Subaru Legacy (2005 year). Manual - part 528

4AT-93

AUTOMATIC TRANSMISSION

Multi-plate Clutch

31.Multi-plate Clutch

A: REMOVAL

Remove the multi-plate clutch following the same
instructions as for the extension case. <Ref. to
4AT-83, REMOVAL, Extension Case.>

B: INSTALLATION

Install the multi-plate clutch following the same in-
structions as for the extension case. <Ref. to 4AT-
83, INSTALLATION, Extension Case.>

C: INSPECTION

• Inspect the drive plate facing for wear and dam-
age.
• Make sure the snap ring is not worn and the re-
turn spring has no permanent distortion, damage,
or deformation.
• Inspect the D-ring for damage.
• Measure the multi-plate clutch clearance and ad-
just it within specification. <Ref. to 4AT-93, AD-
JUSTMENT, Multi-plate Clutch.>

D: ADJUSTMENT

1) Assemble the drive plate and driven plate to cen-
ter differential carrier.
2) Using the ST, measure the depth “A” from mat-
ing surface of extension case to multi-plate clutch
piston.
ST

398643600

GAUGE

3) Using the ST, measure the height “B” from trans-
mission case mating surface to end of ST.
ST

398744300

PISTON GUIDE

4) Calculation formula:
T = A

− B + 0.45 mm

[T = A

− B + 0.0177 in]

NOTE:
• Calculation formula for “T” is applied when mea-
suring using ST (398643600 GAUGE, 398744300
GAUGE). When not using the ST,
T = (A

− α + 0.45 mm) − (B − β)

[T = (A

− α + 0.0177 in) − (B − β)]

is applied.
T: Thrust needle bearing thickness
A: Depth from the end of the substitute as ST to
multi-plate clutch piston
B: Height from mating surface of transmission case
to end of substitution as ST

α: Tool thickness used when measuring “A”

β: Tool thickness used when measuring “B”
0.45: Gasket thickness (mm)
• Measure the thickness of multi-plate clutch pis-
ton driven and drive plate to find the clearance be-
tween measurement value and “T”.

Initial specification:

0.2 — 0.6 mm (0.008 — 0.024 in)

Service limit:

1.6 mm (0.063 in)

If the clearance exceeds the limit, replace the plate
set (drive and driven). Select a driven plate of multi-
plate clutch piston so that the clearance becomes
within specification.

AT-01031

AT-01033

Driven plate

Part No.

Thickness mm (in)

31589AA041

1.6 (0.063)

31589AA050

2.0 (0.079)

31589AA060

2.4 (0.094)

31589AA070

2.8 (0.110)

4AT-94

AUTOMATIC TRANSMISSION

Rear Drive Shaft

32.Rear Drive Shaft

A: REMOVAL

1) Remove the transmission assembly from vehi-
cle. <Ref. to 4AT-39, REMOVAL, Automatic Trans-
mission Assembly.>
2) Remove the rear vehicle speed sensor, and then
separate the extension case from transmission
case. <Ref. to 4AT-83, REMOVAL, Extension
Case.>
3) Pull out the rear drive shaft from center differen-
tial assembly.

4) Remove the drive plate and driven plate.

B: INSTALLATION

1) Select the appropriate shim. <Ref. to 4AT-91,
VTD MODEL, ADJUSTMENT, Transfer Clutch.>
2) Install the drive plate and driven plate.
3) Insert the rear drive shaft into center differential
assembly.
4) Combine the transmission case with extension
case, and then install the rear vehicle speed sen-
sor. <Ref. to 4AT-83, INSTALLATION, Extension
Case.>
5) Install the transmission assembly into vehicle.
<Ref. to 4AT-42, INSTALLATION, Automatic
Transmission Assembly.>

C: DISASSEMBLY

1) Using a press, remove the revolution gear.

2) Using a press, remove the front and rear side
ball bearings and clutch hub.

D: ASSEMBLY

Assemble in the reverse order of disassembly.

NOTE:
• Use new ball bearings and revolution gear.
• Make sure the clutch hub is oriented in the cor-
rect direction.

