Automatic Transmission Assembly: Installation

Attach the ST to converter case.
ST 498277200 STOPPER SET

Fig 1: Attaching Stopper Set (498277200) To Converter Case
Courtesy of SUBARU OF AMERICA, INC.
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.
- When a new differential side retainer oil seal has been installed, replacement is not required.
Install the cushion rubber on the transmission. <Ref. to INSTALLATION , Transmission Mounting System.>
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 2: Lifting Up Transmission
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 3: Locating Transmission Connecting Bolts
Courtesy of SUBARU OF AMERICA, INC.
Install the transmission rear crossmember. <Ref. to TRANSMISSION REAR CROSSMEMBER AND REAR CUSHION RUBBER , INSTALLATION, Transmission Mounting System.>
Install the hanger bracket.
Tightening torque:

23 N.m (2.3 kgf-m, 17.0 ft-lb)
Remove the transmission jack.
Lower the vehicle.
Remove the ST (ENGINE HANGER).
Install the three engine mounting bolts (upper side).
Tightening torque:

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

Fig 4: Locating Transmission Connecting Bolts
Courtesy of SUBARU OF AMERICA, INC.
Install the transmission mounting bracket LH and RH.
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 5: Locating Transmission Mounting Bracket Bolts
Courtesy of SUBARU OF AMERICA, INC.
Set the ST 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 6: Locating Special Tools Setting Locations
Courtesy of SUBARU OF AMERICA, INC.

Fig 7: Setting Special Tools To Vehicle
Courtesy of SUBARU OF AMERICA, INC.
Remove the bolts from ST (ST H4 (FA, FB)).

Fig 8: Locating Engine Side Mounting Bolts
Courtesy of SUBARU OF AMERICA, INC.
Remove the bolt and nut to remove ST (ST H4 (FA, FB)).

Fig 9: Locating Special Tool Bolt And Nut
Courtesy of SUBARU OF AMERICA, INC.
Temporarily attach the front cushion rubber with bolts.

Fig 10: Locating Front Cushion Rubber Bolts
Courtesy of SUBARU OF AMERICA, INC.
Install the bolt and nut to the front cushion rubber.

Fig 11: Locating Bolt And Nut Of Front Cushion Rubber
Courtesy of SUBARU OF AMERICA, INC.
Tighten the bolts and nuts of front cushion rubber.
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 12: Front Cushion Rubber Bolts And Nuts With Torque Specifications
Courtesy of SUBARU OF AMERICA, INC.
Remove the ST (ENGINE HANGER and CHAIN SLING) and the bolt of ø8 mm (0.3 in).
Install the V-belt cover.
Tightening torque:

6.5 N.m (0.7 kgf-m, 4.7 ft-lb)
Install the nut to the transmission mounting bracket.
Tightening torque:

45 N.m (4.6 kgf-m, 33.2 ft-lb)

Fig 13: Transmission Mounting Bracket Nut
Courtesy of SUBARU OF AMERICA, INC.
Install the transmission harness stay.
Tightening torque:

7 N.m (0.7 kgf-m, 5.2 ft-lb)

Fig 14: Locating Transmission Harness Stay Bolt
Courtesy of SUBARU OF AMERICA, INC.
Install the TCM. <Ref. to INSTALLATION , Transmission Control Module (TCM).>
Insert the transmission case cover (small) between transmission case cover (large) and transmission to install.
NOTE: When inserting, be careful that the insulator inside transmission case cover is not turned over.

Tightening torque:

7 N.m (0.7 kgf-m, 5.3 ft-lb)

Fig 15: Inserting Transmission Case Cover (Small) Between Transmission Case Cover (Large)
Courtesy of SUBARU OF AMERICA, INC.

Fig 16: Locating Transmission Case Cover Bolts
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 plug.

Fig 17: Service Hole Plug
Courtesy of SUBARU OF AMERICA, INC.
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 18: Locating Transmission Mounting Bracket Bolts
Courtesy of SUBARU OF AMERICA, INC.
Set the ST to differential side retainer.
ST 28399SA010 OIL SEAL PROTECTOR

Fig 19: Setting Oil Seal Protector (28399SA010) To Differential 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 CVT inlet hose and CVTF CVT outlet hose. (With CVTF cooler (air cool))
NOTE: Use new CVTF CVT inlet hose and CVTF CVT outlet hose.

Fig 20: CVTF CVT Inlet Hose And Outlet Hose
Courtesy of SUBARU OF AMERICA, INC.
Insert the ball joint into housing and secure with bolt.
CAUTION:
- Before tightening, make sure the bottom surface of the housing assembly - front axle and the stepped section of ball joint are in contact.
- Be careful not to damage the boot of the joint.
Tightening torque:

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

Fig 21: Ball Joint Assembly, Raised Section Of Ball Joint And Housing Assy-Front Axle
Courtesy of SUBARU OF AMERICA, INC.
Install the stabilizer link.
NOTE: Use a new flange nut.

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.
CAUTION: When connecting the tie-rod end, do not hit the cap at the bottom of tie-rod end with a hammer.

Tightening torque:

27 N.m (2.8 kgf-m, 19.9 ft-lb)
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 22: Cotter Pin, Tie-Rod End And Castle Nut
Courtesy of SUBARU OF AMERICA, INC.
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:

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

Fig 23: Locating Plate Assembly And Transmission Bolts
Courtesy of SUBARU OF AMERICA, INC.
Install the washer and snap pin to the shifter arm.

Fig 24: Shifter Arm, Snap Pin, Select Cable And Washer
Courtesy of SUBARU OF AMERICA, INC.
Install the center exhaust cover.
Tightening torque:

18 N.m (1.8 kgf-m, 13.3 ft-lb)
Install the center exhaust pipe. <Ref. to INSTALLATION , Center Exhaust Pipe.>
Install the under cover - front.
Lower the vehicle.
Install the front tire LH and RH. <Ref. to INSTALLATION , Tire and Wheel.>
Replace the CVTF inlet hose and CVTF outlet hose with new parts. <Ref. to CVTF Cooler (With Warmer Function) .>
Install the CVTF inlet hose and CVTF outlet hose. (Without CVTF cooler (air cool))

Fig 25: CVTF Inlet Hose And Outlet Hose
Courtesy of SUBARU OF AMERICA, INC.
Install the CVTF outlet hose. (With CVTF cooler (air cool))

Fig 26: CVTF Outlet Hose
Courtesy of SUBARU OF AMERICA, INC.
Install the CVTF cooler (with warmer feature).
Tightening torque:

23 N.m (2.3 kgf-m, 17.0 ft-lb)

Fig 27: Locating CVTF Cooler Bolts
Courtesy of SUBARU OF AMERICA, INC.
Install the CVTF cooler hose. (With CVTF cooler (air cool))

Fig 28: CVTF Cooler Hose
Courtesy of SUBARU OF AMERICA, INC.
Connect the harness connector, and install the clip and transmission radio ground cord terminal.
Tightening torque:

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

Fig 29: Locating Harness Clip
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 30: Locating Battery Cable Clip And Battery Cable Bracket Bolts
Courtesy of SUBARU OF AMERICA, INC.
Install the air intake boot assembly. <Ref. to INSTALLATION , Air Intake Boot.>
Install the air intake duct. <Ref. to INSTALLATION , Air Intake Duct.>
Connect the battery ground terminal.
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. Refer to Variator Chain
CAUTION:
Always execute the rear differential inspection mode at the replacement of the following.
- Variator chain replacement
- Primary pulley and secondary pulley replacement
Perform the operation of AT learning mode. <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.>