PROCEDURE

Shift the select lever to "P" range, and apply the parking brake.
Lift up the vehicle. NOTE: When air bleeding the control valve, the lower part of the tire is to be lifted more than 30 cm above the ground.
Connect the Subaru Select Monitor to the data link connector, then turn the ignition switch to ON (engine OFF).
Perform {Clear Memory} using the Subaru Select Monitor. CLEAR MEMORY MODE , OPERATION, Subaru Select Monitor . >
Using Subaru Select Monitor, check that there is no DTC displayed. READ DIAGNOSTIC TROUBLE CODE (DTC) , OPERATION, Subaru Select Monitor . >
Check that the ATF temperature displayed on Subaru Select Monitor is 60°C (140°F) or less. READ CURRENT DATA , OPERATION, Subaru Select Monitor . >
Shift the select lever to "R" range.
Turn the ignition key to OFF.
When "communication error occurred." is displayed on Subaru Select Monitor, select [OK], and when "Store the data before communication error occurred?" appears, select [NO] and exit the Subaru Select Monitor.
Fully depress the brake pedal until the control valve air bleeding work is completed.
Turn the ignition switch to ON (engine OFF).
Shift the select lever to the "P" range, and wait for 3 seconds or more.
Shift the select lever to the "R" range, and wait for 3 seconds or more.
Shift the select lever to the "N" range, and wait for 3 seconds or more.
Shift the select lever to the "D" range, and wait for 3 seconds or more.
Shift the select lever to the "N" range, and wait for 3 seconds or more.
Slowly depress the accelerator pedal to full throttle.
Slowly release the accelerator pedal to full close.
Start the engine, and idle it.
Shift the select lever to "D" range.
Set the Subaru Select Monitor to the current data read status. READ CURRENT DATA , OPERATION, Subaru Select Monitor . >
Start the control valve air bleed operation. At this time, the SPORT indicator light in the combination meter will start blinking at 2 Hz. When the SPORT indicator light does not blink, turn the ignition switch to OFF and repeat the procedures from step 4 ). When the SPORT indicator light that was flashing at 2 Hz turns off, the control valve air bleed operation is complete. NOTE: When flashing of the SPORT indicator light changes from 2 Hz to 4 Hz during control valve air bleed, repeat the procedures from step 4 ).
Shift the select lever to "N" range, and then turn the ignition switch to OFF.
Shift the select lever to "P" range.

Note. The ATF filter is maintenance free.

Lift up the vehicle.
Using the ST, remove the ATF filter.

ST 498545400 OIL FILTER WRENCH

Scheme 151

Apply a thin coat of ATF to the oil seal part of new ATF filter.
Install the ATF filter. Turn it by hand, being careful not to damage oil seal.
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, 10.3 ft-lb) [Required torque setting] T2: Tightening torque L1: ST length 78 mm (3.07 in) L2: Torque wrench length Example: TIGHTENING TORQUE REFERENCE 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) 10 (1.0,7.2) NOTE: Align the ST with the torque wrench while tightening the ATF filter. ST 498545400 OIL FILTER WRENCH
Fill ATF.
Inspect the level of ATF. AUTOMATIC TRANSMISSION FLUID. >

Check for rust, hole, ATF leaks or other damage.

Scheme 152

Scheme 152: REMOVAL

Disconnect the ground cable from the battery.
Remove the instrument panel lower cover and disconnect the connector.
Disconnect the connector from TCM.
Remove the TCM.

Scheme 153

Scheme 153: INSTALLATION

Install the TCM. Tightening torque: 7.5 N.m (0.76 kgf-m, 5.5 ft-lb)
Connect the connector to the TCM.
Install in the reverse order of removal.
Execute the learning control promotion. FACILITATION OF LEARNING CONTROL , OPERATION, Subaru Select Monitor . >

Scheme 154

Scheme 154: REMOVAL

Scheme 155

Scheme 156

Set the vehicle on a lift.
Remove the battery.
Lift up the vehicle.
Remove the under cover.
Remove the heat shield cover.
Disconnect the ATF cooler hose from the radiator. NOTE: Do not use a screwdriver or other pointed tools. If it is hard to remove the hose, wrap the hose with cloth to prevent from damaging it, and while turning with pliers, pull straight out by hand.
Disconnect the ATF cooler hoses from the pipes. NOTE: Do not use a screwdriver or other pointed tools. If it is hard to remove the hose, wrap the hose with cloth to prevent from damaging it, and while turning with pliers, pull straight out by hand.
Disconnect the ATF cooler pipe from frame.
Remove the ATF inlet pipe and outlet pipe.

