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AT Transmission Main Case: Installation

  1. Install the low and reverse piston without tilting.
    CAUTION: Be careful not to damage the lip seal.
    Fig 1: Identifying Low And Reverse Piston
    G00936410Courtesy of SUBARU OF AMERICA, INC.
  2. Install return spring.
    Fig 2: Identifying Return Spring
    G00936411Courtesy of SUBARU OF AMERICA, INC.
  3. Install spring retainer.
    Fig 3: Identifying Spring Retainer
    G00936412Courtesy of SUBARU OF AMERICA, INC.
  4. Install the one-way clutch inner race.
  5. Tighten socket head bolts evenly from the rear side of the transmission case.
    1. Tightening torque: 25 N.m (2.5 kgf-m, 18.1 ft-lb) 
    Fig 4: Tightening Socket Head Bolts Evenly From Rear Side Of Transmission Case
    G00936413Courtesy of SUBARU OF AMERICA, INC.
  6. Place the front side of transmission body up.
  7. Install thrust needle bearing.
  8. Place the dish plate, driven plate, drive plate and retaining plate in this order on a surface plate.
  9. Set the micro gauge and read the value indicated on the micro gauge scale, and then place the flat board on the plate.
    NOTE: The measured value, which is read in procedure above, becomes the zero-point.
    Fig 5: Setting Micro Gauge And Reading Value Indicated On Micro Gauge
    G00936414Courtesy of SUBARU OF AMERICA, INC.
  10. Measure and record the height A with pushing down the center of retaining plate with 83 N (8.5 kgf, 18.7 lb) using push/pull gauge. Measure the height at equally-spaced three point or more, and then calculate the average value.
    Fig 6: Measuring And Height A With Pushing Down Center Of Retaining Plate
    G00936415Courtesy of SUBARU OF AMERICA, INC.
  11. Installation of the low & reverse brake:

    Install the dish plate, driven plate, drive plate and retaining plate, and then secure them with snap ring.

    NOTE: Pay attention to the orientation of dish plate.
    Fig 7: Identifying Snap Ring
    G00936416Courtesy of SUBARU OF AMERICA, INC.
  12. Apply compressed air intermittently to check for operation.
    Fig 8: Applying Compressed Air Intermittently To Checking For Operation
    G00936417Courtesy of SUBARU OF AMERICA, INC.
  13. Measure and record the clearance B after placing the same thickness shims on both side of plate to prevent the plate from tilting.
    Fig 9: Measuring Clearance B After Placing Same Thickness Shims On Both Side Of Plate
    G00936418Courtesy of SUBARU OF AMERICA, INC.
  14. Calculation of piston stroke:

    Calculate the piston stroke with recorded A and B, and then select the retaining plate to complete the piston stroke within the standard value. If the result of calculation exceeds the service limit, replace the new drive plate and adjust the piston stroke within specification.

