Automatic Transmission Unit: Assembly

Bearing position

Fig 1: Identifying Automatic Transmission Unit Assembly Bearing Position

Courtesy of SUBARU OF AMERICA, INC.

Mark	Front race diameter Inner/outer	Thrust bearing diameter Inner/outer	Rear race diameter Inner/outer
A	74.2mm {2.921in} / 87.7 mm {3.453 in}	71.9mm {2.831in} / 85.6 mm {3.370 in}	-
B	37.0mm {1.457in} / 51.2 mm {2.016 in}	33.5mm {1.319in} / 48.0 mm {1.890 in}	-
C	20.0mm {0.787in} / 35.6 mm {1.402 in}	20.0mm {0.787in} / 41.0 mm {1.614 in}	-
D	31.0mm {1.220in} / 48.0 mm {1.890 in}	33.3mm {1.311in} / 51.2 mm {2.016 in}	-
E	-	42.5mm {1.673in} / 61.2 mm {2.409 in}	-
F	34.9mm {1.374in} / 50.8 mm {1.999 in}	38.6mm {1.520in} / 53.1 mm {2.091 in}	-
G	-	58.5mm {2.303in} / 73.5 mm {2.894 in}	55.2mm {2.173in} / 71.2 mm {2.803 in}
H	29.6mm {1.165in} / 44.9 mm {1.768 in}	27.8mm {1.095in} / 43.8 mm {1.726 in}	27.8mm {1.095in} / 43.7 mm {1.721 in}
I	19.0mm {0.748in} / 35.0 mm {1.378 in}	20.8mm {0.819in} / 38.5 mm {1.516 in}	-
J	43.3mm {1.705in} / 56.7 mm {2.232 in}	40.6mm {1.598in} / 58.0 mm {2.284 in}	-
K	37.0mm {1.457in} / 51.2 mm {2.016 in}	36.1mm {1.421in} / 52.5 mm {2.067 in}	36.1mm {1.421in} / 51.0 mm {2.007 in}

Installation of No. 4 brake piston
1. Apply ATF to 2 new O-rings and install them to the brake reaction sleeve.
  
  Fig 2: Identifying Brake Reaction Sleeve And No. 4 Brake Piston And O-Ring
  Courtesy of SUBARU OF AMERICA, INC.
2. Apply ATF to 2 new O-rings and install them to the No. 4 brake piston.
3. Install the No. 4 brake piston to the brake reaction sleeve.
  CAUTION: Be careful not to damage the O-ring.
Installation of brake reaction sleeve
1. Install the brake reaction sleeve and No. 4 brake piston to the automatic transmission case SUB-ASSY with the No. 4 brake piston facing downward (rear side).
  
  Fig 3: Identifying Brake Reaction Sleeve And No. 4 Brake Piston
  Courtesy of SUBARU OF AMERICA, INC.
  
  CAUTION: Be careful not to damage the O-ring.
Installation of 1st & reverse brake piston
1. Apply ATF to a new O-ring and install it to the 1st & reverse brake piston.
  
  Fig 4: Identifying 1st & Reverse Brake Piston
  Courtesy of SUBARU OF AMERICA, INC.
2. Place the 1st & reverse brake piston in the automatic transmission case SUB-ASSY with the spring seat of the 1st & reverse brake piston facing upward (front side).
  CAUTION: Be careful not to damage the O-ring.
Installation of 1st & reverse brake return spring SUB-ASSY
1. Place the 1st & reverse brake return spring SUB-ASSY on the 1st & reverse brake piston.
2. Place the SST on the 1st & reverse brake return spring SUB-ASSY and press the 1st & reverse brake return spring SUB-ASSY.
  
  Fig 5: Identifying Snap Ring
  Courtesy of SUBARU OF AMERICA, INC.
  
  SST 09350-07050
3. Install the snap ring.
Installation of brake apply tube
1. Install the brake apply tube so that the protrusion fits into the groove of the automatic transmission case SUB-ASSY as shown in the figure.
  CAUTION:
  - Engage the claw of the 1st & reverse brake piston with the protrusion of the brake apply tube.
  - Peep through the rear side rotation sensor installation hole to check that the inside of the transmission case can be seen.
  Fig 6: Installing Brake Apply Tube
  Courtesy of SUBARU OF AMERICA, INC.

Installation of rear planetary gear ASSY

Fig 7: Identifying Rear Planetary Gear Assy

Courtesy of SUBARU OF AMERICA, INC.

Install the thrust needle roller bearing to the automatic transmission case SUB-ASSY.

BEARING DIAMETER

Item	Inner	Outer
Thrust needle roller bearing	40.6mm {1.598in}	58.0mm {2.284in}

Install the thrust needle roller bearing to the rear planetary gear ASSY.

Fig 8: Identifying Thrust Bearing Race, Thrust Needle Roller Bearing And No. 9 Thrust Bearing Race

Courtesy of SUBARU OF AMERICA, INC.

BEARING AND RACE DIAMETER

Item	Inner	Outer
Thrust needle roller bearing	20.8mm {0.819in}	38.5mm {1.516in}
Thrust bearing race	19.0mm {0.748in}	35.0mm {1.378in}
No. 9 thrust bearing race	43.3mm {1.705in}	56.7mm {2.232in}

Apply petroleum jelly to the No. 9 thrust bearing race and thrust bearing race and install them on the rear planetary gear ASSY.
Install the rear planetary gear ASSY to the automatic transmission case SUB-ASSY.

Fig 9: Installing Rear Planetary Gear Assy To Automatic Transmission Case Sub-Assy
Courtesy of SUBARU OF AMERICA, INC.

Check of No. 4 brake pack clearance (refer to DISASSEMBLY )
Installation of No. 4 brake disc
1. Install 2 No. 4 brake flanges, 5 No. 4 brake discs, 4 No. 4 brake plates to the automatic transmission case SUB-ASSY.
  
  Fig 10: Identifying No. 4 Brake Flange, No. 4 Brake Disc And No. 4 Brake Plate
  Courtesy of SUBARU OF AMERICA, INC.
  
  Installation order: *1 - *2 - *3 - *2 - *3 - *2 - *3 - *2 - *3 - *2 - *1
  
  CAUTION: Check that the disc, plate, and flange are installed in the correct order.
Installation of brake plate stopper spring
1. Install the brake plate stopper spring to the automatic transmission case SUB-ASSY.
  
  Fig 11: Locating Brake Plate Stopper Spring
  Courtesy of SUBARU OF AMERICA, INC.

Installation of intermediate shaft

Install the No. 8 thrust bearing race, thrust needle roller bearing, and No. 7 thrust bearing race to the intermediate shaft.

Fig 12: Identifying No. 7 Thrust Bearing Race, Thrust Needle Roller Bearing And No. 8 Thrust Bearing Race

Courtesy of SUBARU OF AMERICA, INC.

BEARING AND RACE DIAMETER

Item	Inner	Outer
No. 7 thrust bearing race	29.6mm {1.165in}	44.9mm {1.768in}
Thrust needle roller bearing	27.8mm {1.095in}	43.8mm {1.726in}
No. 8 thrust bearing race	27.8mm {1.095in}	43.7mm {1.721in}

Install the intermediate shaft to the transmission case SUB-ASSY.

Installation of No. 3 one-way clutch ASSY
1. Install the one-way clutch inner race to the No. 3 one-way clutch ASSY.
  
