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Home >> Subaru >> 2009 >> Forester XT >> Repair and Diagnosis >> Transmission >> Automatic Trans >> Automatic Transmission 4AT >> AT Main Case >> Installation

AT Main Case: Installation

  1. Apply ATF to the lips of the low & reverse brake piston, and install the piston.
    NOTE: Take care not to damage the lip seal.
    Fig 1: Identifying Lip Seal
    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, 18.4 ft-lb) 

    Fig 4: Tightening Socket Head Bolts
    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 weighing less than 8.5 kgf (18.7 lb).
  11. Put the flat board on retaining plate.
    Fig 5: Setting Micro Gauge To 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 or more locations 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 Record Height "A"
    G05956203Courtesy 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
    G05956204Courtesy of SUBARU OF AMERICA, INC.
  15. Apply compressed air intermittently to check for operation.
    Fig 8: Applying Compressed Air
    G05956196Courtesy 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 "B"
    G05002763Courtesy of SUBARU OF AMERICA, INC.
  17. Piston stroke calculation

    Calculate from the recorded dimension A and B, and if the service limit is exceeded, replace the drive plate with a new part, and select a retaining plate to make an adjustment so that it is within standard.

    T = A + B

    T: Piston stroke

    A: Amount of drive plate compression

    B: Clearance between retaining plate and snap ring

    Non-turbo model 

    Initial standard: 

    2.15 - 2.65 mm (0.085 - 0.104 in) 

    Limit thickness: 

    2.95 mm (0.116 in) 

    Turbo model 

    Initial standard: 

    2.70 - 3.20 mm (0.106 - 0.126 in) 

    Limit thickness: 

    3.90 mm (0.154 in) 

    RETAINING PLATE THICKNESS SPECIFICATION

    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
    G05956207Courtesy 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: Aligning Hole Of 2-4 Brake Retainer With Hole On Transmission Case
    G05956208Courtesy of SUBARU OF AMERICA, INC.
  20. Install the 2-4 brake piston spring retainer to the transmission case.
    Fig 12: Identifying 2-4 Brake Piston Spring Retainer To Transmission Case
    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 (498677100)
    G05002767Courtesy of SUBARU OF AMERICA, INC.
  22. Install the planetary gear and low clutch assembly to the transmission case.
    NOTE: Install carefully while rotating the low clutch and planetary gear assembly slowly, being careful not to damage the seal ring.
    Fig 14: Identifying Thrust Needle Bearing, Planetary Gear Assembly And Low Clutch Assembly
    G05002742Courtesy of SUBARU OF AMERICA, INC.
  23. Measure and record a amount of drive plate compression. (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 weighing less than 10.2 kg (22.5 lb).
    4. Put the flat board on retaining plate.
      Fig 15: Setting Micro Gauge To Retaining Plate
      G05002759Courtesy of SUBARU OF AMERICA, INC.
    5. 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

    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 or more locations 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 Record Height "A"
      G05956213Courtesy of SUBARU OF AMERICA, INC.
  24. Install pressure rear plate, drive plate of 2-4 brake, driven plate, retaining plate, and snap ring.
    Fig 17: Identifying Retaining Plate
    G05002741Courtesy of SUBARU OF AMERICA, INC.
  25. Install a new 2-4 brake seal to the transmission case.
    Fig 18: Identifying Brake Seal
    G05956186Courtesy of SUBARU OF AMERICA, INC.
  26. After all 2-4 brake component parts have been installed, blow in air intermittently and confirm the operation of the brake.
    Fig 19: Applying Compressed Air To Brake Component Parts
    G05002771Courtesy of SUBARU OF AMERICA, INC.
  27. Check the piston stroke. (Non-turbo model)
    1. Measure clearance "B" between the retaining plate and snap ring.

      At this time, do not press down the retaining plate.

      Fig 20: Measuring 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 calculated value exceeds the service limits, replace the drive plate and select and adjust the retaining plate to be within 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 SPECIFICATION

    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)
  28. Check the clearance between the retaining plate and snap ring. (Turbo model)
    NOTE: If the clearance exceeds the service limits, replace the driven plate and select and adjust the retaining plate to make the clearance fall within initial 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 Clearance Between Retaining Plate And Snap Ring
    G05002772Courtesy of SUBARU OF AMERICA, INC.
    RETAINING PLATE THICKNESS SPECIFICATION

    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)
  29. Be careful not to mistake the location of the leaf spring to be installed.
    Fig 22: Identifying Leaf Spring And Retaining Plate
    G05956219Courtesy of SUBARU OF AMERICA, INC.
  30. Install the thrust needle bearing in the correct direction.
    Fig 23: Identifying Thrust Needle Bearing Installation Position
    G05956220Courtesy of SUBARU OF AMERICA, INC.
  31. Install the front sun gear and the thrust needle bearing.
    Fig 24: Identifying Front Sun Gear And Thrust Needle Bearing
    G05956221Courtesy of SUBARU OF AMERICA, INC.
  32. Apply vaseline, and attach the thrust needle bearing to the high clutch hub, then engage the splines of the front planetary carrier correctly to install the high clutch hub.
  33. Install the thrust needle bearing in the correct direction.
    Fig 25: Identifying Thrust Needle Bearing Installation Position
    G05956222Courtesy of SUBARU OF AMERICA, INC.
  34. Install the high clutch assembly and reverse clutch assembly.
    Fig 26: Identifying High Clutch Assembly And Reverse Clutch Assembly
    G05956223Courtesy of SUBARU OF AMERICA, INC.
  35. Adjust the total end play. Refer to ADJUSTMENT , Oil Pump Housing.
  36. Install the thrust needle bearing in the correct direction.
    Fig 27: Identifying Thrust Needle Bearing Installation Position
    G05956224Courtesy of SUBARU OF AMERICA, INC.
  37. Install a new gasket along with the oil pump housing assembly. Refer to INSTALLATION , Oil Pump Housing.
  38. Install the converter case to the transmission case assembly. Refer to INSTALLATION , Converter Case.
  39. Insert the inhibitor switch and transmission harness connector to the stay.
    Fig 28: Identifying Inhibitor Switch And Transmission Harness Connector
    G05956225Courtesy of SUBARU OF AMERICA, INC.
  40. Install the air breather hose. Refer to INSTALLATION , Air Breather Hose.
  41. Install the ATF cooler pipe. Refer to INSTALLATION , ATF Cooler Pipe and Hose.
  42. Install the oil charge pipe together with an O-ring. Refer to INSTALLATION , Oil Charge Pipe.
  43. 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 29: Identifying Input Shaft Dimension
    G05002576Courtesy of SUBARU OF AMERICA, INC.
  44. Install the torque converter clutch assembly. Refer to INSTALLATION , Torque Converter Clutch Assembly.
  45. Install the transmission assembly to the vehicle. Refer to INSTALLATION , Automatic Transmission Assembly.
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