Home ReviewsRefund
Home/Subaru/Forester/Subaru Forester SG рестайлинг (2005-2008)/Repair manual/Automatic Trans/Automatic Transmission: Removal & Installation
Contents Section: Automatic Trans All sections

Automatic Transmission: Removal & Installation Subaru Forester SG рестайлинг

Automatic Trans 47 illustrations ~2497 words

INSTALLATION

Install in the reverse order of removal.

Note. Replace O-ring with a new one.

Tightening torque

7 N.m (0.7 kgf-m, 5.1 ft-lb)

REMOVAL

When removing the torque converter turbine speed sensor, refer to " FRONT VEHICLE SPEED SENSOR ". REMOVAL FRONT VEHICLE SPEED SENSOR. >

When installing the torque converter turbine speed sensor, refer to " FRONT VEHICLE SPEED SENSOR ". INSTALLATION FRONT VEHICLE SPEED SENSOR. >

Scheme 263

Scheme 263: REMOVAL
Scheme 263: REMOVAL

Scheme 264

Scheme 264
Scheme 264

Scheme 265

Scheme 265
Scheme 265

Scheme 266

Scheme 266
Scheme 266

Scheme 267

Scheme 267
Scheme 267
  1. Set the vehicle on a lift.
  2. Disconnect the ground cable from battery.
  3. Lift-up the vehicle.
  4. Clean the transmission exterior.
  5. Remove the drain plug (ATF) and gasket to drain ATF.
  6. Replace the gasket with new one, and then tighten the drain plug (ATF). Tightening torque: 25 N.m (2.5 kgf-m, 18.1 ft-lb)
  7. Remove the oil pan. CAUTION: Be careful not to allow foreign matter such as dust or dirt to enter the oil pan.
  8. Remove the magnet.
  9. Clean the magnet.
  10. Completely remove the remaining liquid gasket on the transmission case and oil pan.
  11. Remove the control valve connector.
  12. Remove the ATF cooler pipe.
  13. Remove the control valve body.

Note. The control valve body is replaced as an assembly only, because it is a non-disassembly part.

Scheme 268

Scheme 268
Scheme 268

Scheme 269

Scheme 269
Scheme 269
  1. Check the control valve body for dust and other foreign matter.
  2. Temporarily assembly the control valve body to transmission then install the oil cooler pipe. Tightening torque: 8 N.m (0.8 kgf-m, 5.8 ft-lb)
  3. Tighten the bolts equally. Tightening torque: 8 N.m (0.8 kgf-m, 5.8 ft-lb)
  4. Connect the control valve connector.
  5. Attach the magnet at the specified position of the oil pan.
  6. Apply proper amount of liquid gasket to the entire oil pan mating surface. Liquid gasket: Three bond 1217B (Part No. K0877YA020)
  7. Fill the 3 holes aside from the bolt holes in the transmission case, with liquid gasket. Liquid gasket: Three bond 1217B (Part No. K0877YA020)
  8. Install the oil pan by equally tightening the bolts. Tightening torque: 5 N.m (0.5 kgf-m, 3.6 ft-lb)
  9. Fill ATF from the oil charger pipe. Recommended fluid: SUBARU ATF Substitute fluid: IDEMITSU: APOLLOIL ATF HP Castrol: Transmax J Pennzoil Quaker State: Pennzoil ATF-J Capacity: Fill with the same amount of fluid that was drained from the drain plug hole.
  10. Bleed the air of control valve body. AIR BLEEDING OF CONTROL VALVE. >
  11. Check the ATF level. AUTOMATIC TRANSMISSION FLUID. >
  12. Execute the learning control promotion. FACILITATION OF LEARNING CONTROL OPERATION, Subaru Select Monitor. >

Note. The ATF filter is maintenance free.