  Fig 13: Identifying No. 3 One-Way Clutch Assy And One-Way Clutch Inner Race
  Courtesy of SUBARU OF AMERICA, INC.
Installation of intermediate shaft
1. Install the No. 3 one-way clutch ASSY to the automatic transmission case SUB-ASSY.
  
  Fig 14: Identifying Automatic Transmission Case Sub-Assy
  Courtesy of SUBARU OF AMERICA, INC.
2. Install the snap ring to the automatic transmission case SUB-ASSY.
  NOTE: Install the joint of the snap ring toward the control valve side.
  
  Fig 15: Installing Snap Ring To Automatic Transmission Case Sub-Assy
  Courtesy of SUBARU OF AMERICA, INC.

Installation of center planetary gear ASSY

Install the center planetary gear ASSY and planetary sun gear to the automatic transmission case SUB-ASSY.

Fig 16: Identifying Thrust Needle Roller Bearing, No. 4 Thrust Bearing Race And Center Planetary Gear Assy

Courtesy of SUBARU OF AMERICA, INC.

BEARING AND RACE DIAMETER

Item	Inner	Outer
Thrust needle roller bearing	58.5mm {2.303in}	73.5mm {2.894in}
No. 4 thrust bearing race	55.2mm {2.173in}	71.2mm {2.803in}

Apply petroleum jelly to the No. 4 thrust bearing race and install it on the center planetary gear ASSY.
Install the thrust needle roller bearing to the center planetary gear ASSY.

Installation of No. 2 brake piston
1. Apply ATF to 2 new O-rings and install them to the No. 2 brake piston.
  
  Fig 17: Identifying No. 2 Brake Piston O-Ring
  Courtesy of SUBARU OF AMERICA, INC.
2. Press the No. 2 brake piston into the No. 2 brake cylinder.
  CAUTION: Be careful not to damage the O-ring.
3. Install the No. 2 brake piston to the automatic transmission case SUB-ASSY.
  NOTE: Install the No. 2 brake cylinder so that the protrusion protrudes from the upper side of the automatic transmission case SUB-ASSY.
4. Check that the oil pressure apply hole of the No. 2 brake cylinder is aligned with the oil pressure apply hole of the automatic transmission case SUB-ASSY.
  
  Fig 18: Identifying Oil Pressure Apply Hole Of No. 2 Brake Cylinder
  Courtesy of SUBARU OF AMERICA, INC.
Installation of No. 2 brake disc
1. Install the brake piston return spring.
2. Install 2 No. 2 brake flanges, 4 No. 2 brake discs, and 3 No. 2 brake plates to the automatic transmission case SUB-ASSY.
  
  Fig 19: Identifying No. 2 Brake Flange, Brake Disc, Brake Plate And Brake Piston Return Spring
  Courtesy of SUBARU OF AMERICA, INC.
  
  Installation order: *1 - *2 - *3 - *2 - *3 - *2 - *3 - *2 - *1
  
  CAUTION: Check that the disc, plate, and flange are installed in the correct order.
3. Use the SST and a flat tip screwdriver to press the No. 2 brake piston return spring SUB-ASSY and install the snap ring to the automatic transmission case SUB-ASSY.
  
  Fig 20: Installing Snap Ring To Automatic Transmission Case Sub-Assy Using SST And Flat Tip Screwdriver
  Courtesy of SUBARU OF AMERICA, INC.
  
  SST 09351-04010, 09350-07020, 18762AA020
  
  CAUTION: Insert a cloth, etc. between the SST and transmission case to prevent damage to the case.
  
  NOTE: Wrap the tip of a flat tip screwdriver with tape before using it.
Check of piston stroke of No. 2 brake piston (refer to DISASSEMBLY )
Installation of No. 1 brake piston
1. Apply ATF to 2 new O-rings and install them to the No. 1 brake piston.
  
  Fig 21: Identifying No. 1 Brake Piston O-Rings
  Courtesy of SUBARU OF AMERICA, INC.
2. Press the No. 1 brake piston into the No. 1 brake cylinder.
  CAUTION: Be careful not to damage the O-ring.
Installation of brake piston return spring SUB-ASSY
1. Install the brake piston return spring SUB-ASSY and No. 1 brake cylinder to the automatic transmission case SUB-ASSY.
  
  Fig 22: Identifying Brake Piston Return Spring Sub-Assy And No. 1 Brake Cylinder
  Courtesy of SUBARU OF AMERICA, INC.
  
  NOTE: Install the No. 1 brake cylinder so that the protrusion protrudes from the upper side of the automatic transmission case SUB-ASSY.
2. Check that the oil pressure apply hole of the No. 1 brake cylinder is aligned with the oil pressure apply hole of the automatic transmission case SUB-ASSY.
  
  Fig 23: Identifying Oil Pressure Apply Hole Of No. 1 Brake Cylinder
  Courtesy of SUBARU OF AMERICA, INC.
3. Use the SST and a flat tip screwdriver to press the brake piston return spring SUB-ASSY and install the snap ring to the automatic transmission case SUB-ASSY.
  
  Fig 24: Installing Snap Ring To Automatic Transmission Case Sub-Assy Using SST And Flat Tip Screwdriver
  Courtesy of SUBARU OF AMERICA, INC.
  
  SST 09350-07020, 09351-04010, 09351-04020
  CAUTION:
  - Align the centers of the SST and the shaft to prevent the SST from contacting the No. 1 brake cylinder.
  - Insert a cloth, etc. between the SST and transmission case to prevent damage to the case.
  NOTE: Wrap the tip of a flat tip screwdriver with tape before using it.
Installation of center planetary ring gear
1. Install the front planetary ring gear flange SUB-ASSY to the center planetary ring gear.
  
  Fig 25: Installing Front Planetary Ring Gear Flange Sub-Assy To Center Planetary Ring Gear
  Courtesy of SUBARU OF AMERICA, INC.
2. Use a flat tip screwdriver to install the snap ring.
  CAUTION: Be careful not to damage the center planetary ring gear.
  
  NOTE: Wrap the tip of a flat tip screwdriver with tape before using it.
3. Install the center planetary ring gear to the front planetary ring gear.
4. Use a flat tip screwdriver to install the snap ring.
  
  Fig 26: Installing Center Planetary Ring Gear To Front Planetary Ring Gear
  Courtesy of SUBARU OF AMERICA, INC.
  CAUTION:
  - Be careful not to damage the front planetary ring gear.
  - Install the snap ring to the front planetary ring gear so that the both ends of the snap ring is positioned to the center of the protrusion on the front planetary ring gear.
  NOTE: Wrap the tip of a flat tip screwdriver with tape before using it.
Installation of front planetary ring gear
1. Install the front planetary ring gear to the automatic transmission case SUB-ASSY.
  
  Fig 27: Installing Front Planetary Ring Gear To Automatic Transmission Case Sub-Assy
  Courtesy of SUBARU OF AMERICA, INC.

Installation of front planetary gear ASSY

Install the No. 2 planetary carrier thrust washer and front planetary flange thrust needle roller bearing.

Fig 28: Identifying Front Planetary Flange Rear Thrust Bearing Race And Front Planetary Flange Thrust Needle Roller Bearing

Courtesy of SUBARU OF AMERICA, INC.

