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Home › Subaru › 2005 › Forester XT, Automatic › Repair and Diagnosis › Transmission › Automatic Trans › Automatic Transmission (4AT) › AT Main Case › Installation

AT Main Case: Installation

  1. Install the low & reverse brake piston.
    NOTE:
    • Be careful not to damage the lip seal.
    • Apply ATF to the lip.
      Fig 1: Installing Low & Reverse Brake Piston
      G03807594Courtesy of SUBARU OF AMERICA, INC.
  2. Install the return spring.
    Fig 2: Installing Return Spring
    G03807595Courtesy of SUBARU OF AMERICA, INC.
  3. Install the spring retainer.
    Fig 3: Installing Spring Retainer
    G03807596Courtesy of SUBARU OF AMERICA, INC.
  4. Install the one-way clutch inner race, spring retainer and return spring.
  5. Tighten the socket bolts evenly from the rear side of transmission case.

    Tightening torque: 

    25 N.m (2.5 kgf-m, 18.1 ft-lb) 

    Fig 4: Tightening Socket Bolts
    G03807597Courtesy of SUBARU OF AMERICA, INC.
  6. Place the front side of transmission body up.
  7. Install the thrust needle bearing.
  8. Place the dish plate, driven plate, drive plate and retaining plate neatly in this order on surface table.
  9. Set the micro gauge to clutch, and read its scale.
    NOTE: The value, which is read in the gauge at this time, is zero point.
  10. Scale and record the weight "Z" of a flat board which will be put on plates.
    NOTE:
    • Use a stiff flat board which does not bend against load.
    • Use a flat board of its weight less than 83 N (8.5 kgf, 18.7 1b).
  11. Put the flat board on retaining plate.
    Fig 5: Measuring Weigh Of Flat Board
    G03807598Courtesy of SUBARU OF AMERICA, INC.
  12. Using the following formula, calculate "N" indicated on the push/pull gauge.

    N = 83 N (8.5 kgf, 18.7 1b) Z

    N: Value indicated on push/pull gauge 83 N (8.5 kgf, 18.7 lb): Load applied to clutch plate

    Z: Flat board weight

  13. Press the center of retaining plate applying force of N with push/pull gauge, and then measure and record the height A. Make more than three measurements at even distance and take the average value.
    NOTE: If three points, measure the height every 120 "THETA" If four points, measure the height every 90 "THETA"
    Fig 6: Measuring Height
    G03807599Courtesy of SUBARU OF AMERICA, INC.
  14. Installation of the low & reverse brake: Install the dish plate, driven plate and retaining plate, and then secure them with snap ring.
    NOTE: Pay attention to the orientation of dish plate.
    Fig 7: Identifying Snap Ring
    G03807600Courtesy of SUBARU OF AMERICA, INC.
  15. Apply compressed air intermittently to check for operation.
    Fig 8: Applying Compressed Air Intermittently
    G03807601Courtesy of SUBARU OF AMERICA, INC.
  16. Place the same thickness of shim on both sides to prevent the plate from tilting, and then measure and record the clearance B.
    NOTE: Do not press the shim downward with excessive force, or else the waveform of drive plates will be broken down.
    Fig 9: Identifying Clearance B
    G03807602Courtesy of SUBARU OF AMERICA, INC.
  17. Piston stroke calculation (Low & reverse brake) Select the retaining plate within the specification by calculating with A and B dimensions which have been recorded before. If the calculated value exceeds the service limit, replace the drive plate with a new one and adjust it within the specification.

