Subaru Legacy IV (2008 year). Manual - part 741

5AT-88

Drive Pinion Shaft Assembly

AUTOMATIC TRANSMISSION

C: DISASSEMBLY

1) Flatten the lock nut tab, and then remove the
lock nut while holding the rear spline part of the
shaft using ST1 and ST2. Pull out the drive pinion
collar.
ST1

18667AA010

HOLDER

ST2

499787700

WRENCH

ST3

499787500

ADAPTER

2) Remove the O-ring.
3) Separate the roller bearing and outer race from
shaft using a press.

4) Separate the front roller bearing from the shaft
using a press and the ST.
ST

498517000

REPLACER

D: ASSEMBLY

1) Measure the dimension “A” of the drive pinion
shaft.
ST

398643600

GAUGE

2) Using a press, press-fit the new roller bearing
into the specified position.

NOTE:
If excessive force is applied to roller bearing, the
roller bearing will not turn easily.

3) After fitting a new O-ring to the shaft, attach the
drive pinion collar to the shaft.

(A) Outer race

(A) Front roller bearing

AT-00197

ST1

ST3

ST2

AT-00198

(A)

AT-00199

(A)

ST

A Measured value

(A) Drive pinion shaft

(B) Roller bearing

A

AT-00200

AT-00201

(B)

(A)

5AT-89

Drive Pinion Shaft Assembly

AUTOMATIC TRANSMISSION

4) Tighten the new lock nuts using ST1, ST2 and
ST3.
Use the calculation below to calculate the tighten-
ing torque.
T2 = L2/(L1 + L2) × T1
T1: 116 N·m (11.8 kgf-m, 85.6 ft-lb)
[Required torque setting]
T2: Tightening torque
L1: ST2 length 0.072 m (2.83 in)
L2: Torque wrench length
Example:

ST1

18667AA010

HOLDER

ST2

499787700

WRENCH

ST3

499787500

ADAPTER

NOTE:
Attach ST2 to torque wrench as straight as possi-
ble.

5) Measure the starting torque of the bearing. Make
sure the starting torque is within the specified
range. If the torque is not within specified range, re-
place the roller bearing.

Starting torque:

7.6 — 38.1 N (0.775 — 3.88 kgf, 1.7 — 8.6 lb)

6) Crimp the locknut in 2 locations.

7) Measure the dimension “B” of the drive pinion
shaft.
ST

398643600

GAUGE

8) Calculate the thickness “t” mm (in) of the drive
pinion shim.
t = 6.5

r0.0625 (0.2559r0.0025) – (B – A)

9) Select three or less shims from following table.

E: INSPECTION

• Make sure that all component parts are free of
scratches, holes and other faults.
• Adjust the tooth alignment. <Ref. to 5AT-90, AD-
JUSTMENT, Drive Pinion Shaft Assembly.>

Torque wrench length

m (in)

Tightening torque

N·m (kgf-m, ft-lb)

0.4 (15.75)

98 (10.0, 72.3)

0.45 (17.72)

100 (10.2, 73.8)

0.5 (19.69)

101 (10.3, 74.5)

0.55 (21.65)

102 (10.4, 75.2)

ST1

AT-00202

L1 [m (in)]

L2 [m (in)]

ST2

ST3

AT-00203

B Measured value

Drive pinion shim

Part No.

Thickness mm (in)

31451AA180

0.150 (0.0059)

31451AA190

0.175 (0.0069)

31451AA200

0.200 (0.0079)

31451AA210

0.225 (0.0089)

31451AA220

0.250 (0.0098)

31451AA230

0.275 (0.0108)

B

AT-00204

5AT-90

Drive Pinion Shaft Assembly

AUTOMATIC TRANSMISSION

F: ADJUSTMENT

1) Remove the liquid gasket from the mating sur-
face completely.
2) Install the converter case to oil pump cover, and
secure them with tightening four bolts evenly.

NOTE:
Use an old gasket or aluminum washer to prevent
damaging the mating surface of the housing.

Tightening torque:

41 N·m (4.2 kgf-m, 30.2 ft-lb)

3) Rotate the drive pinion a few times using ST1
and ST2.
ST1

18667AA010

HOLDER

ST2

499787700

WRENCH

4) Adjust the drive pinion and hypoid driven gear
backlash. <Ref. to 5AT-96, ADJUSTMENT, Front
Differential Assembly.>

5) Apply lead-free red dye evenly on the surface of
three to four teeth of the hypoid driven gear. Rotate
the drive pinion in the leftward and rightward for
several times. Remove the oil pump cover, and
check the tooth contact pattern.
If the teeth contact is inappropriate, adjust the
backlash or thickness of the shim. <Ref. to 5AT-96,
ADJUSTMENT, Front Differential Assembly.>
• Correct tooth contact
Check item: Tooth contact surface is slightly
shifted toward the toe side under a no-load con-
dition. (When driving, it moves towards the heel
side.)

• Face contact
Check item: Backlash is too large.
Contact pattern

Corrective action: Increase the thickness of pinion
height adjusting washer according to the proce-
dures for moving the drive pinion closer to the driv-
en gear.

AT-01985

ST2

ST1

(A) Toe side

(B) Heel side

(A)

(B)

MT-01401

AT-00208

AT-00212

5AT-91

Drive Pinion Shaft Assembly

AUTOMATIC TRANSMISSION

• Flank contact
Check item: Backlash is too small.
Contact pattern

Corrective action: Reduce the thickness of pinion
height adjusting washer according to the procedure
for bringing the drive pinion away from driven gear.

• Toe contact (inside contact)
Check item: Contact area is too small.
Contact pattern

Corrective action: Reduce the thickness of pinion
height adjusting washer according to the procedure
for bringing the drive pinion away from driven gear.

• Heel contact (outside end contact)
Check item: Contact area is too small.
Contact pattern

Corrective action: Increase the thickness of pinion
height adjusting washer according to the proce-
dures for moving the drive pinion closer to the driv-
en gear.

6) If tooth contact is correct, mark the retainer posi-
tion and loosen it. After fitting a new O-ring and oil
seal, screw in the retainer to the marked position.
Tighten the lock plate with specified torque.

Tightening torque:

25 N·m (2.5 kgf-m, 18.4 ft-lb)

AT-00209

AT-00213

AT-00210

AT-00213

(A) Lock plate

AT-00211

AT-00212

AT-01988

(A)