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Home › Subaru › 2018 › Outback 3.6R Limited › Repair and Diagnosis › Transmission › Automatic Trans › CVT Transaxle (Tr690) › Automatic Transmission Assembly › Installation

Automatic Transmission Assembly: Installation

  1. Attach the ST to converter case.

    ST 498277200 STOPPER SET 

    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 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)
    G10276007Courtesy 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)

    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 excessive load or impact to the transmission case.
    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)

    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)

    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)

    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)

    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.
    G10274756Courtesy of SUBARU OF AMERICA, INC.
    G10275994Courtesy of SUBARU OF AMERICA, INC.
  16. Remove the bolts from ST (SPECIAL TOOL H6).
    G10275999Courtesy of SUBARU OF AMERICA, INC.
  17. Remove the bolt and nut to remove ST (SPECIAL TOOL H6).
    G10275998Courtesy of SUBARU OF AMERICA, INC.
  18. Temporarily attach the front cushion rubber with bolts.
    G10275995Courtesy of SUBARU OF AMERICA, INC.
  19. Lift down the engine slightly and install the bolt and nut to the front cushion rubber.
    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)

    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)

    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.
    G10275983Courtesy of SUBARU OF AMERICA, INC.
  27. Install the starter. Ref. to STARTING/CHARGING SYSTEMS(H6DO)>Starter>INSTALLATION .
  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)

    G10276013Courtesy of SUBARU OF AMERICA, INC.
  30. Set the ST to differential side retainer.

    ST 28399SA010 OIL SEAL PROTECTOR 

    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.
    G06654371Courtesy of SUBARU OF AMERICA, INC.
  35. Insert the ball joint into housing and secure with bolt.
    CAUTION:
    • Do not apply grease to the tapered portion of ball stud.
    • 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)

    G12410588Courtesy of SUBARU OF AMERICA, INC.
  36. Install the stabilizer link.
    NOTE: Use a new flange nut.

    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.
    G12410589Courtesy of SUBARU OF AMERICA, INC.
  39. Install the propeller shaft. Ref. to DRIVE SHAFT SYSTEM>Propeller Shaft>INSTALLATION .
  40. Install the universal joint. Ref. to POWER ASSISTED SYSTEM (POWER STEERING)>Universal Joint>INSTALLATION .
  41. Install the cable plate assembly.

    Tightening torque:

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

    G12410590Courtesy of SUBARU OF AMERICA, INC.
  42. Connect the select cable and install the washer and snap pin.
    CAUTION: Do not apply extra overload while holding the part (A).
    G11255302Courtesy of SUBARU OF AMERICA, INC.
    G12410592Courtesy of SUBARU OF AMERICA, INC.
  43. Install the exhaust hanger bracket.

    Tightening torque:

    30 N.m (3.1 kgf-m, 22.1 ft-lb)

    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)

    G10274676Courtesy of SUBARU OF AMERICA, INC.
  45. Install the front exhaust pipe. Ref. to EXHAUST(H6DO)>Front Exhaust Pipe>INSTALLATION .
  46. Install the front under cover. Ref. to EXTERIOR/INTERIOR TRIM>Front Under Cover>INSTALLATION .
  47. Lower the vehicle.
  48. Remove the ST (HANGER).
  49. Install the engine hanger rear and the oxygen sensor harness connector (A).

    Tightening torque:

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

    G10263924Courtesy of SUBARU OF AMERICA, INC.
  50. Install the collector cover bracket.

    Tightening torque:

    6.5 N.m (0.7 kgf-m, 4.8 ft-lb)

    G10275981Courtesy of SUBARU OF AMERICA, INC.
  51. Connect the oxygen sensor harness connector.
    G10263923Courtesy of SUBARU OF AMERICA, INC.
  52. Install the throttle body. Ref. to FUEL INJECTION (FUEL SYSTEMS) (H6DO)>Throttle Body>INSTALLATION .
  53. Connect the engine harness connector.
    G10263539Courtesy of SUBARU OF AMERICA, INC.
  54. Install the harness stay.

    Tightening torque:

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

    G10275976Courtesy of SUBARU OF AMERICA, INC.
  55. 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)

    G12410600Courtesy of SUBARU OF AMERICA, INC.
  56. 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)

    G10275977Courtesy of SUBARU OF AMERICA, INC.
  57. Install the air intake boot. Ref. to INTAKE (INDUCTION) (H6DO)>Air Intake Boot>INSTALLATION .
  58. Install the air intake duct. Ref. to INTAKE (INDUCTION) (H6DO)>Air Intake Duct>INSTALLATION .
  59. Install the front tires. Ref. to WHEEL AND TIRE SYSTEM>Tire and Wheel>INSTALLATION .
  60. Install the collector cover.
  61. Connect the ground terminal to battery sensor. Ref. to REPAIR CONTENTS>NOTE>BATTERY .
  62. Refill differential gear oil to adjust the differential gear oil amount. Ref. to CONTINUOUSLY VARIABLE TRANSMISSION(TR690)>Differential Gear Oil>ADJUSTMENT .
  63. Refill CVTF to adjust the CVTF amount. Ref. to CONTINUOUSLY VARIABLE TRANSMISSION(TR690)>CVTF>ADJUSTMENT .
  64. 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
  65. Perform the operation of AT learning mode. Ref. to CONTINUOUSLY VARIABLE TRANSMISSION (DIAGNOSTICS)>LEARNING CONTROL .
  66. Execute the rear differential inspection mode. Ref. to DIFFERENTIALS>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
  67. Perform the road test to make sure there is no fault. Ref. to CONTINUOUSLY VARIABLE TRANSMISSION(TR690)>Road Test>INSPECTION .
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