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Transaxle Reassembly

  1. Install washer and snap ring to speedometer shaft and install oil seal. Using driver, install shaft into converter case. Install NEW vehicle speed sensor "2". Tighten to 39-65 INCH lbs. (4.4-7.4 N.m). Install speedometer driven gear to speedometer shaft, secure with snap ring.
  2. Install oil seal to converter case. Install differential case. DO NOT damage speedometer drive and driven gears and differential side retainer contact surfaces. Install snap rings to axle shafts. Insert shafts into differential case and tap into place. Measure shaft end play. End play should be approximately .012-.020" (.30-.50 mm). If no play is felt or play is too large, replace axle shaft.
  3. Wrap axle shafts splined portions with tape. Install oil seals and taper roller bearing outer races to differential side retainers. Install retainers to converter case. Using Handle (499787000), screw in retainers until light contact is felt. Screw in right side slightly deeper than left side.
  4. Install drive pinion shaft with selected shim(s) to oil pump housing. Tighten bearing retainer bolts to 27-31 ft. lbs. (36-42 N.m). Clean oil pump housing and converter case mating surfaces. Install oil pump housing to converter case. Tighten bolts to 27-31 ft. lbs. (36-42 N.m).
  5. Using Socket (498937100) and Wrench (499787100), rotate drive pinion several times. See Fig 1 . Tighten left side retainer until contact is felt when rotating shaft. Loosen right side retainer. Tighten left side retainer and loosen right side retainer until pinion shaft can no longer be turned. This is the "zero" state.
  6. After zero state is established, loosen left side retainer 3 notches and secure with locking tab. Loosen right side retainer and retighten by hand until it stops. Repeat several times. Tighten right side retainer 1 3/4 notches further and secure with locking tab. This sets preload.
  7. Using Socket (499787100), Magnet Base (498247001) and dial indicator, measure backlash. See Fig 2 . Backlash should be .005-.007" (.13-.18 mm). Turning retainers one notch changes backlash approximately .002" (.05 mm).
  8. Remove pump housing and apply Red Lead to 3 or 4 tooth surfaces of ring gear. Install pump housing. Rotate drive pinion shaft forward and reverse several times. Remove oil pump housing and check tooth contact pattern. See GEAR TOOTH CONTACT PATTERNS article in APPLICATIONS & IDENTIFICATION section.
  9. When tooth contact is correct, mark retainer positions and loosen. Install "O" rings and retighten to marked positions. Tighten lock tab bolts to 17-19 ft. lbs. (23-26 N.m). Install NEW seal pipe to converter case.
  10. Install 2 oil seals to drive pinion shaft oil seal retainer with Installer (499247300). Install "O" ring to oil seal retainer with lubricant. Install seal to oil pump housing bore. Install oil seal retainer and tighten bolts to 53-71 INCH lbs. (6-8 N.m).
  11. Apply lubricant to grooves on oil pump cover and install seal rings. Install rubber seal to converter case. Press bearing into transmission case. Install oil seal using plastic hammer. Install manual plate and shaft. Drive in roll pin and ensure smooth operation. Install manual lever, parking rod and nut. Tighten nut to 33-36 ft. lbs. (45-49 N.m). Install detent manual spring and position so spring's center is aligned with center of manual plate. Tighten bolt to 44-62 INCH lbs. (5-7 N.m).
  12. Install lathe-cut seal rings and lip seal to low and reverse piston. Using compressor, install piston into case. See Fig 3 . DO NOT damage seal lip or tilt piston when installing. Using press, install needle bearing to one-way clutch inner race. Install 4 seal rings. Install spring retainer and spring on inner race and install to recessed portion of piston. Tighten bolts from rear side of transmission case to 17-20 ft. lbs. (23-27 N.m).
  13. Install band servo piston assembly. Install snap ring. Set transmission case vertically on wooden blocks with rear of case down. On non-turbo models, install 2 dish plates, 6 driven plates, 6 drive plates, retaining plate and snap ring. See Figure .
  14. Apply compressed air intermittently to check operation. See Figure . Measure clearance between snap ring and retaining plate. Clearance should be .043-.067" (1.10-1.70 mm). If clearance is not within specifications, install correct retaining plate. See LOW & REVERSE BRAKE RETAINING PLATE table.
  15. Install thrust needle bearing on one-way clutch inner race. Install forward clutch drum assembly. Rotate drum slowly, ensuring not to damage seal ring. Drum is installed correctly when its position is .098" (2.50 mm) below inner race surface.
  16. Install thrust needle bearing and thrust washer to overrunning clutch hub. See Figure . Install overrunning clutch hub into transmission case. Ensure splines are correctly engaged. Install one-way outer race assembly. Ensure splines are correctly engaged.
  17. Install thrust needle bearing and thrust washer to rear internal gear. Install the rear internal gear while rotating it. See Figure . Engage thrust needle bearing with dog of overrunning clutch hub. Installation is complete when snap ring top surface of forward clutch drum is receded approximately .138" (3.50 mm) into rear internal gear.
  18. Install thrust needle bearing to inside of rear planetary carrier with lubricant. Install carrier into transmission case while rotating. Install rear sun gear with oil hole facing up.
  19. Attach thrust needle bearing to both sides of front planetary carrier with lubricant. Install front planetary carrier while aligning splines with forward clutch drum and while rotating pinion. Attach thrust needle bearing to front sun gear and install front sun gear while rotating. Attach thrust needle bearing to high clutch hub with lubricant and install by engaging with splines of front planetary carrier. Install high clutch assembly and engage with clutch splines.
  20. Install reverse clutch assembly by engaging high clutch outer splines with reverse clutch splines and front sun gear with cut-out portion of reverse clutch drum. Install brake band assembly. Install strut to band servo piston stem and tighten temporarily to hold band in place.