BEARING AND RACE DIAMETER

Item	Inner	Outer
Front planetary flange thrust needle roller bearing	38.6mm {1.520in}	53.1mm {2.091in}
Front planetary flange rear thrust bearing race	34.9mm {1.374in}	50.8mm {1.999in}

Apply petroleum jelly to the front planetary flange rear thrust bearing race and install it on the front planetary ring gear.
Install the front planetary gear ASSY and one-way clutch inner race SUB-ASSY to the automatic transmission case SUB-ASSY.

Fig 29: Identifying One-Way Clutch Inner Race Sub-Assy And Front Planetary Gear Assy
Courtesy of SUBARU OF AMERICA, INC.

Check of piston stroke of No. 1 brake piston (refer to DISASSEMBLY )
Installation of No. 1 brake disc
1. Install No. 1 brake flange, 3 No. 1 brake discs, and 3 No. 1 brake plates to the automatic transmission case SUB-ASSY.
  
  Fig 30: Identifying No. 1 Brake Plate, No. 1 Brake Disc And No. 1 Brake Flange
  Courtesy of SUBARU OF AMERICA, INC.
  
  Installation order: *1 - *2 - *1 - *2 - *1 - *2 - *3
  
  CAUTION: Check that the disc, plate, and flange are installed in the correct order.
Installation of one-way clutch ASSY
1. Install the No. 1 planetary carrier thrust washer and one-way clutch ASSY to the automatic transmission case SUB-ASSY.
  
  Fig 31: Identifying One-Way Clutch Assy And No. 1 Planetary Carrier Thrust Washer
  Courtesy of SUBARU OF AMERICA, INC.
Installation of No. 3 brake piston
1. Apply ATF to 2 new O-rings and install them to the No. 3 brake piston.
  
  Fig 32: Identifying No. 3 Brake Piston O-Ring
  Courtesy of SUBARU OF AMERICA, INC.
2. Press the No. 3 brake piston into the No. 3 brake cylinder.
  CAUTION: Be careful not to damage the O-ring.
3. Use the SST and a press to install the snap ring and No. 3 brake piston return spring SUB-ASSY to the No. 3 brake cylinder.
  
  Fig 33: Identifying Snap Ring, No. 3 Brake Piston Return Spring Sub-Assy, No. 3 Brake Cylinder
  Courtesy of SUBARU OF AMERICA, INC.
  
  SST 18762AA030
  CAUTION:
  - Check that the gap of the snap ring end is not aligned with the claw of the spring retainer.
  - Be careful not to damage the No. 3 brake cylinder.
  - Keep the foot of SST from standing on the protrusion of the piston return spring SUB-ASSY.
  NOTE: Wrap the tip of a flat tip screwdriver with tape before using it.
Installation of No. 3 brake cylinder
1. Install the No. 3 brake cylinder to the automatic transmission case SUB-ASSY.
  
  Fig 34: Installing No. 3 Brake Cylinder To Automatic Transmission Case Sub-Assy
  Courtesy of SUBARU OF AMERICA, INC.
2. Check that the oil pressure apply hole of the No. 3 brake cylinder is aligned with the oil pressure apply hole of the automatic transmission case SUB-ASSY.
  
  Fig 35: Identifying Oil Pressure Apply Hole Of No. 3 Brake Cylinder
  Courtesy of SUBARU OF AMERICA, INC.
3. Install the snap ring to the automatic transmission case SUB-ASSY.
  NOTE: Install the joint of the snap ring toward the control valve side.
  
  Fig 36: Installing Snap Ring To Automatic Transmission Case Sub-Assy
  Courtesy of SUBARU OF AMERICA, INC.
Installation of No. 3 brake disc set
1. Install No. 3 brake flange, 3 No. 3 brake discs, and 3 No. 3 brake plates to the automatic transmission case SUB-ASSY.
  
  Fig 37: Identifying No. 3 Brake Plate, No. 3 Brake Disc And No. 3 Brake Flange
  Courtesy of SUBARU OF AMERICA, INC.
  
  Installation order: *1 - *2 - *1 - *2 - *1 - *2 - *3
  
  CAUTION: Check that the disc, plate, and flange are installed in the correct order.
2. Use a flat tip screwdriver to install the snap ring to the automatic transmission case SUB-ASSY.
  
  Fig 38: Installing Snap Ring To Automatic Transmission Case Sub-Assy Using Flat Tip Screwdriver
  Courtesy of SUBARU OF AMERICA, INC.
  
  CAUTION: Be careful not to damage the automatic transmission case SUB-ASSY.
  
  NOTE: Wrap the tip of a flat tip screwdriver with tape before using it.
Installation of direct clutch piston SUB-ASSY
1. Apply ATF to 2 new O-rings and install them to the direct clutch piston SUB-ASSY.
  
  Fig 39: Identifying Direct Clutch Piston Sub-Assy O-Rings
  Courtesy of SUBARU OF AMERICA, INC.
2. Apply ATF to a new O-ring and install it to the No. 2 clutch balancer.
  
  Fig 40: Identifying No. 2 Clutch Balancer O-Ring
  Courtesy of SUBARU OF AMERICA, INC.
3. Install the No. 2 clutch balancer and direct clutch return spring SUB-ASSY to the direct clutch piston SUB-ASSY.
  
  Fig 41: Identifying Direct Clutch Piston Sub-Assy And Direct Clutch Return Spring Sub-Assy
  Courtesy of SUBARU OF AMERICA, INC.
4. Push the direct clutch piston SUB-ASSY into the reverse clutch drum SUB-ASSY by hand.
  CAUTION: Be careful not to damage the O-ring.
5. Place the SST on the No. 2 clutch balancer and press the direct clutch return spring SUB-ASSY using a press.
  SST 09320-89010
  
  CAUTION: To avoid the deformation of the spring seat, stop pressing the spring seat when it descends to 1 to 2 mm {0.0394 to 0.0787 in} from the groove of the snap ring.
6. Install the snap ring.
  CAUTION:
  - Check that the gap of the snap ring end is not aligned with the claw of the spring retainer.
  - Do not stretch the snap ring excessively.
  Fig 42: Pressing Direct Clutch Return Spring Sub-Assy Using Press
  Courtesy of SUBARU OF AMERICA, INC.
7. Insert the gap of the snap ring end into the No. 2 clutch balancer as shown in the figure.
  
  Fig 43: Identifying Snap Ring End Stopper
  Courtesy of SUBARU OF AMERICA, INC.
Installation of reverse clutch piston SUB-ASSY
1. Apply ATF to a new O-ring and install it to the reverse clutch drum SUB-ASSY.
  
  Fig 44: Identifying Reverse Clutch Piston Sub-Assy O-Ring
  Courtesy of SUBARU OF AMERICA, INC.
2. Apply ATF to a new O-ring and install it to the reverse clutch piston SUB-ASSY.
  
  Fig 45: Identifying Reverse Clutch Piston Sub-Assy O-Ring
  Courtesy of SUBARU OF AMERICA, INC.
3. Push the reverse clutch drum SUB-ASSY into the reverse clutch piston SUB-ASSY by both hands.
  
  Fig 46: Identifying Reverse Clutch Drum Sub-Assy And Reverse Clutch Piston Sub-Assy
  Courtesy of SUBARU OF AMERICA, INC.
  
  CAUTION: Be careful not to damage the O-ring.
Installation of reverse clutch return spring SUB-ASSY
1. Apply ATF to a new O-ring and install it to the reverse clutch piston SUB-ASSY.
  