  1. Lift-up the vehicle.
  2. Using the ST, remove the ATF filter. ST 498545400 OIL FILTER WRENCH

Scheme 270

Scheme 270
Scheme 270
  1. Apply a thin coat of ATF to the oil seal part of new ATF filter.
  2. Install the ATF filter. Turn it by hand, being careful not to damage oil seal.
  3. Tighten the ATF filter using ST. Calculate the ATF filter tightening torque using following formula. T2 = L2/(L1 + L2) x T1 T1: 14 N.m (1.4 kgf-m, 10.1 ft-lb) [Required torque setting] T2: Tightening torque L1: ST length 78 mm (3.07 in) L2: Torque wrench length Example: TIGHTENING TORQUE Torque wrench length mm (in) Tightening torque N.m (kgf-m, ft-lb) 100(3.94) 7.7 (0.79, 5.7) 150(5.91) 9.0 (0.92, 6.7) 200 (7.87) 9.8(1.0,7.2) NOTE: Align the ST with the torque wrench while tightening the ATF filter. ST 498545400 OIL FILTER WRENCH
  4. Fill ATF.
  5. Inspect the level of ATF. AUTOMATIC TRANSMISSION FLUID. >
  1. Install the ATF cooler inlet and outlet pipes with the new washer. Tightening torque: T1:25 N.m (2.5 kgf-m, 18.1 ft-lb) T2: 40 N.m (4.1 kgf-m, 29.5 ft-lb) T3:45 N.m (4.6 kgf-m, 33.2 ft-lb)
  2. Install the ATF cooler pipe to frame.
  3. Connect the ATF cooler hose to the pipe on the transmission side. NOTE: Install so that the hose is not folded over, excessively bent or twisted. Insert the hose to the specified position.
  4. Connect the ATF cooler hose to the pipe on the radiator side. (Non-turbo model) NOTE: Install so that the hose is not folded over, excessively bent or twisted. Insert the hose to the specified position.
  5. Connect the ATF cooler hose to the pipe on the radiator side. (Turbo model) TURBO MODEL INSTALLATION, Radiator. >
  6. Install the under cover.
  7. Install the battery and washer tank.
  8. Fill ATF. AUTOMATIC TRANSMISSION FLUID. >

Note. Make sure there are no ATF leaks in joints between the transmission, radiator, pipes, and hoses.

  1. Remove the air intake chamber. (Non-turbo model) REMOVAL Air Intake Chamber. >
  2. Remove the intercooler. (Turbo model) REMOVAL Intercooler. >
  3. Remove the oil charger pipe, and then remove the O-ring from the flange side.

Scheme 271

Scheme 271
Scheme 271

Scheme 272

Scheme 272: INSTALLATION
Scheme 272: INSTALLATION
  1. Install the oil charger pipe with a new O-ring. Tightening torque: 41 N.m (4.2 kgf-m, 30.4 ft-lb)
  2. Install the air intake chamber. (Non-turbo model) INSTALLATION Air Intake Chamber. >
  3. Install the intercooler. (Turbo model) INSTALLATION Intercooler. >
  1. Remove the transmission assembly from vehicle body. REMOVAL AUTOMATIC TRANSMISSION ASSEMBLY. >
  2. Remove the extension case, and take out the transfer clutch assembly. REMOVAL EXTENSION CASE. > DISASSEMBLY EXTENSION CASE. >

Scheme 273

Scheme 273: INSTALLATION
Scheme 273: INSTALLATION
  1. Select the thrust needle bearing. ADJUSTMENT TRANSFER CLUTCH. >
  2. Install the transfer clutch assembly to the case.
  3. Tighten the bolts to secure the case. Tightening torque: 25 N.m (2.5 kgf-m, 18.1 ft-lb)
  4. Install the transmission assembly to the vehicle. INSTALLATION AUTOMATIC TRANSMISSION ASSEMBLY. >

Scheme 274

Scheme 274: DISASSEMBLY
Scheme 274: DISASSEMBLY

Scheme 275

Scheme 275
Scheme 275

Scheme 276

Scheme 276
Scheme 276

Scheme 277

Scheme 277
Scheme 277
  1. Remove the seal ring.
  2. Remove the ball bearing using the ST and the press. ST 498077600 REMOVER
  3. Use a flat tip screwdriver to remove the snap ring, and then take out the pressure plate, retaining plate, drive plate and driven plate.
  4. Using the ST1, ST2 and ST3, remove the snap ring, then take out the return spring and transfer clutch piston seal. ST1 399893600 PLIERS ST2 398673600 COMPRESSOR ST3 398623600 SEAT
  5. Use an air compressor to blow compressed air from the rear drive shaft to remove the transfer clutch piston.

