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Automatic Transmission Assembly: Installation

  1. Attach the ST to converter case.

    ST 498277200 STOPPER SET 

    Fig 1: Attaching ST With Converter Case
    G09480213Courtesy 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 CONTINUOUSLY VARIABLE TRANSMISSION (TR690)>General Description>SPECIFICATION>HYDRAULIC CONTROL AND LUBRICATION .
    NOTE: Use a new gasket.

    Tightening torque: 

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

    Fig 2: Identifying CVTF Transmission Right Side Plug
    G10406832Courtesy of SUBARU OF AMERICA, INC.
  3. 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.
  4. Install the rear cushion rubber.

    Tightening torque: 

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

    Fig 3: Locating Rear 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 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
    G09481956Courtesy of SUBARU OF AMERICA, INC.
  7. Remove the pitching stopper bracket, if mounted.
  8. 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).
  9. 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 Specifications
    G09481957Courtesy of SUBARU OF AMERICA, INC.
  10. 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 Lower Side Engine Connecting Bolts And Nuts
    G06654385Courtesy of SUBARU OF AMERICA, INC.
  11. Remove the transmission jack.
  12. Lower the vehicle.
  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 Upper Side Engine Mounting Bolts
    G09481944Courtesy of SUBARU OF AMERICA, INC.
  14. Remove the ST (STOPPER SET) from converter case.
  15. Remove the ST (ENGINE SUPPORT ASSY).

    ST 41099AC000 ENGINE SUPPORT ASSY 

    Fig 8: Identifying Engine Support Assembly
    G09481943Courtesy of SUBARU OF AMERICA, INC.
  16. 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)

  17. 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)

  18. Install the service hole plug.
    Fig 9: Identifying Service Hole Plug
    G09481933Courtesy of SUBARU OF AMERICA, INC.
  19. Install the engine ground terminals.

    Tightening torque: 

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

    Fig 10: Locating Engine Ground Terminals
    G09481940Courtesy of SUBARU OF AMERICA, INC.
  20. Install the pitching stopper bracket and transmission radio ground cord.
    CAUTION: Be careful not to deform or damage the terminal of transmission radio ground cord.

    Tightening torque: 

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

    Fig 11: Locating Pitching Stopper Bracket And Transmission Radio Ground Cord
    G10406817Courtesy of SUBARU OF AMERICA, INC.
  21. 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
    G10406816Courtesy of SUBARU OF AMERICA, INC.
  22. Install the starter. Ref. to STARTING/CHARGING SYSTEMS(H4DOTC)>General Description .
  23. Install the transmission harness stay.

    Tightening torque: 

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

    Fig 13: Locating Transmission Harness Stay
    G09481937Courtesy of SUBARU OF AMERICA, INC.
  24. 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: Pitching Stopper With Torque Specifications
    G10406844Courtesy of SUBARU OF AMERICA, INC.
  25. Lift up the vehicle.
  26. Set the ST to differential side retainer.

    ST 28399SA010 OIL SEAL PROTECTOR 

    Fig 15: Installing ST With Differential Side Retainer
    G09481967Courtesy of SUBARU OF AMERICA, INC.
  27. Replace the circlip of the drive shaft with a new part.
  28. Insert the front drive shaft spline section into transmission and remove the ST (OIL SEAL PROTECTOR).
    NOTE:
    • Before inserting the front drive shaft RH, turn the steering wheel to the right hand at full lock.
    • Before inserting the front drive shaft LH, turn the steering wheel to the left hand at full lock.
  29. Insert the drive shaft into the transmission securely by pressing the housing from outside of the vehicle.
  30. 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.
  31. Install the stabilizer link.

    Tightening torque: 

    60 N.m (6.1 kgf-m, 44.3 ft-lb)

  32. Install the propeller shaft. Ref. to DRIVE SHAFT SYSTEM>Propeller Shaft>INSTALLATION .
  33. Install the cable plate assembly.

    Tightening torque: 

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

    Fig 16: Identifying Select Cable And Cable Plate Assembly With Torque Specifications
    G11266016Courtesy of SUBARU OF AMERICA, INC.
  34. Install the washer and snap pin.
    Fig 17: Identifying Shifter Arm, Snap Pin, Select Cable, Cable Plate Assembly And Washer
    G11266017Courtesy of SUBARU OF AMERICA, INC.
  35. Connect the secondary pressure sensor harness connector.
    Fig 18: Identifying Secondary Pressure Sensor Harness Connector
    G09481946Courtesy of SUBARU OF AMERICA, INC.
  36. Install the exhaust hanger bracket.

    Tightening torque: 

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

  37. Install the center exhaust cover.

    Tightening torque: 

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

    Fig 19: Identifying Automatic Transmission Assembly Center Exhaust Cover
    G09481945Courtesy of SUBARU OF AMERICA, INC.
  38. Install the center exhaust pipe. Ref. to EXHAUST(H4DOTC)>Center Exhaust Pipe>INSTALLATION .
  39. Install the under cover.
  40. Lower the vehicle.
  41. Replace the CVTF inlet hose and CVTF outlet hose. Ref. to CONTINUOUSLY VARIABLE TRANSMISSION (TR690)>CVTF Cooler (With Warmer Function)>ASSEMBLY .
  42. Install the CVTF cooler (with warmer feature).

    Tightening torque: 

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

    Fig 20: Locating CVTF Cooler Bolts (With Warm Feature)
    G09481942Courtesy of SUBARU OF AMERICA, INC.
  43. Connect the CVTF inlet hose and the outlet hose.
    Fig 21: Identifying CVTF Inlet And Outlet Hoses
    G09481941Courtesy of SUBARU OF AMERICA, INC.
  44. Install the air breather hose to the pitching stopper bracket.
  45. Connect the primary pressure sensor harness connector.
    Fig 22: Identifying Primary Pressure Sensor Harness Connector
    G09481936Courtesy of SUBARU OF AMERICA, INC.
  46. 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
    G09481930Courtesy of SUBARU OF AMERICA, INC.
  47. Install the harness clip.
    Fig 24: Identifying Automatic Transmission Assembly Harness Clip
    G09481931Courtesy of SUBARU OF AMERICA, INC.
  48. 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, Radio Ground Terminal, Inhibitor Harness Connector And Engine Harness Connector
    G11266025Courtesy of SUBARU OF AMERICA, INC.
  49. Install the intercooler. Ref. to INTAKE (INDUCTION) (H4DOTC)>Intercooler>INSTALLATION .
  50. Install the air intake duct. Ref. to INTAKE (INDUCTION) (H4DOTC)>Air Intake Duct>INSTALLATION .
  51. Install the front tires.
  52. Connect the battery ground terminal.
  53. Refill differential gear oil to adjust the differential gear oil amount. Ref. to CONTINUOUSLY VARIABLE TRANSMISSION (TR690)>Differential Gear Oil .
  54. Refill CVTF to adjust the CVTF amount. Ref. to CONTINUOUSLY VARIABLE TRANSMISSION (TR690)>CVTF .
  55. Perform the variator chain break-in. Ref. to CONTINUOUSLY VARIABLE TRANSMISSION (TR690)>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
  56. Perform the operation of AT learning mode. Ref. to TRANSMISSION (DIAGNOSTICS)>Learning Control .
  57. 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
  58. Perform the road test to make sure there is no fault. Ref. to CONTINUOUSLY VARIABLE TRANSMISSION (TR690)>Road Test>INSPECTION .
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