  Fig 47: Identifying Reverse Clutch Return Spring Sub-Assy, O-Ring And Reverse Clutch Piston Sub-Assy
  Courtesy of SUBARU OF AMERICA, INC.
2. Install the reverse clutch return spring SUB-ASSY to the reverse clutch piston SUB-ASSY.
Installation of No. 3 clutch balancer
1. Install the No. 3 clutch balancer to the reverse clutch return spring SUB-ASSY.
2. Place the SST on the No. 3 clutch balancer and press the reverse clutch return spring SUB-ASSY using a press.
  SST 09387-00070
  
  CAUTION: To avoid the deformation of the spring seat, stop pressing the spring seat when it descends to 1 to 2 mm {0.0394 to 0.0787 in} from the groove of the snap ring.
  
  Fig 48: Installing No. 3 Clutch Balancer And Reverse Clutch Return Spring Sub-Assy
  Courtesy of SUBARU OF AMERICA, INC.
3. Install the snap ring.
  CAUTION:
  - Check that the gap of the snap ring end is not aligned with the claw of the spring retainer.
  - Do not stretch the snap ring excessively.
4. Insert the gap of the snap ring end into the No. 3 clutch balancer as shown in the figure.
  
  Fig 49: Identifying Snap Ring, Correct And Wrong
  Courtesy of SUBARU OF AMERICA, INC.
Installation of No. 2 clutch disc (direct clutch disc)
1. Install the direct clutch flange, 5 No. 2 clutch discs, and 5 No. 2 clutch plates to the reverse clutch drum SUB-ASSY.
  
  Fig 50: Identifying No. 2 Clutch Plate, No. 2 Clutch Disc And Direct Clutch Flange
  Courtesy of SUBARU OF AMERICA, INC.
  
  Installation order: *1 - *2 - *1 - *2 - *1 - *2 - *1 - *2 - *1 - *2 - *3
  
  CAUTION: Check that the disc, plate, and flange are installed in the correct order.
2. Use a flat tip screwdriver to install 2 snap rings to the reverse clutch drum SUB-ASSY.
  
  Fig 51: Installing Snap Rings To Reverse Clutch Drum Sub-Assy Using Flat Tip Screwdriver
  Courtesy of SUBARU OF AMERICA, INC.
  
  CAUTION: Be careful not to damage the reverse clutch drum SUB-ASSY.
  
  NOTE: Wrap the tip of a flat tip screwdriver with tape before using it.
Check of No. 2 clutch pack clearance (refer to DISASSEMBLY )
Installation of reverse clutch flange
1. Install the reverse clutch flange to the reverse clutch drum SUB-ASSY.
  
  Fig 52: Installing Reverse Clutch Flange To Reverse Clutch Drum Sub-Assy
  Courtesy of SUBARU OF AMERICA, INC.
Installation of reverse clutch reaction sleeve
1. Install the clutch cushion plate, reverse clutch flange, 4 No. 3 clutch discs, 3 No. 3 clutch plates, and reverse clutch reaction sleeve to the reverse clutch drum SUB-ASSY.
  
  Fig 53: Identifying No. 3 Clutch Disc And No. 3 Clutch Plate, Reverse Clutch Flange And Clutch Cushion Plate
  Courtesy of SUBARU OF AMERICA, INC.
  
  Installation order: *1 - *2 - *1 - *2 - *1 - *2 - *1 - *3 - *4 - *5
  
  CAUTION: Check that the disc, plate, flange, sleeve, and cushion plate are installed in the correct order.
2. Use a flat tip screwdriver to install the snap ring to the reverse clutch piston SUB-ASSY.
  
  Fig 54: Installing Snap Ring To Reverse Clutch Piston Sub-Assy Using Flat Tip Screwdriver
  Courtesy of SUBARU OF AMERICA, INC.
  
  CAUTION: Be careful not to damage the reverse clutch piston SUB-ASSY.
  
  NOTE: Wrap the tip of a flat tip screwdriver with tape before using it.
Check of No. 3 clutch pack clearance (refer to DISASSEMBLY )
Removal of reverse clutch reaction sleeve
1. Use a flat tip screwdriver to remove the snap ring from the reverse clutch piston SUB-ASSY.
  
  Fig 55: Removing Snap Ring From Reverse Clutch Piston Sub-Assy Using Flat Tip Screwdriver
  Courtesy of SUBARU OF AMERICA, INC.
  
  CAUTION: Be careful not to damage the reverse clutch piston SUB-ASSY.
  
  NOTE: Wrap the tip of a flat tip screwdriver with tape before using it.
  
  Fig 56: Identifying Reverse Clutch Reaction Sleeve And Clutch Cushion Plate
  Courtesy of SUBARU OF AMERICA, INC.
2. Remove the reverse clutch reaction sleeve, clutch cushion plate, reverse clutch flange, 4 No. 3 clutch discs, and 3 No. 3 clutch plates from the reverse clutch drum SUB-ASSY.
Installation of forward clutch piston SUB-ASSY
1. Install the coast clutch piston to the forward clutch piston SUB-ASSY.
  
  Fig 57: Identifying Coast Clutch Piston And Forward Clutch Piston Sub-Assy
  Courtesy of SUBARU OF AMERICA, INC.
2. Apply ATF to a new O-ring and install it to the input shaft.
  
  Fig 58: Identifying Input Shaft O-Ring
  Courtesy of SUBARU OF AMERICA, INC.
3. Install the forward clutch piston SUB-ASSY to the input shaft.
Installation of No. 1 clutch balancer
1. Apply ATF to a new D-ring and install it to the No. 1 clutch balancer.
  
  Fig 59: Identifying No. 1 Clutch Balancer D-Ring
  Courtesy of SUBARU OF AMERICA, INC.
2. Install the No. 1 clutch balancer and forward clutch return spring SUB-ASSY to the input shaft.
  
  Fig 60: Identifying No. 1 Clutch Balancer And Forward Clutch Return Spring Sub-Assy
  Courtesy of SUBARU OF AMERICA, INC.
  
  CAUTION: Be careful not to damage the D-ring.
3. Place the SST on the No. 1 clutch balancer and press the forward clutch return spring SUB-ASSY using a press.
  SST 09387-00110
  
  CAUTION: To avoid the deformation of the spring seat, stop pressing the spring seat when it descends to 1 to 2 mm {0.0394 to 0.0787 in} from the groove of the snap ring.
4. Install the snap ring.
  CAUTION:
  - Check that the gap of the snap ring end is not aligned with the claw of the spring retainer.
  - Do not stretch the snap ring excessively.
  Fig 61: Pressing Forward Clutch Return Spring Sub-Assy Using Press
  Courtesy of SUBARU OF AMERICA, INC.
5. Insert the gap of the snap ring end into the No. 1 clutch balancer as shown in the figure.
  
  Fig 62: Identifying Snap Ring, Correct And Wrong
  Courtesy of SUBARU OF AMERICA, INC.
Installation of No. 4 clutch disc (coast clutch disc)
1. Install the coast clutch flange, 4 No. 4 clutch discs, and 4 No. 4 clutch plates to the forward clutch piston SUB-ASSY.
  
  Fig 63: Identifying No. 4 Clutch Plate, No. 4 Clutch Disc And Coast Clutch Flange
  Courtesy of SUBARU OF AMERICA, INC.
  