Scheme 278

Scheme 278
Scheme 278

Scheme 279

Scheme 279: ASSEMBLY
Scheme 279: ASSEMBLY

Scheme 280

Scheme 280
Scheme 280

Scheme 281

Scheme 281
Scheme 281

Scheme 282

Scheme 282
Scheme 282

Scheme 283

Scheme 283
Scheme 283

Scheme 284

Scheme 284
Scheme 284

Scheme 285

Scheme 285
Scheme 285

Scheme 286

Scheme 286
Scheme 286

Scheme 287

Scheme 287
Scheme 287

Scheme 288

Scheme 288
Scheme 288
  1. Install the transfer clutch piston.
  2. Install the return spring to transfer clutch piston.
  3. Install the transfer clutch piston seal.
  4. Attach the ST to the rear drive shaft. ST 499257300 SNAP RING OUTER GUIDE
  5. Install the snap ring to the ST. ST 499257300 SNAP RING OUTER GUIDE
  6. Install the snap ring to the rear drive shaft using ST1 and ST2. ST1 499257300 SNAP RING OUTER GUIDE ST2 499247400 INSTALLER
  7. Install the drive plate, driven plate, pressure plate, retaining plate and snap ring.
  8. Use an air compressor to apply compressed air to see if the assembled parts move smoothly.
  9. Check clearance between the snap ring and pressure plate. INSPECTION TRANSFER CLUTCH. >
  10. Press-fit new ball bearing using ST. ST 899580100 INSTALLER
  11. Apply vaseline to a new seal ring and attach to the seal ring groove of the rear drive shaft. NOTE: While installing the seal ring, not to stretch the seal ring excessively.
  12. Install the transfer clutch assembly while taking care not to damage the seal ring.

Scheme 289

Scheme 289
Scheme 289

Remove the multi-plate clutch following the same instructions as for the extension case. REMOVAL EXTENSION CASE. >

Install the multi-plate clutch following the same instructions as for the extension case. INSTALLATION EXTENSION CASE. >

  1. Select the shim. VTD MODEL ADJUSTMENT, TRANSFER CLUTCH. >
  2. Install drive plate and driven plate.
  3. Insert the rear driveshaft into the center differential assembly.
  4. Join the transmission case and the extension case, and then install the rear vehicle speed sensor. INSTALLATION EXTENSION CASE. >
  5. Install the transmission assembly to the vehicle. INSTALLATION AUTOMATIC TRANSMISSION ASSEMBLY. >

Scheme 290

Scheme 290: DISASSEMBLY
Scheme 290: DISASSEMBLY
  1. Using a press, remove the revolution gear.
  2. Using a press, remove the front and rear side ball bearings and clutch hub.

Scheme 291

Scheme 291
Scheme 291
  1. Remove the transmission assembly from vehicle body. REMOVAL AUTOMATIC TRANSMISSION ASSEMBLY. >
  2. Remove the rear wheel speed sensor, and separate the extension case from transmission case. REMOVAL EXTENSION CASE. >
  3. Remove the reduction drive gear. REMOVAL REDUCTION DRIVE GEAR. >
  4. Remove the parking pawl, return spring and shaft.

Scheme 292

Scheme 292
Scheme 292

Scheme 293

Scheme 293: INSTALLATION
Scheme 293: INSTALLATION
  1. Install the parking pawl, return spring and shaft.
  2. Install the reduction drive gear. INSTALLATION REDUCTION DRIVE GEAR. >
  3. Install the rear vehicle speed sensor and extension case. INSTALLATION EXTENSION CASE. >
  4. Install the transmission assembly to the vehicle. INSTALLATION AUTOMATIC TRANSMISSION ASSEMBLY. >
  1. Remove the transmission assembly from vehicle body. REMOVAL AUTOMATIC TRANSMISSION ASSEMBLY. >
  2. Pull out the torque converter clutch assembly. REMOVAL TORQUE CONVERTER CLUTCH ASSEMBLY. >
  3. Remove the input shaft.
  4. Lift-up the lever on the rear side of transmission harness connector, and then disconnect it from the stay.
  5. Disconnect the inhibitor switch connector from the stay.
  6. Disconnect the air breather hose. REMOVAL AIR BREATHER HOSE. >
  7. Remove the oil charger pipe. REMOVAL OIL CHARGER PIPE. >
  8. Remove the ATF cooler inlet and outlet pipes. REMOVAL ATF COOLER PIPE AND HOSE. >
  9. Separate the converter case and transmission case. REMOVAL CONVERTER CASE. >
  10. Separate the transmission case and extension case section. REMOVAL EXTENSION CASE. >
  11. Remove the reduction drive gear. REMOVAL REDUCTION DRIVE GEAR. >
  12. Remove the reduction driven gear. REMOVAL REDUCTION DRIVEN GEAR. >
  13. Remove the drive pinion shaft mounting bolt and remove the drive shaft assembly from oil pump housing.

