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Automatic Transmission Assembly: Installation

  1. Attach the ST to converter case.

    ST 498277200 STOPPER SET

    Fig 1: Attaching ST To Converter Case
    G08317729Courtesy of SUBARU OF AMERICA, INC.
  2. When completely overhauling the transmission, refill CVTF through the transmission right side plug. Ref. to PREPARATION FOR OVERHAUL .
  3. Replace the front differential side retainer oil seal. Ref. to REPLACEMENT , Differential Side Retainer Oil Seal.
    NOTE:
    • Be sure to replace the differential side retainer oil seal with a new part whenever the front drive shaft is removed from the transmission.
    • When a new differential side retainer oil seal has been installed, replacement is not required.
  4. Install the rear cushion rubber on the transmission.

    Tightening torque: 

    40 N.m (4.1 kgf-m, 29.5 ft-lb) 

    Fig 2: Rear Cushion Rubber On Transmission
    G08317744Courtesy of SUBARU OF AMERICA, INC.
  5. Mount the transmission onto the transmission jack.
  6. Strike and bend the transmission hanger of transmission rear with a rubber hammer etc. so that it gets in contact with the transmission case.
    CAUTION: Do not apply extra overload or impact to the transmission case.
    Fig 3: Striking Transmission Hanger Of Transmission Rear With Rubber Hammer
    G08317747Courtesy of SUBARU OF AMERICA, INC.
  7. Remove the pitching stopper bracket, if mounted.
  8. Install the transmission onto the engine.
    NOTE:
    • While raising the transmission jack gradually, turn the screw of engine support, then tilt the engine forward.
    • Temporarily attach the two engine connecting bolts and two nuts (lower side).
  9. 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 4: Locating Transmission Rear Crossmember Bolts
    G08317748Courtesy of SUBARU OF AMERICA, INC.
  10. Tighten the two engine connecting bolts and two nuts (lower side).

    Tightening torque: 

    50 N.m (5.1 kgf-m, 36.9 ft-lb) 

    Fig 5: Locating Engine Connecting Bolts And Nuts
    G08317742Courtesy of SUBARU OF AMERICA, INC.
  11. Tighten the hanger bracket.

    Tightening torque: 

    23 N.m (2.3 kgf-m, 17.0 ft-lb) 

  12. Remove the transmission jack.
  13. Lower the vehicle.
  14. Install the three engine mounting bolts (upper side).

    Tightening torque: 

    50 N.m (5.1 kgf-m, 36.9 ft-lb) 

    Fig 6: Locating Engine Mounting Bolts (Upper Side) Bolts
    G08317735Courtesy of SUBARU OF AMERICA, INC.
  15. Remove the ST (STOPPER SET) from converter case.
  16. Remove the ST (ENGINE SUPPORT BRACKET and ENGINE SUPPORT).

    ST1 41099AA012 ENGINE SUPPORT BRACKET

    ST2 41099AA020 ENGINE SUPPORT

    Fig 7: Installing ST1 41099AA012 Engine Support Bracket Bolts
    G10218522Courtesy of SUBARU OF AMERICA, INC.
  17. Match the torque converter screw hole with drive plate hole to install the bolt.
    CAUTION:
    • Do not drop the mounting bolt in the converter housing.
    • Do not damage the mounting bolt.

    Tightening torque: 

    25 N.m (2.5 kgf-m, 18.4 ft-lb) 

  18. Install the remaining three bolts by rotating the crank pulley a little at a time in the same direction as engine revolution.

    Tightening torque: 

    25 N.m (2.5 kgf-m, 18.4 ft-lb) 

  19. Install the service hole plug.
    Fig 8: Service Hole Plug
    G10218515Courtesy of SUBARU OF AMERICA, INC.
  20. Install the throttle valve body. Ref. to INSTALLATION , Throttle Body.
  21. Install the engine ground terminals.

    Tightening torque: 

    19 N.m (1.9 kgf-m, 14.0 ft-lb) 

    Fig 9: Locating Engine Ground Terminals Bolts
    G08317731Courtesy of SUBARU OF AMERICA, INC.
  22. Replace the CVTF inlet hose and CVTF outlet hose. Ref. to REMOVAL , CVTF Cooler (With Warmer Function). Ref. to INSTALLATION , CVTF Cooler (With Warmer Function).
  23. Install the CVTF inlet hose and CVTF outlet hose to transmission.
    Fig 10: CVTF Inlet Hose And CVTF Outlet Hose To Transmission
    G08317733Courtesy of SUBARU OF AMERICA, INC.
  24. Install the CVTF cooler (with warmer feature) to the transmission.

    Tightening torque: 

    23 N.m (2.3 kgf-m, 17.0 ft-lb) 

    Fig 11: Locating CVTF Cooler (With Warmer Feature) Transmission Bolts
    G10218520Courtesy of SUBARU OF AMERICA, INC.
  25. Install the starter. Ref. to INSTALLATION , Starter.
  26. Install the engine hanger rear.

