Subaru Legacy (2005 year). Service manual - part 594

5AT-75

AUTOMATIC TRANSMISSION

Rear Drive Shaft

27.Rear Drive Shaft

A: REMOVAL

1) Remove the transmission assembly from vehi-
cle. <Ref. to 5AT-38, REMOVAL, Automatic Trans-
mission Assembly.>
2) Remove the rear vehicle speed sensor, and then
remove the extension case. <Ref. to 5AT-71, RE-
MOVAL, Extension Case and Intermediate Case.>
3) Pull out the rear drive shaft from center differen-
tial assembly.

4) Remove the drive plate and driven plate.

B: INSTALLATION

1) Select the appropriate shim. <Ref. to 5AT-73,
ADJUSTMENT, Transfer Clutch.>
2) Install the drive plate and driven plate.
3) Insert the rear drive shaft into center differential
assembly.
4) Combine the extension case, and then install the
rear vehicle speed sensor. <Ref. to 5AT-71, IN-
STALLATION, Extension Case and Intermediate
Case.>
5) Install the transmission assembly into vehicle.
<Ref. to 5AT-42, INSTALLATION, Automatic
Transmission Assembly.>

C: DISASSEMBLY

1) Using a press, remove the revolution gear.

2) Using a press, remove the front and rear side
ball bearings and clutch hub.

D: ASSEMBLY

Assemble in the reverse order of disassembly.

NOTE:
• Use new ball bearings and revolution gear.
• Make sure the clutch hub is oriented in the cor-
rect direction.

E: INSPECTION

• Check each parts for holes, damages or other
foreign matters.
• Inspect the extension end play and adjust it to
within specification. <Ref. to 5AT-73, ADJUST-
MENT, Transfer Clutch.>

(A) Revolution gear

AT-01963

AT-00149

(A)

(A) Rear ball bearing

(B) Rear drive shaft

(C) Clutch hub

(A) Front side

(B) Clutch hub

(C) Rear side

(D) Revolution gear

AT-00151

(A)

(B)

(C)

AT-00152

(A)

(B)

(C)

(D)

5AT-76

AUTOMATIC TRANSMISSION

Reduction Driven Gear

28.Reduction Driven Gear

A: REMOVAL

1) Remove the transmission assembly from vehi-
cle. <Ref. to 5AT-38, REMOVAL, Automatic Trans-
mission Assembly.>
2) Remove the rear vehicle speed sensor, and then
separate the extension case and intermediate case
from transmission case. <Ref. to 5AT-71, REMOV-
AL, Extension Case and Intermediate Case.>
3) Remove the center differential carrier. <Ref. to
5AT-78, REMOVAL, Center Differential Carrier.>
4) Move the select lever to “P” range.
5) Using the ST1 and ST2, extract the reduction
driven gear.
ST1

499737100

PULLER SET

ST2

18680AA000 HOLDER GEAR

B: INSTALLATION

1) Move the select lever to “P” range.
2) Use a plastic hammer to install reduction driven
gear assembly.
3) Select the reduction gear shim. <Ref. to 5AT-77,
ADJUSTMENT, Reduction Driven Gear.>
4) Connect the transmission case, extension case
and intermediate case, and install the rear wheel
speed sensor. <Ref. to 5AT-71, INSTALLATION,
Extension Case and Intermediate Case.>
5) Install the transmission assembly into vehicle.
<Ref. to 5AT-42, INSTALLATION, Automatic
Transmission Assembly.>

C: DISASSEMBLY

1) Remove the ball bearing from reduction driven
gear using ST.
ST

498077300

REMOVER

2) Remove the ball bearing on the reverse side with
the same procedure as step 1).

3) Remove the snap ring from reduction driven
gear.

D: ASSEMBLY

1) Install the snap ring to reduction driven gear.
2) Install the new ball bearing to reduction driven
gear using press.

(A) Reduction driven gear

AT-01968

ST1

ST2

(A)

(A) Ball bearing

AT-00157

(A)

ST

AT-01969

(A)

ST

AT-01970

5AT-77

AUTOMATIC TRANSMISSION

Reduction Driven Gear

3) Install the ball bearing on the reverse side with
the same procedure as step 2).

E: INSPECTION

Make sure the ball bearing and gear are not de-
formed or damaged.

F: ADJUSTMENT

1) Using a depth gauge, measure the depth “A”
from the mating surface of extension case to ball
bearing on rear end of reduction driven gear.

2) Using a depth gauge, measure the height “B”
from the mating surface of extension case to ball
bearing inside low part of extension case.

3) Calculation formula:
Select the ball bearing shim from the table to adjust
clearances within 0.05 — 0.25 mm (0.0020 —
0.0098 in).
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]

T: Shim clearance
A: Depth from mating surface of extension case to
ball bearing outer ring end surface
B: Height from mating surface of extension case to
ball bearing inside low part

AT-01971

AT-02090

A

AT-02091

B

Reduction gear shim

Part No.

Thickness mm (in)

31288AA030

0.2 (0.008)

31288AA050

0.5 (0.020)

31288AA060

0.3 (0.012)

5AT-78

AUTOMATIC TRANSMISSION

Center Differential Carrier

29.Center Differential Carrier

A: REMOVAL

1) Remove the transmission assembly from vehi-
cle. <Ref. to 5AT-38, REMOVAL, Automatic Trans-
mission Assembly.>
2) Remove the rear wheel speed sensor, and sep-
arate the extension case and intermediate case
from transmission case. <Ref. to 5AT-71, REMOV-
AL, Extension Case and Intermediate Case.>
3) Pull out the rear drive shaft. <Ref. to 5AT-75,
REMOVAL, Rear Drive Shaft.>
4) Pull out the center differential carrier assembly.

5) Pull out the shim(s) from transmission case.

B: INSTALLATION

1) Install the center differential assembly with the
shim(s).

NOTE:
Press-fit it to the bottom of bearing shoulder com-
pletely.

2) Insert the rear drive shaft. <Ref. to 5AT-75, IN-
STALLATION, Rear Drive Shaft.>
3) Connect the transmission case, extension case
and intermediate case, and install the rear wheel
speed sensor. <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: DISASSEMBLY

1) Remove the seal ring (A).

2) Using a press and ST, remove the ball bearing.
ST

498077600

REMOVER

3) Remove the snap ring, and pull out the shaft
from center differential assembly.

4) Remove the thrust washers, pinion gear (A) and
washers from center differential assembly.

AT-01972

AT-01972

(A) Snap ring

(B) Shaft

(A)

AT-02015

AT-00167

AT-01973

(A)

(B)

AT-00169

(A)