Subaru Legacy (2005 year). Manual — part 525

4AT-81

AUTOMATIC TRANSMISSION

Torque Converter Clutch Assembly

28.Torque Converter Clutch As-

sembly

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 and oil pump
shaft horizontally.

NOTE:
Be sure not to scratch the inside of bushing in oil
pump shaft.

3) Remove the input shaft.

NOTE:
When removing the torque converter clutch assem-
bly, the input shaft is also removed.

4) Remove the oil pump shaft from the torque con-
verter clutch as necessary.

B: INSTALLATION

1) Install the shaft to the converter case when oil
pump shaft is removed.
2) Install the oil pump shaft to torque converter
clutch, and then make sure that the clip is secured
on groove.

3) Apply ATF to O-ring, insert the input shaft while
rotating it lightly by hand, and then check the pro-
trusion.

Normal protrusion A:

50 — 55 mm (1.97 — 2.17 in)

4) With holding the torque converter clutch assem-
bly by hand, carefully install it to torque converter
case. Take care not to damage the bushing. Do not
contact the oil pump shaft bush with starter shaft
part of oil pump cover inappropriately.
5) Lightly rotating the shaft by hands to engage the
spline securely, and then check it is within the di-
mension A.

Dimension A:

2.0 L model

1.1 — 1.3 mm (0.043 — 0.051 in)

2.5 L model

2.7 — 2.9 mm (0.106 — 0.114 in)

AT-00113

AT-00114

(A) Dimension A

(A) Dimension A

AT-00291

A

AT-01352

(A)

AT-00311

(A)

4AT-82

AUTOMATIC TRANSMISSION

Torque Converter Clutch Assembly

6) Install the transmission assembly into vehicle.
<Ref. to 4AT-42, INSTALLATION, Automatic
Transmission Assembly.>

C: INSPECTION

Make sure the ring gear and protrusion of torque
converter clutch end are not deformed or damaged.

4AT-83

AUTOMATIC TRANSMISSION

Extension Case

29.Extension Case

A: REMOVAL

1) Remove the transmission assembly.
<Ref. to 4AT-39, REMOVAL, Automatic Transmis-
sion Assembly.>
2) Remove the rear vehicle speed sensor.
• MP-T model

• VTD model

3) Separate the transmission case and extension
case part.

B: INSTALLATION

1) Install the selected thrust needle bearing to the
end surface of reduction drive gear with vaseline.

NOTE:
Install the thrust needle bearing in correct direction.
2) Install a new gasket.
3) Install the extension case to transmission case.

4) Tighten bolts to secure extension case.

Tightening torque:

25 N

⋅

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

5) Install the rear vehicle speed sensor.

Tightening torque:

7 N

⋅

m (0.7 kgf-m, 5.1 ft-lb)

• MP-T model

• VTD model

6) Install the transmission assembly.
<Ref. to 4AT-42, INSTALLATION, Automatic
Transmission Assembly.>

(A) Rear vehicle speed sensor

(A) Rear vehicle speed sensor

AT-02207

(A)

AT-00117

(A)

AT-00118

(A) Rear vehicle speed sensor

(A) Rear vehicle speed sensor

AT-00118

AT-02207

(A)

AT-00117

(A)

4AT-84

AUTOMATIC TRANSMISSION

Extension Case

C: DISASSEMBLY

1. MP-T MODEL

1) Take out the transfer clutch by lightly tapping the
end of rear drive shaft.

NOTE:
Be careful not to damage the oil seal of extension
case.

2) Remove the transfer clutch pipe without deform-
ing the pipe.

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

2. VTD MODEL

1) Remove the snap ring using ST1, ST2 and ST3
and press.
ST1

398673600

COMPRESSOR

ST2

498627100

SEAT

ST3

398663600

PLIERS

2) Remove the test plug.

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

(A) Transfer clutch

(B) Extension case

(A) Extension case

(B) Transfer clutch pipe

AT-00119

(A)

(B)

AT-00120

(A)

(B)

(A) Test plug

(B) Extension case

AT-00121

ST3

ST2

ST1

AT-00122

(A)

(B)

AT-00123