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Transaxle Reassembly: Notes

NOTE: Lubricate all components with ATF prior to reassembly. Hold gaskets and thrust washers in place with petroleum jelly. Ensure bolts are tightened evenly.
  1. If only transaxle and differential section were separated, place final drive housing with converter housing facing down. Install Guide (499257100) on spline portion of drive pinion rear end and join differential section with transaxle section. Install transfer drive shaft (4WD only).
  2. Ensure parking rod and parking actuator engages and sealing lip is not damaged. Install valve body, vacuum diaphragm assembly and downshift solenoid. Install servo apply, servo release tubes and oil pan.
  3. Place transaxle on oil pan and install turbine shaft. Install oil pump drive shaft with single oil supply port positioned toward oil pump. See Fig 1. Install torque converter on stator shaft, turbine shaft and pump drive shaft. Use care not to damage oil seal in converter housing.
  4. If complete transaxle was disassembled, install parking pawl and parking pawl shaft. Install parking rod support plate, parking pawl return spring and parking pawl in housing. See Fig 2. Retain with spring after inserting shaft from front side. Connect parking rod and parking lever and retain with clip.
    Fig 1: Positioning Oil Port
    G93I25195Courtesy of SUBARU OF AMERICA, INC.
    Fig 2: Installing Parking Pawl Assembly
    G93J25196Courtesy of SUBARU OF AMERICA, INC.
  5. Install parking rod on notched portion of parking shaft support plate with cam portion positioned at back of parking pawl. Install parking lever to parking lever pin and retain with clip.
  6. Install Drive Pinion Seal Guide (499257100) to splines of drive pinion rear end. Connect transaxle housing and final drive housing using 8 nuts (8 mm). Use care not to damage oil seal.
  7. Engage planetary gear unit with center support assembly and check operation of one-way clutch. Ensure one-way clutch in planetary gear unit rotates clockwise only as viewed from front side of planetary carrier. Separate assemblies.
  8. Place center support and low-reverse brake assembly in Base (499687000) and select a retaining plate so that dimension "H" is 3.242-3.250" (82.35-82.55 mm). See Fig 3.
    Fig 3: Selecting Retaining Plate
    G93A25197Courtesy of SUBARU OF AMERICA, INC.
  9. If clearance is not within specification, correct by installing a retaining plate of different thickness. Center support and low-reverse brake assembly retaining plates are available in thicknesses of .307-.378" (7.80-9.60 mm) in .008" (.20 mm) increments.
  10. Install snap ring, retaining plate, drive plates, driven plates, center support assembly and snap ring into transaxle housing. When installing center support, install bolts (6 mm) in support while turning support gradually being careful not to damage one-way clutch or bushing.
  11. After assembly, measure clearance between piston and driven plate. Clearance should be .028-.039" (.70-1.0 mm). See Fig 4. With clearance correct, apply compressed air to oil hole in center support and check operation of low-reverse brake piston. See Fig 5.
    Fig 4: Measuring Piston & Low-Reverse Driven Plate Clearance
    G93B25198Courtesy of SUBARU OF AMERICA, INC.
    Fig 5: Checking Operation Of Low-Reverse Brake Piston
    G93C25199Courtesy of SUBARU OF AMERICA, INC.
  12. Install connecting shell and clutch hub as an assembly to spline of reverse sun gear and forward sun gear. Install forward clutch assembly and reverse clutch assembly. Ensure that thickness of washer installed between forward clutch and clutch hub is .047" (1.20 mm).
  13. Match projected portions of brake band with notches in transaxle housing and install brake band. Using Gauge (398643600), check transaxle total end play with thrust bearing removed. See Fig 6.
  14. Place gauge block on rear face of transaxle housing. Using depth gauge, measure distance "L" (from forward clutch to top of gauge block). Place gauge block on top of oil pump carrier (with thrust bearing installed).
  15. Measure distance "I" from rear cover mounting surface to top of gauge block. See Fig 7. Note both values for future reference. Add .016" (.40 mm) to distance "L", then subtract allowable transaxle end play of.010-.020" (.25-.50 mm).
