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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: Identifying Low & Reverse Piston
    G05002754Courtesy of SUBARU OF AMERICA, INC.
  2. Install the return spring.
    Fig 2: Identifying Return Spring
    G05002752Courtesy of SUBARU OF AMERICA, INC.
  3. Install the spring retainer.
    Fig 3: Identifying Spring Retainer
    G05002751Courtesy 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.

    Tightening torque: 25 N.m (2.5 kgf-m, 18.1 ft-lb) 

    Fig 4: Turning Transmission Case
    G05002750Courtesy 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 to clutch, and read its scale.
    NOTE: The value, which is read in the gauge at this time, is zero point.
  10. Scale and record the weight "Z" of a flat board which will be put on plates.
    NOTE:
    • Use a stiff flat board which does not bend against load.
    • Use a flat board of its weight less than 83 N (8.5 kgf, 18.7 1b).
  11. Put the flat board on retaining plate.
    Fig 5: Putting Flat Board On Retaining Plate
    G05002759Courtesy of SUBARU OF AMERICA, INC.
  12. Using the following formula, calculate "N" indicated on the push/pull gauge.

    N = 83 N (8.5 kgf, 18.7 lb)-Z

    N: Value indicated on push/pull gauge

    83 N (8.5 kgf, 18.7 lb): Load applied to clutch plate Z: Flat board weight

  13. Press the center of retaining plate applying force of N with push/pull gauge, and then measure and record the height A. Make more than three measurements at even distance and take the average value.
    NOTE: If three points, measure the height every 120°. If four points, measure the height every 90°.
    Fig 6: Measuring Dish Plate Height
    G04990613Courtesy of SUBARU OF AMERICA, INC.
  14. 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: Identifying Snap Ring
    G04990614Courtesy of SUBARU OF AMERICA, INC.
  15. Apply compressed air intermittently to check for operation.
    Fig 8: Applying Compressed Air
    G05002753Courtesy of SUBARU OF AMERICA, INC.
  16. Measure the clearance. Place the same thickness of shim on both sides to prevent the retaining plate from tilting.
    Fig 9: Identifying Thickness Of Shim On Retaining Plate From Tilting
    G04990616Courtesy of SUBARU OF AMERICA, INC.
  17. Calculation of piston stroke

    Calculate piston stroke from the recorded measurement A and B, and replace the drive plate with new one and adjust it to be within the standard If the value from the equation exceeds the service limit.

    T = A + C

    T: Piston stroke

    A: Amount of the flattened drive plate

    B: Clearance between the retaining plate and the snap ring

    TURBO model 

    Standard value: 2.7 - 3.2 mm (0.106 - 0.126 in) 

    Limit value: 3.9 mm (0.154 in) 

    NON-TURBO model 

    Standard value: 2.4 - 2.9 mm (0.094 - 0.114 in) 

    Limit value: 3.6 mm (0.142 in) 

    RETAINING PLATES THICKNESS CHART

    Retaining plates
    Part No. Thickness mm (in)
    31667AA320 4.1 (0.161)
    31667AA330 4.4 (0.173)
    31667AA340 4.7(0.185)
    31667AA350 5.0(0.197)
    31667AA360 5.3 (0.209)
    31667AA370 5.6 (0.220)
    31667AA380 5.9 (0.232)
  18. Install the low & reverse brake leaf spring.
    Fig 10: Identifying Leaf Spring
    G04990617Courtesy of SUBARU OF AMERICA, INC.
  19. 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 11: Identifying Brake Piston And Brake Piston Retainer
    G04990618Courtesy of SUBARU OF AMERICA, INC.
  20. Install the 2-4 brake piston return spring to transmission case.
    Fig 12: Identifying Brake Return Spring
    G05002745Courtesy of SUBARU OF AMERICA, INC.
  21. Position the snap ring in transmission. Using ST, press the snap ring into place.