    T = A + B

    1. T: Piston stroke
    2. A: Collapse of drive plate
    3. B: Clearance between retaining plate and snap ring
    4. Turbo model 
    5. Initial standard value: 2.7 - 3.2 mm (0.106 - 0.126 in) 
    6. Service limit: 4.2 mm (0.165 in) 
    7. Non-turbo model 
    8. Initial standard value: 2.4 - 2.9 mm (0.094 - 0.114 in) 
    9. Service limit: 3.9 mm (0.154 in) 
    Fig 10: Retaining Plates Thickness Chart
    G00936419Courtesy of SUBARU OF AMERICA, INC.
  15. Install the low & reverse brake leaf spring.
    Fig 11: Identifying Low & Reverse Brake Leaf Spring
    G00936420Courtesy of SUBARU OF AMERICA, INC.
  16. Install the 2-4 brake piston and 2-4 brake retainer by aligning hole of 2-4 brake retainer and hole of transmission case.
    Fig 12: Identifying 2-4 Brake Piston And 2-4 Brake Retainer
    G00936421Courtesy of SUBARU OF AMERICA, INC.
  17. Install 2-4 brake piston spring retainer to transmission case.
    Fig 13: Identifying 2-4 Brake Piston Spring Retainer
    G00936422Courtesy of SUBARU OF AMERICA, INC.
  18. Position snap ring in transmission. Using ST, press the snap ring into place.
    1. ST 498677100 COMPRESSOR
    Fig 14: Pressing Snap Ring Into Place
    G00936423Courtesy of SUBARU OF AMERICA, INC.
  19. Install planetary gear and low clutch assembly to transmission case.
    CAUTION: Install carefully while rotating the low clutch and planetary gear assembly slowly paying special attention not to damage the seal ring.
    Fig 15: Identifying Planetary Gear And Low Clutch Assembly
    G00936424Courtesy of SUBARU OF AMERICA, INC.
  20. Install pressure plate and drive plate, driven plate, retaining plate and snap ring of 2-4 brake.
    Fig 16: Identifying Pressure Plate And Drive Plate
    G00936425Courtesy of SUBARU OF AMERICA, INC.
  21. Install a new 2-4 brake seal to transmission case.
    Fig 17: Identifying New 2-4 Brake Seal
    G00936426Courtesy 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: Compressing Blow In Air Intermittently And Confirm Operation Of Brake
    G00936427Courtesy 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.
    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 And Snap Ring
    G00936428Courtesy of SUBARU OF AMERICA, INC.
    Fig 20: Retaining Plates Thickness Chart
    G00936429Courtesy of SUBARU OF AMERICA, INC.
  24. Install the leaf spring of 2-4 brake.
    CAUTION: Be careful not to mistake the location of the leaf spring to be inserted.
    Fig 21: Identifying Leaf Spring Of 2-4 Brake
    G00936430Courtesy of SUBARU OF AMERICA, INC.
  25. Install thrust needle bearing in the correct direction.
    Fig 22: Identifying Thrust Needle Bearing
    G00936431Courtesy of SUBARU OF AMERICA, INC.
  26. Install front sun gear and thrust needle bearing.
    Fig 23: Identifying Front Sun Gear And Thrust Needle Bearing
    G00936432Courtesy of SUBARU OF AMERICA, INC.
  27. Apply Vaseline to thrust needle bearing, and then install the thrust needle bearing to the high clutch hub and install the high clutch hub by correctly engaging the splines of the front planetary carrier.
  28. Install the thrust needle bearing in proper direction.
    Fig 24: Identifying Thrust Needle Bearing
    G00936433Courtesy of SUBARU OF AMERICA, INC.
  29. Install the high clutch assembly and reverse clutch assembly.
    Fig 25: Identifying High Clutch Assembly And Reverse Clutch Assembly
    G00936434Courtesy of SUBARU OF AMERICA, INC.
  30. Adjust total end play. < Ref. to ADJUSTMENT . >
  31. Install the thrust needle bearing in proper direction.
    Fig 26: Identifying Thrust Needle Bearing
    G00936435Courtesy of SUBARU OF AMERICA, INC.
  32. Install the oil pump housing assembly with new gasket.
  33. Install the torque converter clutch case assembly to the transmission case assembly. < Ref. to INSTALLATION . >
  34. Insert inhibitor switch and transmission connector into stay.
  35. Install air breather hose. < Ref. to INSTALLATION . >
    Fig 27: Identifying Inhibitor Switch And Transmission Connector Into Stay
    G00936436Courtesy of SUBARU OF AMERICA, INC.
  36. Install ATF cooler pipes. < Ref. to INSTALLATION . >
  37. Install the ATF charger pipe with O-ring. < Ref. to INSTALLATION . >
  38. Insert the input shaft while turning lightly by hand and verify the protrusion amount.
    1. Normal protrusion A: 50 - 55 mm (1.97 - 2.17 in) 
    Fig 28: Inserting Input Shaft
    G00936437Courtesy of SUBARU OF AMERICA, INC.
  39. Install the torque converter clutch assembly. < Ref. to INSTALLATION . >
  40. Install the transmission assembly to the vehicle. < Ref. to INSTALLATION . >
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