  21. Adjust total end play and reverse clutch end play. Measure distance from transmission case mating surface to recessed portion of high clutch drum ("H") and record. See Fig 4 . Measure distance from transmission case mating surface to top surface of reverse clutch drum ("M") and record.
  22. Measure distance from oil pump mating surface to top surface of oil pump support with needle bearing ("h"). Measure distance from oil pump mating surface to thrust surface of reverse clutch ("m"). See Fig 4 .
  23. Calculate clearance between high clutch drum and pump support. Use the following equation: Clearance = (H + .016") - h. Gasket thickness is .016" (.40 mm). Select appropriate bearing race that will provide end play of .010-.022" (.25-.55 mm) clearance. See the BEARING RACE SELECTION  table.
  24. Calculate clearance between oil pump support and end of reverse clutch drum. Use the following equation: Clearance = (M + .016") - m. Gasket thickness is .016" (.40 mm). Select appropriate thrust washer that will provide .022-.035" (.55-.90 mm) clearance. See the THRUST WASHER SELECTION  table.
  25. Install selected bearing race in recess of high clutch. Attach thrust washer to oil pump cover with lubricant. Install gasket to case mating surface. Align dowel pins and install oil pump housing to case. Ensure there is no clearance between mating surfaces. Clearance between mating surfaces indicates a damaged seal ring. Install oil pump housing nuts and tighten to 28-33 ft. lbs. (38-44 N.m).
  26. Apply Liquid Gasket (Three-Bond 1215) to converter case mating surface. Ensure rubber seal and seal pipe are fitted in position. Install converter case to transmission case and tighten bolts to 28-33 ft. lbs. (38-44 N.m).
  27. Install accumulators and springs to transmission case. Ensure proper spring installation positions. See ACCUMULATOR SPRING SPECIFICATIONS  table.
  28. Install and route transmission harness. Set range select lever to No. 2 position. Install control valve body by engaging manual valve and manual lever and tightening bolts to 62-80 INCH lbs. (7-9 N.m). DO NOT pinch harness or damage gasket. Tighten control valve body bolts evenly in crisscross pattern.
  29. Install oil filter to control valve body. Connect 4 electrical connectors. Install oil cooler outlet pipe. Install oil pan with magnet to transmission case. Tighten bolts evenly in crisscross pattern to 30-39 INCH lbs. (3.4-4.4 N.m).
  30. On AWD models, press in NEW oil seal in extension housing. Install filter in extension housing. Install transfer clutch valve assembly and tighten bolts to 62-80 INCH lbs. (7-9 N.m). Install pipe and clamp and transfer clutch assembly to extension housing.
  31. On FWD models, install vehicle speed sensor "1" to transmission case. On all models, install reduction driven gear, parking pawl and shaft. Set shift select lever to "P" and tighten drive pinion lock nut to 69-76 ft. lbs. (93-103 N.m). Stake lock nut securely.
  32. On AWD models, determine extension housing end play. Measure distance from transmission case mating surface to reduction drive gear end surface ("h"). See Fig 4 . Measure distance from extension mating surface to rear drive shaft end face ("H"). On FWD models, measure distance from transmission case mating surface to bearing end face ("h"). Measure distance from cover case mating surface to bearing mounting surface ("H").
  33. Calculate clearance between end of reduction drive gear and end of rear drive shaft (AWD). Use the following equation to calculate: Clearance = (H + .016") - h. Thickness of gasket is .016". Select appropriate thrust needle bearing to provide clearance of .002-.010" (.05-.25 mm). See THRUST BEARING SELECTION (AWD)  table.
  34. Calculate clearance between end of reduction drive gear and end of bearing (FWD). Use the following equation to calculate: Clearance = (H + .016") - h. Thickness of gasket is .016". Select appropriate combination of thrust shim(s) to provide clearance of .002-.010" (.05-.25 mm). Thrust washer is available in .006" (.15 mm) thickness. Part number is 31288AA000.
  35. On AWD models, install selected thrust needle bearing to end surface of reduction drive gear with lubricant. Install parking return spring. Remove transfer clutch from extension housing. Install needle bearing on reduction drive shaft and install transfer clutch to transfer clutch hub. Ensure correct spline teeth engagement. Install gasket and extension housing halfway. Connect duty solenoid "C" connector. Complete gasket and extension housing installation. Tighten bolts to 17-20 ft. lbs. (23-27 N.m). Install vehicle speed sensor "1".
  36. On FWD models, install selected aluminum washer(s) on cover case with lubricant. Set parking return spring. Install gasket and cover case to transmission case. Ensure proper alignment of bearing, parking shaft and reduction driven gear. Tighten bolts to 17-20 ft. lbs. (23-27 N.m).
  37. On all models, install inhibitor switch to transmission case. Fit projecting portion of switch into recessed portion of case and tighten bolts temporarily. Insert range selector lever into shaft and tighten nut to 27-31 ft. lbs. (36-42 N.m). Set selector lever to "N" and adjust inhibitor switch so hole of range selector lever is aligned with inhibitor switch hole.
  38. Attach transmission harness, inhibitor switch cord and vehicle sensor cord (AWD). Install oil cooler inlet and outlet pipe. Install oil charge pipe. Tighten brake band adjusting screw to 80 INCH lbs. (9 N.m) then back off 3 turns. Tighten lock nut to 18-21 ft. lbs. (25-28 N.m). Install strut bar bracket. Install air breather hoses to transmission case and oil pump housing.
  39. Install input shaft while turning lightly. Install oil pump shaft to torque converter. Ensure clip fits securely in groove. Install torque converter assembly to converter case, ensuring not to damage bushing. Rotate shaft lightly by hand to engage splines securely.
LOW & REVERSE BRAKE RETAINING PLATE