    ST 498677100 COMPRESSOR

    Fig 13: Identifying Compressor
    G05002767Courtesy of SUBARU OF AMERICA, INC.
  22. 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 14: Identifying Thrust Needle Bearing, Planetary Gear Assembly And Low Clutch Assembly
    G05002742Courtesy of SUBARU OF AMERICA, INC.
  23. Install pressure plate, drive plate, driven plate, retaining plate and snap ring.
    Fig 15: Identifying Retaining Plate, Drive Plate And Driven Plate
    G05002741Courtesy of SUBARU OF AMERICA, INC.
  24. Install a new 2-4 brake oil seal to transmission case.
    Fig 16: Locating Brake Seal
    G05002743Courtesy of SUBARU OF AMERICA, INC.
  25. After all 2-4 brake component parts have been installed, blow in air intermittently and confirm the operation of the brake.
    Fig 17: Blowing Air In Brake Components
    G05002771Courtesy of SUBARU OF AMERICA, INC.
  26. Check the clearance between the retaining plate and the snap ring.
    NOTE: If the clearance is above the limit, replace the drive plate with new one and adjust so that the clearance becomes the standard value.

    Standard value: 0.8 - 1.2 mm (0.031 - 0.047 in) 

    Allowable limit: 1.5 mm (0.059 in) 

    Fig 18: Identifying Drive Plate Thickness
    G05002772Courtesy of SUBARU OF AMERICA, INC.
    RETAINING PLATES THICKNESS CHART

    Retaining plates
    Part No. Thickness mm (in)
    31567AA991 5.6 (0.220)
    31567AB001 5.8 (0.228)
    31567AB011 6.0 (0.236)
    31567AB021 6.2 (0.244)
    31567AB031 6.4 (0.252)
    31567AB041 6.6 (0.260)
  27. Be careful not to mistake the location of the leaf spring to be inserted.
    Fig 19: Identifying Leaf Spring And Retaining Plate
    G04990626Courtesy of SUBARU OF AMERICA, INC.
  28. Install thrust needle bearing in the correct direction.
    Fig 20: Identifying Thrust Needle Bearing And Snap Ring
    G04990627Courtesy of SUBARU OF AMERICA, INC.
  29. Install front sun gear and thrust needle bearing.
    Fig 21: Identifying Front Sun Gear And Thrust Needle Bearing
    G04990628Courtesy of SUBARU OF AMERICA, INC.
  30. 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.

  31. Install the thrust needle bearing in proper direction.
    Fig 22: Identifying Thrust Needle Bearing And High Clutch Hub
    G04990629Courtesy of SUBARU OF AMERICA, INC.
  32. Install the high clutch assembly.
    Fig 23: Identifying High Clutch Assembly
    G04990630Courtesy of SUBARU OF AMERICA, INC.
  33. Adjust total end play. < Ref. to ADJUSTMENT , Oil Pump Housing. >
  34. Install the thrust needle bearing in proper direction.
    Fig 24: Identifying Thrust Needle Bearing In Proper Direction
    G04990631Courtesy of SUBARU OF AMERICA, INC.
  35. Install the oil pump housing assembly.
  36. Install the torque converter clutch case assembly to the transmission case assembly. < Ref. to INSTALLATION . >
  37. Insert inhibitor switch and transmission connector into stay.
  38. Install air breather hose. < Ref. to INSTALLATION . >
    Fig 25: Identifying Transmission Harness And Inhibitor Switch Harness
    G04990632Courtesy of SUBARU OF AMERICA, INC.
  39. Install oil cooler pipes. < Ref. to INSTALLATION . >
  40. Install the oil charger pipe with O-ring. < Ref. to INSTALLATION . >
  41. Insert the input shaft while turning lightly by hand. At this time, not to damage the bushing.

    Normal protrusion A: 50 - 55 mm (1.97 - 2.17 in) 

    Fig 26: Identifying Torque Converter Input Shaft Dimension
    G04990427Courtesy of SUBARU OF AMERICA, INC.
  42. Install the torque converter clutch assembly. < Ref. to INSTALLATION . >
  43. Install the transmission assembly to the vehicle. < Ref. to INSTALLATION . >
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