Subaru 2004 LEGACY Bedienungsanleitung

FUJI HEAVY INDUSTRIES LTD. G2320GE5

2004 LEGACY SERVICE MANUAL QUICK REFERENCE INDEX

TRANSMISSION SECTION

This service manual has been prepared

to provide SUBARU service personnel

with the necessary information and data

for the correct maintenance and repair

of SUBARU vehicles.

This manual includes the procedures

for maintenance, disassembling, reas-

sembling, inspection and adjustment of

components and diagnostics for guid-

ance of experienced mechanics.

Please peruse and utilize this manual

fully to ensure complete repair work for

satisfying our customers by keeping

their vehicle in optimum condition.

When replacement of parts during

repair work is needed, be sure to use

SUBARU genuine parts.

All information, illustration and specifi-

cations contained in this manual are

based on the latest product information

available at the time of publication

approval.

CONTROL SYSTEMS CS

AUTOMATIC TRANSMISSION 4AT

AUTOMATIC TRANSMISSION

(DIAGNOSTICS) 4AT(diag)

AUTOMATIC TRANSMISSION 5AT

AUTOMATIC TRANSMISSION

(DIAGNOSTICS) 5AT(diag)

MANUAL TRANSMISSION AND

DIFFERENTIAL 5MT

CLUTCH SYSTEM CL

CONTROL SYSTEMS CS

Page

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

2. Select Lever................................................................................................7

3. Select Cable..............................................................................................12

4. AT Steering Shift Switch ...........................................................................16

5. Shift Lock Solenoid ...................................................................................18

6. MT Gear Shift Lever..................................................................................21

7. MT Drive Select Lever...............................................................................28

8. Drive Select Cable ....................................................................................30

9. General Diagnostic Table..........................................................................32

CS-2

CONTROL SYSTEMS General Description

1. General Description

A: SPECIFICATION

B: COMPONENT

1. AT SELECT LEVER

Item Specification

Swing torque of rod against lever N (kgf, lb) 3.7 (0.38, 0.84) or less

CS-00370

(30)

(31)

(33)

(32)

(34)

(3)

(4)

(5)

(6)

(7)

(1)

(2)

(27)

(26)

(28)

(25)

(18)

(19)

(29)

(17)

(20)

(15)

(16)

(9)

(10)

(11) (12)

(13)

(14)

(8)

(24)

(23)

(21)

(22)

CS-3

CONTROL SYSTEMS

General Description

(1) Ring indicator (15) Shift lock solenoid UNIT (29) Connector pin

(2) Front cover (16) Plate (30) Snap pin

(3) Grip (17) Grommet (31) Washer

(4) Indicator cover ASSY (18) Plate nut (32) Select cable

(5) Blind (19) Detent spring (33) Nut A

(6) Guide plate (20) Detent plate (34) Clamp

(7) Pin (21) Bushing

(8) Clamp (22) Packing Tightening torque: N

⋅

m (kgf-m, ft-lb)

(9) Lever ASSY (23) Rod T1: 2.2 (0.22, 1.62)

(10) Bushing (24) Spring T2: 6 (0.61, 4.4)

(11) Rod (25) Bracket T3: 7.5 (0.76, 5.5)

(12) Spring (26) Packing T4: 18 (1.8, 13.3)

(13) Arm (27) Spacer

(14) Spring pin (28) Arm ASSY

CS-4

CONTROL SYSTEMS General Description

2. 5MT GEAR SHIFT LEVER

(1) Gear shift knob (11) O-ring (21) Washer

(2) Front cover ASSY (12) Spring pin (22) Stay

(3) Clamp (13) Bushing B (23) Cushion rubber

(4) Boot and insulator ASSY (14) O-ring (24) Boss

(5) Plate ASSY (15) Boot (25) Bushing

(6) Lever (16) Spring pin (26) Self-locking nut

(7) Bushing (17) Joint

(8) Lock wire (18) Rod Tightening torque: N

⋅

m (kgf-m, ft-lb)

(9) Snap ring (19) Spacer T1: 12 (1.2, 8.9)

(10) Bushing (20) Bracket T2: 18 (1.8, 13.3)

CS-00267

T2 (23)

(22)

(21)

(20)

(8)

(25)

(7)

(6)

(9)

(10)

(5)

(12)

(7) (19)

(18)

(17) (7)

(7)

(19)

(26)

(24)

(19)

(7)

(11)

(13)

(14)

(15)

(26) (26)

(26)

(16)

(3)

(4)

(2)

(1)

CS-5

CONTROL SYSTEMS

General Description

3. DRIVE SELECT LEVER

(1) Cover (7) Plate ASSY Tightening torque: N

⋅

m (kgf-m, ft-lb)

(2) Knob (8) Bushing T1: 4.5 (0.46, 3.3)

(3) Lever ASSY (9) Clevis pin T2: 12 (1.2, 8.9)

(4) Bushing (10) Snap pin T3: 27.5 (2.80, 20.3)

(5) Spacer (11) Cable

(6) Spring (12) Clip

CS-00371

(10)

(11)

(12)

(4)

(3)

(7)

(8)

(9)

(5)

(1)

(2)

(6)

CS-6

CONTROL SYSTEMS General Description

C: CAUTION

• Wear work clothing, including a cap, protective

goggles, and protective shoes during operation.

• Remove contamination including dirt and corro-

sion before removal, installation or disassembly.

• Keep the disassembled parts in order and pro-

tect them from dust and dirt.

