Transaxle Disassembly

NOTE: Transaxle assembly should be thoroughly cleaned before disassembly. Disassemble only those parts which require repair or replacement. Use compressed air for drying components and oil passages. DO NOT use rags to dry parts.

On 4WD transaxles, remove rear engine mount and place transaxle on work bench with oil pan facing down. Remove solenoid from extension housing. Disconnect temperature switch lead wire from clip and remove temperature switch from left side of extension housing.
On 4WD transaxles, remove 8 bolts (8 mm) and remove extension housing. Drain ATF, being careful not to drop rear drive gear thrust plate and transfer drive gear assembly. Remove washer from bearing bore on upper side of intermediate housing.
On 4WD transaxles, remove rear shaft assembly from extension housing, using care not to damage oil seal. Remove seal ring. Using Removal Plates (899864100 and 499717000), remove ball bearing, washer and transfer driven gear from shaft.
On 4WD transaxles, remove drum and ball bearing. Disassemble transfer clutch assembly by removing snap ring and front pressure plate. Remove driven plates, drive plates and rear pressure plate.
NOTE: Automatic transaxle and differential sections are not normally separated. If they must be separated, place transaxle section on Stand (399933610).
On all models, if transaxle and differential sections are to be separated, drain remaining ATF. Remove oil pan. Remove valve body on 4WD transaxles. See Fig 1.
Wrap vinyl tape around spline portion of drive pinion rear end so as not to damage oil seal on 4WD transaxles. Separate transaxle and differential.
If complete transaxle is being disassembled, remove turbine and oil pump drive shafts by pulling straight out with pliers (wrapped with vinyl tape), using care not to damage shafts. Disconnect oil cooler pipe from transaxle housing.
Remove wire clips by removing nuts securing transaxle housing to final drive housing. Remove downshift solenoid, transfer solenoid and temperature switch wire clips. Disconnect vacuum pipe and ground cable. Remove oil supply pipe from transaxle after draining fluid. DO NOT lose "O" ring located at end of pipe.
Drain differential gear oil. Drain remaining ATF. Remove oil pan, downshift solenoid, vacuum diaphragm, diaphragm rod and "O" ring.
Remove servo apply and servo release tubes. Remove valve body. Remove transfer valve by separating bend portion of transfer tube clip from transfer pipe. Disconnect transfer tube and remove 2 bolts securing transfer clutch body.
Remove oil pump assembly by tightening band adjustment screw until reverse clutch is lightly held. Remove bolts which secure transaxle cover (intermediate housing on 4WD transaxles). Gently tap housing until oil pump assembly is removed. DO NOT lose thrust washer on oil pump carrier.
NOTE: Note positions of thrust washers, toothed thrust washers and needle bearings for reassembly reference.

Fig 1: Exploded View Of Transaxle Assembly
Courtesy of SUBARU OF AMERICA, INC.
Move transfer drive shaft upward and remove transfer coupling from rear spline of drive pinion. Remove transfer drive shaft. Remove band servo piston and strut band. Remove brake band assembly, reverse clutch assembly and forward clutch assembly.
Remove connecting shell. Remove center support assembly by using 2 bolts (6 mm) bolts. Remove planetary input gears. Remove planetary gear assembly and low-reverse brake plates. Remove retaining plate. Remove planetary output gear.
If necessary, remove selector arm, manual plate and parking rod. Remove transaxle housing by wrapping vinyl tape around splines of drive pinion to prevent damage to oil seal.
If necessary, remove nuts securing transaxle housing to final drive housing. Separate transaxle housing from final drive housing by gently tapping final drive housing. Remove parking pawl, parking pawl shaft and parking pawl support plate.