  Installation order: *1 - *2 - *1 - *2 - *1 - *2 - *1 - *2 - *3
  
  CAUTION: Check that the disc, plate, and flange are installed in the correct order.
2. Use a flat tip screwdriver to install the snap ring.
  
  Fig 64: Installing Snap Ring Using Flat Tip Screwdriver
  Courtesy of SUBARU OF AMERICA, INC.
  
  CAUTION: Be careful not to damage the forward clutch piston SUB-ASSY.
  
  NOTE: Wrap the tip of a flat tip screwdriver with tape before using it.
Check of No. 4 clutch pack clearance (refer to DISASSEMBLY )
Installation of No. 1 clutch disc (forward clutch disc)
1. Install the forward clutch flange, 4 No. 1 clutch discs, 4 No. 1 clutch plates, and clutch cushion plate to the input shaft.
  
  Fig 65: Identifying Clutch Cushion Plate, No. 1 Clutch Plate, No. 1 Clutch Disc And Forward Clutch Flange
  Courtesy of SUBARU OF AMERICA, INC.
  
  Installation order: *1 - *2 - *3 - *2 - *3 - *2 - *3 - *2 - *3 - *4
  
  CAUTION: Check that the disc, plate, flange, and cushion plate are installed in the correct order.
2. Use a flat tip screwdriver to install the snap ring.
  
  Fig 66: Installing Snap Ring Using Flat Tip Screwdriver
  Courtesy of SUBARU OF AMERICA, INC.
  
  CAUTION: Be careful not to damage the input shaft.
  
  NOTE: Wrap the tip of a flat tip screwdriver with tape before using it.
Check of No. 1 clutch pack clearance (refer to DISASSEMBLY )
Installation of clutch drum oil seal ring
1. Apply ATF to 4 new clutch drum oil seal rings.
2. Push out both ends of the 4 clutch drum oil seal rings all together and install them to the input shaft groove.
  CAUTION: Do not stretch the ring ends excessively.
  
  NOTE: After installing the clutch drum oil seal rings, check that they can rotate smoothly.
  
  Fig 67: Identifying Clutch Drum Oil Seal Ring
  Courtesy of SUBARU OF AMERICA, INC.

Installation of input shaft

Install the input shaft to the reverse clutch drum SUB-ASSY.

Fig 68: Identifying Input Shaft
Courtesy of SUBARU OF AMERICA, INC.

Install the input shaft rear thrust bearing race and thrust needle roller bearing to the input shaft.

Fig 69: Identifying Input Shaft Rear Thrust Bearing Race And Thrust Needle Roller Bearing

Courtesy of SUBARU OF AMERICA, INC.

BEARING AND RACE DIAMETER

Item	Inner	Outer
Thrust needle roller bearing	50.8mm {1.999in}	41.0mm {1.614in}
Input shaft rear thrust bearing race	20.0mm {0.787in}	35.6mm {1.402in}

Installation of No. 4 one-way clutch ASSY
1. Install the No. 2 clutch hub thrust washer and No. 4 one-way clutch ASSY to the coast clutch hub ASSY.
  
  Fig 70: Identifying Coast Clutch Hub Sub-Assy, No. 2 Clutch Hub Thrust Washer And No. 4 One-Way Clutch Assy
  Courtesy of SUBARU OF AMERICA, INC.
Installation of coast clutch hub SUB-ASSY
1. Install the coast clutch hub SUB-ASSY to the reverse clutch drum SUB-ASSY.
  
  Fig 71: Identifying Coast Clutch Hub Sub-Assy
  Courtesy of SUBARU OF AMERICA, INC.

Installation of forward clutch hub SUB-ASSY

Install the 2 thrust needle roller bearings and No. 2 thrust bearing race to the forward clutch hub ASSY.

Fig 72: Identifying Thrust Needle Roller Bearing A, Thrust Needle Roller Bearing B And No. 2 Thrust Bearing Race

Courtesy of SUBARU OF AMERICA, INC.

BEARING AND RACE DIAMETER

Item	Inner	Outer
Thrust needle roller bearing A	42.5mm {1.673in}	61.2mm {2.409in}
Thrust needle roller bearing B	33.3mm {1.311in}	51.2mm {2.016in}
No. 2 thrust bearing race	31.0mm {1.220in}	48.0mm {1.890in}

Install the No. 3 clutch hub thrust washer and forward clutch hub SUB-ASSY to the reverse clutch drum SUB-ASSY.

Fig 73: Identifying Forward Clutch Hub Sub-Assy And No. 3 Clutch Hub Thrust Washer
Courtesy of SUBARU OF AMERICA, INC.

Installation of No. 3 clutch disc
1. Install the clutch cushion plate, reverse clutch flange, 4 No. 3 clutch discs, and 3 No. 3 clutch plates to the reverse clutch hub SUB-ASSY.
  
  Fig 74: Identifying No. 3 Clutch Disc, No. 3 Clutch Plate And Reverse Clutch Flange And Clutch Cushion Plat
  Courtesy of SUBARU OF AMERICA, INC.
  
  Installation order:: *1 - *2 - *1 - *2 - *1 - *2 - *1 - *3 - *4
  
  CAUTION: Check that the disc, plate, flange, and cushion plate are installed in the correct order.
Installation of reverse clutch reaction sleeve
1. Install the reverse clutch reaction sleeve to the reverse clutch hub SUB-ASSY.
  
  Fig 75: Identifying Reverse Clutch Reaction Sleeve
  Courtesy of SUBARU OF AMERICA, INC.
Installation of reverse clutch hub SUB-ASSY
1. Install the reverse clutch hub SUB-ASSY to the reverse clutch drum SUB-ASSY.
  
  Fig 76: Identifying Reverse Clutch Hub Sub-Assy
  Courtesy of SUBARU OF AMERICA, INC.
2. Use a flat tip screwdriver to install the snap ring to the reverse clutch piston SUB-ASSY.
  
  Fig 77: Installing Snap Ring To Reverse Clutch Piston Sub-Assy Using Flat Tip Screwdriver
  Courtesy of SUBARU OF AMERICA, INC.
  
  CAUTION: Be careful not to damage the reverse clutch piston SUB-ASSY.
  
  NOTE: Wrap the tip of a flat tip screwdriver with tape before using it.
Installation of No. 2 one-way clutch ASSY
1. Install the input shaft clutch drum thrust washer and No. 2 one-way clutch ASSY to the clutch drum & input shaft ASSY.
  
  Fig 78: Identifying No. 2 One-Way Clutch Assy And Input Shaft Clutch Drum Thrust Washer
  Courtesy of SUBARU OF AMERICA, INC.

Installation of clutch drum & input shaft ASSY

Install the input shaft front thrust needle roller bearing and thrust needle roller bearing to the clutch drum & input ASSY.

Fig 79: Identifying Thrust Needle Roller Bearing, Input Shaft Front Thrust Bearing Race And Input Shaft Front Thrust Needle Roller Bearing

Courtesy of SUBARU OF AMERICA, INC.

BEARING AND RACE DIAMETER

Item	Inner	Outer
Thrust needle roller bearing	71.9mm {2.831in}	85.6mm {3.370in}
Input shaft front thrust bearing race	37.0mm {1.457in}	51.2mm {2.016in}
Input shaft front thrust needle roller bearing	33.5mm {1.319in}	48.0mm {1.890in}

Apply petroleum jelly to the input shaft front thrust bearing race and clutch drum thrust washer, and then install them on the clutch drum & input shaft ASSY.
Install the clutch drum & input shaft ASSY to the automatic transmission case SUB-ASSY.