CAUTION

When disconnecting the outlet pipe, be careful not to lose the ball and spring used together with the retaining screw.

Scheme 157

Install the ATF inlet pipe and outlet pipe along with new washers. Tightening torque: T1: 25 N.m (2.5 kgf-m, 18.4 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)
Install the ATF cooler pipe to frame.
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.
Connect the ATF cooler hose to the pipe on the radiator side. NOTE: Install so that the hose is not folded over, excessively bent or twisted. Insert the hose to the specified position.
Install the heat shield cover. Tightening torque: 3 N.m (0.3 kgf-m, 2.2 ft-lb)
Install the under cover.
Install the battery.
Fill ATF. AUTOMATIC TRANSMISSION FLUID. >

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

Repair or replace any faulty hoses, pipes, clamps, and washers found in the inspection below.

Check for ATF leaks in joints between the transmission, radiator, pipes, and hoses.
Check the clamp for deformation.
Lightly bend the hose and check for cracks in the surface or other damages.
Pinch the hose with your fingers and check for poor elasticity. Also check for poor elasticity in the parts where the clamp was installed by pressing with your fingernail.
Check for peeling, cracks, and deformation at the tip of the hose.

Scheme 158

Scheme 158: REMOVAL

Scheme 159

Remove the air intake chamber. (Non-turbo model) REMOVAL , Air Intake Chamber for H4SO engine. >
Remove the intercooler. (Turbo model) REMOVAL , Intercooler for H4DOTC engine. >
Disconnect the air breather hose. Non-turbo model Turbo model

Scheme 160

Scheme 160: INSTALLATION

Scheme 161

Install the air breather hose. Non-turbo model Turbo model
Install the air intake chamber. (Non-turbo model) INSTALLATION , Air Intake Chamber for H4SO engine. >
Install the intercooler. (Turbo model)

INSTALLATION , Inter-cooler for H4DOTC engine. >

Make sure the hose is not cracked or clogged.

Scheme 162

Scheme 162: REMOVAL

Remove the air intake chamber. (Non-turbo model) REMOVAL , Air Intake Chamber for H4SO engine. >
Remove the intercooler. (Turbo model) REMOVAL , Intercooler for H4DOTC engine. >
Remove the oil charge pipe, and then remove the O-ring from the flange side.

Scheme 163

Scheme 163: INSTALLATION

Apply ATF on a new O-ring and install together with the oil charge pipe. NOTE: Use a new bolt. Tightening torque: 38 N.m (3.9 kgf-m, 28.0 ft-lb)
Install the air intake chamber. (Non-turbo model) INSTALLATION , Air Intake Chamber for H4SO engine. >
Install the intercooler. (Turbo model)

INSTALLATION , Intercooler for H4DOTC engine. >

Make sure the oil charge pipe is not deformed or damaged.

Scheme 164

Scheme 164: REMOVAL

Scheme 165

Remove the transmission assembly from vehicle body. REMOVAL, Automatic Transmission Assembly. >
Pull out the torque converter clutch assembly and oil pump shaft horizontally. NOTE: Be sure not to scratch the inside of bushing in oil pump shaft.
Remove the input shaft. NOTE: When the torque converter clutch assembly is removed, the input shaft will also come off.
Remove the oil pump shaft from torque converter clutch assembly as necessary.

