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Automatic Transmission: Other Subaru Forester SG

Automatic Trans 57 illustrations ~2194 words

CAUTION

  1. Wear working clothing, including a cap, protective goggles, and protective shoes during operation.
  2. Remove contamination including dirt and corrosion before removal, installation, and disassembly.
  3. Keep the disassembled parts in order and protect them from dust or dirt.
  4. Until the oil pan is removed, do not place with the oil pan side facing up to prevent foreign matter from entering the valve body.
  5. Before removal, installation or disassembly, be sure to clarify the failure. Avoid unnecessary removal, installation, disassembly and replacement.
  6. When disassembling the case and other light alloy parts, use a plastic hammer to force it apart. Do not pry it apart with a screwdriver or other tool.
  7. Be careful not to burn your hands, because each part on the vehicle is hot after running.
  8. Use Subaru genuine gear oil, grease etc. or the equivalent. Do not mix gear oil, grease etc. with that of another grade or from other manufacturers.
  9. Be sure to tighten fasteners including bolts and nuts to the specified torque.
  10. Place shop jacks or safety stands at the specified points.
  11. Apply gear oil onto sliding or revolution surfaces before installation.
  12. Replace deformed or otherwise damaged snap rings with new ones.
  13. Before installing O-rings or oil seals, apply sufficient amount of ATF fluid to avoid damage and deformation.
  14. Be careful not to incorrectly install or fail to install O-rings, snap rings and other such parts.
  15. Before securing a part on a vise, place cushioning material such as wood blocks, aluminum plate, or shop cloth between the part and the vise.
  16. Avoid damaging the mating surface of the case.
  17. Before applying sealant, completely remove the old seal.

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Scheme 479: SPECIAL TOOLS
Scheme 479: SPECIAL TOOLS

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Scheme 490

Scheme 490: GENERAL PURPOSE TOOLS
Scheme 490: GENERAL PURPOSE TOOLS

GENERAL PRECAUTION

Road tests should be conducted to properly diagnose the condition of the automatic transmission.

Note. When performing the test, do not exceed posted speed limit.

D RANGE SHIFT FUNCTION

Check shifting between 1st <=> 2nd <=> 3rd <=> 4th while driving on normal city streets.

D RANGE SHIFT SHOCK

Check the shock level when shifting up during normal driving.

KICK-DOWN FUNCTION

Check kick-down for each gear. Also check the kick-down shock level.

LOCK-UP FUNCTION

Check that rpm does not change sharply when the accelerator pedal is lightly depressed when driving on flat roads at normal speed in the lock-up range.

CLIMBING CONTROL FUNCTION

  1. Check that the gear remains in 3rd when going up a grade.
  2. Check that the gear remains in 3rd when applying the brakes while going down a grade.

TRANSFER CLUTCH

Check if the tight corner braking occurs when the vehicle is started with steering wheel held at fully turned position.

OIL LEAKS

After the driving test, inspect for oil leaks.

EVALUATION

  1. If "N" --> "D" time lag is longer than specified: Line pressure too low Low clutch worn One-way clutch not operating properly
  2. If "N" --> "R" time lag is longer than specified: Line pressure too low Reverse clutch worn Low & reverse brake worn

Note. If oil pressure is not produced or if it does not change in the AWD mode, the transfer duty solenoid or transfer valve assembly may be malfunctioning. If oil pressure is produced in the FWD mode, the problem is similar to that in the AWD mode.

Scheme 491

Scheme 491: EVALUATION
Scheme 491: EVALUATION

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Scheme 492: REMOVAL
Scheme 492: REMOVAL

