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

Automatic Transmission Assembly: Installation

  1. Replace the differential side oil seal with a new part. Refer to DIFFERENTIAL SIDE RETAINER OIL SEAL .
    NOTE: When a new oil seal has been installed, replacement is not required.
  2. Install the rear cushion rubber to the transmission assembly.

    Tightening torque: 

    40 N.m (4.1 kgf-m, 29.5 ft-lb) 

  3. Attach the ST to the converter case.

    ST 498277200 STOPPER SET

    Fig 1: Identifying ST To Converter Case
    G05661653Courtesy of SUBARU OF AMERICA, INC.
  4. Install the transmission onto the engine.
    1. Lift up the transmission gradually using transmission jack.
      Fig 2: Lifting Torque Converter With Jack
      G05955949Courtesy of SUBARU OF AMERICA, INC.
    2. Insert the engine side stud bolt into the transmission bolt hole.
    3. While raising the transmission jack gradually, turn the screw of engine support, then tilt the engine forward and connect.
  5. Install the transmission rear crossmember.

    Tightening torque: 

    T1: 35 N.m (3.6 kgf-m, 25.8 ft-lb) 

    T2: 70 N.m (7.1 kgf-m, 51.6 ft-lb) 

    Fig 3: Identifying Transmission Rear Crossmember
    G05326558Courtesy of SUBARU OF AMERICA, INC.
  6. Remove the transmission jack.
  7. Tighten the bolts and nuts which hold the lower side of transmission to the engine.

    Tightening torque: 

    50 N.m (5.1 kgf-m, 36.9 ft-lb) 

    Fig 4: Locating Clutch Housing Cover Bolts
    G05002488Courtesy of SUBARU OF AMERICA, INC.
  8. Install the clutch housing cover bolts.
  9. Lower the lift.
  10. Connect the engine and transmission.
    1. Remove the ST from converter case.
      NOTE: When removing the ST, be careful not to drop it into converter case.

      ST 498277200 STOPPER SET

    2. Install the starter. Refer to INSTALLATION , Starter.
    3. Tighten the bolts which hold the upper side of the transmission to the engine.

    Tightening torque: 

    50 N.m (5.1 kgf-m, 36.9 ft-lb) 

    Fig 5: Identifying Transmission Upper Side Bolts
    G05002484Courtesy of SUBARU OF AMERICA, INC.
  11. Install the torque converter clutch assembly to the drive plate.
    CAUTION:
    • Be careful not to damage the mounting bolts.
    • Be careful not to drop bolts into the converter case.
    1. Tighten the bolts which hold the torque converter clutch to the drive plate.
    2. Place the wrench on the crank pulley bolt, and remove all the bolts while rotating the crank pulley a little bit at a time.

      Tightening torque: 

      25 N.m (2.5 kgf-m, 18.4 ft-lb) 

      Fig 6: Placing Wrench On Crank Pulley Bolt
      G05002480Courtesy of SUBARU OF AMERICA, INC.
    3. Fit the plug to service hole.
    4. Install the V-belt cover.
  12. Remove the ST.
    Fig 7: Identifying Engine Support Assy (41099AC000)
    G04994049Courtesy of SUBARU OF AMERICA, INC.
  13. Install the engine harness bracket. (Non-turbo model)

    Tightening torque: 

    T: 16 N.m (1.6 kgf-m, 11.8 ft-lb) 

    Fig 8: Locating Engine Harness Bracket (Non-Turbo Model)
    G05661655Courtesy of SUBARU OF AMERICA, INC.
  14. Install the harness connector to engine harness bracket, then connect the harness. (Non-turbo model)
  15. Install the engine hanger. (Turbo model)

    Tightening torque: 

    16 N.m (1.6 kgf-m, 11.8 ft-lb) 

    Fig 9: Identifying Engine Hanger (Turbo Model)
    G05661656Courtesy of SUBARU OF AMERICA, INC.
  16. Install the pitching stopper bracket.

    Tightening torque: 

    41 N.m (4.2 kgf-m, 30.2 ft-lb) 

    Fig 10: Identifying Pitching Stopper Bracket With Bolts
    G05955959Courtesy of SUBARU OF AMERICA, INC.
  17. Install the throttle body. (Non-turbo model) Refer to INSTALLATION , Throttle Body.
  18. Install the pitching stopper.

