Subaru Legacy (2005 year). Service manual — part 593

5AT-71

AUTOMATIC TRANSMISSION

Extension Case and Intermediate Case

25.Extension Case and Interme-

diate Case

A: REMOVAL

1) Remove the transmission assembly.
<Ref. to 5AT-38, REMOVAL, Automatic Transmis-
sion Assembly.>
2) Remove the rear vehicle speed sensor.

3) Separate the extension case and intermediate
case.

4) Separate the intermediate case and transmis-
sion main case.

B: INSTALLATION

1) Secure the intermediate case to transmission
main case.

Tightening torque:

25 N

⋅

m (2.5 kgf-m, 18.4 ft-lb)

NOTE:
Use a new gasket.

2) Attach the selected reduction driven gear shim
to end surface of reduction driven gear with vase-
line. <Ref. to 5AT-77, ADJUSTMENT, Reduction
Driven Gear.>
3) Install the extension case to intermediate case.

NOTE:
Use a new gasket.

Tightening torque:

25 N

⋅

m (2.5 kgf-m, 18.4 ft-lb)

4) Install the rear vehicle speed sensor.

Tightening torque:

7 N

⋅

m (0.7 kgf-m, 5.2 ft-lb)

5) Install the transmission assembly.
<Ref. to 5AT-42, INSTALLATION, Automatic
Transmission Assembly.>

AT-01950

AT-01951

AT-01952

AT-01952

AT-01951

AT-01950

5AT-72

AUTOMATIC TRANSMISSION

Extension Case and Intermediate Case

C: DISASSEMBLY

1) Take out the transfer clutch and multi-plate
clutch hub assembly by lightly tapping the end of
rear drive shaft.

NOTE:
Be careful not to damage the oil seal of extension.
2) Remove the snap ring using ST and press.
ST

18762AA000

COMPRESSOR SPECIAL
TOOL

3) Supply compressed air to remove the clutch pis-
ton.

4) Remove the dust cover from extension case.
5) Remove the oil seal from extension case.

D: ASSEMBLY

1) Press-fit new oil seal using ST and press.
ST

498057300

INSTALLER

2) Press-fit the dust cover.

3) Insert the transfer clutch assembly, spring re-
tainer, return spring and clutch spring retainer.

4) Using the ST and compressor, install the snap
ring.
ST

18762AA000

COMPRESSOR SPECIAL
TOOL

5) Install the transfer clutch. <Ref. to 5AT-73, IN-
STALLATION, Transfer Clutch.>

NOTE:
For 3-transfer clutch model, make sure the pres-
sure plate is included.
6) Install the multi-plate hub assembly.

E: INSPECTION

• Use compressed air to make sure the extension
case routes are not clogged or leaked.
• Inspect the extension end play, and adjust it to
within specification.
<Ref. to 5AT-73, ADJUSTMENT, Transfer Clutch.>

AT-01960

ST

AT-01961

(A) Clutch spring retainer

(B) Return spring

(C) Spring retainer

(D) Transfer clutch piston assembly

AT-03120

(A)

(B)

(C)

(D)

AT-01960

ST

5AT-73

AUTOMATIC TRANSMISSION

Transfer Clutch

26.Transfer Clutch

A: REMOVAL

1) Remove the transmission assembly from vehi-
cle. <Ref. to 5AT-38, REMOVAL, Automatic Trans-
mission Assembly.>
2) Remove the extension case, and then remove
the transfer clutch. <Ref. to 5AT-71, REMOVAL,
Extension Case and Intermediate Case.> <Ref. to
5AT-72, DISASSEMBLY, Extension Case and In-
termediate Case.>

B: INSTALLATION

1) Select the rear drive shaft shim. <Ref. to 5AT-73,
ADJUSTMENT, Transfer Clutch.>
2) Select the driven plate No. 3. <Ref. to 5AT-73,
ADJUSTMENT, Transfer Clutch.>
3) Install the extension case and intermediate
case. <Ref. to 5AT-71, INSTALLATION, Extension
Case and Intermediate Case.>
4) Install the transmission assembly into vehicle.
<Ref. to 5AT-42, INSTALLATION, Automatic
Transmission Assembly.>

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.
• Check that the D-ring is not damaged.
• Inspect the extension end play and adjust it to
within specification. <Ref. to 5AT-73, ADJUST-
MENT, Transfer Clutch.>

D: ADJUSTMENT

1. SELECTION OF REAR DRIVE SHAFT
SHIM

1) Insert the rear drive shaft into the reduction drive
gear and center differential assembly.

