Subaru Legacy (2005 year). Service manual — part 638

5AT(diag)-143

AUTOMATIC TRANSMISSION (DIAGNOSTICS)

General Diagnostic Table

Engine skids when driving at 5th. Or slipping occurred.

• Fluid level and condition
• Line pressure
• Accelerator pedal position sensor
• Throttle position sensor
• CAN communication signal
• Oil pressure switch 1 and Front brake solenoid valve

Slip at lock up.

• Fluid level and condition
• Line pressure
• Engine speed signal
• Torque converter turbine speed sensor
• Lock up solenoid valve
• CAN communication signal

Maximum vehicle speed is low.

• Fluid level and condition
• Line pressure
• Accelerator pedal position sensor
• Throttle position sensor
• CAN communication signal
• Direct clutch solenoid valve
• Vehicle speed sensor 1 and 2

There is completely no creep.

• Fluid level and condition
• Engine speed signal
• CAN communication signal
• Oil pressure switch 4 and Direct clutch solenoid valve
• Line pressure

Excessive large creep.

• Engine speed signal
• CAN communication signal
• Oil pressure switch 4

Vehicle cannot be parking condition on “P” range. Parking con-
dition is not released though shifting to other ranges.

• Inhibitor switch
• Control cable adjustment

Vehicle can drive on “P” range.

• Inhibitor switch
• Fluid level and condition
• Control cable adjustment
• Line pressure

Vehicle can drive on “N” range.

• Inhibitor switch
• Fluid level and condition
• Control cable adjustment
• Line pressure

Vehicle cannot drive at any range.

• Fluid level and condition
• Line pressure
• Inhibitor switch
• Control cable adjustment
• Loosing or damaging of propeller shaft.
• Loosing or damaging of drive shaft.

Vehicle cannot drive on “D” range.

• Fluid level and condition
• Line pressure
• Inhibitor switch
• Control cable adjustment
• Loosing or damaging of propeller shaft.
• Loosing or damaging of drive shaft.

Vehicle cannot drive on “R” range.

• Fluid level and condition
• Line pressure
• Inhibitor switch
• Control cable adjustment
• Loosing or damaging of propeller shaft.
• Loosing or damaging of drive shaft.

Symptom

Problem parts

5AT(diag)-144

AUTOMATIC TRANSMISSION (DIAGNOSTICS)

General Diagnostic Table

Engine cannot start on “P” or “N” range

• Key switch and Starter
• Control cable adjustment
• Inhibitor switch
• CAN communication line
• TCM

Engine start other than “N” or “P” range

• Key switch and Starter
• Control cable adjustment
• Inhibitor switch
• TCM

Engine stalls.

• Fluid level and condition
• Engine speed signal
• Torque converter turbine speed sensor
• Lock up solenoid valve
• Line pressure

Engine stalls when shifting to “N”

→ “D” and “R” range.

• Fluid level and condition
• Engine speed signal
• Torque converter turbine speed sensor
• Lock up solenoid valve
• Line pressure

Symptom

Problem parts

MANUAL TRANSMISSION
AND DIFFERENTIAL

5MT

Page

1.

General Description . . . . . . . . . . . . . . . . . . . . . 2

2.

Transmission Gear Oil . . . . . . . . . . . . . . . . . . . ..29

3.

Manual Transmission Assembly . . . . . . . . . . . . . . . ...30

4.

Transmission Mounting System . . . . . . . . . . . . . . . . 36

5.

Oil Seal. . . . . . . . . . . . . . . . . . . . . . . . . ..38

6.

Differential Side Retainer Oil Seal. . . . . . . . . . . . . . . .39

7.

Switches and Harness . . . . . . . . . . . . . . . . . . . ..40

8.

Preparation for Overhaul. . . . . . . . . . . . . . . . . . ...42

9.

Transfer Case and Extension Case Assembly. . . . . . . . . . ..43

10.

Transfer Drive Gear . . . . . . . . . . . . . . . . . . . . ..47

11.

Transfer Driven Gear . . . . . . . . . . . . . . . . . . . . 49

12.

Center Differential . . . . . . . . . . . . . . . . . . . . . .51

13.

Reverse Check Sleeve. . . . . . . . . . . . . . . . . . . ..52

14.

Transmission Case . . . . . . . . . . . . . . . . . . . . ...55

15.

Main Shaft Assembly for Single-Range . . . . . . . . . . . . . 61

16.

Main Shaft Assembly for Dual-Range . . . . . . . . . . . . . ...66

17.

Input Shaft Assembly . . . . . . . . . . . . . . . . . . . . 72

18.

Drive Pinion Shaft Assembly. . . . . . . . . . . . . . . . . .76

19.

Front Differential Assembly . . . . . . . . . . . . . . . . . ...84

20.

Reverse Idler Gear. . . . . . . . . . . . . . . . . . . . . 91

21.

Shifter Fork and Rod . . . . . . . . . . . . . . . . . . . . .93

22.

Counter Gear . . . . . . . . . . . . . . . . . . . . . . . 96

23.

General Diagnostic Table. . . . . . . . . . . . . . . . . . ..98

5MT-2

MANUAL TRANSMISSION AND DIFFERENTIAL

General Description

1. General Description

A: SPECIFICATION

1. MANUAL TRANSMISSION AND DIFFERENTIAL

★1

: For option code, refer to ID section. <Ref. to ID-5, MODEL NUMBER PLATE, IDENTIFICATION, Identification.>

★2

: Dual-range model only

Option code

★1

EC, K4, EK

KA

EC, K4, EK

KA, KS

Model

2.0 L

2.5 L

2.0 i

2.0 GT

Except for

OUTBACK

OUTBACK

Except for

OUTBACK

OUTBACK

Type

5-forward speeds and 1-reverse

(5

× 2-forward speeds and 1 × 2-reverse)

★2

Transmission gear ratio

1st

3.454

3.166

3.454

2nd

1.947

1.882

2.062

3rd

1.366

1.296

1.448

4th

0.972

1.088

5th

0.738

0.825

0.78

0.825

Reverse

3.333

Auxiliary transmission gear

ratio

★2

High

1.000

Low

1.447

1.196

Front reduction
gear

Final

Type of gear

Hypoid

Gear ratio

4.111

3.700

3.900

4.111

Rear reduction
gear

Transfer

Type of gear

Helical

Gear ratio

1.000

Final

Type of gear

Hypoid

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)

Center differential

Type and number of gear

Straight bevel gear (Bevel pinion: 2, Bevel gear: 2 and viscous coupling)

Transmission gear oil

GL-5

Transmission gear oil capacity

Single-range
model

3.5

2 (3.7 US qt, 3.1 Imp qt)

Dual-range
model

4.0

2 (4.2 US qt, 3.5 Imp qt)