Automatic Transmission Assembly: Installation

Attach the ST to converter case.
ST 498277200 STOPPER SET

Fig 1: Attaching ST To Converter Case
Courtesy of SUBARU OF AMERICA, INC.
When completely overhauling the transmission, refill approx. 10 L (2.6 US qt, 8.8 Imp qt) of CVTF through the transmission right side plug, and install the plug.
CAUTION: Always use specified CVTF. Using other fluid will cause malfunction. Ref. to CONTINUOUSLY VARIABLE TRANSMISSION(TR690)>General Description> HYDRAULIC CONTROL AND LUBRICATION .

NOTE: Use a new gasket.

Tightening torque:

35 N.m (3.6 kgf-m, 25.8 ft-lb)

Fig 2: Locating CVTF Through Transmission Right Side Plug
Courtesy of SUBARU OF AMERICA, INC.
Replace the front differential side retainer oil seal. Ref. to CONTINUOUSLY VARIABLE TRANSMISSION(TR690)>Differential Side Retainer Oil Seal> REPLACEMENT .
NOTE:
- Be sure to replace the differential side retainer oil seal with a new part whenever the front drive shaft is removed from the transmission.
- When a new differential side retainer oil seal has been installed, replacement is not required.
Install the cushion rubber on the transmission.
Tightening torque:

40 N.m (4.1 kgf-m, 29.5 ft-lb)

Fig 3: Locating Cushion Rubber Bolts
Courtesy of SUBARU OF AMERICA, INC.
Mount the transmission onto the transmission jack.
Strike and bend the transmission hanger of transmission rear with a rubber hammer etc. so that it gets in contact with the transmission case.
CAUTION: Do not apply extra overload or impact to the transmission case.

Fig 4: Bending Transmission Hanger Of Transmission Rear
Courtesy of SUBARU OF AMERICA, INC.
Remove the pitching stopper bracket, if mounted.
Install the transmission onto the engine.
NOTE:
- While raising the transmission jack gradually, turn the screw of engine support, then tilt the engine forward.
- Temporarily attach the two engine connecting bolts and two nuts (lower side).
Install the transmission rear crossmember.
Tightening torque:

T1: 35 N.m (3.6 kgf-m, 25.8 ft-lb)

T2: 70 N.m (7.1 kgf-m, 51.6 ft-lb)

Fig 5: Identifying Transmission Rear Crossmember Bolts With Torque Specification
Courtesy of SUBARU OF AMERICA, INC.
Tighten the two engine connecting bolts and two nuts (lower side).
Tightening torque:

50 N.m (5.1 kgf-m, 36.9 ft-lb)

Fig 6: Locating Engine Connecting Bolts And Nuts
Courtesy of SUBARU OF AMERICA, INC.
Remove the transmission jack.
Lower the vehicle.
Install the three engine mounting bolts (upper side).
Tightening torque:

50 N.m (5.1 kgf-m, 36.9 ft-lb)

Fig 7: Locating Engine Mounting Bolts
Courtesy of SUBARU OF AMERICA, INC.
Remove the ST (STOPPER SET) from converter case.
Remove the ST (ENGINE SUPPORT ASSY).
ST 41099AC000 ENGINE SUPPORT ASSY

Fig 8: Removing Engine Support Assy (ST 41099AC000)
Courtesy of SUBARU OF AMERICA, INC.
Match the torque converter screw hole with drive plate hole to install the bolt.
CAUTION:
- Do not drop the mounting bolt in the converter housing.
- Do not damage the mounting bolt.
Tightening torque:

25 N.m (2.5 kgf-m, 18.4 ft-lb)
Install the remaining three bolts by rotating the crank pulley a little at a time in the same direction as engine revolution.
Tightening torque:

25 N.m (2.5 kgf-m, 18.4 ft-lb)
Install the service hole plug.

Fig 9: Identifying Service Hole Plug
Courtesy of SUBARU OF AMERICA, INC.
Install the engine ground terminals.
Tightening torque:

19 N.m (1.9 kgf-m, 14.0 ft-lb)

Fig 10: Locating Engine Ground Terminal Bolts
Courtesy of SUBARU OF AMERICA, INC.
Install the pitching stopper bracket and transmission radio ground cord.
Tightening torque:

41 N.m (4.2 kgf-m, 30.2 ft-lb)

Fig 11: Locating Pitching Stopper Bracket Bolt
Courtesy of SUBARU OF AMERICA, INC.
Install the CVTF cooler pipe COMPL.
Tightening torque:

16 N.m (1.6 kgf-m, 11.8 ft-lb)

Fig 12: Locating CVTF Cooler Pipe COMPL Bolts
Courtesy of SUBARU OF AMERICA, INC.
Install the starter. Ref. to STARTING/CHARGING SYSTEMS(H4DOTC)> GENERAL DESCRIPTION .
Install the transmission harness stay.
Tightening torque:

16 N.m (1.6 kgf-m, 11.8 ft-lb)

Fig 13: Locating Transmission Harness Stay Bolt
Courtesy of SUBARU OF AMERICA, INC.
Install the pitching stopper.
Tightening torque:

T1: 50 N.m (5.1 kgf-m, 36.9 ft-lb)

T2: 58 N.m (5.9 kgf-m, 42.8 ft-lb)

Fig 14: Installing Pitching Stopper
Courtesy of SUBARU OF AMERICA, INC.
Lift up the vehicle.
Apply grease to the side retainer oil seal lip.
Set the ST to side retainer.
ST 28399SA010 OIL SEAL PROTECTOR