• Before removal, installation or disassembly, be

sure to clarify the failure. Avoid unnecessary re-

moval, installation, disassembly and replacement.

• Use SUBARU genuine fluid, grease etc. or

equivalent. Do not mix fluid, grease etc. with that of

another grade or from other manufacturers.

• Be sure to tighten fasteners including bolts and

nuts to the specified torque.

• Place shop jacks or rigid racks at the specified

points.

• Apply grease onto sliding or revolution surfaces

before installation.

• Before installing O-rings or snap rings, apply suf-

ficient amount of fluid to avoid damage and defor-

mation.

• Before securing a part in a vice, place cushioning

material such as wood blocks, aluminum plate, or

cloth between the part and vice.

• Before disconnecting electrical connectors, be

sure to disconnect the negative terminal from bat-

tery.

CS-7

CONTROL SYSTEMS

Select Lever

2. Select Lever

A: REMOVAL

1) Set the vehicle on a lift.

2) Disconnect the ground cable from battery.

3) Shift the select lever to “N” range.

4) Lift-up the vehicle.

5) Remove the rear exhaust pipe and muffler.

• SOHC model

<Ref. to EX(H4SO 2.0)-11, REMOVAL, Rear Ex-

haust Pipe.> <Ref. to EX(H4SO 2.0)-13, REMOV-

AL, Muffler.>

• DOHC non-turbo model

<Ref. to EX(H6DO)-8, REMOVAL, Rear Exhaust

Pipe.> <Ref. to EX(H6DO)-10, REMOVAL, Muf-

fler.>

• DOHC turbo model

<Ref. to EX(H4DOTC)-11, REMOVAL, Rear Ex-

haust Pipe.> <Ref. to EX(H4DOTC)-12, REMOV-

AL, Muffler.>

6) Remove the heat shield cover.

7) Remove the cable from arm assembly.

8) Raise the pawl of clamp to remove cable.

9) Lower the vehicle.

10) Remove the console box. <Ref. to EI-53, RE-

MOVAL, Console Box.>

11) Remove the harness clips from bracket.

12) Disconnect the connectors, and then remove

the four bolts to take out the select lever assembly

from vehicle body.

B: INSTALLATION

1) Set the select lever to vehicle body.

2) Tighten the four bolts to install the select lever to

vehicle body, and then connect the connector.

(1) Temporarily tighten the bolt A.

(2) Tighten the bolt B.

(3) Tighten the bolt A.

(4) Tighten the bolts C and D.

(A) Adjusting nut

(B) Arm ASSY

AT-01331

(B)

CS-00278

(A)

(A) Claw

CS-00279

(A)

CS-00372

CS-00373

CS-8

CONTROL SYSTEMS Select Lever

Tightening torque:

18 N

⋅

m (1.8 kgf-m, 13.3 ft-lb)

3) Install the harness clips to bracket.

4) Install the console box. <Ref. to EI-53, INSTAL-

LATION, Console Box.>

5) Shift the select lever to “N” range.

6) Lift-up the vehicle.

7) Shift the range select lever to “N” range.

8) Fix the cable to bracket. <Ref. to CS-13, IN-

STALLATION, Select Cable.>

9) Adjust the select cable position. <Ref. to CS-15,

ADJUSTMENT, Select Cable.>

10) Afterthe completion of adjustment, confirm that

the select lever operates properly at all range posi-

tions.

11) Install the heat shield cover.

12) Install the rear exhaust pipe and muffler.

• SOHC model

<Ref. to EX(H4SO 2.0)-11, INSTALLATION, Rear

Exhaust Pipe.> <Ref. to EX(H4SO 2.0)-13, IN-

STALLATION, Muffler.>

• DOHC non-turbo model

<Ref. to EX(H6DO)-8, INSTALLATION, Rear Ex-

haust Pipe.> <Ref. to EX(H6DO)-10, INSTALLA-

TION, Muffler.>

• DOHC turbo model

<Ref. to EX(H4DOTC)-11, INSTALLATION, Rear

Exhaust Pipe.> <Ref. to EX(H4DOTC)-12, IN-

STALLATION, Muffler.>

13) Inspect the following items. When malfunctions

are found in the inspection, adjust the select cable

and inhibitor switch.

NOTE:

Inhibitor switch for 5AT model is not adjustable.

<Ref. to CS-15, ADJUSTMENT, Select Cable.>

<Ref. to 4AT-52, ADJUSTMENT, Inhibitor Switch.>

(1) Engine starts when the select lever is in “P”

and “N” range, but not in other range.

(2) Back-up light illuminates when the select le-

ver is in “R” range, but not in other range.

(3) Select lever and indicator positions are

matched.

C: DISASSEMBLY

1) Remove the packing and plate.

2) Remove the grip.

3) Insert a flat-tip screwdriver with thin tip under the

connector to disconnect each connector from plate

assembly.

CS-00373

CS-00372

CS-00281

CS-00374

CS-00375

CS-9

CONTROL SYSTEMS

Select Lever

4) Remove the indicator cover.

5) Remove the blind.

6) Remove the bolts, and then remove the guide

plate.

7) Remove the clamp, spring, rod, packing and

bushing.

8) Remove the bracket.

9) Remove the detent spring.

10) Remove the detent plate.

11) Remove the shift lock solenoid assembly.

(A) Clamp

(B) Spring

(D) Bushing

(E) Plate

CS-00376

CS-00285

CS-00377

CS-00378

(A)

(B)

(D)

(C)

(E)

CS-00288

CS-00379

CS-00380

CS-00381

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