2) Using the ST, measure the depth “A”, which is
from mating surface of extension case to ball bear-
ing outer ring contact surface.

ST

398643600

GAUGE

3) Using the ST, measure the height “B” from the
intermediate case mating surface to ball bearing
outer ring contact surface.
ST

398643600

GAUGE

4) Calculation formula:
When clearances are 0.05 mm (0.0020 in):
T (mm) = A

− B + 0.23

[T (in) = A

− B + 0.0091]

When clearances are 0.25 mm (0.0098 in):
T (mm) = A

− B + 0.03

[T (in) = A

− B + 0.0012]

Specification:

0.05 — 0.25 mm (0.0020 — 0.0098 in)

A: Depth from end of extension case to ball bearing
outer ring contact surface
B: Height from end of intermediate case to ball
bearing outer ring contact surface
T: Shim thickness

NOTE:
Calculation formula for “T” is applied when measur-
ing using ST (398643600 GAUGE). When not us-
ing ST, apply following.
When clearances are 0.05 mm (0.0020 in):
T (mm) = (A

− α) − ((B − β) − 0.28) − 0.05

[T (in) = (A

− α) − ((B − β) − 0.011) − 0.0020]

When clearances are 0.25 mm (0.0098 in):
T (mm) = (A

− α) − ((B − β) − 0.28) − 0.25

[T (in) = (A

− α) − ((B − β) − 0.011) − 0.0098]

AT-01963

AT-01964

A

AT-01965

B

5AT-74

AUTOMATIC TRANSMISSION

Transfer Clutch

T: Shim thickness
A: Depth from end of extension case to ball bearing
outer ring contact surface
B: Height from end of intermediate case to ball
bearing outer ring contact surface

α: Tool thickness used when measuring “A”

β: Tool thickness used when measuring “B”
0.28 (0.011): Gasket thickness (Unit mm (in))

2. SELECTION OF DRIVEN PLATE No. 3

1) Install the drive plate and driven plate to center
differential carrier.
2) Measure the depth “A” from the mating surface
of extension case to multi-plate clutch (LSD) piston.

3) Using the ST, measure the height “B” from the
intermediate case mating surface to end of ST, and
then subtract the thickness of ST (piston guide) (50
mm (1.97 in)) from measured value.
ST

398744300

PISTON GUIDE

4) Calculation formula:
When clearances are 0.2 mm (0.008 in):
T (mm) = A

− B + 0.08

[T (in) = A

− B + 0.0031]

When clearances are 0.6 mm (0.024 in):
T (mm) = A

− B + 0.32

[T (in) = A

− B + 0.0126]

T: Thickness of driven plate No. 3
A: Depth from mating surface of extension case to
multi-plate clutch (LSD) piston
B: Height from mating surface of intermediate case
to end surface of ST

Specification:

0.2 — 0.6 mm (0.008 — 0.024 in)

NOTE:
Calculation formula for “T” is applied when measur-
ing using ST (398643600 GAUGE, 398744300
PISTON GUIDE). When not using ST, apply follow-
ing.
When clearances are 0.2 mm (0.008 in):
T (mm) = A

− (B − α − 0.28) − 0.2

[T (in) = A

− (B − α − 0.011) − 0.008]

When clearances are 0.6 mm (0.024 in):
T (mm) = A

− (B − α − 0.28) − 0.6

[T (in) = A

− (B − α − 0.011) − 0.024]

T: Thickness of driven plate No. 3
A: Depth from mating surface of extension case to
multi-plate clutch (LSD) piston
B: Height from mating surface of intermediate case
to end surface of tool as substitution for ST

α: Tool thickness used when measuring “B”
0.28 (0.011): Gasket thickness (Unit mm (in))
If out of specification, select the driven plate No. 3
to adjust within the specification.

Adjustment shim

Part No.

Thickness mm (in)

33281AA040

0.2 (0.008)

33281AA050

0.5 (0.020)

33281AA060

0.3 (0.012)

AT-01966

A

AT-03077

B

ST

Driven plate No. 3.

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)