E: INSPECTION

• Check that the holes, damages or other foreign
matters are not on each parts.
• Inspect the extension end play and adjust it to
within specification. <Ref. to 4AT-91, VTD MODEL,
ADJUSTMENT, Transfer Clutch.>

(A) Rear drive shaft

(B) Center differential carrier

(A) Revolution gear

AT-02211

(A)

(B)

AT-00149

(A)

(A) Rear ball bearing

(B) Rear drive shaft

(A) Front side

(B) Clutch hub

(D) Revolution gear

AT-00151

(A)

(B)

(C)

AT-00152

(A)

(B)

(C)

(D)

4AT-95

AUTOMATIC TRANSMISSION

Reduction Driven Gear

33.Reduction Driven Gear

A: REMOVAL

1. MP-T MODEL

1) Remove the transmission assembly from vehi-
cle. <Ref. to 4AT-39, REMOVAL, Automatic Trans-
mission Assembly.>
2) Remove the rear vehicle speed sensor, and then
separate the extension case from transmission
case. <Ref. to 4AT-83, REMOVAL, Extension
Case.>
3) Set the select lever to “P” range.
4) Remove the caulking part, and then remove the
lock nut.

5) Using the ST1 and ST2, extract the reduction
driven gear.
ST1

499737000

PULLER

ST2

899524100

PULLER SET

2. VTD MODEL

3) Remove the rear drive shaft. <Ref. to 4AT-94,
REMOVAL, Rear Drive Shaft.>
4) Set the select lever to “P” range.
5) Remove the caulking part, and then remove the
lock nut.

6) Using the ST1 and ST2, extract the reduction
driven gear.
ST1

499737000

PULLER

ST2

899524100

PULLER SET

7) Pull out the center differential assembly. <Ref. to
4AT-99, REMOVAL, Center Differential Carrier.>

B: INSTALLATION

1. MP-T MODEL

1) Set the select lever to “P” range.
2) Using a plastic hammer, install the reduction
driven gear assembly and new washer, and tighten
new drive pinion lock nut.

Tightening torque:

100 N

⋅

m (10.2 kgf-m, 73.8 ft-lb)

3) After tightening, caulk the lock nut.
4) Combine the transmission case with extension
case, and then install the rear vehicle speed sen-
sor. <Ref. to 4AT-83, INSTALLATION, Extension
Case.>
5) Install the transmission assembly into vehicle.
<Ref. to 4AT-42, INSTALLATION, Automatic
Transmission Assembly.>

(A) Reduction driven gear

(B) Reduction drive gear

(A) Reduction driven gear

(B) Reduction drive gear

AT-02212

(A)

(B)

AT-00154

(A)

(B)

ST1

ST2

(A) Reduction driven gear

(B) Reduction drive gear

AT-00155

AT-02212

(A)

(B)

4AT-96

AUTOMATIC TRANSMISSION

Reduction Driven Gear

2. VTD MODEL

1) Set the select lever to “P” range.
2) Use a plastic hammer to install reduction driven
gear assembly.
3) Use a plastic hammer to install the center differ-
ential.
4) Install new lock nut and washer.

Tightening torque:

100 N

⋅

m (10.2 kgf-m, 73.8 ft-lb)

5) After tightening, caulk the lock nut.
6) Insert the rear drive shaft assembly. <Ref. to
4AT-94, INSTALLATION, Rear Drive Shaft.>
7) Combine the transmission case with extension
case, and then install the rear vehicle speed sen-
sor. <Ref. to 4AT-83, INSTALLATION, Extension
Case.>
8) Install the transmission assembly into vehicle.
<Ref. to 4AT-42, INSTALLATION, Automatic
Transmission Assembly.>

C: DISASSEMBLY

1) Remove the snap ring from reduction driven
gear.

2) Remove the ball bearing from reduction driven
gear using ST.
ST

498077600

REMOVER

3) Remove the snap ring from reduction driven
gear.

D: ASSEMBLY

1) Install the snap ring to reduction driven gear.
2) Install the new ball bearing to reduction driven
gear using press.

3) Install the snap ring to reduction driven gear.

E: INSPECTION

Make sure the ball bearing and gear are not de-
formed or damaged.

(A) Snap ring

AT-00155

AT-00156

(A)

(A) Ball bearing

(A) Snap ring

AT-00157

(A)

AT-00158

(A)

AT-00156

(A)

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