Automatic Transmission Assembly: Installation

Attach the ST to converter case.
ST 498277200 Stopper set

Fig 1: Attaching ST To Converter Case
Courtesy of SUBARU OF AMERICA, INC.
When completely overhauling the transmission, refill approx. 10 l (2.6 US qt, 8.8 lmp qt) of CVTF through the transmission right side plug, and install the plug.
CAUTION: Always use specified CVTF or equivalent. Using other fluid except for specified or equivalent will cause malfunction. Ref. to HYDRAULIC CONTROL AND LUBRICATION , SPECIFICATION, General Description.

NOTE: Use a new gasket.

Tightening torque:

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

Fig 2: Locating Transmission Right Side Plug
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Replace the front differential side retainer oil seal. Ref. to REPLACEMENT , Differential Side Retainer Oil Seal.
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.
Install the cushion rubber on the transmission.
Tightening torque:

40 N.m (4.1 kgf-m, 29.5 ft-lb)
Mount the transmission onto the transmission jack.
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 extra overload or impact to the transmission case.

Fig 3: Identifying Transmission Hanger
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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.
Install the two engine connecting bolts and two nuts (lower side).
Tightening torque:

50 N.m (5.1 kgf-m, 36.9 ft-lb)

Fig 4: Locating Transmission Connecting Bolts
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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)

Fig 5: Identifying Transmission Rear Crossmember Bolts
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Remove the transmission jack.
Lower the vehicle.
Remove the ST (ENGINE HANGER).
Install the four engine mounting bolts (upper side).
Tightening torque:

50 N.m (5.1 kgf-m, 36.9 ft-lb)

Fig 6: Locating Transmission Connecting Bolts
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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 one bolt arrowed in the figure.
Tightening torque:

75 N.m (7.6 kgf-m, 55.3 ft-lb)

Fig 7: Locating Left And Right Transmission Mounting Brackets
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Set the ST1 to 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 hit the engine parts.
- Set the arms of ST (ENGINE HANGER) at the locations shown in the figure.
Fig 8: Identifying ST1 And ST2 (1 Of 2)
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Remove the bolts from ST (FRONT MOUNTING H4).

Fig 9: Locating Attachment Bolts
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Remove the bolt and nut to remove ST (FRONT MOUNTING H4).

Fig 10: Locating Bolt And Nut
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Temporarily attach the front engine mounting with bolts

Fig 11: Locating Front Engine Mounting With Bolts
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Install the bolt and nut to the front engine mounting.

Fig 12: Locating Front Engine Mounting With Bolts
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Tighten the bolt and nut of the front engine mounting.
NOTE: Start tightening from the engine side bolt.

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)

Fig 13: Identifying Engine Side Bolt
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Remove the ST (ENGINE HANGER and CHAIN SLING).
Install the stopper rod.
Tightening torque:

36 N.m (3.7 kgf-m, 26.6 ft-lb)

Fig 14: Locating Stopper Rod
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Install the nut to the transmission mounting bracket.
Tightening torque:

45 N.m (4.6 kgf-m, 51.6 ft-lb)

Fig 15: Locating Nuts And Transmission Mounting Brackets
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Remove the ST (STOPPER SET) from converter case.
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)
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)
Install the service hole.

Fig 16: Identifying Engine Hanger Rear For Turbo Model
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Install the starter. Ref. to INSTALLATION , Starter.
Lift up the vehicle.
Tighten the single mounting bolt of transmission mounting bracket.
Tightening torque:

75 N.m (7.6 kgf-m, 55.3 ft-lb)

Fig 17: Locating Left And Right Transmission Mounting Brackets
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Set the ST to side retainer.
ST 28399SA010 OIL SEAL PROTECTOR

Fig 18: Setting ST To Side Retainer
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Replace the circlip of the drive shaft with a new part.
Insert the front drive shaft spline section into transmission and remove the ST (OIL SEAL PROTECTOR).
Insert the drive shaft into the transmission securely by pressing the housing from outside of the vehicle.
Install the CVTF inlet hose and CVTF outlet hose.
NOTE: Use the new CVTF inlet hose and CVTF outlet hose.

