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Home › Subaru › 2016 › Outback 3.6R Limited › Repair and Diagnosis › Transmission › Automatic Trans › Continuously Variable Transaxle (CVT) (H6DO) › Automatic Transmission Assembly › Installation

Automatic Transmission Assembly: Installation

  1. Attach the ST to converter case.

    ST 498277200 STOPPER SET

    Fig 1: Attaching ST To Torque Converter Clutch Case
    G06654366Courtesy of SUBARU OF AMERICA, INC.
  2. 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 HYDRAULIC CONTROL AND LUBRICATION , SPECIFICATION, General Description. >
    NOTE: Use a new gasket.

    Tightening torque: 

    35 N.m (3.6 kgf-m, 25.8 ft-lb) 

    Fig 2: Locating Front Differential Side Retainer Oil Seal
    G10276007Courtesy of SUBARU OF AMERICA, INC.
  3. Replace the front differential side retainer oil seal. < Ref. to REPLACEMENT , Differential Side Retainer Oil Seal. >
    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.
  4. Install the cushion rubber on the transmission.

    Tightening torque: 

    40 N.m (4.1 kgf-m, 29.5 ft-lb) 

    Fig 3: Locating Transmission Cushion Rubber Bolts
    G09481952Courtesy of SUBARU OF AMERICA, INC.
  5. Mount the transmission onto the transmission jack.
  6. Strike and bend the transmission hanger of transmission rear with a soft 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: Mounting Transmission Onto Transmission Jack
    G09481956Courtesy of SUBARU OF AMERICA, INC.
  7. While lifting up the transmission gradually, install the transmission to the engine.
    CAUTION: This operation requires at least two persons.
    NOTE: Keep the engine level.
  8. Install the two engine connecting bolts and two nuts (lower side).

    Tightening torque: 

    50 N.m (5.1 kgf-m, 36.9 ft-lb) 

    Fig 5: Locating Engine Connecting Bolts And Nuts
    G06654385Courtesy of SUBARU OF AMERICA, INC.
  9. Secure the transmission rear crossmember to the vehicle body.

    Tightening torque: 

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

    T2: 75 N.m (7.6 kgf-m, 55.3 ft-lb) 

    Fig 6: Identifying Transmission Rear Crossmember Bolts
    G10276011Courtesy of SUBARU OF AMERICA, INC.
  10. Remove the transmission jack.
  11. Lower the vehicle.
  12. Remove the ST (ENGINE HANGER).
  13. Install the three engine mounting bolts (upper side).

    Tightening torque: 

    50 N.m (5.1 kgf-m, 36.9 ft-lb) 

    Fig 7: Locating Transmission Connecting Bolts (Upper Side)
    G09481944Courtesy of SUBARU OF AMERICA, INC.
  14. Install the left and right transmission mounting brackets.
    NOTE:
    • Install to the left side of vehicle first because the engine inclines to the left.
    • Temporarily tighten the bolt arrowed in the figure.

    Tightening torque: 

    75 N.m (7.6 kgf-m, 55.3 ft-lb) 

    Fig 8: Locating Transmission Mounting Brackets Bolts (Left And Right)
    G10276013Courtesy of SUBARU OF AMERICA, INC.
  15. Set the ST1 and ST2 to the vehicle body and lift up the engine unit slightly.

    ST1 99099AJ000 ENGINE HANGER

    ST2 99099AJ010 CHAIN BALANCER

    CAUTION:
    • Set so that the chain sling does not contact the engine parts.
    • Install a bolt of 8 mm (0.3 in) at the locations shown in the figure, and place the front side arms of ST (ENGINE HANGER).
    • Set the rear arms of ST (ENGINE HANGER) at the locations shown in the figure.
    Fig 9: Locating Engine Hanger Bolts
    G10274756Courtesy of SUBARU OF AMERICA, INC.
    Fig 10: Setting Chain Balancer (ST2 99099AJ010) To Vehicle
    G10275994Courtesy of SUBARU OF AMERICA, INC.
  16. Remove the bolts from ST (SPECIAL TOOL H6).
    Fig 11: Locating Engine Side Mounting Bolts
    G10275999Courtesy of SUBARU OF AMERICA, INC.
  17. Remove the bolt and nut to remove ST (SPECIAL TOOL H6).
    Fig 12: Locating Mounting Bracket Stud Bolt
    G10275998Courtesy of SUBARU OF AMERICA, INC.
  18. Temporarily attach the front cushion rubber with bolts.
    Fig 13: Locating Front Cushion Rubber Bolts
    G10275995Courtesy of SUBARU OF AMERICA, INC.
  19. Lift down the engine slightly and install the bolt and nut to the front cushion rubber.
    Fig 14: Locating Front Cushion Rubber Bolt And Nuts
    G10276019Courtesy of SUBARU OF AMERICA, INC.
  20. Tighten the bolts and nuts of front cushion rubber.
    NOTE: Always start tightening from the bolts on the engine side.

