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Home >> Subaru >> 2006 >> Forester X, Automatic >> Repair and Diagnosis >> Transmission >> Automatic Trans >> Automatic Transmission >> AT Main Case >> Installation

AT Main Case: Installation

  1. Install the low & reverse piston.
    CAUTION: Do not let the lip seal be damaged.
    Fig 1: Identifying Low & Reverse Piston
    G05002754Courtesy of SUBARU OF AMERICA, INC.
  2. Install the return spring.
    Fig 2: Identifying Return Spring
    G05002752Courtesy of SUBARU OF AMERICA, INC.
  3. Install the spring retainer.
    Fig 3: Identifying Spring Retainer
    G05002751Courtesy of SUBARU OF AMERICA, INC.
  4. Install the one-way clutch inner race.
  5. Tighten the socket head bolts evenly from the rear side of transmission case.

    Tightening torque: 

    25 N.m (2.5 kgf-m, 18.1 ft-lb) 

    Fig 4: Turning Transmission Case
    G05002750Courtesy of SUBARU OF AMERICA, INC.
  6. Place the front side of transmission body up.
  7. Install the thrust needle bearing.
  8. Place the dish plate, driven plate, drive plate and retaining plate neatly in this order on surface table.
  9. Set the micro gauge to clutch, and read its scale.
    NOTE: The value, which is read in the gauge at this time, is zero point.
  10. 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 of its weight less than 83 N (8.5 kgf, 18.7 lb).
  11. Put the flat board on retaining plate.
    Fig 5: Putting Flat Board On Retaining Plate
    G05002759Courtesy of SUBARU OF AMERICA, INC.
  12. Using the following formula, read the push/pull gage, and calculate "N".

    N = 83 N (8.5 kgf, 18.7 lb) - Z

    N: Value indicated on push/pull gauge

    83 N (8.5 kgf, 18.7 lb): Load applied to clutch plate

    Z: Flat board weight

  13. Press the center of retaining plate by applying a force of N using push/pull gauge, and then measure and record the height A. Measure at three locations or more spaced by equal distances and take the average value.
    NOTE: If measuring in three locations, measure every 120°. If in four locations, measure every 90°.
    Fig 6: Pressing Center Of Retaining Plate
    G04994322Courtesy of SUBARU OF AMERICA, INC.
  14. Installation of the low & reverse brake: Install the dish plate, driven plate, drive plate and retaining plate, and then secure them with a snap ring.
    NOTE: Pay attention to the orientation of the dish plate.
    Fig 7: Identifying Snap Ring
    G04994323Courtesy of SUBARU OF AMERICA, INC.
  15. Apply compressed air intermittently to check for operation.
    Fig 8: Applying Compressed Air
    G05002753Courtesy of SUBARU OF AMERICA, INC.
  16. Measure the clearance.
    1. Place same thickness shims on both sides to prevent plate from tilting, then measure and record the clearance B.
      Fig 9: Identifying Thickness Shims
      G04990616Courtesy of SUBARU OF AMERICA, INC.
    2. Piston stroke calculation

      Calculate with A and B dimensions recorded before. If the calculated value exceeds the service limit, replace the drive plate with a new one and select and adjust the retaining plate to be within the default specification values.

      T = A + B

      T: Piston stroke

      A: Amount of drive plate compression

      B: Clearance between retaining plate and snap ring

      Turbo model 

      Initial standard: 

      2.7 - 3.2 mm (0.106 - 0.126 in) 

      Limit thickness: 

      3.9 mm (0.153 in) 

      Non-turbo model 

      Initial standard: 

      2.15 - 2.65 mm (0.085 - 0.104 in) 

      Limit thickness: 

      2.95 mm (0.116 in) 