    T = A + B

    T: Piston stroke

    A: Collapse amount of drive plate

    B: Clearance between retaining plate and snap ring

    Non-turbo model 

    Initial standard: 

    2.15 - 2.65 mm (0.085 - 0.104 in) 

    Limit thickness: 

    2.95 mm (0.116 in) 

    Turbo model 

    Initial standard: 

    2.7 - 3.2 mm (0.106 - 0.126 in) 

    Limit thickness: 

    3.9 mm (0.154 in) 

    RETAINING PLATE SPECIFICATIONS

    Retaining plate
    Part number Thickness mm (in)
    31667AA420 3.8 (0.150)
    31667AA320 4.1 (0.161)
    31667AA330 4.4 (0.173)
    31667AA340 4.7 (0.185)
    31667AA350 5.0 (0.197)
    31667AA360 5.3 (0.209)
    31667AA370 5.6 (0.220)
    31667AA380 5.9 (0.232)
  18. Install the leaf spring of low & reverse brake.
    Fig 10: Installing Leaf Spring Of Low & Reverse Brake
    G03807603Courtesy of SUBARU OF AMERICA, INC.
  19. Install the 2-4 brake piston and 2-4 brake retainer by aligning the holes of 2-4 brake retainer and hole of transmission case.
    Fig 11: Installing 2-4 Brake Piston And 2-4 Brake Retainer
    G03807604Courtesy of SUBARU OF AMERICA, INC.
  20. Install 2-4 brake piston return spring to transmission case.
    Fig 12: Installing 2-4 Brake Piston Return Spring To Transmission Case
    G03807605Courtesy of SUBARU OF AMERICA, INC.
  21. Position the snap ring in transmission. Using the ST, press the snap ring into specified place.

    ST 498677100 COMPRESSOR

    Fig 13: Positioning Snap Ring In Transmission Using Compressor ST 498677100
    G03807606Courtesy of SUBARU OF AMERICA, INC.
  22. Install the planetary gear and low clutch assembly to transmission case.

    Install carefully while slowly rotating the low clutch and planetary gear assembly paying special attention not to damage the seal ring.

    Fig 14: Installing Planetary Gear And Low Clutch Assembly
    G03807607Courtesy of SUBARU OF AMERICA, INC.
  23. Place the dish plate, driven plate, drive plate and retaining plate neatly in this order on surface table.
  24. Set the micro gauge to clutch, and read its scale.
    NOTE: The value, which is read in the gauge at this time, is zero point.
  25. Scale and record the weight "Z" of a flat board which will be put on plates.
    NOTE:
    • Use a stiff flat board which does not bend against load.
    • Use a flat board of its weight less than 100 N (10.2 kgf, 22.5 lb).
  26. Put the flat board on retaining plate.
    Fig 15: Measuring Weight Of Flat Board
    G03807608Courtesy of SUBARU OF AMERICA, INC.
  27. Using the following formula, calculate "N" indicated on the push/pull gauge.

    N = 100 N (10.2 kgf, 22.5 lb) Z

    N: Value indicated on push/pull gauge

    100 N (10.2 kgf, 22.5 lb): Load applied to clutch plate

    Z: Flat board weight

  28. Press the center of retaining plate applying force of N with push/pull gauge, and then measure and record the height A. Make more than three measurements at even distance and take the average value.
    NOTE: If three points, measure the height every 120 "THETA" If four points, measure the height every 90 "THETA"
    Fig 16: Measuring Height A
    G03807609Courtesy of SUBARU OF AMERICA, INC.
  29. Install the pressure plate, drive plate, driven plate, retaining plate and snap ring.
    Fig 17: Installing Pressure Plate, Drive Plate, Driven Plate, Retaining Plate And Snap Ring
    G03807610Courtesy of SUBARU OF AMERICA, INC.
  30. Install a new 2-4 brake oil seal to transmission case.
    Fig 18: Installing New 2-4 Brake Oil Seal To Transmission Case
    G03807611Courtesy of SUBARU OF AMERICA, INC.
  31. After all 2-4 brake component parts have been installed, blow air intermittently and confirm the operation of brake.
    Fig 19: Blowing Air
    G03807612Courtesy of SUBARU OF AMERICA, INC.
  32. Measure and record the clearance B between the retaining plate and snap ring.
    Fig 20: Identifying Clearance B Between Retaining Plate And Snap Ring
    G03807613Courtesy of SUBARU OF AMERICA, INC.
  33. Piston stroke calculation (2-4 brake)
    • Non-turbo model

      Select the retaining plate within the specification by calculating with A and B dimensions which have been recorded before. If the calculated value exceeds the usage limit, replace the drive plate with a new one and adjust it within the specification.