Fig 80: Installing Clutch Drum & Input Shaft Assy To Automatic Transmission Case Sub-Assy
Courtesy of SUBARU OF AMERICA, INC.

Installation of oil pump ASSY

Use the SST to install the oil seal to the oil pump.
SST 499755602
Apply ATF to 3 new clutch drum oil seal rings.

Fig 81: Installing Oil Seal To Oil Pump Using SST
Courtesy of SUBARU OF AMERICA, INC.
Push out both ends of the clutch drum oil seal ring until the gap length becomes 8 mm {0.31 in} or less and install it to the stator shaft groove.
CAUTION: Do not stretch the ring ends excessively.

NOTE: After installing the clutch drum oil seal rings, check that the seal ring can rotate smoothly.

Fig 82: Identifying Clutch Drum Oil Seal Ring
Courtesy of SUBARU OF AMERICA, INC.

Install the No. 1 thrust bearing race to the oil pump ASSY.

Fig 83: Identifying No. 1 Thrust Bearing Race, Oil Pump Assy And O-Ring

Courtesy of SUBARU OF AMERICA, INC.

RACE DIAMETER

Item	Inner	Outer
No. 1 thrust bearing race	74.2mm {2.921in}	87.7mm {3.453in}

Apply ATF to a new O-ring and install it to the oil pump ASSY.
Insert the oil pump ASSY into the input shaft and align the bolt hole of the oil pump ASSY with the automatic transmission case SUB-ASSY.
CAUTION: Be careful not to damage the O-ring.
Hold the input shaft and press the oil pump lightly to slide the clutch drum oil seal ring into the clutch drum & input shaft ASSY.
Install 9 bolts.
Standard value: T=21N.m {215kgf.cm} {15.5ft.lbf}

Fig 84: Locating Oil Pump Assy Bolts
Courtesy of SUBARU OF AMERICA, INC.

Operation check of each piston (refer to DISASSEMBLY )
Installation of manual valve lever shaft oil seal
1. Tap 2 manual valve lever shaft oil seals lightly to insert them into the automatic transmission case SUB-ASSY using the SST and a hammer.
  SST 18657AA010
2. Apply auto fluid WS to the manual valve lever shaft oil seal lip.
  
  Fig 85: Installing Of Manual Valve Lever Shaft Oil Seal
  Courtesy of SUBARU OF AMERICA, INC.
Installation of manual valve lever SUB-ASSY
1. Install a new spacer to the manual valve lever SUB-ASSY.
  
  Fig 86: Installing Spacer To Manual Valve Lever Sub-Assy
  Courtesy of SUBARU OF AMERICA, INC.
2. Install the manual valve lever shaft to the automatic transmission case SUB-ASSY through the manual valve lever SUB-ASSY.
3. Tap a new spring pin lightly to insert using a hammer.
  
  Fig 87: Taping Spring Pin Using Hammer
  Courtesy of SUBARU OF AMERICA, INC.
4. Align the dent of the manual valve lever with the spacer hole and fix them together with a punch.
5. Check that the shaft can rotate smoothly.
  
  Fig 88: Aligning Dent Of Manual Valve Lever With Spacer Hole
  Courtesy of SUBARU OF AMERICA, INC.
Installation of parking lock pole shaft
1. Install a new E-ring to the parking lock pole shaft.
2. Install the parking lock pole, parking lock pole shaft, and torsion spring to the automatic transmission case SUB-ASSY.
  
  Fig 89: Identifying Parking Lock Pole, E-Ring, Parking Lock Pole Shaft And Torsion Spring
  Courtesy of SUBARU OF AMERICA, INC.
Installation of parking lock rod SUB-ASSY
1. Install the parking lock rod SUB-ASSY to the manual valve lever SUB-ASSY.
  
  Fig 90: Installing Parking Lock Rod Sub-Assy To Manual Valve Lever Sub-Assy
  Courtesy of SUBARU OF AMERICA, INC.
Installation of parking lock pole bracket
1. Install the parking lock pole bracket to the automatic transmission case SUB-ASSY with 3 bolts.
  Standard value: T=7.3N.m {74kgf.cm} {5.4ft.lbf}
  
  Fig 91: Locating Parking Lock Pole Bracket Bolts
  Courtesy of SUBARU OF AMERICA, INC.
2. Shift the manual valve lever SUB-ASSY to P position and check that the rear planetary gear is properly locked with the parking lock pole.
  
  Fig 92: Identifying Rear Planetary Gear, Manual Valve Lever Sub-Assy And Parking Lock Pole
  Courtesy of SUBARU OF AMERICA, INC.

Installation of B-1 accumulator valve

Install the spring and B-1 accumulator valve to the hole.

B-1 ACCUMULATOR SPRING

Free length	Outer diameter	Color
46.36mm {1.825in}	17.1mm {0.673in}	Natural

Fig 93: Identifying Spring And B-1 Accumulator Valve

Courtesy of SUBARU OF AMERICA, INC.

Apply ATF to 2 new O-rings and install them to the C-3 accumulator piston.

Fig 94: Identifying O-Ring, Inner Spring And Outer Spring
Courtesy of SUBARU OF AMERICA, INC.

Install 2 springs and C-3 accumulator piston to the hole.

C-3 ACCUMULATOR SPRING

Spring	Free length	Outer diameter	Color
Inner	44.0mm {1.732in}	14.0mm {0.551in}	Yellow
Outer	76.65mm {3.018in}	20.1mm {0.791in}	White

Installation of B-3 accumulator piston

Use a flat tip screwdriver to install the spring SUB-ASSY to the B-3 accumulator piston with a snap ring.

B-3 ACCUMULATOR SPRING SUB-ASSY

Free length	Coil outer diameter	Color
25.77mm {1.015in}	16.3mm {0.642in}	Violet

CAUTION: Be careful not to damage the B-3 accumulator piston.

NOTE: Wrap the tip of a flat tip screwdriver with tape before using it.

Fig 95: Identifying B-3 Accumulator Piston Components

Courtesy of SUBARU OF AMERICA, INC.

Apply ATF to 2 new O-rings and install them to the B-3 accumulator piston.

Fig 96: Identifying O-Ring And Spring
Courtesy of SUBARU OF AMERICA, INC.

Install the spring and B-3 accumulator piston to the hole.

B-3 ACCUMULATOR SPRING

Free length	Outer diameter	Color
70.5mm {2.776in}	19.7mm {0.776in}	Violet

Installation of C-2 accumulator piston

Use a flat tip screwdriver to install the spring SUB-ASSY to the C-2 accumulator piston with a snap ring.

C-2 ACCUMULATOR SPRING SUB-ASSY

Free length	Coil outer diameter	Color
15.16mm {0.597in}	11.3mm {0.445in}	Natural

CAUTION: Be careful not to damage the C-2 accumulator piston.

NOTE: Wrap the tip of a flat tip screwdriver with tape before using it.

Fig 97: Identifying C-2 Accumulator Piston Components

Courtesy of SUBARU OF AMERICA, INC.

Apply ATF to 2 new O-rings and install them to the C-2 accumulator piston.

Fig 98: Identifying C-2 Accumulator Piston O-Ring And Spring
Courtesy of SUBARU OF AMERICA, INC.