Scheme 166

Scheme 166: INSTALLATION

Scheme 167

Scheme 168

When the oil pump shaft is removed, install the shaft to converter case.
Install the oil pump shaft to the torque converter clutch assembly, and make sure the clip is secured on the groove.
Apply ATF to the O-ring and insert on the input shaft while rotating the shaft slowly by hand. Normal protrusion A: 50 - 55 mm (1.97 - 2.17 in)
While holding the torque converter clutch assembly by hand, carefully install it to the torque converter case. Take care not to damage the bushing. Do not allow the oil pump shaft bushing to touch the stator shaft section of the oil pump cover inappropriately.
Slowly rotate the shaft by hand to engage the splines securely, then check that dimension A is within the specified range. Dimension A: Non-turbo model 1.1 - 1.3 mm (0.043 - 0.051 in) Turbo model 2.7 - 2.9 mm (0.106 - 0.114 in)
Install the transmission assembly to the vehicle. INSTALLATION, Automatic Transmission Assembly. >

Make sure the ring gear and protrusion of the torque converter clutch assembly end are not deformed or damaged.

Scheme 169

Scheme 169: REMOVAL

Remove the transmission assembly. REMOVAL, Automatic Transmission Assembly. >
Remove the rear vehicle speed sensor.
Separate the transmission case and extension case section.

Scheme 170

Scheme 171

Apply vaseline to the contact surface, and attach the selected thrust needle bearing to the end surface of the reduction drive gear. NOTE: Install the thrust needle bearing in the correct direction.
Install a new gasket.
Install the extension case to transmission case.
Tighten bolts to secure the extension case. Tightening torque: 25 N.m (2.5 kgf-m, 18.4 ft-lb)
Install the rear vehicle speed sensor. Tightening torque: 7 N.m (0.7 kgf-m, 5.1 ft-lb)
Install the transmission assembly.

INSTALLATION, Automatic Transmission Assembly. >

Scheme 172

Scheme 172: DISASSEMBLY

Scheme 173

Hit the extension case lightly with a plastic hammer, and take out the transfer clutch. NOTE: Be careful not to damage the oil seal of the extension case.
Remove the transfer clutch pipe while being careful not to deform the pipe.
Remove the dust cover from extension case.
Remove the oil seal from the extension case.

Scheme 174

Scheme 174: ASSEMBLY

Press-fit the new oil seal using ST and the press. ST 498057300 INSTALLER
Press-fit the dust cover.
Install the transfer clutch pipe to the extension case while being careful not to deform the pipe.
Install the transfer clutch assembly to the case.

Note. Be careful not to damage the seal ring. Insert the transfer clutch assembly all the way to the bottom of the bearing shoulder.

Scheme 175

Blow with compressed air to make sure the transfer clutch pipe and extension case routes are not clogged or leaking.
Inspect the extension end play, and adjust it to within the standard value. ADJUSTMENT, Transfer Clutch. >

Remove the transmission assembly from vehicle body. REMOVAL, Automatic Transmission Assembly. >
Remove the extension case, and then remove the transfer clutch. REMOVAL, Extension Case. > DISASSEMBLY, Extension Case. >

Scheme 176

Scheme 176: INSTALLATION

Select the thrust needle bearing. ADJUSTMENT, Transfer Clutch. >
Install the transfer clutch assembly to the case.
Tighten the bolts to secure the case. Tightening torque: 25 N.m (2.5 kgf-m, 18.4 ft-lb)
Install the transmission assembly to the vehicle. INSTALLATION, Automatic Transmission Assembly. >

Scheme 177

Scheme 177: DISASSEMBLY

Scheme 178

Scheme 179

Scheme 180

Remove the seal ring.
Remove the ball bearing using the ST and the press. ST 498077600 REMOVER
Using a flat tip screwdriver, etc. remove the snap ring, and take out the retaining plate, drive plate and driven plate.
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
Apply compressed air to the rear drive shaft, to remove the transfer clutch piston.

