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Home >> Subaru >> 2009 >> Outback R Limited >> Repair and Diagnosis >> Transmission >> Automatic Trans >> Automatic Transmission 5AT >> AT Main Case >> Installation

AT Main Case: Installation

  1. Apply ATF to a new seal ring.
  2. Install the thrust bearing and a new seal ring to the drum support.
    Fig 1: Identifying Thrust Bearing And Seal Ring
    G06337804Courtesy of SUBARU OF AMERICA, INC.
  3. Install the reverse brake piston.
    NOTE: Apply ATF onto the piston sliding surface.

    ST1 18762AA000 COMPRESSOR SPECIAL TOOL

    ST2 18765AA000 COMPRESSOR SUPPORT

    ST3 18763AA000 COMPRESSOR SHAFT

  4. Install the return spring.
    Fig 2: Installing Return Spring
    G05022404Courtesy of SUBARU OF AMERICA, INC.
  5. Install the spring retainer and snap ring.

    ST1 18762AA000 COMPRESSOR SPECIAL TOOL

    ST2 18765AA000 COMPRESSOR SUPPORT

    ST3 18763AA000 COMPRESSOR SHAFT

    Fig 3: Installing Spring Retainer And Snap Ring
    G05022402Courtesy of SUBARU OF AMERICA, INC.
  6. Install the dish plate.
    NOTE: When installing, make sure that the identification mark is facing the front side of transmission.
  7. Install the drive plate and driven plate.
  8. Install the leaf spring.
    Fig 4: Identifying Leaf Spring
    G06337807Courtesy of SUBARU OF AMERICA, INC.
  9. Install the retaining plate.
  10. Install the snap ring of the reverse brake.
    Fig 5: Identifying Snap Ring Of Reverse Brake
    G05022400Courtesy of SUBARU OF AMERICA, INC.
  11. Perform the clearance check of reverse brake.
    1. Measure the clearance between retainer plate and snap ring using thickness gauge.

      Standard: 0.7 - 1.1 mm (0.028 - 0.043 in) 

      Fig 6: Measuring Clearance Between Retainer Plate And Snap Ring
      G05022411Courtesy of SUBARU OF AMERICA, INC.
    2. If it is out of specification, select a suitable retainer plate from the following table and assemble it.
      THICKNESS CHART

      Retainer plate
      Part No. Thickness mm (in)
      31567AB100 4.2 (0.165)
      31567AB170 4.4(0.173)
      31567AB180 4.6(0.181)
      31567AB190 4.8(0.189)
      31567AB200 5.0(0.197)
  12. Install the direct clutch assembly.
    Fig 7: Installing Direct Clutch Assembly
    G05022399Courtesy of SUBARU OF AMERICA, INC.
  13. Install the high & low reverse clutch assembly.
    Fig 8: Installing High And Low Reverse Clutch Assembly
    G05022398Courtesy of SUBARU OF AMERICA, INC.
  14. Install the thrust needle bearing of the high & low reverse clutch.
    Fig 9: Identifying Thrust Needle Bearing Of High And Low Reverse Clutch
    G05022397Courtesy of SUBARU OF AMERICA, INC.
  15. Install the middle & rear sun gear assembly.
    Fig 10: Identifying Middle & Rear Sun Gear Assembly
    G05022396Courtesy of SUBARU OF AMERICA, INC.
  16. Install the rear carrier assembly.
    Fig 11: Identifying Rear Carrier Assembly
    G05022395Courtesy of SUBARU OF AMERICA, INC.
  17. Install the middle carrier assembly.
    Fig 12: Identifying Middle Carrier Assembly
    G05022394Courtesy of SUBARU OF AMERICA, INC.
  18. Install the thrust needle bearing of middle carrier assembly.
    Fig 13: Identifying Needle Bearing Of Middle Carrier Assembly
    G05022393Courtesy of SUBARU OF AMERICA, INC.
  19. Measure the total end play, and select the bearing. Refer to ADJUSTMENT , AT Main Case.
  20. Install the impact clutch pack assembly to oil pump cover.
    Fig 14: Measuring Total End Play
    G06337817Courtesy of SUBARU OF AMERICA, INC.
  21. Turn the transmission sideways.
  22. Install the oil pump cover.
    1. Apply ATF to the O-ring of input clutch shaft.
    2. Install the oil pump cover to AT main case while supporting the input clutch shaft and oil pump housing with your hand.
      Fig 15: Identifying Input Clutch Pack Assembly And Front Sun Gear Assembly
      G05022392Courtesy of SUBARU OF AMERICA, INC.
    3. Make sure the rear end of drive pinion shaft is engaged to the spline of reduction driven gear.
      Fig 16: Identifying Drive Pinion Shaft
      G06337819Courtesy of SUBARU OF AMERICA, INC.
    4. Protect the input clutch shaft with a cloth, and rotate to engage the spline of the input clutch and rear carrier using pliers.
      NOTE: Work with pressing the oil pump cover.
      Fig 17: Protecting Input Clutch Shaft Using Cloth
      G06337820Courtesy of SUBARU OF AMERICA, INC.
    5. Combine the oil pump cover with transmission main case.

      Tightening torque: 41 N.m (4.2 kgf-m, 30.2 ft-lb) 

      Fig 18: Identifying Oil Pump Cover Bolts
      G05022338Courtesy of SUBARU OF AMERICA, INC.
  23. Install the center differential carrier. Refer to INSTALLATION , Center Differential Carrier.
  24. Install the reduction driven gear. Refer to INSTALLATION , Reduction Driven Gear.
  25. Install the extension case. Refer to INSTALLATION , Extension Case.
  26. Install the control valve body. Refer to INSTALLATION , Control Valve Body.
  27. Install the converter case assembly to the transmission case assembly. Refer to INSTALLATION , Converter Case.
  28. Install the air breather hose. Refer to INSTALLATION , Air Breather Hose.
  29. Install the ATF cooler pipe. Refer to INSTALLATION , ATF Cooler Pipe and Hose.
  30. Install the oil charge pipe together with an O-ring. Refer to INSTALLATION , Oil Charge Pipe.
  31. Install the torque converter assembly. Refer to INSTALLATION , Torque Converter Assembly.
  32. Install the transmission assembly to the vehicle. Refer to INSTALLATION , Automatic Transmission Assembly.
  33. Perform Clear Memory 2 operation. Refer to CLEAR MEMORY MODE , OPERATION, Subaru Select Monitor.
  34. Execute the learning control promotion. Refer to PROCEDURE , Learning Control.
  35. Perform the inspection at the end of repair work, and make sure there is no faulty as below;
    • Excessive shift shock
    • Oil leakage from the transmission body, etc.
    • Occurrence of noise caused by interference etc.
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