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Home › Subaru › 2005 › Outback R › Repair and Diagnosis › Transmission › Automatic Trans › Automatic Transmission (5AT) › Automatic Transmission › AT Main Case › Installation

AT Main Case: Installation

  1. Install the reverse brake piston.
    NOTE: Apply ATF onto the piston sliding surface.

    ST1 18762AA000 COMPRESSOR SPECIAL TOOL

    ST2 18765AA000 COMPRESSOR SUPPORT

    ST3 18763AA000 COMPRESSOR SHAFT

  2. Install the return spring.
    Fig 1: Installing Return Spring
    G03831854Courtesy of SUBARU OF AMERICA, INC.
  3. Install the spring retainer and snap ring.

    ST1 18762AA000 COMPRESSOR SPECIAL TOOL

    ST2 18765AA000 COMPRESSOR SUPPORT

    ST3 18763AA000 COMPRESSOR SHAFT

    Fig 2: Installing Spring Retainer And Snap Ring Using Compressor Special Tool ST1 18762AA000
    G03831855Courtesy of SUBARU OF AMERICA, INC.
  4. Install the dish plate.
    NOTE: When installing, make sure that the identification mark is facing the front side of transmission.
  5. Install the drive plate and driven plate.
  6. Install the leaf spring.
    Fig 3: Installing Leaf Spring
    G03831856Courtesy of SUBARU OF AMERICA, INC.
  7. Install the retaining plate.
  8. Install the snap ring of reverse brake.
    Fig 4: Installing Snap Ring Of Reverse Brake
    G03831857Courtesy of SUBARU OF AMERICA, INC.
  9. Perform the clearance check of reverse brake.
    1. Measure the clearance between retaining plate and snap ring using thickness gauge.

      Standard value: 

      0.7-1.1 mm (0.028-0.043 in) 

      Fig 5: Identifying Clearance Between Retainer Plate And Snap Ring
      G03831858Courtesy of SUBARU OF AMERICA, INC.
    2. If the clearance is out of specification, select a suitable retainer plate from following table an assemble it.
    RETAINER PLATE THICKNESS SPECIFICATION

    Retainer plate
    Part Number Thickness mm (in)
    31567AB100 4.2 (0.165)
    31567AB170 4.4 (0.173)
    31567AB180 4.6 (0.181)
    31567AB190 4.8 (0.189)
    31567AB200 5.0 (0.197)
  10. Install the direct clutch assembly.
    Fig 6: Installing Direct Clutch Assembly
    G03831859Courtesy of SUBARU OF AMERICA, INC.
  11. Install the high & low reverse clutch assembly.
    Fig 7: Installing High & Low Reverse Clutch Assembly
    G03831860Courtesy of SUBARU OF AMERICA, INC.
  12. Install the thrust needle bearing of high & low reverse clutch.
    Fig 8: Installing Thrust Needle Bearing Of High & Low Reverse Clutch
    G03831861Courtesy of SUBARU OF AMERICA, INC.
  13. Install the middle & rear sun gear assembly.
    Fig 9: Installing Middle & Rear Sun Gear Assembly
    G03831862Courtesy of SUBARU OF AMERICA, INC.
  14. Install the rear carrier assembly.
    Fig 10: Installing Rear Carrier Assembly
    G03831863Courtesy of SUBARU OF AMERICA, INC.
  15. Install the middle carrier assembly.
    Fig 11: Installing Middle Carrier Assembly
    G03831864Courtesy of SUBARU OF AMERICA, INC.
  16. Install the thrust needle bearing of middle carrier assembly.
    Fig 12: Installing Thrust Needle Bearing Of Middle Carrier Assembly
    G03831865Courtesy of SUBARU OF AMERICA, INC.
  17. Measure the total end play, and select the bearing. < Ref. to , ADJUSTMENT , AT Main Case. >
  18. Install the impact clutch pack assembly to oil pump cover.
    Fig 13: Installing Impact Clutch Pack Assembly To Oil Pump Cover
    G03831866Courtesy of SUBARU OF AMERICA, INC.
  19. Turn the transmission sideways.
  20. Install the oil pump cover.
    1. Apply ATF to the O-ring of input clutch shaft.
    2. Install the oil pump cover to AT main case while supporting the input clutch shaft and oil pump housing by hand.
      Fig 14: Installing Oil Pump Cover To AT Main Case
      G03831867Courtesy of SUBARU OF AMERICA, INC.
    3. Make sure the rear end of drive pinion shaft is engaged to the spline of reduction driven gear.
      Fig 15: Engaging Rear End Of Drive Pinion Shaft To Spline Of Reduction Driven Gear
      G03831868Courtesy of SUBARU OF AMERICA, INC.
    4. Using a cloth, protect the input clutch shaft and rotate to engage the spline of input clutch and rear carrier using pliers.
      NOTE: Work with pressing oil pump cover.
      Fig 16: Rotating Input Clutch Shaft For Engaging Spline Of Input Clutch And Rear Carrier
      G03831869Courtesy of SUBARU OF AMERICA, INC.
    5. Combine the oil pump cover with transmission main case.

    Tightening torque: 

    41 N.m (4.2 kgf-m, 30.4 ft-lb) 

    Fig 17: Combining Oil Pump Cover With Transmission Main Case
    G03831870Courtesy of SUBARU OF AMERICA, INC.
  21. Install the center differential carrier. < Ref. to , INSTALLATION , Center Differential Carrier. >
  22. Install the reduction driven gear. < Ref. to , INSTALLATION , Reduction Driven Gear. >
  23. Install the extension case and intermediate case. < Ref. to , INSTALLATION , Extension Case and Intermediate Case. >
  24. Install the control valve body. < Ref. to , INSTALLATION , Control Valve Body. >
  25. Install the converter case assembly into transmission case assembly. < Ref. to , INSTALLATION , Converter Case. >
  26. Install the air breather hose. < Ref. to , INSTALLATION , Air Breather Hose. >
  27. Install the ATF filter pipe. < Ref. to , INSTALLATION , ATF Filter. >
  28. Install the oil charge pipe with O-ring. < Ref. to , INSTALLATION , Oil Charge Pipe. >
  29. Install the torque converter assembly. < Ref. to , INSTALLATION , Torque Converter Assembly. >
  30. Install the transmission assembly into vehicle. < Ref. to , INSTALLATION , Automatic Transmission Assembly. >
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