Subaru Legacy (2005 year). Service manual — part 532

4AT-109

AUTOMATIC TRANSMISSION

Drive Pinion Shaft Assembly

39.Drive Pinion Shaft Assembly

A: REMOVAL

1) Remove the transmission assembly from vehi-
cle. <Ref. to 4AT-39, REMOVAL, Automatic Trans-
mission Assembly.>
2) Pull out the torque converter clutch assembly.
<Ref. to 4AT-81, REMOVAL, Torque Converter
Clutch Assembly.>
3) Remove the input shaft.

4) Lift up the lever on rear side of transmission har-
ness connector, and then disconnect it from the
stay.
5) Disconnect the inhibitor switch connector from
stay.
6) Disconnect the air breather hose. <Ref. to 4AT-
79, REMOVAL, Air Breather Hose.>
7) Remove the oil charge pipe. <Ref. to 4AT-80,
REMOVAL, Oil Charge Pipe.>
8) Remove the oil cooler inlet and outlet pipes.
<Ref. to 4AT-68, REMOVAL, ATF Cooler Pipe and
Hose.>
9) Separate the converter case and transmission
case part. <Ref. to 4AT-102, REMOVAL, Converter
Case.>
10) Separate the transmission case and extension
case part. <Ref. to 4AT-83, REMOVAL, Extension
Case.>
11) Remove the reduction drive gear. (MP-T mod-
el) <Ref. to 4AT-97, REMOVAL, Reduction Drive
Gear.>
12) Remove the center differential carrier. (VTD
model) <Ref. to 4AT-99, REMOVAL, Center Differ-
ential Carrier.>
13) Remove the reduction driven gear. <Ref. to
4AT-95, REMOVAL, Reduction Driven Gear.>

14) Remove the drive pinion shaft mounting bolt
and remove the drive pinion shaft assembly from oil
pump housing.

B: INSTALLATION

1) Assemble the drive pinion assembly to oil pump
housing.

NOTE:
• Be careful not to bend the shim.
• Be careful not to press-fit the pinion into housing
bore.

Tightening torque:

40 N

⋅

m (4.1 kgf-m, 29.5 ft-lb)

2) Combine the torque converter case with trans-
mission case. <Ref. to 4AT-102, INSTALLATION,
Converter Case.>
3) Install the reduction driven gear. <Ref. to 4AT-
95, INSTALLATION, Reduction Driven Gear.>
4) Install the reduction drive gear. (MP-T model)
<Ref. to 4AT-97, INSTALLATION, Reduction Drive
Gear.>
5) Install the center differential carrier. (VTD model)
<Ref. to 4AT-99, INSTALLATION, Center Differen-
tial Carrier.>
6) Combine the transmission case with extension
case, and then install the rear vehicle speed sen-
sor. <Ref. to 4AT-83, INSTALLATION, Extension
Case.>
7) Insert the inhibitor switch and transmission con-
nector to stay.
8) Install the oil cooler inlet and outlet pipes. <Ref.
to 4AT-70, INSTALLATION, ATF Cooler Pipe and
Hose.>
9) Install the oil charge pipe with O-ring.

AT-00114

AT-01252

AT-01252

4AT-110

AUTOMATIC TRANSMISSION

Drive Pinion Shaft Assembly

10) Insert the input shaft while rotating it lightly by
hand, and then check the protrusion amount.

Normal protrusion A:

50 — 55 mm (1.97 — 2.17 in)

11) Install the torque converter clutch assembly.
<Ref. to 4AT-81, INSTALLATION, Torque Convert-
er Clutch Assembly.>
12) Install the transmission assembly into vehicle.
<Ref. to 4AT-42, INSTALLATION, Automatic
Transmission Assembly.>

C: DISASSEMBLY

1) Remove the caulking part of lock nut, and then
remove the lock nut with holding rear spline part of
shaft using ST1 and ST2. Pull out the drive pinion
collar.
ST1

498937110

HOLDER

ST2

499787700

WRENCH

ST3

499787500

ADAPTER

2) Remove the O-ring.