Fig 19: Identifying CVTF Inlet Hose And CVTF Outlet Hose
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Insert the ball joint into housing and secure with bolt.
Tightening torque:

50 N.m (5.1 kgf-m, 36.9 ft-lb)
CAUTION:
- Do not apply grease to the tapered portion of ball stud.
- Before tightening, make sure the lower side of housing and stepped section of ball joint are in con tact.
Install the stabilizer link.
Tightening torque:

60 N.m (6.1 kgf-m, 44.3 ft-lb)
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.
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.

Fig 20: Identifying Tie-Rod End, Knuckle Arm And Castle Nut
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Install the propeller shaft. Ref. to INSTALLATION , Propeller Shaft.
Install the universal joint. Ref. to INSTALLATION , Universal Joint.
Install the plate assembly to transmission.
Tightening torque:

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

Fig 21: Identifying Select Cable And Plate Assy
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Install the washer and snap pin to shifter arm.

Fig 22: Identifying Washer, Snap Pin And Shifter Arm
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Install the heat shield cover.
Tightening torque:

18 N.m (1.8 kgf-m, 13.3 ft-lb)

Fig 23: Identifying Heat Shield Cover
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Install the center exhaust pipe. Ref. to INSTALLATION , Center Exhaust Pipe.
Install the under cover.
Lower the vehicle.
Remove the engine hanger rear for turbo model and install the engine hanger rear for non-turbo model.
Tightening torque:

T1: 16 N.m (1.6 kgf-m, 11.8 ft-lb)

T2: 19 N.m (1.9 kgf-m, 14.0 ft-lb)

Fig 24: Identifying Engine Hanger Rear Bolts
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Install the engine harness connector to the engine hanger rear, and connect the harness connector, and install the harness connector bracket.
Tightening torque:

7.5 N.m (0.76 kgf-m, 5.5 ft-lb)

Fig 25: Locating Bolt And Engine Harness Connector
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Install the throttle body. Ref. to INSTALLATION , Throttle Body.
Install the manifold absolute pressure sensor. Ref. to INSTALLATION , Manifold Absolute Pressure Sensor.
Connect the following harness connectors.
- Transmission harness
- Transmission radio ground terminal
Tightening torque:

13 N.m (1.3 kgf-m, 9.6 ft-lb)

Fig 26: Identifying Transmission Harness And Transmission Radio Ground Terminal
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Install the battery cable bracket, and install the battery cable clip to the bracket.
Tightening torque:

7.5 N.m (0.76 kgf-m, 5.5 ft-lb)

Fig 27: Locating Bracket Bolts
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Attach the grille bracket.

Fig 28: Locating Clips And Grille Bracket
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Install the air intake boot assembly. Ref. to INSTALLATION , Air Intake Boot.
Install the air intake duct. Ref. to INSTALLATION , Air Intake Duct.
Install the front wheels.
Connect the ground cable to battery.
Refill differential gear oil to adjust the differential gear oil amount. Ref. to DIFFERENTIAL GEAR OIL .
Refill CVTF to adjust the CVTF amount. Ref. to CVTF .
Perform the variator chain break-in. Ref. to VARIATOR CHAIN BREAK-IN .
CAUTION:
Always execute the variator chain break-in at the replacement of the following.
- Variator chain replacement
- Primary pulley and secondary pulley replacement
Execute the learning control promotion. Ref. to LEARNING CONTROL .
Execute the rear differential inspection mode. Ref. to REAR DIFFERENTIAL INSPECTION MODE .
CAUTION:
Always execute the rear differential inspection mode at the replacement of the following.
- Replacement of transmission assembly
- Replacement of front differential hypoid gear set
Perform the road test to make sure there is no fault. Ref. to INSPECTION , Road Test.