      RETAINING PLATE THICKNESS

      Retaining plate
      Part No. Thickness mm (in)
      31667AA320 4.1 (0.161)
      31667AA330 4.4(0.173)
      31667AA340 4.7(0.185)
      31667AA350 5.0(0.197)
      31667AA360 5.3 (0.209)
      31667AA370 5.6 (0.220)
      31667AA380 5.9 (0.232)
  17. Install the leaf spring of the low & reverse brake.
    Fig 10: Identifying Leaf Spring Of Low & Reverse Brake
    G04994326Courtesy of SUBARU OF AMERICA, INC.
  18. Install the 2-4 brake piston and 2-4 brake retainer by aligning the hole of the 2-4 brake retainer with the hole on the transmission case.
    Fig 11: Identifying 2-4 Brake Piston And 2-4 Brake Retainer
    G04994327Courtesy of SUBARU OF AMERICA, INC.
  19. Install 2-4 brake piston spring retainer to the transmission case.
    Fig 12: Identifying 2-4 Brake Piston Spring Retainer
    G05002745Courtesy of SUBARU OF AMERICA, INC.
  20. Position the snap ring in the transmission. Using ST, press the snap ring into the specified location.

    ST 498677100 COMPRESSOR

    Fig 13: Identifying Snap Ring In Transmission
    G05002767Courtesy of SUBARU OF AMERICA, INC.
  21. Install the planetary gear and low clutch assembly to the transmission case.
    CAUTION: Install carefully while rotating the low clutch and planetary gear assembly slowly, paying special attention not to damage the seal ring.
    Fig 14: Identifying Planetary Gear And Low Clutch Assembly
    G05002742Courtesy of SUBARU OF AMERICA, INC.
  22. Measure the amount of drive plate compression and record that value. (Non-turbo model)
    1. Place the dish plate, driven plate, drive plate and retaining plate neatly in this order on surface table.
    2. Set the micro gauge to clutch, 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 of its weight less than 100 N (10.2 kgf, 22.5 lb).
    4. Put the flat board on retaining plate.
      Fig 15: Putting Flat Board On Retaining Plate
      G05002759Courtesy of SUBARU OF AMERICA, INC.
    5. Using the following formula, read the push/pull gage, and calculate "N".

      N = 100 N (10.2 kgf, 22.5 lbf) - Z

      N: Value indicated on push/pull gauge

      100 N (10.2 kgf, 22.5 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 height A. Measure at three locations or more spaced by equal distances and take the average value.
    NOTE: If measuring in three locations, measure every 120° If measuring in four locations, measure every 90°.
    Fig 16: Pressing Center Of Retaining Plate
    G04994332Courtesy of SUBARU OF AMERICA, INC.
  23. Install the pressure rear plate, 2-4 brake drive plate, driven plate, retaining plate and snap ring.
    Fig 17: Identifying Pressure Rear Plate, 2-4 Brake Drive Plate, Driven Plate, Retaining Plate And Snap Ring
    G05002741Courtesy of SUBARU OF AMERICA, INC.
  24. Install a new 2-4 brake seal to transmission case.
    Fig 18: Locating 2-4 Brake Seal
    G05002743Courtesy of SUBARU OF AMERICA, INC.
  25. After all 2-4 brake component parts have been installed, blow in air intermittently and confirm the operation of brake.
    Fig 19: Blowing Air In Brake Components
    G05002771Courtesy of SUBARU OF AMERICA, INC.
  26. Check the piston stroke. (Non-turbo model)
    1. Measure the clearance B between the retaining plate and snap ring.
      Fig 20: Identifying Clearance "B" Between Retaining Plate And Snap Ring
      G05002778Courtesy of SUBARU OF AMERICA, INC.
    2. Piston stroke calculation

      Calculate with A and B dimensions recorded before. If the service limits from the calculation formula are exceeded, replace the drive plate and select and adjust the retaining plate to be with in standard values.