3) Separate the roller bearing and outer race from
shaft using press.

4) Separate the front roller bearing from shaft using
press and ST.
ST

498517000

REPLACER

D: ASSEMBLY

1) Measure the dimension “A” of drive pinion shaft
using ST.
ST

398643600

GAUGE

AT-03204

A

AT-00197

ST1

ST3

ST2

(A) Outer race

(A) Front roller bearing

AT-00198

(A)

AT-00199

(A)

ST

A

AT-00200

4AT-111

AUTOMATIC TRANSMISSION

Drive Pinion Shaft Assembly

2) Using a press, press-fit the new roller bearing
into specified position.

NOTE:
If excessive force is applied to roller bearing, the
roller bearing will not turn easily.

3) After applying ATF to a new O-ring and fitting it
to the shaft, attach the drive pinion collar to 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-
tion using following formula.
T2 = L2/(L1 + L2)

× T1

T1: 116 N

⋅m (11.8 kgf-m, 85.3 ft-lb)

[Required torque setting]
T2: Tightening torque
L1: ST2 length 0.072 m (2.83 in)
L2: Torque wrench length
Example:

ST1

498937110

HOLDER

ST2

499787700

WRENCH

ST3

499787500

ADAPTER

NOTE:
Install the ST2 to torque wrench as straight as pos-
sible.

6) Measure the starting torque of bearing. Make
sure the starting torque is within the specification. If
the torque is not within specification, replace the
roller bearing.

Starting torque:

7.6 — 38.1 N (0.776 — 3.88 kgf, 1.7 — 8.6 lbf)

7) Stake the caulking of lock nut at two points.
8) Measure the dimension “B” of drive pinion shaft
ST

398643600

GAUGE

9) Calculate the thickness “t” (mm) of drive pinion
shim.
t = 6.5

± 0.0625 − (B − A)

(A) Drive pinion shaft

(B) Roller bearing

Torque wrench length

m (in)

Tightening torque

N

⋅m (kgf-m, ft-lb)

0.4 (15.75)

98 (10.0, 72)

0.45 (17.72)

100 (10.2, 73.8)

0.5 (19.69)

101 (10.3, 74.5)

0.55 (21.65)

102 (10.4, 75)

AT-00201

(B)

(A)

ST1

AT-00202

L1 [m (in)]

L2 [m (in)]

ST2

ST3

AT-00203

B

AT-00204

4AT-112

AUTOMATIC TRANSMISSION

Drive Pinion Shaft Assembly

10) Select three or less shims from following table.

E: INSPECTION

• Make sure that all component parts are free of
scratches, holes and other faults.
• Adjust the teeth alignment. <Ref. to 4AT-112,
ADJUSTMENT, Drive Pinion Shaft Assembly.>

F: ADJUSTMENT

1) Remove the liquid gasket from the mating sur-
face completely.
2) Install the oil pump housing assembly to convert-
er 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)

3) Rotate the drive pinion several times using ST1
and ST2.
ST1

498937110

HOLDER

ST2

499787700

WRENCH

4) Adjust backlash between drive pinion and driven
gear. <Ref. to 4AT-119, ADJUSTMENT, Front Dif-
ferential Assembly.>
5) Apply red lead evenly to the surfaces of three or
four teeth on driven 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-119, 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, it moves toward heel
side.)

• Face contact
Checking item: Backlash is too large.
Contact pattern

Drive pinion shim

Part No.

Thickness mm (in)

31451AA050

0.150 (0.0059)

31451AA060

0.175 (0.0069)

31451AA070

0.200 (0.0079)

31451AA080

0.225 (0.0089)

31451AA090

0.250 (0.0098)

31451AA100

0.275 (0.0108)

AT-00205

AT-00206

ST2

ST1

(A) Toe side

(B) Heel side

AT-00207

(A)

(B)

AT-00208