Part No. Thickness - In. (mm)
31667AA180 .256 (6.50)
31667AA190 .268 (6.80)
31667AA200 .280 (7.10)
31667AA210 .291 (7.40)
31667AA220 .303 (7.70)
31667AA230 .315 (8.00)
31667AA240 .323 (8.20)
31667AA250 .331 (8.40)
BEARING RACE SELECTION

Part No. In. (mm)
803031021 .031 (.80)
803031022 .039 (1.00)
803031023 .047 (1.20)
803031024 .055 (1.40)
803031025 .063 (1.60)
803031026 .071 (1.80)
803031027 .079 (2.00)
THRUST WASHER SELECTION

Part No. In. (mm)
31299AA000 .028 (.70)
31299AA010 .035 (.90)
31299AA020 .043 (1.10)
31299AA030 .051 (1.30)
31299AA040 .059 (1.50)
31299AA050 .067 (1.70)
31299AA060 .075 (1.90)
ACCUMULATOR SPRING SPECIFICATIONS

Spring Outer Diameter In. (mm) Free Length In. (mm)
1-2 1.122 (28.50) 1.752 (44.50)
2-3 .807 (20.50) 1.220 (31.00)
3-4 .681 (17.30) 1.720 (43.70)
N-D .701 (17.80) 1.437 (36.50)
THRUST BEARING SELECTION (AWD)

Part No. In. (mm)
806535020 .150 (3.80)
806535030 .157 (4.00)
806535040 .165 (4.20)
806535050 .173 (4.40)
806535060 .181 (4.60)
806535070 .189 (4.80)
806535090 .197 (5.00)
Fig 1: Setting Drive Pinion Preload
G93F24666Courtesy of SUBARU OF AMERICA, INC.
Fig 2: Measuring Differential Backlash
G93H24668Courtesy of SUBARU OF AMERICA, INC.
Fig 3: Installing Low & Reverse Piston
G93B24670Courtesy of SUBARU OF AMERICA, INC.
Fig 4: Measuring Reverse Clutch & Total End Play
G93D24672Courtesy of SUBARU OF AMERICA, INC.
Fig 5: Measuring Transfer Clutch End Play
G93H24676Courtesy of SUBARU OF AMERICA, INC.
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