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Primary Pulley and Secondary Pulley: Installation

  1. Select shims for pulley alignment. Refer to , ADJUSTMENT , Primary Pulley and Secondary Pulley.
  2. Install the two seal rings to drive pinion retainer.
    NOTE:
    • Use a new seal ring.
    • Apply CVTF to the seal rings.
    • When installing the seal ring, do not expand the seal ring too much.
      Fig 1: Locating Seal Rings On Drive Pinion Retainer
      G06654652Courtesy of SUBARU OF AMERICA, INC.
  3. Install the selected shims to the primary pulley bearing catch surface.
  4. Install the two seal rings to primary pulley.
    NOTE:
    • Use a new seal ring.
    • Apply CVTF to the seal rings.
      Fig 2: Identifying Seal Rings On Primary Pulley
      G06654653Courtesy of SUBARU OF AMERICA, INC.
  5. Install the primary pulley and adjust the position of bolt holes of primary bearing retainer and converter case to tighten the primary pulley bolt.
    NOTE: Use a new seal washer.

    Tightening torque: 

    21 N.m (2.1 kgf-m, 15.5 ft-lb) 

    Fig 3: Identifying Seal Washer
    G06654651Courtesy of SUBARU OF AMERICA, INC.
  6. Set the ST to secondary pulley and expand the V groove of pulley.

    ST1 18769AA000 EXPANDER PULLEY

    Fig 4: Identifying Secondary Pulley With Expander Pulley
    G06654657Courtesy of SUBARU OF AMERICA, INC.
  7. Place the variator chain on the primary pulley groove and attach the secondary pulley and variator chain together to the drive pinion retainer.
    CAUTION: Cover the V grooves of primary pulley and secondary pulley with cloth to protect the both pulleys and variator chain from scratching.
    1. Place the variator chain on primary pulley.
    2. Intersect the V groove of primary pulley and the V groove of secondary pulley and install the secondary pulley while placing the variator chain on secondary pulley.
      Fig 5: Identifying V Grooves Of Primary And Secondary Pulley
      G06654650Courtesy of SUBARU OF AMERICA, INC.
    3. While aligning the bolt hole of secondary bearing retainer and the bolt hole of driving pinion retainer, install the secondary pulley to drive pinion retainer.
  8. Install the secondary pulley bolt.

    Tightening torque: 

    33 N.m (3.4 kgf-m, 24.3 ft-lb) 

    Fig 6: Locating Secondary Pulley Bolt
    G06654649Courtesy of SUBARU OF AMERICA, INC.
  9. Install the chain guide.
    NOTE: Install it with two claws facing outward and with four claws facing inward.
    Fig 7: Locating Outward And Inward Facing Claws
    G06654648Courtesy of SUBARU OF AMERICA, INC.
  10. Engage the cutout portions of support rod and drive pinion retainer and install the support rod.
    Fig 8: Locating Cutout Portions Of Support Rod And Drive Pinion Retainer
    G06654661Courtesy of SUBARU OF AMERICA, INC.
  11. Engage the cutout portions of lubrication pipe and drive pinion retainer and install the lubrication pipe.
    Fig 9: Locating Cutout Portions Of Lubrication Pipe And Drive Pinion Retainer
    G06654662Courtesy of SUBARU OF AMERICA, INC.
  12. Install the chain guide so that the lubrication pipe and support rod run through between the protrusions of each chain guide. Then remove the ST (PULLEY EXPANDER).
    Fig 10: Identifying Lubrication Pipe And Support Rod
    G06654663Courtesy of SUBARU OF AMERICA, INC.
  13. Install the O-ring to the lubrication pipe.
    NOTE: Use new O-rings.
  14. Install the lubrication pipe.
    Fig 11: Identifying Lubrication Pipe
    G06654664Courtesy of SUBARU OF AMERICA, INC.
  15. Install the transmission case. Refer to , INSTALLATION , Transmission Case.
  16. Install the forward clutch assembly. Refer to , INSTALLATION , Forward Clutch Assembly.
  17. Install the intermediate case. Refer to , INSTALLATION , Intermediate Case.
  18. Install the transfer reduction driven gear assembly. Refer to , INSTALLATION , Transfer Reduction Driven Gear.
  19. Install the transfer clutch assembly. Refer to , INSTALLATION , Transfer Clutch.
  20. Install the rear drive shaft. Refer to , INSTALLATION , Rear Drive Shaft.
  21. Install the extension case. Refer to , INSTALLATION , Extension Case.
  22. Install the transmission harness. Refer to , INSTALLATION , Transmission Harness.
  23. Install the control valve body and oil pan. Refer to , INSTALLATION , Control Valve Body.
  24. Install the air breather hose. Refer to , INSTALLATION , Air Breather Hose.
  25. Install the transmission assembly to the vehicle. Refer to , INSTALLATION , Automatic Transmission Assembly.
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