    Tightening torque: 

    21 N.m (2.1 kgf-m, 15.5 ft-lb) 

    Fig 12: Locating Engine Hanger Rear Bolts
    G10218514Courtesy of SUBARU OF AMERICA, INC.
  27. Install the pitching stopper bracket and transmission radio ground cord.
    CAUTION: Be careful not to deform or damage the terminal of transmission radio ground cord.

    Tightening torque: 

    41 N.m (4.2 kgf-m, 30.2 ft-lb) 

    Fig 13: Locating Pitching Stopper Bracket And Transmission Radio Ground Cord Bolts
    G09481408Courtesy of SUBARU OF AMERICA, INC.
  28. Install the air breather hose to the pitching stopper bracket.
  29. 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 14: Pitching Stopper
    G09475923Courtesy of SUBARU OF AMERICA, INC.
  30. Connect the EGR control valve harness connector, throttle position sensor harness connector and manifold absolute pressure sensor harness connector.
  31. Connect the engine harness connectors, then install the harness connector bracket.

    Tightening torque: 

    7.5 N.m (0.8 kgf-m, 5.5 ft-lb) 

  32. Lift up the vehicle.
  33. Set the ST to side retainer.

    ST 28399SA010 OIL SEAL PROTECTOR

    Fig 15: Setting ST To Side Retainer
    G08317759Courtesy of SUBARU OF AMERICA, INC.
  34. Replace the circlip of the drive shaft with a new part.
  35. Insert the front drive shaft spline section into transmission and remove the ST (OIL SEAL PROTECTOR).
    NOTE:
    • Before inserting the RH front drive shaft into transmission, turn the steering wheel to the right hand at full lock.
    • Before inserting the LH front drive shaft into transmission, turn the steering wheel to the left hand at full lock.
  36. Insert the drive shaft into the transmission securely by pressing the housing from outside of the vehicle.
  37. Insert the ball joint into housing and secure with bolt.

    Tightening torque: 

    50 N.m (5.1 kgf-m, 36.9 ft-lb) 

    NOTE:
    • Do not apply grease to the tapered portion of ball stud.
    • Before tightening, make sure the lower side of housing and stepped section of ball joint are in contact.
    Fig 16: Locating Lower Side Of Housing And Stepped Section Bolts
    G08317741Courtesy of SUBARU OF AMERICA, INC.
  38. Install the stabilizer bracket.

    Tightening torque: 

    25 N.m (2.5 kgf-m, 18.4 ft-lb) 

    Fig 17: Locating Stabilizer Bracket Bolts
    G08317740Courtesy of SUBARU OF AMERICA, INC.
  39. Install the jack-up plate.

    Tightening torque: 

    60 N.m (6.1 kgf-m, 44.3 ft-lb) 

    Fig 18: Locating Jack-Up Plate Bolts
    G08317739Courtesy of SUBARU OF AMERICA, INC.
  40. Install the plate assembly to transmission.

    Tightening torque: 

    25 N.m (2.5 kgf-m, 18.4 ft-lb) 

    Fig 19: Locating Plate Assembly Bolts
    G11568279Courtesy of SUBARU OF AMERICA, INC.
  41. Install the washer and snap pin to the shifter arm.
    CAUTION: Do not apply extra overload while holding the part (A).
    Fig 20: Select Cable From Shifter Arm Dimensions
    G11255302Courtesy of SUBARU OF AMERICA, INC.
    Fig 21: Shifter Arm, Snap Pin, Select Cable And Washer
    G11568281Courtesy of SUBARU OF AMERICA, INC.
  42. Install the propeller shaft. Ref. to INSTALLATION , Propeller Shaft.
  43. Install the center exhaust cover.

    Tightening torque: 

    18 N.m (1.8 kgf-m, 13.3 ft-lb) 

    Fig 22: Locating Center Exhaust Cover Bolts
    G11270138Courtesy of SUBARU OF AMERICA, INC.
  44. Install the center exhaust pipe. Ref. to INSTALLATION , Center Exhaust Pipe.
  45. Install the under cover.
  46. Lower the vehicle.
  47. Connect the following harness connectors.
    • Transmission harness connectors
    • Inhibitor harness connector
    • Transmission radio ground terminal

    Tightening torque: 

    13 N.m (1.3 kgf-m, 9.6 ft-lb) 

    Fig 23: Transmission Harness Connectors, Inhibitor Harness Connector And Transmission Radio Ground Terminal
    G11568283Courtesy of SUBARU OF AMERICA, INC.
  48. Install the air intake boot assembly. Ref. to INSTALLATION , Air Intake Boot.
  49. Install the front tires. Ref. to INSTALLATION , Tire and Wheel.
  50. Connect the battery ground terminal.
  51. Refill differential gear oil to adjust the differential gear oil amount. Ref. to DIFFERENTIAL GEAR OIL .
  52. Refill CVTF to adjust the CVTF level. Ref. to CVTF .
  53. Perform the operation of AT learning mode. Ref. to Learning Control .
  54. Execute the rear differential inspection mode. Ref. to Rear Differential Inspection Mode .
    CAUTION: Always execute the rear differential inspection mode at the replacement of the following.
    • Replacement of transmission assembly
    • Replacement of front differential hypoid gear set
  55. Perform the road test to make sure there is no fault. Ref. to INSPECTION , Road Test.
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