      T = A + B

      T: Piston stroke

      A: Amount of drive plate compression

      B: Clearance between retaining plate and snap ring

      Initial standard: 

      1.7 -2.1 mm (0.067 - 0.083 in) 

      Limit thickness: 

      2.3 mm (0.091 in) 

    RETAINING PLATE THICKNESS

    Retaining plate
    Part No. Thickness mm (in)
    31567AA991 5.6 (0.220)
    31567AB001 5.8 (0.228)
    31567AB011 6.0 (0.236)
    31567AB021 6.2 (0.244)
    31567AB031 6.4 (0.252)
    31567AB041 6.6 (0.260)
  27. Measure the clearance between the retaining plate and snap ring. (Turbo model) If the clearance exceeds the service limits, replace the driven plate and select and adjust the retaining plate so that the clearance is within default standard values.

    Initial standard: 

    0.8 - 1.2 mm (0.031 - 0.047 in) 

    Limit thickness: 

    1.5 mm (0.059 in) 

    Fig 21: Identifying Drive Plate Thickness
    G05002772Courtesy of SUBARU OF AMERICA, INC.
    RETAINING PLATE THICKNESS

    Retaining plate
    Part No. Thickness mm (in)
    31567AA991 5.6 (0.220)
    31567AB001 5.8 (0.228)
    31567AB011 6.0 (0.236)
    31567AB021 6.2 (0.244)
    31567AB031 6.4 (0.252)
    31567AB041 6.6 (0.260)
  28. Install the 2-4 brake leaf spring.
    CAUTION: Make sure to install in the correct position.
    Fig 22: Locking 2-4 Brake Leaf Spring
    G04994338Courtesy of SUBARU OF AMERICA, INC.
  29. Install the thrust needle bearing in the correct direction.
    Fig 23: Identifying Thrust Needle Bearing
    G04994339Courtesy of SUBARU OF AMERICA, INC.
  30. Install the front sun gear and the thrust needle bearing.
    Fig 24: Identifying Front Sun Gear And Thrust Needle Bearing
    G04994340Courtesy of SUBARU OF AMERICA, INC.
  31. Apply vaseline, then attach the thrust needle bearing to the high clutch hub. Install the high clutch hub by correctly engaging the splines of the front planetary carrier.
  32. Install the thrust needle bearing in the correct direction.
    Fig 25: Identifying Thrust Needle Bearing
    G04994341Courtesy of SUBARU OF AMERICA, INC.
  33. Install the high clutch assembly and reverse clutch assembly.
    Fig 26: Identifying High Clutch Assembly And Reverse Clutch Assembly
    G04994342Courtesy of SUBARU OF AMERICA, INC.
  34. Adjust the total end play. <Ref. to ADJUSTMENT  Oil Pump Housing. >
  35. Install the thrust needle bearing in the correct direction.
    Fig 27: Identifying Thrust Needle Bearing
    G04994343Courtesy of SUBARU OF AMERICA, INC.
  36. Install a new gasket along with the oil pump housing assembly.
  37. Install the converter case assembly to the transmission case assembly. <Ref. to INSTALLATION  CONVERTER CASE. >
  38. Insert the inhibitor switch and transmission connector to the stay.
    Fig 28: Inserting Inhibitor Switch And Transmission Connector
    G04994344Courtesy of SUBARU OF AMERICA, INC.
  39. Install the air breather hose. <Ref. to INSTALLATION  AIR BREATHER HOSE. >
  40. Install the ATF cooler pipe. <Ref. to INSTALLATION  ATF COOLER PIPE AND HOSE. >
  41. Install the oil charger pipe along with the O-ring. <Ref. to INSTALLATION  OIL CHARGER PIPE. >
  42. Insert the input shaft while rotating it lightly by hand, and then check the amount of protrusion.

    Normal protrusion A: 

    SO - 55 mm (1.97 - 2.17 in) 

    Fig 29: Identifying Input Shaft
    G04990427Courtesy of SUBARU OF AMERICA, INC.
  43. Install the torque converter clutch assembly. <Ref. to INSTALLATION  TORQUE CONVERTER CLUTCH ASSEMBLY. >
  44. Install the transmission assembly to the vehicle. <Ref. to INSTALLATION  AUTOMATIC TRANSMISSION ASSEMBLY. >
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