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Home › Subaru › 2007 › Forester X, Automatic › Repair and Diagnosis › Transmission › Automatic Trans › Automatic Transmission (4AT) › AT Main Case › Installation

AT Main Case: Installation

  1. Apply ATF fluid to the lip, then attach the low & reverse brake piston.
    NOTE: Do not damage the lip seal.
    Fig 1: Identifying Lip Seal
    G05002754Courtesy of SUBARU OF AMERICA, INC.
  2. Install the return spring.
    Fig 2: Identifying Return Spring
    G05002752Courtesy of SUBARU OF AMERICA, INC.
  3. Install the spring retainer.
    Fig 3: Identifying Spring Retainer
    G05002751Courtesy of SUBARU OF AMERICA, INC.
  4. Install the one-way clutch inner race.
  5. Tighten the socket head 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 Head Bolts
    G05002750Courtesy 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 retaining plate.
    NOTE:
    • Use a stiff board which does not bend against load as a flat board to be put on retaining plate.
    • Use a flat board weighing less than 8.5 kg (18.7 lb).
  11. Put the flat board on retaining plate.
    Fig 5: Setting Micro Gauge To Clutch
    G05002759Courtesy of SUBARU OF AMERICA, INC.
  12. Using the following formula, read the push/pull gauge, and calculate "N".

    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 by applying a force of N using push/pull gauge, and then measure and record the height A. Measure at three locations or more spaced by equal distances and take the average value.
    NOTE: If measuring in three locations, measure every 120°. If in four locations, measure every 90°.
    Fig 6: Checking Dish Plate
    G05326792Courtesy of SUBARU OF AMERICA, INC.
  14. Installation of the low & reverse brake: Install the dish plate, driven plate, drive plate and retaining plate, and then secure them with a snap ring.
    NOTE: Pay attention to the orientation of the dish plate.
    Fig 7: Identifying Snap Ring
    G05326793Courtesy of SUBARU OF AMERICA, INC.
  15. Apply compressed air intermittently to check for operation.
    Fig 8: Applying Compressed Air Intermittently To Check For Operation
    G05002753Courtesy of SUBARU OF AMERICA, INC.
  16. Measure the clearance.
    1. Place same thickness shims on both sides to prevent plate from tilting, then measure and record the clearance B.
      Fig 9: Measuring Clearance
      G04990616Courtesy of SUBARU OF AMERICA, INC.
    2. Piston stroke calculation

      Calculate with A and B dimensions recorded before. If the calculated value exceeds the service limit, replace the drive plate with a new part and select and adjust the retaining plate to be within the default specification values.

      T = A + B

      T: Piston stroke

      A: Amount of drive plate compression

      B: Clearance between retaining plate and snap ring

      Turbo model 

      Initial standard: 

      2.7 - 3.2 mm (0.106 - 0.126 in) 

      Limit thickness: 

      3.9 mm (0.153 in) 

      Non-turbo model 

      Initial standard: 

      2.15 - 2.65 mm (0.085 - 0.104 in) 

      Limit thickness: 

      2.95 mm (0.116 in) 

      RETAINING PLATE THICKNESS SPECIFICATION

      Retaining plate
      Part No. 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)
  17. Install the leaf spring of the low & reverse brake.
    Fig 10: Identifying Leaf Spring
    G05326796Courtesy of SUBARU OF AMERICA, INC.
  18. Install the 2-4 brake piston and 2-4 brake retainer by aligning the hole of the 2-4 brake retainer with the hole on the transmission case.
    Fig 11: Identifying Brake Piston And Brake Retainer
    G05326797Courtesy of SUBARU OF AMERICA, INC.
  19. Install 2-4 brake piston spring retainer to the transmission case.
    Fig 12: Identifying Brake Piston Spring Retainer To Transmission Case
    G05326798Courtesy of SUBARU OF AMERICA, INC.
  20. Position the snap ring in the transmission. Using ST, press the snap ring into the specified location.

    ST 498677100 COMPRESSOR

    Fig 13: Identifying ST Compressor (498677100)
    G05002767Courtesy of SUBARU OF AMERICA, INC.
  21. Install the planetary gear and low clutch assembly to the transmission case.
    NOTE: Install carefully while rotating the low clutch and planetary gear assembly slowly, paying special attention not to damage the seal ring.
    Fig 14: Identifying Planetary Gear Assembly And Low Clutch Assembly
    G05002742Courtesy of SUBARU OF AMERICA, INC.
  22. Measure the amount of drive plate compression and record that value. (Non-turbo model)
    1. Place the dish plate, driven plate, drive plate and retaining plate neatly in this order on surface table.
    2. 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.
    3. Scale and record the weight "Z" of a flat board which will be put on retaining plate.
      NOTE:
      • Use a stiff board which does not bend against load as a flat board to be put on retaining plate.
      • Use a flat board weighing less than 10. 2 kg (22.5 lb).
    4. Put the flat board on retaining plate.
      Fig 15: Setting Micro Gauge To Clutch
      G05002759Courtesy of SUBARU OF AMERICA, INC.
    5. Using the following formula, read the push/ pull gauge, and calculate "N".

