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Front Reduction Driven Gear: Assembly

  1. Place the dish plate, driven plate, drive plate and retaining plate neatly in this order on surface table.
    NOTE: Make sure of the direction of dish plate.
  2. Set the dial gauge to retaining plate, and read its scale.
    NOTE: The value, which is read in the gauge at this time, is zero point.
  3. Scale and record the weight "Z" of a flat board which will be put on retaining plate.
    NOTE:
    • Use a stiff board which does not bend against load as a flat board to be put on retaining plate.
    • Use a flat board weighing less than 130 N (13.3 kgf, 29.2 lb).
  4. Put the flat board on retaining plate.
    G10321124Courtesy of SUBARU OF AMERICA, INC.
  5. Using the following formula, calculate load "N", a force of pressing with push/pull gauge.

    N = 130 N (13.3 kgf, 29.2 lb) - Z

    130 N (13.3 kgf, 29.2 lb): Load applied to clutch plate

    Z: Flat board weight

  6. Press the center of retaining plate by applying a force of "N" using push/pull gauge, and then measure and record the compression amount "A".
    NOTE: Measure at four points with a 90° interval and calculate the average.
    G13864188Courtesy of SUBARU OF AMERICA, INC.
  7. Install the dish plate, driven plate, drive plate, retaining plate and snap ring.
    NOTE: Make sure of the direction of dish plate.
  8. Measure and record the clearance "B" between the retaining plate and snap ring.
    NOTE: Before measuring, press down the whole circumference of retaining plate using your finger.
    G09482358Courtesy of SUBARU OF AMERICA, INC.
  9. Calculate the piston stroke "S" with A and B dimensions recorded before.

    S mm (in) = A + B

    S: Piston stroke

    A: Compression amount of drive plate and dish plate

    B: Clearance between retaining plate and snap ring

    Specification: 

    2.4 - 2.8 mm (0.094 - 0.11 in)

  10. Using a new drive plate, select the retaining plate so that the piston stroke is within the standard value.
  11. Using a press, press-fit a new ball bearing into the front driven shaft.
    CAUTION:
    • Be sure to apply CVTF to press-fitting surface of ball bearing.
    • Use SUBARU genuine CVTF.
    G13200374Courtesy of SUBARU OF AMERICA, INC.
  12. With a new seal ring, install it to the front driven shaft.
    CAUTION:
    • Before installing seal rings, apply sufficient amount of CVTF to avoid damage and deformation.
    • Use SUBARU genuine CVTF.
    • When installing the seal rings, do not expand the seal rings too much.
  13. Install the front reduction driven shaft to the front reduction driven gear.
  14. Install the front reduction driven gear to the converter case cover.
    G13864191Courtesy of SUBARU OF AMERICA, INC.
  15. Apply compressed air to check the piston operation.
    NOTE: Hold the arrowed area with a finger.
    G13864192Courtesy of SUBARU OF AMERICA, INC.
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