Scheme 294

Scheme 294
Scheme 294
  1. Assemble the drive pinion assembly to the oil pump housing. NOTE: Be careful not to bend the shim. Be careful not to press-fit the pinion into housing bore. Tightening torque: 40 N.m (4.1 kgf-m, 29.5 ft-lb)
  2. Join the converter case with the transmission case. INSTALLATION CONVERTER CASE. >
  3. Install the reduction driven gear. INSTALLATION REDUCTION DRIVEN GEAR. >
  4. Install the reduction drive gear. INSTALLATION REDUCTION DRIVE GEAR. >
  5. Join the transmission case and the extension case. INSTALLATION EXTENSION CASE. >
  6. Insert the inhibitor switch and transmission connector to the stay.
  7. Install the air breather hose. INSTALLATION AIR BREATHER HOSE. >
  8. Install the ATF cooler inlet and outlet pipes. INSTALLATION ATF COOLER PIPE AND HOSE. >
  9. Install the oil charger pipe along with the O-ring.
  10. Insert the input shaft while rotating it lightly by hand, and then check the amount of protrusion. Normal protrusion A: 50 - 55 mm (1.97 - 2.17 in)
  11. Install the torque converter clutch assembly. INSTALLATION TORQUE CONVERTER CLUTCH ASSEMBLY. >
  12. Install the transmission assembly to the vehicle. INSTALLATION AUTOMATIC TRANSMISSION ASSEMBLY. >

Scheme 295

Scheme 295: DISASSEMBLY
Scheme 295: DISASSEMBLY

Scheme 296

Scheme 296
Scheme 296
  1. Lift the crimped part of the locknut, and then remove the lock nut while holding the rear spline part of the drive pinion shaft using ST1 and ST2. Pull out the drive pinion collar. ST1 498937110 HOLDER ST2 499787700 WRENCH ST3 499787500 ADAPTER
  2. Remove the O-ring.
  3. Separate the roller bearing and outer race from the drive pinion shaft using a press.
  4. Separate the front roller bearing from the drive pinion shaft using a press and the ST. ST 498517000 REPLACER