Scheme 181

Scheme 182

Scheme 182: ASSEMBLY

Scheme 183

Scheme 184

Scheme 185

Scheme 186

Scheme 187

Scheme 188

Scheme 189

Scheme 190

Scheme 191

Install the transfer clutch piston.
Install the return spring to transfer clutch piston.
Apply ATF to the lip of transfer clutch piston seal, then install.
Attach the ST to the rear drive shaft. ST 499257300 SNAP RING OUTER GUIDE
Install the snap ring to the ST. ST 499257300 SNAP RING OUTER GUIDE
Install the snap ring to the rear drive shaft using ST1 and ST2. ST1 499257300 SNAP RING OUTER GUIDE ST2 499247400 INSTALLER
Install the driven plate, drive plate, retaining plate and snap ring.
Apply compressed air to see if the assembled parts move smoothly.
Check the clearance between the snap ring and retaining plate. INSPECTION, Transfer Clutch. >
Press-fit new ball bearing using ST. ST 899580100 INSTALLER
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.
Install the transfer clutch assembly while taking care not to damage the seal ring.

Scheme 192

Inspect the drive plate facing for wear and damage.
Make sure the snap ring is not worn and the return spring has no permanent distortion, damage, or deformation.
Inspect the D-ring for damage.
Inspect the extension end play, and adjust it to within the standard value. ADJUSTMENT, Transfer Clutch. >

Scheme 193

Check the clearance between the snap ring and retaining plate.
Before measuring clearance, place same thickness shims on both sides to prevent the retaining plate from tilting.
If the clearance exceeds the service limits, replace the plate set (drive plate and driven plate), and select and adjust a retaining plate to be within the initial standard value. Initial standard: 0.7 - 1.1 mm (0.028 - 0.043 in) Limit thickness: 1.6 mm (0.063 in) RETAINING PLATE REFERENCE Retaining plate Part number Thickness mm (in) 31593AA151 3.3 (0.130) 31593AA161 3.7 (0.146) 31593AA171 4.1 (0.161) 31593AA181 4.5 (0.177)
Check for tight comer braking phenomenon when the vehicle is moved forward with the steering fully turned. If tight corner braking occurs, perform the following procedures. With the steering wheel held at fully turned position, drive the vehicle in "D" range and with vehicle speed at approx. 5 km/h (3 MPH) in both clockwise and counterclockwise directions for approx. ten times each, while repeating acceleration and braking intermittently. If the tight corner braking phenomenon still persists, drive the vehicle again in a circle for several laps.

Scheme 194

Scheme 194: ADJUSTMENT

Scheme 195

Measure the distance "A" from the end of ST to the rear drive shaft using the ST. ST 398643600 GAUGE
Measure distance "B" from the transmission case mating surface to the end of ST using ST1 and ST2. ST1 398643600 GAUGE ST2 499577000 GAUGE
Calculation formula

T = A - B + 35.4 mm

[T = A-B + 1.3937 in]

T: Thrust needle bearing thickness

A: Distance from the end of the ST to end of rear drive shaft

B: Distance from the mating surface of the transmission case to the end of the ST

Thrust needle bearing
Part number	Thickness mm (in)
806536020	3.8 (0.150)
806535030	4.0 (0.157)
806535040	4.2 (0.165)
806535050	4.4 (0.173)
806535060	4.6 (0.181)
806535070	4.8 (0.189)
806535090	5.0 (0.197)

THRUST NEEDLE BEARING REFERENCE

Scheme 196

Scheme 196: REMOVAL

Remove the transmission assembly from vehicle body. REMOVAL, Automatic Transmission Assembly. >
Remove the rear wheel speed sensor, and separate the extension case from transmission case. REMOVAL, Extension Case. >
Set the range select lever to the "P" range.
Lift the crimped section, and then remove the lock nut.
Using the ST1 and ST2, extract the reduction driven gear.

ST1 499737000 PULLER

ST2 899524100 PULLER SET

Scheme 197

Scheme 198

Scheme 198: INSTALLATION

Set the range select lever to the "P" range.
Using a plastic hammer, install the reduction driven gear assembly and the new washer, and tighten the new drive pinion lock nut. Tightening torque: 100 N.m (10.2 kgf-m, 73.8 ft-lb)
After tightening, stake the lock nut securely.
Join the transmission case and the extension case, and then install the rear vehicle speed sensor. INSTALLATION, Extension Case. >
Install the transmission assembly to the vehicle.