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Automatic Transmission Assembly: Installation

WARNING: This page is about a different car, the 2003 Subaru Outback, 2003 Subaru Legacy, and 2003 Subaru Baja. However, it is still accessible from the selected car via links, so may be relevant.
  1. Install rear cushion rubber to transmission assembly.
    1. Tightening torque:  39 N.m (4.0 kgf-m, 29 ft-lb)
  2. Install ST to torque converter clutch case.
    1. ST 498277200 STOPPER SET
    Fig 1: Installing ST To Torque Converter Clutch Case
    G02875743Courtesy of SUBARU OF AMERICA, INC.
  3. Install transmission onto engine.
    1. Gradually raise transmission with transmission jack.
      Fig 2: Installing Transmission Onto Engine
      G02875744Courtesy of SUBARU OF AMERICA, INC.
    2. Engage them at splines.
  4. Install transmission rear crossmember.

    Tightening torque: 

    1. T1:  35 N.m (3.6 kgf-m, 26 ft-lb)
    2. T2:  75 N.m (7.6 kgf-m, 55 ft-lb)
    Fig 3: Installing Transmission Rear Crossmember
    G02875745Courtesy of SUBARU OF AMERICA, INC.
  5. Take off transmission jack.
  6. Tighten nuts and bolts which hold lower side of transmission to engine.
    1. Tightening torque:  50 N.m (5.1 kgf-m, 36.9 ft-lb)
    Fig 4: Tightening Lower Side Of Transmission (Except 3.0 L Model)
    G02875746Courtesy of SUBARU OF AMERICA, INC.
    Fig 5: Tightening Lower Side Of Transmission (3.0 L Model)
    G02875747Courtesy of SUBARU OF AMERICA, INC.
  7. Lower the vehicle.
  8. Connect engine and transmission.
    1. Remove ST from torque converter clutch case.
      NOTE: Be careful not to drop the ST into the torque converter clutch case when removing ST.
      1. ST 498277200 STOPPER SET
    2. Install starter. <Ref. to INSTALLATION , Starter.>
    3. Tighten bolt which holds right upper side of transmission to engine.
    1. Tightening torque:  50 N.m (5.1 kgf-m, 36.9 ft-lb)
    Fig 6: Tightening Bolt Holding Right Upper Side Of Transmission (Except 3.0 L Model)
    G02875748Courtesy of SUBARU OF AMERICA, INC.
    Fig 7: Tightening Bolt Holding Right Upper Side Of Transmission (3.0 L Model)
    G02875749Courtesy of SUBARU OF AMERICA, INC.
  9. Install torque converter clutch to drive plate.
    1. Tighten bolts which hold torque converter clutch to drive plate.
    2. Tighten other bolts while rotating the engine by using ST.
      NOTE: Be careful not to drop bolts into torque converter clutch housing.
      1. ST 499977100 CRANK PULLEY WRENCH
      1. Tightening torque:  25 N.m (23 kgf-m, 18.1 ft-lb)
      Fig 8: Installing Torque Converter Clutch To Drive Plate
      G02875750Courtesy of SUBARU OF AMERICA, INC.
    3. Clog plug onto service hole.
  10. Remove ST.
    Fig 9: Removing ST
    G02875751Courtesy of SUBARU OF AMERICA, INC.
  11. Install pitching stopper.

    Tightening torque: 

    1. T1:  50 N.m (5.1 kgf-m, 37 ft-lb)
    2. T2:  58 N.m (5.9 kgf-m, 43 ft-lb)
      Fig 10: Installing Pitching Stopper
      G02875752Courtesy of SUBARU OF AMERICA, INC.
  12. Lift-up the vehicle.

    Install front drive shafts into transmission.

    1. Lift-up the vehicle.
    2. Install front drive shaft into transmission.
    3. New drive spring pin into chamfered hole of drive shaft.
      Fig 11: Installing Front Drive Shafts Into Transmission
      G02875753Courtesy of SUBARU OF AMERICA, INC.
  13. Install ball joint into housing.
  14. Connect stabilizer link to transverse link, and temporarily tighten bolts.
    NOTE: Discard loosened self-locking nut and replace with a new one.

    Tightening torque: 

    1. T1:  30 N.m (3.1 kgf-m, 22.4 ft-lb)
    2. T2:  50 N.m (5.1 kgf-m, 37 ft-lb)
      Fig 12: Connecting Stabilizer Link To Transverse Link
      G02875754Courtesy of SUBARU OF AMERICA, INC.
  15. Install shift select cable onto select lever.

    < Ref. to INSTALLATION , Select Cable.>

  16. Install ATF level gauge guide, and connect ATF cooler hoses to pipe.
    Fig 13: Installing ATF Level Gauge Guide
    G02875755Courtesy of SUBARU OF AMERICA, INC.
  17. Install propeller shaft.

  18. Install heat shield cover.
    Fig 14: Installing Heat Shield Cover
    G02875756Courtesy of SUBARU OF AMERICA, INC.
  19. Install rear exhaust pipe and muffler assembly.

    2.5 L model 

    1. < Ref. to INSTALLATION , Rear Exhaust Pipe> and < Ref. to INSTALLATION , Muffler.>

    3.0 L model 

    1. < Ref. to INSTALLATION , Rear Exhaust Pipe> and < Ref. to INSTALLATION , Muffler.>
  20. Install front and center exhaust pipe.

    2.5 L model 

    1. < Ref. to INSTALLATION , Front Exhaust Pipe.>

    3.0 L model 

    1. < Ref. to INSTALLATION , Front Exhaust Pipe.>
  21. Install under cover.
  22. Lower the vehicle.
  23. Install ATF level gauge.
    Fig 15: Installing ATF Level Gauge
    G02875757Courtesy of SUBARU OF AMERICA, INC.
  24. Connect the following connectors.
    1. Transmission harness connectors
    2. Transmission ground terminal
  25. Connect the following cables.
    1. Cruise control cable (With cruise control vehicles)
  26. Install air cleaner case stay.
    1. Tightening torque:  16 N.m (1.6 kgf-m, 11.6 ft-lb)
  27. Install air cleaner case or air intake chamber.

    2.5 L model 

    1. < Ref. to INSTALLATION , Air Cleaner Case.>

    3.0 L model 

    1. < Ref. to INSTALLATION , Air Intake Chamber.>
  28. Connect battery ground cable.
  29. Fill ATF up to the middle of the "COLD" side on level gauge by using the gauge hole. < Ref. to AUTOMATIC TRANSMISSION FLUID .>
  30. Take off vehicle from lift arms.
  31. Check select lever operation.

    < Ref. to INSPECTION , Inhibitor Switch.>

  32. Check the ATF level. < Ref. to AUTOMATIC TRANSMISSION FLUID .>
  33. Check the vehicle on the road tester. < Ref. to ROAD TEST .>
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