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AT Main Case: Installation

  1. Install the low and reverse piston without tilting.
    NOTE: Be careful not to damage the lip seal.
    Fig 1: Installing Low & Reverse Piston
    G00924262Courtesy of SUBARU OF AMERICA, INC.
  2. Install the return spring.
    Fig 2: Installing Return Spring
    G00924263Courtesy of SUBARU OF AMERICA, INC.
  3. Install the spring retainer.
    Fig 3: Installing Spring Retainer
    G00924264Courtesy of SUBARU OF AMERICA, INC.
  4. Install the one-way clutch inner race, spring retainer and return spring.
  5. Tighten the socket head bolts evenly from the rear side of transmission case.
    1. Tightening torque: 25 N.m (2.5 kgf-m, 18.1 ft-lb) 
    Fig 4: Installing One-Way Clutch Inner Race, Spring Retainer & Return Spring
    G00924265Courtesy of SUBARU OF AMERICA, INC.
  6. Place the front side of transmission body upward.
  7. Install thrust needle bearing.
  8. Place dish plate, driven plate, and retaining plate on a surface plate in order.
  9. Set the micro gauge, read the scale, and then place a flat plate on the plate.
    NOTE: The value of the scale shall be from 0 starting point.
    Fig 5: Installing Thrust Needle Bearing
    G00924266Courtesy of SUBARU OF AMERICA, INC.
  10. Press at the center of the retaining plate with 83 N (8.5 kgf, 18.7 lb), using push gauge and pull gauge. Then measure and record the height A. Measure more than three points at even intervals and calculate the average.
    Fig 6: Pressing At Center Of Retaining Plate & Measuring Height A
    G00924267Courtesy of SUBARU OF AMERICA, INC.
  11. Installation of the low & reverse brake: Install dish plate, driven plates, drive plates, and a retaining plate, and secure with a snap ring.
    NOTE: Pay attention to the orientation of the dish plate.
    Fig 7: Installing Dish Plate, Driven Plates, Drive Plates & Retaining Plate
    G00924268Courtesy of SUBARU OF AMERICA, INC.
  12. Apply compressed air intermittently to check for operation.
    Fig 8: Applying Compressed Air
    G00924269Courtesy of SUBARU OF AMERICA, INC.
  13. Measure the clearance. Place the same thickness of shim on both sides to prevent the retaining plate from tilting.
    Fig 9: Placing Same Thickness Of Shim On Both Sides To Prevent Retaining Plate From Tilting
    G00924270Courtesy of SUBARU OF AMERICA, INC.
  14. Calculation of piston stroke

    Calculate piston stroke from the recorded measurement A and B, and select the retaining plate so that the piston stroke is within the standard value.

    If the value from the equation exceeds the service limit, replace the drive plate with new one and adjust it to be within the standard.

    T = A + C

    T: Piston stroke

    A: Amount of the flattened drive plate

    B: Clearance between the retaining plate and the snap ring

    3.0 L model and TURBO model 

    1. Standard value: 2.7 - 3.2 mm (0.106 - 0.126) 
    2. Limit value: 4.2 mm (0.165 in) 

    Except 3.0 L model and TURBO model 

    1. Standard value: 2.4 - 2.9 mm (0.094 - 0.114 in) 
    2. Limit value: 3.9 mm (0.154 in) 
    Fig 10: Retaining Plate Specifications
    G00924271Courtesy of SUBARU OF AMERICA, INC.
  15. Install the low & reverse brake leaf spring.
    Fig 11: Installing Low & Reverse Brake Leaf Spring
    G00924272Courtesy of SUBARU OF AMERICA, INC.
  16. Install the 2-4 brake piston and 2-4 brake retainer by aligning the hole of 2-4 brake retainer and the hole of transmission case.
    Fig 12: Installing 2-4 Brake Piston & 2-4 Brake Retainer
    G00924273Courtesy of SUBARU OF AMERICA, INC.
  17. Install the 2-4 brake piston return spring to transmission case.
    Fig 13: Installing 2-4 Brake Piston Return Spring To Transmission Case
    G00924274Courtesy of SUBARU OF AMERICA, INC.
  18. Position the snap ring in transmission. Using ST, press the snap ring into place.