    Tightening torque: 

    T1: 25 N.m (2.5 kgf-m, 18.4 ft-lb) 

    T2: 45 N.m (4.6 kgf-m, 33.2 ft-lb) 

    Fig 15: Identifying Front Cushion Rubber Bolts
    G10276020Courtesy of SUBARU OF AMERICA, INC.
  21. Remove the ST (ENGINE HANGER and CHAIN SLING).
    CAUTION: Be sure to remove the 8 mm (0.3 in) bolt.
  22. Install the nut to the transmission mounting bracket.

    Tightening torque: 

    45 N.m (4.6 kgf-m, 33.2 ft-lb) 

    Fig 16: Locating Transmission Mounting Brackets Nut
    G10275992Courtesy of SUBARU OF AMERICA, INC.
  23. Remove the ST (STOPPER SET) from converter case.
  24. 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) 

  25. 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) 

  26. Install the service hole plug.
    Fig 17: Identifying Service Hole Plug Cover
    G10275983Courtesy of SUBARU OF AMERICA, INC.
  27. Install the starter. < Ref. to INSTALLATION , Starter. >
  28. Lift up the vehicle.
  29. Tighten the single mounting bolt of transmission mounting bracket.

    Tightening torque: 

    75 N.m (7.6 kgf-m, 55.3 ft-lb) 

    Fig 18: Locating Transmission Mounting Brackets Bolts (Left And Right)
    G10276013Courtesy of SUBARU OF AMERICA, INC.
  30. Set the ST to side retainer.

    ST 28399SA010 OIL SEAL PROTECTOR

    Fig 19: Setting Oil Seal Protector (ST 28399SA010) To Side Retainer
    G10276024Courtesy of SUBARU OF AMERICA, INC.
  31. Replace the circlip of the drive shaft with a new part.
  32. Insert the front drive shaft spline section into transmission and remove the ST (OIL SEAL PROTECTOR).
  33. Insert the drive shaft into the transmission securely by pressing the housing from outside of the vehicle.
  34. Install the CVTF CVT inlet hose and CVTF CVT outlet hose.
    NOTE: Use new CVTF CVT inlet hose and CVTF CVT outlet hose.
    Fig 20: Identifying CVTF CVT Inlet And Outlet Hoses
    G06654371Courtesy of SUBARU OF AMERICA, INC.
  35. Insert the ball joint into housing and secure with bolt.
    CAUTION:
    • Before tightening, make sure the bottom surface of the housing assembly - front axle and the stepped section of ball joint are in contact.
    • Be careful not to damage the boot of the joint.

    Tightening torque: 

    50 N.m (5.1 kgf-m, 36.9 ft-lb) 

    Fig 21: Identifying Bottom Surface Of Housing Assembly
    G10313566Courtesy of SUBARU OF AMERICA, INC.
  36. Install the stabilizer link.

    Tightening torque: 

    60 N.m (6.1 kgf-m, 44.3 ft-lb) 

  37. Connect the tie-rod end and knuckle arm, and attach the castle nut.

    Tightening torque: 

    27 N.m (2.75 kgf-m, 19.9 ft-lb) 

    CAUTION: When connecting, do not hit the cap at the bottom of tie-rod end with hammer.
  38. After tightening the castle nut to the specified tightening torque, tighten it further within 60° until the cotter pin hole is aligned with slot in the nut. Fit the cotter pin into the nut, and then bend the pin to lock.
    Fig 22: Tightening Castle Nut
    G10313567Courtesy of SUBARU OF AMERICA, INC.
  39. Install the propeller shaft. < Ref. to INSTALLATION , Propeller Shaft. >
  40. Install the universal joint. < Ref. to INSTALLATION , Universal Joint. >
  41. Install the plate assembly to transmission.