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Scheme 506
  1. Set the vehicle on a lift.
  2. Open the front hood fully, and support with stay.
  3. Disconnect the ground cable from battery.
  4. Remove the air intake duct. Refer to «REMOVAL»(ref-200787-S34281602712005102300000) , Air Intake Duct.
  5. Remove the air cleaner case. Refer to «REMOVAL»(ref-200787-S24445141242005102300000) , Air Cleaner Case.
  6. Remove the air cleaner case stay.
  7. Disconnect the following connectors. Transmission harness connector Transmission ground cable
  8. Remove the starter. Refer to «REMOVAL»(ref-167769-S39205696652004102100000) , Starter.
  9. Remove the pitching stopper.
  10. Separate the torque converter clutch from drive plate. Remove the service hole plug. Remove the V-belt cover. Remove the bolts which hold torque converter clutch to drive plate. By inserting a wrench into the crank pulley bolt, rotate the crank pulley in the direction of engine rotation to remove the other bolts.
  11. Install the ST to torque converter clutch case. ST 498277200 STOPPER SET
  12. Set the ST. NOTE: Also the ENGINE SUPPORT BRACKET 41099AA010 can be used. ST 41099AA020 ENGINE SUPPORT ASSY
  13. Remove the bolt which holds right upper side of transmission to engine.
  14. Lift-up the vehicle.
  15. Remove the under cover.
  16. Remove the front, center, rear exhaust pipe and muffler. Refer to «REMOVAL»(ref-200789-S02976811952005102300000) , Front Exhaust Pipe, «REMOVAL»(ref-200789-S21679616402005102300000) , Rear Exhaust Pipe and «REMOVAL»(ref-200789-S31333937342005102300000) , Muffler.
  17. Remove the heat shield cover.
  18. Remove the ATF drain plug to drain ATF.
  19. Drain the differential gear oil. Refer to «REPLACEMENT»(ref-200793-S10457881402005102300000) , Differential Gear Oil.
  20. Disconnect the ATF cooler hoses from pipes of transmission side, and remove the ATF level gauge guide. NOTE: Plug the opening to prevent entry of foreign particles into transmission fluid.
  21. Remove the propeller shaft.
  22. Remove the shift select cable. Refer to «REMOVAL»(ref-200792-S42694290512005102300000) , Select Cable.
  23. Disconnect the stabilizer link from transverse link.
  24. Remove the bolt securing ball joint of transverse link to housing, and then separate the transverse link from housing.
  25. Pull the front drive shaft out of transmission. Face the "AT" letter ST to transmission side. ST 28399SA000 DRIVE SHAFT REMOVER Insert the ST between transmission and front drive shaft. NOTE: Put the projection of ST on torque converter clutch housing. ST 28399SA000 DRIVE SHAFT REMOVER While holding the joint portion (AAR) of front drive shaft with your hand, push the housing outside to remove from transmission.
  26. Remove the nuts which hold lower side of transmission to engine.
  27. Place the transmission jack under transmission. NOTE: Make sure that the support plates of transmission jack don't touch the oil pan.
  28. Remove the transmission rear crossmember from vehicle.
  29. Remove the transmission. CAUTION: Separate the transmission and torque converter as a unit away from engine.
  30. Separate the transmission assembly and rear cushion rubber.

