AT Main Case: Installation

Apply ATF to the new seal ring.
Install the thrust bearing and new seal ring to the drum support.

Fig 1: Identifying Thrust Bearing And Seal Ring
Courtesy of SUBARU OF AMERICA, INC.
Install the reverse brake piston.
NOTE: Apply ATF onto the piston sliding surface.

ST1 18762AA000 COMPRESSOR SPECIAL TOOL

ST2 18765AA000 COMPRESSOR SUPPORT

ST3 18763AA000 COMPRESSOR SHAFT
Install the return spring.

Fig 2: Installing Return Spring
Courtesy of SUBARU OF AMERICA, INC.
Install the spring retainer and snap ring.
ST1 18762AA000 COMPRESSOR SPECIAL TOOL

ST2 18765AA000 COMPRESSOR SUPPORT

ST3 18763AA000 COMPRESSOR SHAFT

Fig 3: Installing Snap Ring And Spring Retainer Using Compressor Special Tool And Compressor Support
Courtesy of SUBARU OF AMERICA, INC.
Install the dish plate.
NOTE: When installing, make sure that the identification mark is facing the rear side of transmission.
Install the drive plate and driven plate.
NOTE: When the reverse brake is disassembled, use a new drive plate and driven plate set.
Install the leaf spring.

Fig 4: Identifying Leaf Spring Dimensions
Courtesy of SUBARU OF AMERICA, INC.
Install the retaining plate.
Install the snap ring of the reverse brake.

Fig 5: Identifying Snap Ring Of Reverse Brake
Courtesy of SUBARU OF AMERICA, INC.
Apply compressed air intermittently to check for operation.

Fig 6: Applying Compressed Air Intermittently
Courtesy of SUBARU OF AMERICA, INC.

Check the piston stroke.

Check the amount of drive plate compression "A" described in the wave clutch set of repair parts.

Fig 7: Identifying Drive Plate Compression Dimensions
Courtesy of SUBARU OF AMERICA, INC.
Measure the clearance "B" between the retaining plate and snap ring using a thickness gauge.
NOTE:
- Set shims of the same thickness on both sides so that the retaining plate will not tilt.
- Do not push the shim down with force to a point where the waves on the drive plate will become crushed.
  
  Fig 8: Identifying Clearance Between Retaining Plate And Snap Ring
  Courtesy of SUBARU OF AMERICA, INC.

Select and install a retaining plate so that the value calculated from the dimension A and B is within the standard.

T = A + B

T: Piston stroke

A: Amount of drive plate compression

B: Clearance between retaining plate and snap ring

Initial standard:

2.0 - 2.4 mm (0.08 - 0.09 in)

Retaining plate
Part No.	Thickness mm (in)
31567AB100	4.2 (0.165)
31567AB170	4.4 (0.173)
31567AB180	4.6 (0.181)
31567AB190	4.8 (0.189)
31567AB200	5.0 (0.197)

Install the direct clutch assembly.

Fig 9: Installing Direct Clutch Assembly
Courtesy of SUBARU OF AMERICA, INC.
Install the high & low reverse clutch assembly.

Fig 10: Installing High And Low Reverse Clutch Assembly
Courtesy of SUBARU OF AMERICA, INC.
Install the thrust needle bearing of the high & low reverse clutch.

Fig 11: Installing Thrust Needle Bearing Of High And Low Reverse Clutch
Courtesy of SUBARU OF AMERICA, INC.
Install the middle & rear sun gear assembly.

Fig 12: Installing Middle And Rear Sun Gear Assembly
Courtesy of SUBARU OF AMERICA, INC.
Install the rear carrier assembly.

Fig 13: Installing Rear Carrier Assembly
Courtesy of SUBARU OF AMERICA, INC.
Install the middle carrier assembly.

Fig 14: Removing Middle Carrier Assembly
Courtesy of SUBARU OF AMERICA, INC.
Install the thrust needle bearing of middle carrier assembly.

Fig 15: Identifying Needle Bearing Of Middle Carrier Assembly
Courtesy of SUBARU OF AMERICA, INC.
Measure the total end play, and select the bearing. Refer to , ADJUSTMENT , AT Main Case.
Install the input clutch pack assembly to oil pump cover.

Fig 16: Identifying Impact Clutch Pack Assembly And Front Sun Gear Assembly
Courtesy of SUBARU OF AMERICA, INC.
Turn the transmission sideways.
Install the oil pump cover.
1. Apply ATF to the O-ring of input clutch shaft.
2. Install the oil pump cover to AT main case while supporting the input clutch shaft and oil pump housing with your hand.
  
  Fig 17: Installing Oil Pump Cover
  Courtesy of SUBARU OF AMERICA, INC.
3. Make sure the rear end of drive pinion shaft is engaged to the spline of reduction driven gear.
  
  Fig 18: Identifying Drive Pinion Shaft
  Courtesy of SUBARU OF AMERICA, INC.
4. Protect the input clutch shaft with a cloth, and rotate to engage the spline of the input clutch and rear carrier using pliers.
  NOTE: Work with pressing the oil pump cover.
  
  Fig 19: Rotating Spline Of Input Clutch And Rear Carrier Using Pliers
  Courtesy of SUBARU OF AMERICA, INC.
5. Combine the oil pump cover with transmission main case.
  Tightening torque:
  
  41 N.m (4.2 kgf-m, 30.2 ft-lb)
  
  Fig 20: Identifying Oil Pump Cover Mounting Bolts
  Courtesy of SUBARU OF AMERICA, INC.
Install the center differential carrier. Refer to , INSTALLATION , Center Differential Carrier.
Install the reduction driven gear. Refer to , INSTALLATION , Reduction Driven Gear.
Install the extension case. Refer to , INSTALLATION , Extension Case.
Install the control valve body. Refer to , INSTALLATION , Control Valve Body.
Install the converter case assembly to the transmission case assembly. Refer to , INSTALLATION , Converter Case.
Install the ATF cooler pipe. Refer to , INSTALLATION , ATF Cooler Pipe and Hose.
Install the torque converter assembly. Refer to , INSTALLATION , Torque Converter Assembly.
Install the transmission assembly to the vehicle. Refer to , INSTALLATION , Automatic Transmission Assembly.
Perform Clear Memories 2 operation. Refer to CLEAR MEMORY MODE .
Perform the diagnosis again. Refer to LEARNING CONTROL .
Perform the inspection at the end of repair work, and make sure there is no faulty as below;
- Excessive shift shock
- Oil leakage from the transmission body, etc.
- Occurrence of noise caused by interference etc.