    Tightening torque: 

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

    Fig 23: Identifying Select Cable And Plate Assembly
    G10313568Courtesy of SUBARU OF AMERICA, INC.
  42. Install the washer and snap pin to the shifter arm.
    Fig 24: Identifying Washer, Snap Pin, Shifter Arm
    G10313569Courtesy of SUBARU OF AMERICA, INC.
  43. Install the exhaust hanger bracket.

    Tightening torque: 

    30 N.m (3.1 kgf-m, 22.1 ft-lb) 

    Fig 25: Identifying Exhaust Hanger Bracket
    G10275988Courtesy of SUBARU OF AMERICA, INC.
  44. Install the center exhaust cover.

    Tightening torque: 

    18 N.m (1.8 kgf-m, 13.3 ft-lb) 

    Fig 26: Identifying Center Exhaust Cover
    G10274676Courtesy of SUBARU OF AMERICA, INC.
  45. Install the front exhaust pipe. < Ref. to INSTALLATION , Front Exhaust Pipe. >
  46. Install the front under cover. < Ref. to INSTALLATION , Front Under Cover. >
  47. Lower the vehicle.
  48. Remove the ST (HANGER) and install the engine rear hanger.

    Tightening torque: 

    19 N.m (1.9 kgf-m, 14.0 ft-lb) 

    Fig 27: Locating Engine Hanger Rear Harness Connector Bolts
    G10275980Courtesy of SUBARU OF AMERICA, INC.
  49. Install the collector cover bracket.

    Tightening torque: 

    6.5 N.m (0.7 kgf-m, 4.8 ft-lb) 

    Fig 28: Locating Collector Cover Bracket Bolts
    G10275981Courtesy of SUBARU OF AMERICA, INC.
  50. Connect the oxygen sensor harness connector.
    Fig 29: Locating Oxygen Sensor Harness Connector
    G10263923Courtesy of SUBARU OF AMERICA, INC.
  51. Install the throttle body. < Ref. to INSTALLATION , Throttle Body. >
  52. Connect the engine harness connector.
    Fig 30: Locating Engine Harness Connector
    G10263539Courtesy of SUBARU OF AMERICA, INC.
  53. Install the harness stay.

    Tightening torque: 

    16 N.m (1.6 kgf-m, 11.8 ft-lb) 

    Fig 31: Locating Transmission Harness Stay Bolt
    G10275976Courtesy of SUBARU OF AMERICA, INC.
  54. Connect the following harness connectors.
    • Transmission harness connectors
    • Transmission radio ground terminal
    • Inhibitor harness connector

    Tightening torque: 

    13 N.m (1.3 kgf-m, 9.6 ft-lb) 

    Fig 32: Identifying Transmission And Inhibitor Harness Connector
    G10313577Courtesy of SUBARU OF AMERICA, INC.
  55. Install the battery cable bracket, and install the battery cable clip to the bracket.

    Tightening torque: 

    7.5 N.m (0.8 kgf-m, 5.5 ft-lb) 

    Fig 33: Locating Battery Cable Bracket Ground Cable Clips
    G10275977Courtesy of SUBARU OF AMERICA, INC.
  56. Install the air intake boot. < Ref. to INSTALLATION , Air Intake Boot. >
  57. Install the air intake duct. < Ref. to INSTALLATION , Air Intake Duct. >
  58. Install the front tires.
  59. Connect the ground terminal to battery sensor. < Ref. to BATTERY , NOTE, Repair Contents. >
  60. Refill differential gear oil to adjust the differential gear oil amount. < Ref. to DIFFERENTIAL GEAR OIL . >
  61. Refill CVTF to adjust the CVTF amount. < Ref. to CVTF . >
  62. Perform the variator chain break-in. < Ref. to 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
  63. Perform AT learning mode. < Ref. to LEARNING CONTROL . >
  64. Execute the rear differential inspection mode. < Ref. to REAR DIFFERENTIAL INSPECTION MODE . >
    CAUTION: Always execute the rear differential inspection mode after the replacement of the following.
    • Replacement of transmission assembly
    • Replacement of front differential hypoid gear set
  65. Perform the road test to make sure there is no fault. < Ref. to INSPECTION , Road Test. >
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