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Home >> Subaru >> 2006 >> Outback i, Automatic >> Repair and Diagnosis >> Transmission >> Automatic Trans >> Automatic Transmission 4AT >> AT Main Case >> Installation

AT Main Case: Installation

  1. Install the low & reverse brake piston.
    NOTE:
    • Take care not to damage the lip seal.
    • Apply ATF to the lip.
      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, spring retainer and return spring.
  5. Tighten the socket head bolts evenly from the rear side of transmission case.

    Tightening torque: 

    25 N.m (2.5 kgf-m, 18 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 retaining plate, 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 82 N (8.5 kgf, 18.7 1b).
  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 gauge, 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 measuring in four locations, measure every 90°.
    Fig 6: Measuring Flat Board Weight
    G05022036Courtesy 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
    G05022037Courtesy 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. Place same thickness shims on both sides to prevent plate from tilting, then measure and record the clearance B.
    NOTE: Do not push in the shim down with force to a point where the waves on the drive plate will be crushed.
    Fig 9: Measuring Record Clearance
    G05002763Courtesy of SUBARU OF AMERICA, INC.
  17. 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 part and adjust it within the initial specification.

    T = A + B

    T: Piston stroke

    A: Amount of drive plate compression

    B: Clearance between retaining plate and snap ring

    Initial standard: 

    2.15 - 2.65 mm (0.085 - 0.104 in) 

    Limit thickness: 

    2.95 mm (0.116 in) 

    THICKNESS SPECIFICATIONS

    Retaining plate
    Part number Thickness mm (in)
    31667AA420 3.8 (0.150)
    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)
  18. Install the leaf spring of the low & reverse brake.
    Fig 10: Identifying Leaf Spring
    G05022040Courtesy of SUBARU OF AMERICA, INC.
  19. 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 Brake Piston And Brake Retainer
    G05022041Courtesy of SUBARU OF AMERICA, INC.
  20. Install 2-4 brake piston return spring to the transmission case.
    Fig 12: Identifying 2-4 Brake Piston Spring Retainer
    G05002745Courtesy of SUBARU OF AMERICA, INC.
  21. Position the snap ring in the transmission. Using ST, press the snap ring into the specified location.

    ST 498677100 COMPRESSOR

    Fig 13: Identifying Compressor With ST
    G05002767Courtesy of SUBARU OF AMERICA, INC.
  22. Install the planetary gear and low clutch assembly to the transmission case.

    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.
  23. Place the dish plate, driven plate, drive plate and retaining plate neatly in this order on surface table.
  24. Set the micro gauge to retaining plate, and read its scale.
    NOTE: The value, which is read in the gauge at this time, is zero point.
  25. 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 100 N (10.2 kgf, 22.5 lb).
  26. Put the flat board on retaining plate.
    Fig 15: Putting Flat Board On Retaining Plate
    G05002759Courtesy of SUBARU OF AMERICA, INC.
  27. Using the following formula, read the push/pull gauge, and calculate "N".

    N = 100 N (10.2 kgf, 22.5 lb) - 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

  28. 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: Measuring Flat Board Weight
    G05022046Courtesy of SUBARU OF AMERICA, INC.
  29. Install the pressure plate, 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.
  30. Install a new 2-4 brake oil seal to the transmission case.
    Fig 18: Locating Brake Oil Seal To Transmission Case
    G05002776Courtesy of SUBARU OF AMERICA, INC.
  31. After all 2-4 brake component parts have been installed, blow in air intermittently and confirm the operation of the brake.
    Fig 19: Blowing Air In Brake Components
    G05002771Courtesy of SUBARU OF AMERICA, INC.
  32. 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.
  33. 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 part and adjust it within the initial specification.

    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) 

    THICKNESS SPECIFICATIONS

    Retaining plate
    Part number 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)
  34. Be careful not to mistake the location of the leaf spring to be installed.
    Fig 21: Identifying Leaf Spring
    G05022051Courtesy of SUBARU OF AMERICA, INC.
  35. Install the thrust needle bearing in the correct direction.
    Fig 22: Identifying Thrust Needle Bearing
    G05022052Courtesy of SUBARU OF AMERICA, INC.
  36. Install the front sun gear and the thrust needle bearing.
    Fig 23: Identifying Front Sun Gear And Thrust Needle Bearing
    G05022053Courtesy of SUBARU OF AMERICA, INC.
  37. Install the high clutch hub.

    Attach the thrust needle bearing to hub using Vaseline, and then install the hub by correctly engaging the splines of the front planetary carrier.

  38. Install the thrust needle bearing in the proper direction.
    Fig 24: Identifying Thrust Needle Bearing
    G05022054Courtesy of SUBARU OF AMERICA, INC.
  39. Install the high clutch assembly.
    Fig 25: Identifying High Clutch Assembly
    G05022055Courtesy of SUBARU OF AMERICA, INC.
  40. Adjust the total end play. < Ref. to ADJUSTMENT  . >
  41. Install the thrust needle bearing in the proper direction.
    Fig 26: Identifying Thrust Needle Bearing
    G05022056Courtesy of SUBARU OF AMERICA, INC.
  42. Install a new gasket along with the oil pump housing assembly. < Ref. to INSPECTION , Oil Pump Housing. >
  43. Install the converter case to the transmission case assembly. < Ref. to INSTALLATION , Converter Case. >
  44. Insert the inhibitor switch and transmission connector to the stay.
  45. Install the air breather hose. < Ref. to INSTALLATION , Air Breather Hose. >
    Fig 27: Identifying Inhibitor Switch And Transmission Connector
    G05022057Courtesy of SUBARU OF AMERICA, INC.
  46. Install the oil cooler pipe. < Ref. to INSTALLATION , ATF Cooler Pipe and Hose. >
  47. Install the oil charge pipe together with an O-ring. < Ref. to INSTALLATION , Oil Charge Pipe. >
  48. Insert the input shaft while rotating it lightly by hand, and then check the amount of protrusion.

    Normal protrusion 

    A: 50 - 55 mm (1.97 - 2.17 in) 

    Fig 28: Identifying Input Shaft
    G04990427Courtesy of SUBARU OF AMERICA, INC.
  49. Install the torque converter assembly. < Ref. to INSTALLATION , Torque Converter Assembly. >
  50. Install the transmission assembly to the vehicle. < Ref. to INSTALLATION , Automatic Transmission Assembly. >
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