Scheme 507

Scheme 507: INSTALLATION
Scheme 507: INSTALLATION

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Scheme 519
  1. Replace the differential side oil seal with a new one. Refer to «REPLACEMENT»(ref-200793-S33654295482005102300000) , Differential Side Retainer Oil Seal.
  2. Install the rear cushion rubber to transmission assembly. Tightening torque: 39 N.m (4.0 kgf-m, 29 ft-lb)
  3. Install the ST to torque converter clutch case. ST 498277200 STOPPER SET
  4. Install the transmission onto engine. Gradually raise the transmission with transmission jack. Engage them at splines.
  5. Install the transmission rear crossmember. Tightening torque: T1: 35 N.m (3.6 kgf-m, 26 ft-lb) T2: 70 N.m (7.1 kgf-m, 51 ft-lb)
  6. Take off the transmission jack.
  7. Tighten the nuts and bolts which hold lower side of transmission to engine. Tightening torque: 50 N.m (5.1 kgf-m, 36.9 ft-lb)
  8. Lower the vehicle.
  9. Connect the engine and transmission. Remove the ST from torque converter clutch case. ST 498277200 STOPPER SET Install the starter. Refer to «INSTALLATION»(ref-167769-S00031971462004102100000) , Starter. Tighten the bolt which holds upper side of transmission to engine. Tightening torque: 50 N.m (5.1 kgf-m, 36.9 ft-lb)
  10. Install the torque converter clutch to drive plate. Tighten the bolts which hold torque converter clutch to drive plate. By inserting a wrench into the crank pulley bolt, rotate the crank pulley in the direction of engine rotation to remove the other bolts. ST 499977300 CRANK PULLEY WRENCH Tightening torque: 25 N.m (2.5 kgf-m, 18.1 ft-lb) Clog the plug onto service hole. Install the V-belt cover.
  11. Remove the ST.
  12. Install the pitching stopper. Tightening torque: T1: 50 N.m (5.1 kgf-m, 37 ft-lb) T2: 58 N.m (5.9 kgf-m, 43 ft-lb)
  13. Lift-up the vehicle.
  14. Replace the front drive shaft circlip with a new one.
  15. Apply a coat grease to the lip of oil seal.
  16. Install the ST to side retainer. ST 28399SA010 OIL SEAL PROTECTOR
  17. Insert the front drive shaft by aligning spline part of front drive shaft and spline part of differential bevel gear, and then remove the ST. ST 28399SA010 OIL SEAL PROTECTOR
  18. Insert the front drive shaft to transmission securely by pressing front housing.
  19. Connect the ball joint into housing.
  20. Tighten the installing bolts. Tightening torque: 49 N.m (5.0 kgf-m, 36 ft-lb)
  21. Install the stabilizer link from transverse link. Tightening torque: 45 N.m (4.6 kgf-m, 33.2 ft-lb)
  22. Install the shift select cable onto select lever. Refer to «INSTALLATION»(ref-200792-S00902581622005102300000) , Select Cable.
  23. Install the ATF level gauge guide and level gauge, and connect the ATF cooler hoses to pipe.
  24. Install the propeller shaft.
  25. Install the heat shield cover.
  26. Install the rear exhaust pipe and muffler assembly. Refer to «INSTALLATION»(ref-200789-S01457167832005102300000) , Rear Exhaust Pipe and «INSTALLATION»(ref-200789-S41832764532005102300000) , Muffler.
  27. Install the front and center exhaust pipe. Refer to «INSTALLATION»(ref-200789-S17193731862005102300000) , Front Exhaust Pipe.
  28. Install the under cover.
  29. Lower the vehicle.
  30. Connect the following connectors. Transmission harness connectors Transmission ground cable
  31. Install the air cleaner case stay. Tightening torque: 16 N.m (1.6 kgf-m, 11.6 ft-lb)
  32. Install the air cleaner case and intake duct. Refer to «INSTALLATION»(ref-200787-S32054192432005102300000) , Air Cleaner Case and «INSTALLATION»(ref-200787-S29216310462005102300000) , Air Intake Duct.
  33. Connect the battery ground cable to battery.
  34. Fill ATF up to the middle of the "COLD" side on level gauge by using the gauge hole. Refer to «AUTOMATIC TRANSMISSION FLUID»(ref-200793-S33250629602005102300000) .
  35. Fill the differential gear oil through front differential gauge hole. Refer to «REPLACEMENT»(ref-200793-S10457881402005102300000) , Differential Gear Oil.
  36. Take off the vehicle from lift arms.
  37. Check the ATF level. Refer to «AUTOMATIC TRANSMISSION FLUID»(ref-200793-S33250629602005102300000) .
  38. Check the select lever operation. Refer to «INSPECTION»(ref-200793-S14720584502005102300000) , Inhibitor Switch.
  39. Check the level of differential gear oil. Refer to «INSPECTION»(ref-200793-S19558080552005102300000) , Differential Gear Oil.
  40. Test the vehicle on the road. Refer to «ROAD TEST»(ref-200793-S37714211192005102300000) .

Scheme 520

Scheme 520: PITCHING STOPPER
Scheme 520: PITCHING STOPPER
  1. Disconnect the ground cable from battery.
  2. Remove the air cleaner case. Refer to «REMOVAL»(ref-200787-S24445141242005102300000) , Air Cleaner Case.
  3. Remove the pitching stopper.

Scheme 521

Scheme 521: CROSSMEMBER AND CUSHION RUBBER
Scheme 521: CROSSMEMBER AND CUSHION RUBBER
  1. Disconnect the ground cable from battery.
  2. Jack-up the vehicle and support it with sturdy racks.
  3. Remove the front, center, rear exhaust pipes and muffler. Refer to «REMOVAL»(ref-200789-S02976811952005102300000) , Front Exhaust Pipe, «REMOVAL»(ref-200789-S21679616402005102300000) , Rear Exhaust Pipe and «REMOVAL»(ref-200789-S31333937342005102300000) , Muffler.
  4. Remove the heat shield cover.
  5. Set the transmission jack under the transmission. Make sure that the support plates of transmission jack don't touch the oil pan.
  6. Remove the transmission rear crossmember.
  7. Remove the rear cushion rubber.