Install the spring and C-2 accumulator piston to the hole.

C-2 ACCUMULATOR SPRING

Free length	Outer diameter	Color
65.07mm {2.562in}	16.2mm {0.638in}	Pink

Installation of check ball body
1. Install the check ball body and compression spring to the automatic transmission case SUB-ASSY.
  
  Fig 99: Identifying Check Ball Body And Compression Spring
  Courtesy of SUBARU OF AMERICA, INC.
Installation of brake drum gasket
1. Install 3 new brake drum gaskets to the automatic transmission case SUB-ASSY.
  
  Fig 100: Identifying Brake Drum Gasket
  Courtesy of SUBARU OF AMERICA, INC.
Installation of transmission case gasket
1. Install 3 new transmission case gaskets on the automatic transmission case SUB-ASSY.
  
  Fig 101: Identifying Transmission Case Gasket
  Courtesy of SUBARU OF AMERICA, INC.
Installation of transmission valve body ASSY
1. Couple the manual valve connecting rod SUB-ASSY to the manual valve lever SUB-ASSY.
  
  Fig 102: Identifying Manual Valve Connecting Rod Sub-Assy And Manual Valve Lever Sub-Assy
  Courtesy of SUBARU OF AMERICA, INC.
2. Install the transmission valve body ASSY to the automatic transmission case SUB-ASSY with 19 bolts.
  Standard value: T=11N.m {112kgf.cm} {8.1ft.lbf}
  
  NOTE: The bolt lengths are shown below.
  Bolt length:
  Bolt A: 25mm {0.984in}
  Bolt B: 36mm {1.42in}
  Bolt C: 45mm {1.77in}
  Bolt D: 50mm {1.97in}
  
  Fig 103: Identifying Transmission Valve Body Assy To Automatic Transmission Case Sub-Assy Bolts
  Courtesy of SUBARU OF AMERICA, INC.
3. Install the detent spring and detent spring cover to the transmission valve body ASSY with a bolt.
  Standard value: T=10N.m {102kgf.cm} {7.4ft.lbf}
  
  Fig 104: Locating Transmission Valve Body Assy Bolt
  Courtesy of SUBARU OF AMERICA, INC.
Installation of transmission wire
1. Apply ATF to a new O-ring and install it to the transmission wire.
  
  Fig 105: Locating Transmission Wire O-Ring
  Courtesy of SUBARU OF AMERICA, INC.
2. Install the transmission wire with the bolt.
  Standard value: T=5.4N.m {55kgf.cm} {4.0ft.lbf}
  
  Fig 106: Locating Transmission Wire Bolt
  Courtesy of SUBARU OF AMERICA, INC.
3. Connect 9 solenoid valve connectors.
4. Apply ATF to the ATF temperature sensor O-ring.
  
  Fig 107: Locating Solenoid Valve Connectors
  Courtesy of SUBARU OF AMERICA, INC.
5. Install the ATF temperature sensor and temperature sensor clamp with a bolt.
  Standard value: T=10N.m {102kgf.cm} {7.4ft.lbf}
  
  Fig 108: Locating Temperature Sensor Clamp Bolt
  Courtesy of SUBARU OF AMERICA, INC.
6. Install the valve body wiring harness clamp with the bolt.
  Standard value: T=6.4N.m {65kgf.cm} {4.7ft.lbf}
7. Secure the wiring harness to the clamp.
  
  Fig 109: Locating Valve Body Wiring Harness Clamp Bolt
  Courtesy of SUBARU OF AMERICA, INC.
Installation of valve body oil strainer ASSY
1. Apply ATF to a new O-ring and install it to the valve body oil strainer ASSY.
  
  Fig 110: Identifying Valve Body Oil Strainer Assy O-Ring
  Courtesy of SUBARU OF AMERICA, INC.
2. Install the valve body oil strainer ASSY to the transmission valve body ASSY with 4 bolts.
  Standard value: T=10N.m {102kgf.cm} {7.4ft.lbf}
  
  Fig 111: Locating Valve Body Oil Strainer Assy To Transmission Valve Body Assy Bolts
  Courtesy of SUBARU OF AMERICA, INC.
Installation of automatic transmission oil pan SUB-ASSY
1. Install 3 transmission oil cleaner magnets to the automatic transmission oil pan SUB-ASSY.
  
  Fig 112: Identifying Transmission Oil Cleaner Magnet
  Courtesy of SUBARU OF AMERICA, INC.
2. Install a new automatic transmission oil pan gasket and automatic transmission oil pan SUB-ASSY with 20 bolts.
  Standard value: T=7.0N.m {71kgf.cm} {5.2ft.lbf}
3. Install the drain plug and a new gasket.
  Standard value: T=20N.m {204kgf.cm} {14.8ft.lbf}
4. Use a 5-mm socket hexagon wrench to install the overflow plug and a new gasket.
  Standard value: T=20N.m {204kgf.cm} {14.8ft.lbf}
  
  Fig 113: Locating Automatic Transmission Oil Pan Sub-Assy Bolts
  Courtesy of SUBARU OF AMERICA, INC.

Installation of output shaft thrust bearing

Install the output shaft thrust bearing race, output shaft thrust bearing, and rear output shaft thrust bearing case to the output shaft of the rear planetary gear ASSY.

BEARING AND RACE DIAMETER

Item	Inner	Outer
Output shaft thrust bearing race	37.0mm {1.457in}	51.2mm {2.016in}
Output shaft thrust bearing	36.1mm {1.421in}	52.5mm {2.067in}
Rear output shaft thrust bearing race	36.1mm {1.421in}	51.0mm {2.007in}

Use a snap ring expander to install the snap ring.

Fig 114: Installing Snap Ring Using Snap Ring Expander
Courtesy of SUBARU OF AMERICA, INC.

Use a feeler gauge to measure the clearance between the snap ring and rear output shaft thrust bearing race.

Normal clearance: 0.02 to 0.12 mm {0.000787 to 0.00472 in}

If the clearance is out of the normal range, select another rear output shaft thrust bearing race with the clearance within the normal range.

NOTE: There are 12 different thicknesses of rear output shaft thrust bearing races.

Fig 115: Measuring Clearance Between Snap Ring And Rear Output Shaft Thrust Bearing Race

Courtesy of SUBARU OF AMERICA, INC.

RACE THICKNESS

Part number	Mark	Thickness
35789-35060		3.80mm {0.150in}
35789-50070		3.85mm {0.152in}
35789-35070		3.90mm {0.154in}
35789-50080		3.95mm {0.156in}
35789-35080		4.00mm {0.157in}
35789-50090		4.05mm {0.159in}
35789-35090		4.10mm {0.161in}
35789-50100		4.15mm {0.163in}
35789-35100		4.20mm {0.165in}
35789-50110		4.25mm {0.167in}
35789-50120		4.30mm {0.169in}
35789-50130		4.35mm {0.171in}

Installation of automatic transmission extension housing oil seal
1. Tap the automatic transmission extension housing oil seal lightly to insert it into the extension housing SUB-ASSY using the SST and a hammer.
  SST 09325-40010
  
  Insertion depth: 5.4 to 5.8 mm {0.213 to 0.228 in}
2. Apply auto fluid WS to the lip of the automatic transmission extension housing oil seal.
  
