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Home >> Subaru >> 2004 >> Forester XT, Automatic >> Repair and Diagnosis >> Transmission >> Automatic Trans >> Automatic Transmission >> Automatic Transmission Assembly >> Installation

Automatic Transmission Assembly: Installation

  1. Replace the differential side oil seal with a new one. < Ref. to REPLACEMENT . >
  2. Install the rear cushion rubber to transmission assembly.
    1. Tightening torque: 39 N.m (4.0 kgf-m, 29 ft-lb) 
  3. Install the ST to torque converter clutch case.
    1. ST 498277200 STOPPER SET
    Fig 1: Identifying ST To Torque Converter Clutch Case
    G00936112Courtesy of SUBARU OF AMERICA, INC.
  4. Install the transmission onto engine.
    1. Gradually raise the transmission with transmission jack.
      Fig 2: Raising Transmission With Transmission Jack
      G00936113Courtesy of SUBARU OF AMERICA, INC.
    2. Engage them at splines.
  5. Install the transmission rear crossmember.

    Tightening torque: 

    1. T1: 35 N.m (3.6 kgf-m, 26 ft-lb) 
    2. T2: 70 N.m (7.1 kgf-m, 51 ft-lb) 
    Fig 3: Identifying Transmission Rear Crossmember
    G00936114Courtesy of SUBARU OF AMERICA, INC.
  6. Take off the transmission jack.
  7. Tighten the nuts and bolts which hold the lower side of transmission to engine.
    1. Tightening torque: 50 N.m (5.1 kgf-m, 36.9 ft-lb) 
    Fig 4: Locating Nuts And Bolts Lower Side Of Transmission To Engine For Installation
    G00936115Courtesy of SUBARU OF AMERICA, INC.
  8. Lower the vehicle.
  9. Connect the engine and transmission.
    1. Remove the ST from torque converter clutch case.
      NOTE: Be careful not to drop the ST into the torque converter clutch case when Identifying ST.
      1. ST 498277200 STOPPER SET
    2. Install the starter.

      < Ref. to INSTALLATION , Starter . >

    3. Tighten the bolt which holds the right upper side of transmission to engine.
    1. Tightening torque: 50 N.m (5.1 kgf-m, 36.9 ft-lb) 
    Fig 5: Identifying Tightening Torque Of Right Upper Side Of Transmission To Engine Bolt
    G00936116Courtesy of SUBARU OF AMERICA, INC.
  10. Install the torque converter clutch ASSY to drive plate.
    1. Tighten the bolts which hold the torque converter clutch ASSY to drive plate.
    2. Tighten the other bolts while rotating the crankshaft sprocket by using ST.
      1. Tightening torque: 25 N.m (2.5 kgf-m, 18.1 ft-lb) 
      Fig 6: Tightening Bolts Which Hold Torque Converter Clutch Assy To Drive Plate
      G00936117Courtesy of SUBARU OF AMERICA, INC.
    3. Clog the plug onto service hole.
  11. Remove the ST.
    Fig 7: Identifying ST
    G00936118Courtesy of SUBARU OF AMERICA, INC.
  12. Install the pitching stopper.

    Tightening torque: 

    1. T1: 50 N.m (5.1 kgf-m, 37 ft-lb) 
    2. T2: 58 N.m (5.9 kgf-m, 43 ft-lb) 
    Fig 8: Identifying Pitching Stopper
    G00936119Courtesy of SUBARU OF AMERICA, INC.
  13. Lift-up the vehicle.
  14. Replace the front drive shaft circlip with a new one.
  15. Apply a coat grease to the lip of oil seal.
  16. Install the ST to side retainer.

    ST 28399SA010 OIL SEAL PROTECTOR

    Fig 9: Identifying ST & Side Retainer
    G00936120Courtesy of SUBARU OF AMERICA, INC.
  17. Insert the front drive shaft by aligning spline part of front drive shaft and serration part of differential bevel gear, and then remove the ST.

    ST 28399SA010 OIL SEAL PROTECTOR

  18. Insert the front drive shaft to transmission securely by pressing front housing.
    Fig 10: Inserting Front Drive Shaft To Transmission
    G00936121Courtesy of SUBARU OF AMERICA, INC.
  19. Connect the ball joint into front housing.
  20. Tighten the Identifying bolts.
    1. Tightening torque: 49 N.m (5.0 kgf-m, 36 ft-lb) 
    Fig 11: Connecting Ball Joint Into Front Housing
    G00936122Courtesy of SUBARU OF AMERICA, INC.
  21. Install the stabilizer link from transverse link.
    1. Tightening torque: 45 N.m (4.6 kgf-m, 33.2 ft-lb) 
    Fig 12: Identifying Stabilizer Link
    G00936123Courtesy of SUBARU OF AMERICA, INC.
  22. Install the shift select cable onto select lever.

    < Ref. to INSTALLATION , Select Cable . >

  23. Install the ATF level gauge guide and level gauge, and connect the ATF cooler hoses to pipe.
    Fig 13: Connecting ATF Cooler Hoses To Pipe
    G00936124Courtesy of SUBARU OF AMERICA, INC.
  24. Install the propeller shaft.
  25. Install the heat shield cover. (If equipped)
  26. Install the rear exhaust pipe and muffler assembly.

    Non-turbo model

    < Ref. to INSTALLATION , Rear Exhaust Pipe . > < Ref. to INSTALLATION , Muffler . >

    Turbo model

    < Ref. to INSTALLATION , Rear Exhaust Pipe . > < Ref. to INSTALLATION , Muffler . >

  27. Install the front and center exhaust pipe. (Non-turbo model)

    < Ref. to INSTALLATION , Front Exhaust Pipe . >

  28. Install the center exhaust pipe. (Turbo model)

    < Ref. to INSTALLATION , Center Exhaust Pipe . >

  29. Install the under cover.
  30. Lower the vehicle.
  31. Install the ATF level gauge.
    Fig 14: Identifying ATF Level Gauge
    G00936125Courtesy of SUBARU OF AMERICA, INC.
  32. Connect the following connectors.
    1. Transmission harness connectors
    2. Transmission ground terminal
  33. Install the air cleaner case stay.
    1. Tightening torque: 16 N.m (1.6 kgf-m, 11.6 ft-lb) 
  34. Install the air cleaner case or air intake chamber. (Non-turbo model)

    < Ref. to INSTALLATION , Air Cleaner Case . >

    < Ref. to INSTALLATION , Resonator Chamber . >

  35. Install the intercooler. (Turbo model)

    < Ref. to INSTALLATION , Intercooler . >

  36. Connect the battery ground cable.
  37. Pour ATF into the ATF charge pipe. < Ref. to AUTOMATIC TRANSMISSION FLUID . >
  38. Check the ATF level. < Ref. to AUTOMATIC TRANSMISSION FLUID . >
  39. Take off the vehicle from lift arms.
  40. Check select lever operation.

    < Ref. to INSPECTION . >

  41. Check the ATF level. < Ref. to AUTOMATIC TRANSMISSION FLUID . >
  42. Check the road test.

    < Ref. to ROAD TEST . >

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