Scheme 522

Scheme 522: PITCHING STOPPER
Scheme 522: PITCHING STOPPER
  1. Install the pitching stopper. Tightening torque: T1: 50 N.m (5.1 kgf-m, 37 ft-lb) T2: 58 N.m (5.9 kgf-m, 43 ft-lb)
  2. Install the air cleaner case. Refer to «INSTALLATION»(ref-200787-S32054192432005102300000) , Air Cleaner Case.

Scheme 523

Scheme 523: CROSSMEMBER AND CUSHION RUBBER
Scheme 523: CROSSMEMBER AND CUSHION RUBBER
  1. Install the rear cushion rubber. Tightening torque: 39 N.m (4.0 kgf-m, 29 ft-lb)
  2. Install the crossmember. Tightening torque: T1: 35 N.m (3.6 kgf-m, 26 ft-lb) T2: 70 N.m (7.1 kgf-m, 51 ft-lb)
  3. Remove the transmission jack.
  4. Install the heat shield cover.
  5. Install the front, center, rear exhaust pipes and the muffler. Refer to «INSTALLATION»(ref-200789-S17193731862005102300000) , Front Exhaust Pipe, «INSTALLATION»(ref-200789-S01457167832005102300000) , Rear Exhaust Pipe and «INSTALLATION»(ref-200789-S41832764532005102300000) , Muffler.

PITCHING STOPPER

Make sure that the pitching stopper is not bent or damaged. Make sure that the rubber is not stiff, cracked, or otherwise damaged.

CROSSMEMBER AND CUSHION RUBBER

Make sure that the crossmember is not bent or damaged. Make sure that the cushion rubber is not stiff, cracked, or otherwise damaged.

SIDE RETAINER

Note. After adjusting the drive pinion backlash and tooth contact, remove and install the oil seal and O-ring.

Scheme 524

Scheme 524: SIDE RETAINER
Scheme 524: SIDE RETAINER

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Scheme 528
  1. Remove O-ring.
  2. Remove oil seal.
  3. Take out either split pin, remove claw. ST 398527700 PULLER ASSY
  4. Securely attach two claws to outer race, set ST to side retainer. ST 398527700 PULLER ASSY
  5. Return removed claw to the original position, and install pin and split pin.
  6. Hold the shaft of ST to avoid removing from side retainer, and then remove the bearing outer race. ST 398527700 PULLER ASSY< NOTE: Replace bearing inner and outer races as a single unit.

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Scheme 529: DIFFERENTIAL CASE ASSEMBLY
Scheme 529: DIFFERENTIAL CASE ASSEMBLY

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  1. Install the washer, differential bevel gear and differential bevel pinion in the differential case (RH). Insert the pinion shaft.
  2. Install straight pin from reverse direction.
  3. Install the washer and differential bevel gear to the differential case (LH). Then put the case over the differential case (RH), and connect both cases.
  4. Install the crown gear and secure by tightening the bolt. Standard tightening torque: 62 N.m (6.3 kgf-m, 45.6 ft-lb)
  5. Measurement of backlash (Selection of washer) Install Subaru genuine axle shaft to differential case. Part No. 38415AA070 AXLE SHAFT Measure the gear backlash with ST1 and ST2, and insert ST2 through the access window of the case. ST1 498247001 MAGNET BASE ST2 498247100 DIAL GAUGE NOTE: Measure the backlash by applying a pinion tooth between two bevel gear teeth. Fix bevel pinion gear in place with a screwdriver or similar tool when measuring. Standard value: 0.13 - 0.18 mm (0.0051 - 0.0071 in) If backlash is not as specified, select a washer from the table below.
  6. Using ST, install taper roller bearing. ST 398437700 DRIFT

Scheme 534

Scheme 534: SIDE RETAINER
Scheme 534: SIDE RETAINER

Scheme 535

Scheme 535
Scheme 535
  1. Install bearing outer race to side retainer.
  2. Install a new oil seal using the ST and hammer. ST 18675AA000 INSTALLER
  3. Install new O-ring.

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