Scheme 297

Scheme 297
Scheme 297

Scheme 298

Scheme 298: ASSEMBLY
Scheme 298: ASSEMBLY

Scheme 299

Scheme 299
Scheme 299

Scheme 300

Scheme 300
Scheme 300

Scheme 301

Scheme 301
Scheme 301

Scheme 302

Scheme 302
Scheme 302
  1. Measure the dimension "A" of drive pinion shaft. ST 398643600 GAUGE
  2. Using a press, press-fit the new roller bearing into the specified position. NOTE: If excessive force is applied to roller bearing, the roller bearing will not turn easily.
  3. After fitting a new O-ring to the drive pinion shaft, attach the drive pinion collar to the drive pinion shaft.
  4. Install the lock washer to drive pinion shaft in the proper direction.
  5. Tighten the new lock nuts using ST1, ST2 and ST3. Calculate the lock washer and lock nut specifications using following formula. T2 = L2/(L1 + L2) x T1 T1: 116 N.m (11.8 kgf-m, 85.3 ft-lb) [Required torque setting] T2: Tightening torque L1: ST2 length 0.072 m (2.83 in) L2: Torque wrench length Example: TIGHTENING TORQUE Torque wrench length m (in) Tightening torque N.m( kgf-m, ft-lb) 0.4 (15.75) 98(10.0,72.3) 0.45 (17.72) 100(10.2,73.5) 0.5(19.69) 101 (10.3,74.6) 0.55 (21.65) 102(10.4,75.4) ST1 498937110 Holder ST2 499787700 WRENCH ST3 499787500 Adapter NOTE: Attach ST2 to torque wrench as straight as possible.
  6. Measure the starting torque of the bearing. Make sure the starting torque is within the specified range. If the torque is not within specified range, replace the roller bearing. Starting torque: MPT model 7.6 - 38.1 N (0.776 - 3.88 kgf, 1.7 - 8.6 lb) VTD model 6.8 - 47.5 N (0.69 - 4.84 kgf, 1.52 - 70.67 lb)
  7. Crimp the locknut in 2 locations.
  8. Measure dimension "B" of drive pinion shaft ST 398643600 GAUGE
  9. Calculate the thickness "t" (mm) of the drive pinion shim. t = 6.5±0.0625 - (B - A)
  10. Select three or less shims from following table. DRIVE PINION SHIM THICKNESS Drive pinion shim Part No. Thickness mm (in) 31451AA050 0.150(0.0059) 31451AA060 0.175(0.0069) 31451AA070 0.200 (0.0079) 31451AA080 0.225 (0.0089) 31451AA090 0.250 (0.0098) 31451AA100 0.275(0.0108)
  1. Remove the transmission assembly from vehicle body. REMOVAL AUTOMATIC TRANSMISSION ASSEMBLY. >
  2. Pull out the torque converter clutch assembly. REMOVAL TORQUE CONVERTER CLUTCH ASSEMBLY. >
  3. Remove the input shaft.
  4. Lift-up the lever on the rear side of transmission harness connector, and then disconnect it from the stay.
  5. Disconnect the inhibitor switch from the stay.
  6. Remove the oil charger pipe. REMOVAL OIL CHARGER PIPE. >
  7. Remove the ATF cooler inlet and outlet pipes. REMOVAL ATF COOLER PIPE AND HOSE. >
  8. Separate the converter case from the transmission case. REMOVAL CONVERTER CASE. >
  9. Remove the seal pipe.
  10. Remove the differential side retainers using ST. NOTE: Hold the differential case assembly by hand to avoid damaging the retainer mounting hole of the converter case. ST 499787000 WRENCH ASSY
  11. Remove the differential assembly while being careful not to damage the attachment part of retainer.

Scheme 303

Scheme 303: INSTALLATION
Scheme 303: INSTALLATION

Scheme 304

Scheme 304
Scheme 304

Scheme 305

Scheme 305
Scheme 305

Scheme 306

Scheme 306
Scheme 306
  1. Install the differential assembly to the torque converter clutch case. CAUTION: Do not damage the inside of the torque converter clutch case (particularly the mating surface of the differential side retainer).
  2. Install the O-ring to the left and right side differential side retainer.
  3. Using the ST, install the side retainer. INSTALLATION FRONT DIFFERENTIAL ASSEMBLY. > ST 499787000 WRENCH ASSY
  4. Adjust the backlash of the front differential. ADJUSTMENT FRONT DIFFERENTIAL ASSEMBLY. >
  5. Install the lock plate. Tightening torque: 25 N.m (2.5 kgf-m, 18.1 ft-lb)
  6. Install new seal pipe to converter case.
  7. Install the converter case to the transmission case. INSTALLATION CONVERTER CASE. >
  8. Insert the inhibitor switch and transmission connector to the stay.
  9. Install the ATF cooler pipe. INSTALLATION ATF COOLER PIPE AND HOSE. >
  10. Install the oil charger pipe along with the O-ring. INSTALLATION OIL CHARGER PIPE. >
  11. Insert the input shaft while rotating it lightly by hand, and then check the amount of protrusion. Normal protrusion A: 50 - 55 mm (1.97 - 2.17 in)
  12. Install the torque converter clutch assembly. INSTALLATION TORQUE CONVERTER CLUTCH ASSEMBLY. >
  13. Install the transmission assembly to the vehicle. INSTALLATION AUTOMATIC TRANSMISSION ASSEMBLY. >

Scheme 307

Scheme 307: DIFFERENTIAL CASE ASSEMBLY
Scheme 307: DIFFERENTIAL CASE ASSEMBLY

Scheme 308

Scheme 308
Scheme 308

Scheme 309

Scheme 309
Scheme 309
  1. Remove the taper roller bearing using the ST and a press. ST 498077000 REMOVER
  2. Secure the case in a vise and remove the hypoid driven gear tightening bolts. Then separate the hypoid driven gear into the differential case (RH) and the differential case (LH).
  3. Pull out the straight pin and pinion shaft, and then remove the differential bevel gear, washer and differential bevel pinion.

More articles — Automatic Transmission