  16. Final value is thickness of washer to be installed. End play washers are available in thicknesses of .150-.197" (3.80-5.00 mm) in increments of .008" (.20 mm).
  17. Using Gauge (398643600), check reverse clutch end play. See Fig 8. Place gauge on rear face of transaxle housing and measure distance "M" from rear face of reverse clutch drum to top of gauge block.
    Fig 6: Measuring Distance "L" For End Play Adjustment
    G93F25200Courtesy of SUBARU OF AMERICA, INC.
    Fig 7: Measuring Distance "I" For End Play Adjustment
    G93G25201Courtesy of SUBARU OF AMERICA, INC.
  18. Place gauge on oil pump face and measure distance "m" from rear cover mounting surface to top of gauge. See Fig 9. Add .016" (.40 mm) to distance "M", then subtract allowable end play of .020-.031" (.50-.80 mm) and subtract distance "m".
  19. Final value is thickness of reverse clutch drum thrust washer to be installed. Reverse clutch drum thrust washers are available in thicknesses of .067-.075" (1.70-1.90 mm) in increments of .008" (.20 mm).
  20. Install transfer drive shaft. Secure transfer coupling to transfer drive shaft with a NEW spring pin and engage shaft with drive pinion splines. Install thrust bearing on forward clutch. Apply petroleum jelly to washers and place on oil pump carrier.
  21. Before installing oil pump assembly, ensure mating surfaces of transaxle cover (intermediate housing on 4WD transaxles) and transaxle housing are free of oil. Install oil pump assembly, using care not to drop washers.
  22. Install servo return spring on servo piston. Install band servo piston and piston cover into transaxle housing by using piston rod as a guide. Ensure "O" ring is not damaged. Secure piston with snap ring.
  23. Install brake band apply strut and torque band adjusting screw to 80 INCH lbs. (9 N.m), then back off screw 2 complete turns. Torque lock nut to 20 ft. lbs. (27 N.m). Using shims, adjust clearance between manual plate and spacer to .012" (.30 mm) and torque nut to 24-32 ft. lbs. (33-44 N.m). See Fig 10.
    Fig 8: Measuring Distance "M" For Reverse Clutch End Play
    G93H25202Courtesy of SUBARU OF AMERICA, INC.
    Fig 9: Measuring Distance "m" For Reverse Clutch End Play
    G93I25203Courtesy of SUBARU OF AMERICA, INC.
  24. Install valve body into transaxle housing. Ensure groove in manual valve engages pin in manual plate. Torque valve body bolts to 53-71 INCH lbs. (6-8 N.m). With valve body installed, fully compress vacuum throttle valve and measure distance from end of valve where modulator rod will seat to outside of transaxle housing. See Fig 11.
  25. Resulting measurement will determine length of modulator rod to be installed. Select rod from MODULATOR ROD SELECTION  table. Install "O" ring on vacuum diaphragm and install rod together withvacuum diaphragm.
    MODULATOR ROD SELECTION

    Measurement In. (mm) Rod In. (mm)
    1.201 (30.50) or Less 1.34 (34.0)
    1.2067-1.2224 (30.650-31.050) 1.36 (34.5)
    1.2264-1.2421 (31.150-31.550) 1.38 (35.0)
    1.2461-1.2618 (31.650-32.050) 1.40 (35.5)
    1.2618 (32.050) or More 1.42 (36.0)
    Fig 10: Adjusting Manual Plate-To-Spacer Clearance
    G93J25204Courtesy of SUBARU OF AMERICA, INC.
    Fig 11: Measuring For Modulator Rod Selection
    G93A25205Courtesy of SUBARU OF AMERICA, INC.
  26. Install NEW servo apply and servo release tubes by lightly tapping into position. Ensure tube installed height does not exceed 1.61" (41 mm), as measured from transaxle housing oil pan mating surface. Install oil pan. Place transaxle on oil pan and install turbine shaft and oil pump drive shaft with single oil port toward oil pump.
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