      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

    6. Press the center of retaining plate by applying a force of N using push/pull gauge, and then measure and record the height A. Measure at three locations or more spaced by equal distances and take the average value.
      NOTE: If measuring in three locations, measure every 120°. If measuring in four locations, measure every 90°.
      Fig 16: Measuring Drive Plate
      G05326802Courtesy of SUBARU OF AMERICA, INC.
  23. Install the pressure rear plate, 2-4 brake drive plate, driven plate, retaining plate and snap ring.
    Fig 17: Identifying Drive Plate And Driven Plate
    G05002741Courtesy of SUBARU OF AMERICA, INC.
  24. Install a new 2-4 brake seal to transmission case.
    Fig 18: Identifying Brake Seal
    G05002743Courtesy of SUBARU OF AMERICA, INC.
  25. After all 2-4 brake component parts have been installed, blow in air intermittently and confirm the operation of brake.
    Fig 19: Blowing Air Brake Component Parts
    G05002771Courtesy of SUBARU OF AMERICA, INC.
  26. Check the piston stroke. (Non-turbo model)
    1. Measure the clearance B between the retaining plate and snap ring.
      Fig 20: Measuring Clearance B Between Retaining Plate And Snap Ring (Non-Turbo Model)
      G05002778Courtesy of SUBARU OF AMERICA, INC.
    2. Piston stroke calculation

      Calculate with A and B dimensions recorded before. If the service limits from the calculation formula are exceeded, replace the drive plate and select and adjust the retaining plate to be with in standard values.

      T = A + B

      T: Piston stroke

      A: Amount of drive plate compression

      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 THICKNESS SPECIFICATION

      Retaining plate
      Part No. 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)
  27. Measure the clearance between the retaining plate and snap ring. (Turbo model)

    If the clearance exceeds the service limits, replace the driven plate and select and adjust the retaining plate so that the clearance is within default standard values.

    Initial standard: 

    0.8 - 1.2 mm (0.031 - 0.047 in) 

    Limit thickness: 

    1.5 mm (0.059 in) 

    Fig 21: Measuring Clearance Between Retaining Plate And Snap Ring (Turbo Model)
    G05002772Courtesy of SUBARU OF AMERICA, INC.
    RETAINING PLATE THICKNESS SPECIFICATION

    Retaining plate
    Part No. 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)
  28. Attach while making sure that the position of the leaf spring is correct.
    Fig 22: Identifying Leaf Spring And Retaining Plate
    G05326808Courtesy of SUBARU OF AMERICA, INC.
  29. Install the thrust needle bearing in the correct direction.
    Fig 23: Identifying Thrust Needle Bearing Position
    G05326809Courtesy of SUBARU OF AMERICA, INC.
  30. Install the front sun gear and the thrust needle bearing.
    Fig 24: Identifying Front Sun Gear And Thrust Needle Bearing
    G05326810Courtesy of SUBARU OF AMERICA, INC.
  31. Apply Vaseline, then attach the thrust needle bearing to the high clutch hub. Install the high clutch hub by correctly engaging the splines of the front planetary carrier.
  32. Install the thrust needle bearing in the correct direction.
    Fig 25: Identifying Thrust Needle Bearing Position
    G05326811Courtesy of SUBARU OF AMERICA, INC.
  33. Install the high clutch assembly and reverse clutch assembly.
    Fig 26: Identifying High Clutch Assembly And Reverse Clutch Assembly
    G05326812Courtesy of SUBARU OF AMERICA, INC.
  34. Adjust the total end play. <Ref. to ADJUSTMENT , Oil Pump Housing . >
  35. Install the thrust needle bearing in the correct direction.
    Fig 27: Identifying Thrust Needle Bearing Position
    G05326813Courtesy of SUBARU OF AMERICA, INC.
  36. Install the converter case assembly to the transmission case assembly. <Ref. to INSTALLATION , Converter Case . >
  37. Insert the inhibitor switch and transmission harness connector onto the stay.
    Fig 28: Identifying Inhibitor Switch And Transmission Harness Connector
    G05326814Courtesy of SUBARU OF AMERICA, INC.
  38. Install the air breather hose. <Ref. to INSTALLATION , Air Breather Hose . >
  39. Install the ATF cooler pipe. <Ref. to INSTALLATION , ATF Cooler Pipe and Hose . >
  40. Install the oil charge pipe along with the O-ring. <Ref. to INSTALLATION , Oil Charge Pipe . >
  41. Insert the input shaft while rotating it lightly by hand, and then check the amount of protrusion.

    Normal protrusion A: 

    50 - 55 mm (1.97 - 2.17 in) 

    Fig 29: Identifying Input Shaft Dimension
    G04990427Courtesy of SUBARU OF AMERICA, INC.
  42. Install the torque converter clutch assembly. <Ref. to INSTALLATION , Torque Converter Clutch Assembly . >
  43. Install the transmission assembly to the vehicle. <Ref. to INSTALLATION , Automatic Transmission Assembly . >
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