamp, and remove the drive select cable from plate assembly. A: REMOVAL 1) Set the vehicle on a lift. 2) Place the drive select lever in HI position. 3) Push the both sides of knob, and remove the cover.
  • Page 32 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. 2) Push the both sides of knob, and remove the cover. (Rubber type) CS-00404 13) Lift-up the vehicle, and then remove the cable under vehicle.

  • Page 33: General Diagnostic Table

    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.

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