Subaru 2004 LEGACY User manual

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)
T1
T1
T2
T4
T3
T4
P
R
N
D
(20)
(15)
(16)
(9)
(10)
(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
T1
T2
T2
T1
T2
T2 (23)
(22)
(21)
(20)
(8)
(25)
(7)
(6)
(9)
(10)
(5)
(12)
(7) (19)
(18)
(17) (7)
(7)
(7)
(19)
(26)
(24)
(19)
(7)
(11)
(13)
(14)
(15)
(26) (26)
(26)
(16)
(3)
(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)
(4)
(3)
(7)
T2
T2
T2
T1
T1
T3
(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
A
C
D
B

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
A
C
D
B
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
(C) Rod
(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