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AT Main Case: Installation

  1. Apply ATF to the new seal ring.
  2. Install the thrust bearing and new seal ring to the drum support.
    Fig 1: Identifying Thrust Bearing And Seal Ring
    G08579398Courtesy of SUBARU OF AMERICA, INC.
  3. 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

  4. Install the return spring.
    Fig 2: Installing Return Spring
    G05022404Courtesy of SUBARU OF AMERICA, INC.
  5. Install the spring retainer and snap ring.

    ST1 18762AA000 COMPRESSOR SPECIAL TOOL

    ST2 18765AA000 COMPRESSOR SUPPORT

    ST3 18763AA000 COMPRESSOR SHAFT

    Fig 3: Installing Spring Retainer And Snap Ring
    G05022402Courtesy of SUBARU OF AMERICA, INC.
  6. Install the dish plate.
    NOTE: When installing, make sure that the identification mark is facing the rear side of transmission.
  7. Install the drive plate and driven plate.
    NOTE: When the reverse brake is disassembled, use a new drive plate and driven plate set.
  8. Install the leaf spring.
    Fig 4: Installing Leaf Spring
    G08579401Courtesy of SUBARU OF AMERICA, INC.
  9. Install the retaining plate.
  10. Install the snap ring of the reverse brake.
    Fig 5: Identifying Retaining Plate
    G08579402Courtesy of SUBARU OF AMERICA, INC.
  11. Apply compressed air intermittently to check for operation.
    Fig 6: Applying Compressed Air
    G08579403Courtesy of SUBARU OF AMERICA, INC.
  12. Check the piston stroke.
    1. Check the amount of drive plate compression "A" described in the wave clutch set of repair parts.
      Fig 7: Identifying Amount Of Drive Plate Compression
      G08579404Courtesy of SUBARU OF AMERICA, INC.
    2. 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
        G08579405Courtesy of SUBARU OF AMERICA, INC.
    3. Select and install a retaining plate so that the value calculated from the dimensions 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)
  13. Install the direct clutch assembly.
    Fig 9: Installing Direct Clutch Assembly
    G05022399Courtesy of SUBARU OF AMERICA, INC.
  14. Install the high & low reverse clutch assembly.
    Fig 10: Installing High & Low Reverse Clutch Assembly
    G05022398Courtesy of SUBARU OF AMERICA, INC.
  15. Install the thrust needle bearing of the high & low reverse clutch.
    Fig 11: Installing Thrust Needle Bearing Of High & Low Reverse Clutch
    G05022397Courtesy of SUBARU OF AMERICA, INC.
  16. Install the middle & rear sun gear assembly.
    Fig 12: Installing Middle & Rear Sun Gear Assembly
    G05022396Courtesy of SUBARU OF AMERICA, INC.
  17. Install the rear carrier assembly.
    Fig 13: Installing Rear Carrier Assembly
    G05022395Courtesy of SUBARU OF AMERICA, INC.
  18. Install the middle carrier assembly.
    Fig 14: Installing Middle Carrier Assembly
    G05022394Courtesy of SUBARU OF AMERICA, INC.
  19. Install the thrust needle bearing of middle carrier assembly.
    Fig 15: Identifying Thrust Needle Bearing Of Middle Carrier Assembly
    G05022393Courtesy of SUBARU OF AMERICA, INC.
  20. Measure the total end play, and select the bearing. Refer to ADJUSTMENT .
  21. Install the input clutch pack assembly to oil pump cover.
    Fig 16: Identifying Input Clutch Pack Assy And Front Sun Gear Assy
    G08579413Courtesy of SUBARU OF AMERICA, INC.
  22. Turn the transmission sideways.
  23. 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.
      NOTE: Use a new gasket.
      Fig 17: Installing Oil Pump Cover To AT Main Case
      G05022392Courtesy of SUBARU OF AMERICA, INC.
    3. 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 18: Rotating Spline Of Input Clutch And Rear Carrier Using Pliers
      G08579415Courtesy of SUBARU OF AMERICA, INC.
    4. Combine the oil pump cover with transmission main case.

      Tightening torque: 

      41 N.m (4.2 kgf-m, 30.2 ft-lb) 

      Fig 19: Identifying Oil Pump Cover
      G05022338Courtesy of SUBARU OF AMERICA, INC.
  24. Install the center differential carrier. Refer to INSTALLATION .
  25. Install the reduction driven gear. Refer to INSTALLATION .
  26. Install the extension case. Refer to INSTALLATION .
  27. Install the control valve body. Refer to INSTALLATION .
  28. Install the converter case assembly to the transmission case assembly. Refer to INSTALLATION .
  29. Install the ATF cooler pipe. Refer to INSTALLATION .
  30. Install the torque converter assembly. Refer to INSTALLATION .
  31. Install the transmission assembly to the vehicle. Refer to INSTALLATION .
  32. Perform Clear Memory 2 operation. Refer to CLEAR MEMORY MODE .
  33. Perform the diagnosis again. Refer to LEARNING CONTROL .
  34. 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.
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