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Home › Subaru › 2005 › Outback i, 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.
  2. Install the return spring.
    Fig 1: Installing Return Spring
    G03831440Courtesy of SUBARU OF AMERICA, INC.
  3. Install the spring retainer.
    Fig 2: Installing Spring Retainer
    G03831441Courtesy 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 ft-lb) 

    Fig 3: Installing One-Way Clutch Inner Race
    G03831442Courtesy 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 retaining plate, 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 retaining plate.
    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 lb).
  11. Put the flat board on retaining plate.
    Fig 4: Setting Micro Gauge To Retaining Plate
    G03831443Courtesy 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 lb) - 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°. If four points, measure the height every 90°.
    Fig 5: Measuring Height Using Gauge
    G03831444Courtesy 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 6: Identifying Snap Ring
    G03831445Courtesy of SUBARU OF AMERICA, INC.
  15. Apply compressed air intermittently to check for operation.
    Fig 7: Applying Compressed Air
    G03831446Courtesy 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 8: Identifying Shim Thickness
    G03831447Courtesy of SUBARU OF AMERICA, INC.
  17. Piston stroke calculation

    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

    Initial standard: 

    2.15 - 2.65 mm (0.085 - 0.104 in) 

    Limit thickness: 

    2.95 mm (0.116 in) 

    RETAINING PLATE

    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 9: Installing Leaf Spring
    G03831448Courtesy 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 10: Installing Brake Piston
    G03831449Courtesy of SUBARU OF AMERICA, INC.
  20. Install 2-4 brake piston return spring to transmission case.
    Fig 11: Installing Brake Piston
    G03831450Courtesy 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 12: Pressing Snap Ring Using ST
    G03831451Courtesy 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 13: Slowly Rotating Low Clutch
    G03831452Courtesy 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 retaining plate, 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 retaining plate.
    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 14: Putting Flat Board On Retaining Plate
    G03831453Courtesy 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°. If four points, measure the height every 90°.
    Fig 15: Measuring Height Using Gauge
    G03831454Courtesy of SUBARU OF AMERICA, INC.
  29. Install the pressure plate, drive plate, driven plate, retaining plate and snap ring.
    Fig 16: Installing Pressure Plate
    G03831455Courtesy of SUBARU OF AMERICA, INC.
  30. Install a new 2-4 brake oil seal to transmission case.
    Fig 17: Installing Brake Oil Seal
    G03831456Courtesy 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 18: Blowing Air Intermittently
    G03831457Courtesy of SUBARU OF AMERICA, INC.
  32. Measure and record the clearance B between the retaining plate and snap ring.
    Fig 19: Identifying Clearance Between Retaining Plate And Snap Ring
    G03831458Courtesy of SUBARU OF AMERICA, INC.
  33. Piston stroke calculation

    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) 

    RETAINING PLATE

    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 20: Identifying Leaf Spring
    G03831459Courtesy of SUBARU OF AMERICA, INC.
  35. Install the thrust needle bearing in correct direction.
    Fig 21: Installing Thrust Needle Bearing
    G03831460Courtesy of SUBARU OF AMERICA, INC.
  36. Install the front sun gear and thrust needle bearing.
    Fig 22: Installing Front Sun Gear And Thrust Needle Bearing
    G03831461Courtesy 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 23: Installing Thrust Needle Bearing
    G03831462Courtesy of SUBARU OF AMERICA, INC.
  39. Install the high clutch assembly.
    Fig 24: Installing High Clutch Assembly
    G03831463Courtesy 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 25: Installing Thrust Needle Bearing
    G03831464Courtesy 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 into transmission case assembly. < Ref. to , INSTALLATION , Converter Case. >
  44. Insert the inhibitor switch and transmission connector to the stay.
  45. Install the air breather hose. < Ref. to , INSTALLATION , Air Breather Hose. >
    Fig 26: Installing Air Breather Hose
    G03831465Courtesy of SUBARU OF AMERICA, INC.
  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 27: Inserting Input Shaft
    G03831466Courtesy of SUBARU OF AMERICA, INC.
  49. Install the torque converter assembly. < Ref. to , INSTALLATION , Torque Converter Assembly. >
  50. Install the transmission assembly into vehicle. < Ref. to , INSTALLATION , Automatic Transmission Assembly. >
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