Automatic Transmission Assembly: Installation

Attach the ST to converter case.
ST 498277200 STOPPER SET

Fig 1: Identifying Stopper Set On Converter Case
Courtesy of SUBARU OF AMERICA, INC.
When completely overhauling the transmission, refill approx. 10 l (2.6 US qt, 8.8 Imp qt) of CVTF through the transmission right side plug, and install the plug.
CAUTION: Always use specified CVTF or equivalent. Using other fluid than specified or equivalent will cause malfunction. Refer to , HYDRAULIC CONTROL AND LUBRICATION , SPECIFICATION, General Description.

NOTE: Use a new gasket.

Tightening torque:

35 N.m (3.6 kgf-m, 25.8 ft-lb)

Fig 2: Locating Transmission Right Side Plug
Courtesy of SUBARU OF AMERICA, INC.
Replace the front differential side retainer oil seal. Refer 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)

Fig 3: Identifying Cushion Rubber Bolts
Courtesy of SUBARU OF AMERICA, INC.
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 4: Identifying Bending Direction Of Transmission Hanger Of Transmission Rear
Courtesy of SUBARU OF AMERICA, INC.
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 5: Locating Two Engine Connecting Bolts And Two Nuts (Lower Side)
Courtesy of SUBARU OF AMERICA, INC.
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 6: Identifying Transmission Rear Crossmember On Vehicle Body
Courtesy of SUBARU OF AMERICA, INC.
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 7: Locating Engine Mounting Bolts (Upper Side) Position
Courtesy of SUBARU OF AMERICA, INC.
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 the bolt arrowed in the figure.
Tightening torque:

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

Fig 8: Locating Left And Right Transmission Mounting Brackets Bolts
Courtesy of SUBARU OF AMERICA, INC.
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 contact the engine parts.
- Set the arms of ST (ENGINE HANGER) at the locations shown in the figure.
  
  Fig 9: Identifying Engine Hanger And Chain Balancer On Transmission
  Courtesy of SUBARU OF AMERICA, INC.
Remove the bolts from ST (SPECIAL TOOL H4).

Fig 10: Locating ST Mounting Bolts
Courtesy of SUBARU OF AMERICA, INC.
Remove the bolt and nut to remove ST (FRONT MOUNTING H4).

Fig 11: Locating ST (Front Mounting H4) Mounting Bolt And Nut
Courtesy of SUBARU OF AMERICA, INC.
Temporarily attach the front engine mounting with bolts.

Fig 12: Locating Front Engine Mounting Bolts
Courtesy of SUBARU OF AMERICA, INC.
Install the bolt and nut to the front engine mounting.

Fig 13: Locating Front Engine Mounting Bolt And Nut
Courtesy of SUBARU OF AMERICA, INC.
Tighten the bolts and nuts of front engine mounting.
NOTE: Always start tightening from the bolts on the engine side.

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 14: Identifying Front Engine Mounting Bolt And Nut
Courtesy of SUBARU OF AMERICA, INC.
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 15: Locating Stopper Rod Mounting Bolt
Courtesy of SUBARU OF AMERICA, INC.
Install the nut to the transmission mounting bracket.
Tightening torque:

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

Fig 16: Locating Transmission Mounting Bracket Nut
Courtesy of SUBARU OF AMERICA, INC.
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 17: Identifying Service Hole
Courtesy of SUBARU OF AMERICA, INC.
Install the starter. Refer to STARTER SC(H4SO)-9, 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 18: Locating Transmission Mounting Bracket Bolt
Courtesy of SUBARU OF AMERICA, INC.
Set the ST to side retainer.
ST 28399SA010 OIL SEAL PROTECTOR

Fig 19: Identifying Oil Seal Protector On Side Retainer
Courtesy of SUBARU OF AMERICA, INC.
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 20: Identifying Inlet CVTF Inlet Hose And CVTF Outlet Hose
Courtesy of SUBARU OF AMERICA, INC.
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 contact.
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 21: Identifying Cotter Pin, Tie-Rod End And Castle Nut
Courtesy of SUBARU OF AMERICA, INC.
Install the propeller shaft. Refer to PROPELLER SHAFT DS-11, INSTALLATION, Propeller Shaft.
Install the universal joint. Refer to UNIVERSAL JOINT PS-22, INSTALLATION, Universal Joint.
Install the plate assembly to transmission.
Tightening torque:

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

Fig 22: Identifying Select Cable And Plate Assy
Courtesy of SUBARU OF AMERICA, INC.
Install the washer and snap pin to the shifter arm.

Fig 23: Identifying Shifter Arm, Snap Pin, Select Cable And Washer
Courtesy of SUBARU OF AMERICA, INC.
Install the heat shield cover.
Tightening torque:

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

Fig 24: Identifying Heat Shield Cover
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Install the center exhaust pipe. Refer to CENTER EXHAUST PIPE EX(H4SO)-7, 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 25: Identifying Engine Hanger Rear Mounting Bolt
Courtesy of SUBARU OF AMERICA, INC.
Install the engine harness connector to the engine hanger rear, 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 26: Locating Harness Connector Bracket Bolt
Courtesy of SUBARU OF AMERICA, INC.
Install the throttle body. Refer to THROTTLE BODY FU(H4SO)-15, INSTALLATION, Throttle Body.
Install the manifold absolute pressure sensor. Refer to INTAKE MANIFOLD FU(H4SO)-32, INSTALLATION, Manifold Absolute Pressure Sensor.
Connect the following harness connectors.
- Transmission harness connectors
- Transmission radio ground terminal
- Inhibitor harness connector
Tightening torque:

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

Fig 27: Identifying Transmission Harness Connectors, Transmission Radio Ground Terminal And Inhibitor Harness Connector
Courtesy of SUBARU OF AMERICA, INC.
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 28: Locating Battery Cable Clip And Bolts
Courtesy of SUBARU OF AMERICA, INC.
Attach the grille bracket.

Fig 29: Locating Grille Bracket Mounting Bolts
Courtesy of SUBARU OF AMERICA, INC.
Install the air intake boot assembly. Refer to AIR INTAKE BOOT IN(H4SO)-8, INSTALLATION, Air Intake Boot.
Install the air intake duct. Refer to AIR INTAKE DUCT IN(H4SO)-9, INSTALLATION, Air Intake Duct.
Install the front wheels.
Connect the battery ground terminal.
Refill differential gear oil to adjust the differential gear oil amount. Refer to , DIFFERENTIAL GEAR OIL .
Refill CVTF to adjust the CVTF amount. Refer to , CVTF .
Perform the variator chain break-in. Refer to , VARIATOR CHAIN BREAK-IN .
CAUTION:
Always execute the variator chain break-in after the replacement of the following.
- Variator chain replacement
- Primary pulley and secondary pulley replacement
Perform learning control promotion. Refer to LEARNING CONTROL CVT(diag)-20, Learning Control.
Execute the rear differential inspection mode. Refer to REAR DIFFERENTIAL INSPECTION MODE DI-83, 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. Refer to , INSPECTION , Road Test.