Fig 15: Setting Oil Seal Protector (ST 28399SA010) To Side Retainer
Courtesy of SUBARU OF AMERICA, INC.
Replace the circlip of the drive shaft with a new part.
Insert the front drive shaft spline section into transmission and remove the ST (OIL SEAL PROTECTOR).
NOTE:
- Before inserting the RH front drive shaft into transmission, turn the steering wheel to the right hand at full lock.
- Before inserting the LH front drive shaft into transmission, turn the steering wheel to the left hand at full lock.
Insert the drive shaft into the transmission securely by pressing the housing from outside of the vehicle.
Insert the ball joint into housing and secure with bolt.
Tightening torque:

50 N.m (5.1 kgf-m, 36.9 ft-lb)
CAUTION:
- Do not apply grease to the tapered portion of ball stud.
- Before tightening, make sure the lower side of housing and stepped section of ball joint are in contact.
Install the stabilizer link.
Tightening torque:

60 N.m (6.1 kgf-m, 44.3 ft-lb)
Install the propeller shaft. Ref. to DRIVE SHAFT SYSTEM>Propeller Shaft> INSTALLATION .
Install the plate assembly to transmission.
Tightening torque:

T: 25 N.m (2.5 kgf-m, 18.4 ft-lb)

Fig 16: Identifying Plate Assembly Bolts With Torque Specification
Courtesy of SUBARU OF AMERICA, INC.
Install the washer and snap pin to the shifter arm.

Fig 17: Identifying Shifter Arm, Snap Pin, Select Cable, Plate Assy And Washer
Courtesy of SUBARU OF AMERICA, INC.
Connect the secondary pressure sensor harness connector.

Fig 18: Identifying Secondary Pressure Sensor Harness Connector
Courtesy of SUBARU OF AMERICA, INC.
Install the exhaust hanger bracket.
Tightening torque:

23 N.m (2.3 kgf-m, 17.0 ft-lb)
Install the center exhaust cover.
Tightening torque:

18 N.m (1.8 kgf-m, 13.3 ft-lb)

Fig 19: Identifying Center Exhaust Cover
Courtesy of SUBARU OF AMERICA, INC.
Install the center exhaust pipe. Ref. to EXHAUST(H4DOTC)>Center Exhaust Pipe> INSTALLATION .
Install the under cover.
Lower the vehicle.
Replace the CVTF inlet hose and CVTF outlet hose. Ref. to CONTINUOUSLY VARIABLE TRANSMISSION(TR690)>CVTF Cooler (With Warmer Function)> ASSEMBLY .
Install the CVTF cooler (with warmer feature) to the transmission.
Tightening torque:

23 N.m (2.3 kgf-m, 17.0 ft-lb)

Fig 20: Locating CVTF Cooler Bolts
Courtesy of SUBARU OF AMERICA, INC.
Connect the CVTF inlet hose and the outlet hose.

Fig 21: Identifying CVTF Inlet Hose And Outlet Hose
Courtesy of SUBARU OF AMERICA, INC.
Install the air breather hose to the pitching stopper bracket.
Connect the primary pressure sensor harness connector.

Fig 22: Identifying Primary Pressure Sensor Harness Connector
Courtesy of SUBARU OF AMERICA, INC.
Install the engine hanger rear.
Tightening torque:

21 N.m (2.1 kgf-m, 15.5 ft-lb)

Fig 23: Locating Engine Hanger Rear Bolts
Courtesy of SUBARU OF AMERICA, INC.
Install the harness clip to the CVTF cooler bracket.

Fig 24: Identifying CVTF Cooler Bracket Harness Clip
Courtesy of SUBARU OF AMERICA, INC.
Connect the following harness connectors.
- Transmission harness connectors
- Transmission radio ground terminal
- Inhibitor harness connector
- Engine harness connectors
  Tightening torque:
  
  13 N.m (1.3 kgf-m, 9.6 ft-lb)
Fig 25: Identifying Transmission Harness Connectors And Transmission Radio Ground Terminal
Courtesy of SUBARU OF AMERICA, INC.
Install the intercooler. Ref. to INTAKE (INDUCTION) (H4DOTC) >Intercooler> INSTALLATION .
Install the air intake duct. Ref. to INTAKE (INDUCTION) (H4DOTC)>Air Intake Duct> INSTALLATION .
Install the front tires.
Connect the battery ground terminal.
Refill differential gear oil to adjust the differential gear oil amount. Ref. to CONTINUOUSLY VARIABLE TRANSMISSION(TR690)> DIFFERENTIAL GEAR OIL .
Refill CVTF to adjust the CVTF amount. Ref. to CONTINUOUSLY VARIABLE TRANSMISSION(TR690)> CVTF .
Perform the variator chain break-in.
CAUTION:
Always execute the variator chain break-in after the replacement of the following.
- Variator chain replacement
- Primary pulley and secondary pulley replacement
Perform the operation of AT learning mode. Ref. to CONTINUOUSLY VARIABLE TRANSMISSION (DIAGNOSTICS)> LEARNING CONTROL .
Execute the rear differential inspection mode. Ref. to DIFFERENTIALS> REAR DIFFERENTIAL INSPECTION MODE .
CAUTION:
Always execute the rear differential inspection mode at the replacement of the following.
- Replacement of transmission assembly
- Replacement of front differential hypoid gear set
Perform the road test to make sure there is no fault. Ref. to CONTINUOUSLY VARIABLE TRANSMISSION(TR690)>Road Test> INSPECTION .