    Tightening torque: 

    T1: 50 N.m (5.1 kgf-m, 36.9 ft-lb) 

    T2: 58 N.m (5.9 kgf-m, 42.8 ft-lb) 

    Fig 11: Identifying Pitching Stopper Nuts
    G05661689Courtesy of SUBARU OF AMERICA, INC.
  19. Lift up the vehicle.
  20. Replace the circlip of the front drive shaft with a new part.
  21. Apply grease to the oil seal lip.
  22. Attach the ST to side retainer.

    ST 28399SA010 OIL SEAL PROTECTOR

    Fig 12: Identifying Oil Seal Protector (28399SA010)
    G05002499Courtesy of SUBARU OF AMERICA, INC.
  23. Align and insert the spline of the front drive shaft to the splines of the differential bevel gear, and remove the ST.

    ST 28399SA010 OIL SEAL PROTECTOR

  24. Insert the front drive shaft into the transmission securely by pressing the front housing from the outside.
    Fig 13: Pressing Front Housing From Outside
    G05002500Courtesy of SUBARU OF AMERICA, INC.
  25. Install the ball joint into the front housing.
  26. Tighten the attachment bolts.

    Tightening torque: 

    50 N.m (5.1 kgf-m, 36.9 ft-lb) 

    Fig 14: Identifying Ball Joint And Front Arm
    G05955963Courtesy of SUBARU OF AMERICA, INC.
  27. Attach the stabilizer link to the front arm.

    Tightening torque: 

    45 N.m (4.6 kgf-m, 33.2 ft-lb) 

    Fig 15: Locating Stabilizer Link Arm
    G05661662Courtesy of SUBARU OF AMERICA, INC.
  28. Install the front height sensor. Refer to INSTALLATION , Front Height Sensor.
  29. Install the shift select cable onto the select lever. Refer to INSTALLATION , Select Cable.
  30. Install the oil charge pipe, and connect the ATF cooler hoses to the pipe.
    Fig 16: Identifying ATF Cooler Hoses From Pipes
    G05955944Courtesy of SUBARU OF AMERICA, INC.
  31. Install the propeller shaft. Refer to INSTALLATION , Propeller Shaft.
  32. Install the heat shield cover.
    Fig 17: Identifying Heat Shield Cover
    G05661183Courtesy of SUBARU OF AMERICA, INC.
  33. Install the rear exhaust pipe and muffler assembly.

    Refer to INSTALLATION , Rear Exhaust Pipe. Refer to INSTALLATION , Muffler.

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

    Refer to INSTALLATION , Front Exhaust Pipe.

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

    Refer to INSTALLATION , Center Exhaust Pipe.

  36. Install the under cover.
  37. Lower the lift.
  38. Install the ATF level gauge.
    Fig 18: Identifying Harness Connector
    G05661654Courtesy of SUBARU OF AMERICA, INC.
  39. Connect the following connectors and terminals.
    • Non-turbo model
      Fig 19: Identifying Transmission Harness Connectors And Ground Terminal - (Non-Turbo Model)
      G05955968Courtesy of SUBARU OF AMERICA, INC.
    • Turbo model
    Fig 20: Identifying Rear Oxygen Sensor Connector - Turbo Model
    G05955969Courtesy of SUBARU OF AMERICA, INC.
  40. Install the air intake chamber stay. (Non-turbo model)

    Tightening torque: 

    16 N.m (1.6 kgf-m, 11.8 it-lb) 

  41. Install the air intake chamber and intake boot. (Non-turbo model) Refer to INSTALLATION , Air Intake Chamber.
  42. Install the intercooler. (Turbo model)

    Refer to INSTALLATION , Intercooler.

  43. Connect the ground cable to the battery.
  44. Fill transmission with ATF through the oil charge pipe until the fluid level is between the upper and lower level on the "COLD" side of the level gauge. Refer to AUTOMATIC TRANSMISSION FLUID .
  45. Lower the vehicle from the lift.
  46. Check the differential gear oil level. Refer to INSPECTION , Differential Gear Oil.
  47. Check the select lever operation. Refer to INSPECTION , Inhibitor Switch.
  48. Bleed the air of control valve. (Turbo model) Refer to PROCEDURE , Air Bleeding of Control Valve.
  49. Check the ATF level. Refer to AUTOMATIC TRANSMISSION FLUID .
  50. Execute learning control promotion. Refer to PROCEDURE , Learning Control.
  51. Perform reinitialization of the auto headlight beam leveler. Refer to PROCEDURE , Auto Headlight Beam Leveler System.
  52. Perform a road test. Refer to ROAD TEST .
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