Subaru Legacy IV (2008 year). Manual - part 680

4AT-68

Extension Case

AUTOMATIC TRANSMISSION

25.Extension Case

A: REMOVAL

1) Remove the transmission assembly. <Ref. to
4AT-35, REMOVAL, Automatic Transmission As-
sembly.>
2) Remove the rear vehicle speed sensor.

3) Separate the transmission case and extension
case section.

B: INSTALLATION

1) Apply vaseline to the contact surface, and attach
the selected thrust needle bearing to the end sur-
face of the reduction drive gear.

NOTE:
Install the thrust needle bearing in the correct direc-
tion.
2) Install a new gasket.
3) Install the extension case to transmission case.
4) Tighten bolts to secure the 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, 5.2 ft-lb)

6) Install the transmission assembly. <Ref. to 4AT-
38, INSTALLATION, Automatic Transmission As-
sembly.>

(A) Rear vehicle speed sensor

AT-02207

(A)

AT-04584

(A) Rear vehicle speed sensor

AT-04584

AT-02207

(A)

4AT-69

Extension Case

AUTOMATIC TRANSMISSION

C: DISASSEMBLY

1) Hit the extension case lightly with a plastic ham-
mer, and take out the transfer clutch.

NOTE:
Be careful not to damage the oil seal of the exten-
sion case.

2) Remove the transfer clutch pipe while being
careful not to deform the pipe.

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

D: ASSEMBLY

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

498057300

INSTALLER

2) Press-fit the dust cover.
3) Install the transfer clutch pipe to the extension
case while being careful not to deform the pipe.

4) Install the transfer clutch assembly to the case.

NOTE:
• Be careful not to damage the seal ring.
• Insert the transfer clutch assembly all the way to
the bottom of the bearing shoulder.

E: INSPECTION

• Blow with compressed air to make sure the
transfer pipe and extension case routes are not
clogged or leaking.
• Inspect the extension end play, and adjust it to
within the standard value. <Ref. to 4AT-74, AD-
JUSTMENT, Transfer Clutch.>

(A) Extension case

(B) Transfer clutch

(A) Extension case

(B) Transfer clutch pipe

AT-04656

(A)

(B)

AT-00120

(A)

(B)

(A) Extension case

(B) Transfer pipe

(A) Transfer clutch ASSY

(B) Extension case

AT-00120

(A)

(B)

AT-00125

(A)

(B)

4AT-70

Transfer Clutch

AUTOMATIC TRANSMISSION

26.Transfer Clutch

A: REMOVAL

1) Remove the transmission assembly from vehicle
body. <Ref. to 4AT-35, REMOVAL, Automatic
Transmission Assembly.>
2) Remove the extension case, and then remove
the transfer clutch. <Ref. to 4AT-68, REMOVAL,
Extension Case.> <Ref. to 4AT-69, DISASSEM-
BLY, Extension Case.>

B: INSTALLATION

1) Select the thrust needle bearing. <Ref. to 4AT-
74, ADJUSTMENT, Transfer Clutch.>
2) Install the transfer clutch assembly to the case.

3) Tighten the bolts to secure the case.

Tightening torque:

25 N·m (2.5 kgf-m, 18.4 ft-lb)

4) Install the transmission assembly to the vehicle.
<Ref. to 4AT-38, INSTALLATION, Automatic
Transmission Assembly.>

C: DISASSEMBLY

1) Remove the seal ring.

2) Remove the ball bearing using the ST and the
press.
ST

498077600

REMOVER

3) Using a flat tip screwdriver, etc. remove the snap
ring, and take out the retaining plate, drive plate
and driven plate.

(A) Transfer clutch ASSY

(B) Extension case

AT-00125

(A)

(B)

AT-04584

(A) Seal ring

(B) Rear drive shaft

(A) Snap ring

(B) Rear drive shaft

AT-00127

AT-00128

AT-00129

4AT-71

Transfer Clutch

AUTOMATIC TRANSMISSION

4) Using the ST1, ST2 and ST3, remove the snap
ring, then take out the return spring and transfer
clutch piston seal.
ST1

399893600

PLIER

ST2

398673600

COMPRESSOR

ST3

398623600

SEAT

5) Apply compressed air to the rear drive shaft, to
remove the transfer clutch piston.

D: ASSEMBLY

1) Install the transfer clutch piston.

2) Install the return spring to transfer clutch piston.

3) Apply ATF to the lip of transfer clutch piston seal,
then install.

(A) Snap ring

(B) Transfer clutch piston seal

AT-00130

(B)

(A)

ST1

ST2

ST3

AT-00131

(A) Transfer clutch piston

(B) Rear drive shaft

(A) Return spring

(B) Rear drive shaft

(A) Transfer clutch piston seal

(B) Rear drive shaft

(B)

AT-00132

(A)

(B)

AT-00133

(A)

(B)

AT-00134

(A)