    ST 498677100 COMPRESSOR

    Fig 14: Pressing Snap Ring Into Place Using Special Tool
    G00924275Courtesy of SUBARU OF AMERICA, INC.
  19. Install the planetary gear and low clutch assembly to transmission case.

    Install carefully while rotating the low clutch and planetary gear assembly slowly paying special attention not to damage the seal ring.

    Fig 15: Installing Planetary Gear & Low Clutch Assembly To Transmission Case
    G00924276Courtesy of SUBARU OF AMERICA, INC.
  20. Install pressure plate, drive plate, driven plate, retaining plate and snap ring.
    Fig 16: Installing Pressure Plate, Drive Plate, Driven Plate, Retaining Plate & Snap Ring
    G00924277Courtesy of SUBARU OF AMERICA, INC.
  21. Install a new 2-4 brake oil seal to transmission case.
    Fig 17: Installing 2-4 Brake Oil Seal To Transmission Case
    G00924278Courtesy of SUBARU OF AMERICA, INC.
  22. After all 2-4 brake component parts have been installed, blow in air intermittently and confirm the operation of the brake.
    Fig 18: Applying Air
    G00924279Courtesy of SUBARU OF AMERICA, INC.
  23. Check the clearance between the retaining plate and the snap ring.
    NOTE: Select a retaining plate with a suitable value from the following table, so that the clearance becomes the standard value.
    If the clearance is above the limit, replace the drive plate with new one and adjust so that the clearance becomes the standard value.
    1. Standard value: 0.8 - 1.2 mm (0.031 - 0.047 in) 
    2. Allowable limit: 1.5 mm (0.059 in) 
    Fig 19: Checking Clearance Between Retaining Plate & Snap Ring
    G00924280Courtesy of SUBARU OF AMERICA, INC.
    Fig 20: Retaining Plate Specifications
    G00924281Courtesy of SUBARU OF AMERICA, INC.
  24. Be careful not to mistake the location of the leaf spring to be inserted.
    Fig 21: Identifying Leaf Spring Location
    G00924282Courtesy of SUBARU OF AMERICA, INC.
  25. Install thrust needle bearing in the correct direction.
    Fig 22: Installing Thrust Needle Bearing In Correct Direction
    G00924283Courtesy of SUBARU OF AMERICA, INC.
  26. Install front sun gear and thrust needle bearing.
    Fig 23: Installing Front Sun Gear & Thrust Needle Bearing
    G00924284Courtesy of SUBARU OF AMERICA, INC.
  27. Install the high clutch hub.

    Attach the thrust needle bearing to the hub with vaseline and install the hub by correctly engaging the splines of the front planetary carrier.

  28. Install the thrust needle bearing in proper direction.
    Fig 24: Installing Thrust Needle Bearing In Proper Direction
    G00924285Courtesy of SUBARU OF AMERICA, INC.
  29. Install the high clutch assembly.
    Fig 25: Installing High Clutch Assembly
    G00924286Courtesy of SUBARU OF AMERICA, INC.
  30. Adjust total end play. Refer to ADJUSTMENT , Oil Pump Housing.
  31. Install the thrust needle bearing in proper direction.
    Fig 26: Installing Thrust Needle Bearing In Proper Direction
    G00924287Courtesy of SUBARU OF AMERICA, INC.
  32. Install the oil pump housing assembly.
  33. Install the torque converter clutch case assembly to the transmission case assembly. Refer to INSTALLATION .
  34. Insert inhibitor switch and transmission connector into stay.
  35. Install air breather hose. Refer to INSTALLATION .
    Fig 27: Inserting Inhibitor Switch & Transmission Connector Into Stay
    G00924288Courtesy of SUBARU OF AMERICA, INC.
  36. Install oil cooler pipes. Refer to INSTALLATION .
  37. Install the oil charger pipe with O-ring. Refer to INSTALLATION .
  38. Insert the input shaft while turning lightly by hand. At this time, not to damage the bushing.
    1. Normal protrusion A: 50 - 55 mm (1.97 - 2.17 in) 
    Fig 28: Inserting Input Shaft
    G00924289Courtesy of SUBARU OF AMERICA, INC.
  39. Install the torque converter clutch assembly.

    Refer to INSTALLATION .

  40. Install the transmission assembly to the vehicle. Refer to INSTALLATION .
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