Automatic Transmission: Removal & Installation Subaru Forester SG

REMOVAL

When removing the rear vehicle speed sensor, refer to REMOVAL , Front Vehicle Speed Sensor.

B: INSTALLATION

When installing the rear vehicle speed sensor, refer to INSTALLATION , Front Vehicle Speed Sensor.

When removing the torque converter turbine speed sensor, refer to REMOVAL , Front Vehicle Speed Sensor.

INSTALLATION

When installing the torque converter turbine speed sensor, refer to INSTALLATION , Front Vehicle Speed Sensor.

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1. Lift-up the vehicle.
2. Clean the transmission exterior
3. Drain the ATF completely. NOTE: Tighten the ATF drain plug after draining the ATF. Replace the gasket with a new one. Tightening torque: 25 N.m (2.5 kgf-m, 18.1 ft-lb)
4. Remove the oil pan.
5. Remove and clean the magnet.
6. Remove the old gasket on the oil pan and transmission case completely.
7. Disconnect the duty solenoids and ATF temperature sensor connectors. Remove the connectors from clip and disconnect the connectors.
8. Remove the control valve.

Note. When removing the control valve body, be careful not to interfere with transfer duty solenoid wiring.

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1. Set the range select lever in "N" range.
2. Install the control valve and ground connectors. Tightening torque: 8 N.m (0.8 kgf-m, 5.8 ft-lb)
3. Connect all connectors.
4. Attach the magnet at specified position.
5. Apply proper amount of liquid gasket to the entire oil pan mating surface. Liquid gasket: THREE BOND 1217B (Part No. K0877YA020)
6. Apply liquid gasket fully to three holes other than screw holes on transmission case. Liquid gasket: THREE BOND 1217B (Part No. K0877YA020)
7. Install the oil pan. Tightening torque: 5 N.m (0.5 kgf-m, 3.6 ft-lb)
8. Pour ATF into the oil charge pipe. Recommended fluid: Dexron III type automatic transmission fluid Fluid capacity: Fill the same amount of fluid drained from drain plug hole.
9. Check the level of ATF. Refer to «AUTOMATIC TRANSMISSION FLUID»(ref-200793-S33250629602005102300000) .

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1. Remove oil strainer from lower control valve body. NOTE: Arrange the removed bolts in good order to assemble in the same place as disassembly, because the bolts length are different.
2. Remove the duty solenoids, solenoids and sensor from the lower valve body. NOTE: Arrange the removed bolts in good order to assemble in the same place as disassembly, because the bolts length are different.
3. Remove the upper-lower valve body tightening bolts. NOTE: Arrange the removed bolts in good order to assemble in the same place as disassembly, because the bolts length are different.
4. Remove the lower valve body.
5. Remove the oil filter and plate.
6. Remove six steel balls from middle valve body.
7. Remove the middle valve body.
8. Remove upper separator plate from middle valve body.
9. Remove valve springs and four steel balls from upper valve body.
10. Place a shop cloth to the piston removal hole.
11. Using an air compressor, apply air slowly to each piston hole and remove the pistons.
12. Remove the seal ring from piston.

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1. Install a new seal ring to piston.
2. Apply ATF to the seal ring.
3. Insert the piston fully into upper valve body.
4. Install the spring and four steel balls to specified positions of upper valve body.
5. Align the hole in side plate with the hole in separator plate, and then install support plate and upper separator plate to middle valve body. Tightening torque: 8 N.m (0.8 kgf-m, 5.8 ft-lb)
6. Insert six steel balls in their proper positions to middle valve body.
7. Install three filters to lower valve body. NOTE: Pay attention to the location of filters.
8. Install lower separate plate to lower valve body.
9. Temporarily assemble valve body. NOTE: Be careful not to drop the middle valve body and upper body interior steel ball, or the lower body filter.
10. Tighten bolts. NOTE: Install the bolts (D) from upper valve body side. Tightening torque: 8 N.m (0.8 kgf-m, 5.8 ft-lb)
11. Install the sensor, solenoids and duty solenoids to specified positions.
12. Tighten the bolts and nuts. Tightening torque: 8 N.m (0.8 kgf-m, 5.8 ft-lb)
13. Install oil strainer to lower valve body. Tightening torque: 8 N.m (0.8 kgf-m, 5.8 ft-lb)

Note. The ATF filter is maintenance free.

Scheme 461

1. Lift-up the vehicle.
2. Using the ST, remove the ATF filter. ST 498545400 OIL FILTER WRENCH
3. Use a new ATF filter and apply a thin coat of ATF to the oil seal.

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1. Disconnect the ground cable from battery.
2. Remove the lower cover and then disconnect the connector.
3. Remove the knee bolster.
4. Disconnect the connectors from transmission control module.
5. Remove the transmission control module.

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1. Install the transmission control module. Tightening torque: 25 N.m (2.5 kgf-m, 18.1 ft-lb)
2. Connect the connectors to transmission control module.
3. Install in the reverse order of removal.

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1. Disconnect the ground terminal from battery.
2. Disconnect the connector from dropping resistor.
3. Remove the dropping resistor.

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1. Install in the reverse order of removal. Tightening torque: 6.4 N.m (0.65 kgf-m, 4.7 ft-lb)

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1. Set the vehicle on a lift.
2. Remove the battery and washer tank.
3. Lift-up the vehicle.
4. Remove the under cover.
5. Disconnect the ATF cooler hose from radiator. NOTE: Do not remove with a screwdriver or other pointed tools. When the hose is difficult to remove, wrap a shop cloth around the hose to protect it. Turn it with pliers, and then pull directly out with your hand.
6. Disconnect the ATF cooler hoses from pipes. NOTE: Do not remove with a screwdriver or other pointed tools. When the hose is difficult to remove, wrap a shop cloth around the hose to protect it. Turn it with pliers, and then pull directly out with your hand.
7. Disconnect the ATF cooler pipe from frame.
8. Disconnect the oil cooler inlet and outlet pipes. NOTE: When disconnecting the outlet pipe, be careful not to lose ball and spring used with retaining screw.

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1. Install the oil cooler outlet and inlet pipes with new washer. Tightening torque: T1: 25 N.m (2.5 kgf-m, 18.1 ft-lb) T2: 44 N.m (4.5 kgf-m, 32.5 ft-lb)
2. Install the ATF cooler pipe to frame.
3. Connect the ATF cooler hose to pipe transmission side. NOTE: Install so that the hose is not folded over, excessively bent, or twisted. Be careful to insert the hose to the specified position.
4. Connect the ATF cooler hose to the pipe of radiator side. NOTE: Install so that the hose is not folded over, excessively bent, or twisted. Be careful to insert the hose to the specified position.
5. Install the under cover.
6. Install the battery and washer tank.
7. Fill ATF. Refer to «AUTOMATIC TRANSMISSION FLUID»(ref-200793-S33250629602005102300000) . NOTE: Make sure there are no ATF leaks in joints between the transmission, radiator, pipes, and hoses.