  Fig 116: Installing Automatic Transmission Extension Housing Oil Seal
  Courtesy of SUBARU OF AMERICA, INC.
Installation of extension housing dust deflector
1. Use the SST and a press to install a new extension housing dust deflector to the extension housing SUB-ASSY.
  SST 398177700
  
  Fig 117: Installing Extension Housing Dust Deflector
  Courtesy of SUBARU OF AMERICA, INC.
Installation of transmission case adapter radial ball bearing
1. Install the transmission case adapter radial ball bearing to the extension housing SUB-ASSY.
2. Use snap ring pliers to install the snap ring to the extension housing SUB-ASSY.
  
  Fig 118: Installing Snap Ring To Extension Housing Sub-Assy
  Courtesy of SUBARU OF AMERICA, INC.
Installation of extension housing SUB-ASSY
1. Clean the threads of the 6 bolts and the contact surfaces of the case and housing with appropriate detergent to remove grease.
2. Apply seal gasket to the extension housing SUB-ASSY as shown in the figure.
  
  Fig 119: Identifying Extension Housing Sub-Assy Seal Gasket
  Courtesy of SUBARU OF AMERICA, INC.
  
  Seal gasket: Three Bond 1281 or the equivalent
  
  CAUTION: Assemble the extension housing SUB-ASSY within 10 minutes after applying seal gasket.
3. Apply Adhesive to 2 or 3 threads at the tip of the 6 bolts.
  
  Fig 120: Applying Adhesive To Threads At Tip Of Bolts
  Courtesy of SUBARU OF AMERICA, INC.
  
  Adhesive: Three Bond 1344 or the equivalent
4. Install the extension housing SUB-ASSY to the automatic transmission case SUB-ASSY with 6 bolts.
  Standard value: T=34N.m {345kgf.cm} {25.1ft.lbf}
  
  NOTE: The bolt lengths are shown below.
  Bolt length
  Bolt A: 40mm {1.575in}
  Bolt B: 45mm {1.772in}
  
  Fig 121: Locating Extension Housing Sub-Assy To Automatic Transmission Case Sub-Assy Bolts
  Courtesy of SUBARU OF AMERICA, INC.
Installation of automatic transmission housing
1. Clean the bolts and the bolt holes with appropriate detergent to remove grease.
2. Install the automatic transmission housing to the automatic transmission case SUB-ASSY with 6 bolts.
  Standard value: T=34N.m {345kgf.cm} {25.1ft.lbf}
  
  Fig 122: Locating Automatic Transmission Housing To Automatic Transmission Case Sub-Assy Bolts
  Courtesy of SUBARU OF AMERICA, INC.
3. Apply Adhesive to 2 or 3 threads at the tip of the 4 bolts.
  
  Fig 123: Applying Adhesive To Threads At Tip Of Bolt
  Courtesy of SUBARU OF AMERICA, INC.
  
  Adhesive: Three Bond 1344 or the equivalent
4. Install the automatic transmission housing to the automatic transmission case SUB-ASSY with 4 bolts.
  Standard value: Bolt A (M10 bolt)
  
  T=34N.m {345kgf.cm} {25.1ft.lbf}
  
  Bolt B (M12 bolt)
  
  T=57N.m {579kgf.cm} {42.0ft.lbf}
  
  Fig 124: Locating Automatic Transmission Housing To Automatic Transmission Case Sub-Assy Bolts
  Courtesy of SUBARU OF AMERICA, INC.
Installation of automatic transmission case plug
1. Apply ATF to a new O-ring and install it to the automatic transmission case plug.
2. Use a TORX socket wrench T55 to install the automatic transmission case plug to the automatic transmission case SUB-ASSY. Standard value: T=39N.m {400kgf.cm} {28.8ft.lbf}
  
  Fig 125: Locating Automatic Transmission Case Plug
  Courtesy of SUBARU OF AMERICA, INC.
3. Apply ATF to 5 new O-rings and install them to the 5 automatic transmission case plugs.
4. Install the 5 automatic transmission case plugs to the automatic transmission case SUB-ASSY.
  Standard value: T=7.4N.m {75kgf.cm} {5.5ft.lbf}
  
  Fig 126: Locating Automatic Transmission Case Plugs
  Courtesy of SUBARU OF AMERICA, INC.
Installation of automatic transmission breather tube
1. Install the automatic transmission breather tube to the automatic transmission case SUB-ASSY with 6 bolts.
  Standard value: T=5.4N.m {55kgf.cm} {4.0ft.lbf}
  
  Fig 127: Locating Automatic Transmission Breather Tube To Automatic Transmission Case Sub-Assy Bolt
  Courtesy of SUBARU OF AMERICA, INC.
Installation of transmission revolution sensor
1. Apply ATF to 2 new O-rings and install them to the 2 transmission revolution sensors.
2. Install the 2 transmission revolution sensors to the automatic transmission case SUB-ASSY with 2 bolts.
  Standard value: T=5.4N.m {55kgf.cm} {4.0ft.lbf}
  
  Fig 128: Locating Transmission Revolution Sensors To Automatic Transmission Case Sub-Assy Bolts
  Courtesy of SUBARU OF AMERICA, INC.
Installation of transmission oil cooler
1. Install the 2 oil cooler tube unions to the automatic transmission case SUB-ASSY.
  Standard value: T=29.4N.m {300kgf.cm} {21.7ft.lbf}
  
  Fig 129: Locating Oil Cooler Tube Unions
  Courtesy of SUBARU OF AMERICA, INC.
Installation of neutral start switch ASSY
1. Clean the bolt and the bolt hole.
2. Apply Adhesive to 2 or 3 threads at the tip of the bolt.
  
  Fig 130: Applying Adhesive To Threads At Tip Of Bolt
  Courtesy of SUBARU OF AMERICA, INC.
  
  Adhesive: Three Bond 1344 or the equivalent
3. Temporarily install the neutral start switch ASSY to the automatic transmission case SUB-ASSY with the bolt.
  
  Fig 131: Identifying Neutral Start Switch Assy
  Courtesy of SUBARU OF AMERICA, INC.
4. Install a new lock washer and a nut.
  Standard value: T=6.9N.m {70kgf.cm} {5.1ft.lbf}
5. Turn the transmission control shaft lever RH counterclockwise until it stops, then turn it clockwise by 2 notches to set to N position.
  
  Fig 132: Turning Transmission Control Shaft Lever RH Counterclockwise
  Courtesy of SUBARU OF AMERICA, INC.
6. Align the neutral basic line with the groove as shown in the figure and tighten the bolt.
  
  Fig 133: Identifying Neutral Basic Line And Groove
  Courtesy of SUBARU OF AMERICA, INC.
  
  Standard value: T=13N.m {130kgf.cm} {9.6ft.lbf}
7. Use a flat tip screwdriver to bend the tab of the lock washer.
  
  Fig 134: Bending Tab Of Lock Washer Using Flat Tip Screwdriver
  Courtesy of SUBARU OF AMERICA, INC.
Installation of transmission control shaft lever RH
1. Install the transmission control shaft lever RH to the neutral start switch ASSY with the spring washer and the nut.
  Standard value: T=16N.m {160kgf.cm} {11.8ft.lbf}
  
  Fig 135: Identifying Transmission Control Shaft Lever RH
  Courtesy of SUBARU OF AMERICA, INC.
Installation of refill plug.
1. Apply ATF to a new O-ring and install it to the refill plug.
2. Install the refill plug.
  Standard value: T=39N.m {400kgf.cm} {28.8ft.lbf}