      T = A + B

      T: Piston stroke

      A: Collapse amount of drive plate

      B: Clearance between retaining plate and snap ring

      Initial standard: 

      1.7 - 2.1 mm (0.067 - 0.083 in) 

      Limit thickness: 

      2.3 mm (0.091 in) 

    • Turbo model

      Measure the clearance B between the retaining plate and the snap ring, and select the retaining plate so that the clearance is within the standard value. At this time, do not push down the retaining plate.

      T = B

      T: Piston stroke

      B: Clearance between retaining plate and snap ring

      NOTE: For calculation of the 2-4 brake piston stroke, measuring of the drive plate collapse amount may omitted.

      Initial standard: 

      0.8 - 1.2 mm (0.031 - 0.047 in) 

      Limit thickness: 

      1.5 mm (0.059 in) 

      RETAINING PLATE SPECIFICATIONS

      Retaining plate
      Part number Thickness mm (in)
      31567AA991 5.6 (0.220)
      31567AB001 5.8 (0.228)
      31567AB011 6.0 (0.236)
      31567AB021 6.2 (0.244)
      31567AB031 6.4 (0.252)
      31567AB041 6.6 (0.260)
  34. Be careful not to mistake the location of the leaf spring to be inserted.
    Fig 21: Identifying Leaf Spring
    G03807614Courtesy of SUBARU OF AMERICA, INC.
  35. Install the thrust needle bearing in correct direction.
    Fig 22: Installing Thrust Needle Bearing
    G03807615Courtesy of SUBARU OF AMERICA, INC.
  36. Install the front sun gear and thrust needle bearing.
    Fig 23: Installing Front Sun Gear And Thrust Needle Bearing
    G03807616Courtesy of SUBARU OF AMERICA, INC.
  37. Install the high clutch hub.

    Attach the thrust needle bearing to hub using Vaseline, and then install the hub by correctly engaging the splines of the front planetary carrier.

  38. Install the thrust needle bearing in proper direction.
    Fig 24: Installing Thrust Needle Bearing
    G03807617Courtesy of SUBARU OF AMERICA, INC.
  39. Install the high clutch assembly.
    Fig 25: Installing High Clutch Assembly
    G03807618Courtesy of SUBARU OF AMERICA, INC.
  40. Adjust the total end play. < Ref. to ADJUSTMENT , Oil Pump Housing. >
  41. Install the thrust needle bearing in proper direction.
    Fig 26: Installing Thrust Needle Bearing
    G03807619Courtesy of SUBARU OF AMERICA, INC.
  42. Install the oil pump housing assembly with a new gasket. < Ref. to OIL PUMP HOUSING . >
  43. Install the converter case assembly into transmission case assembly. < Ref. to INSTALLATION , Converter Case. >
  44. Insert the inhibitor switch and transmission connector to the stay.
    Fig 27: Inserting Inhibitor Switch And Transmission Connector To Stay
    G03807620Courtesy of SUBARU OF AMERICA, INC.
  45. Install the air breather hose. < Ref. to INSTALLATION , Air Breather Hose. >
  46. Install the oil cooler pipe. < Ref. to INSTALLATION , ATF Cooler Pipe and Hose. >
  47. Install the oil charge pipe with a O-ring. < Ref. to INSTALLATION , Oil Charge Pipe. >
  48. Insert the input shaft with rotating it by hand lightly, and then check the protrusion amount.

    Normal protrusion A: 

    50 - 55 mm (1.97 - 2.17 in) 

    Fig 28: Identifying Normal Protrusion A
    G03807621Courtesy of SUBARU OF AMERICA, INC.
  49. Install the torque converter clutch assembly. < Ref. to INSTALLATION , Torque Converter Clutch Assembly. >
  50. Install the transmission assembly into vehicle. < Ref. to INSTALLATION , Automatic Transmission Assembly. >
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