Automatic Transmission 4AT (Except Sti): Removal & Installation Subaru Impreza GH

INSTALLATION

Install in the reverse order of removal.

Note. Replace O-ring with a new part.

Tightening torque

7 N.m (0.7 kgf-m, 5.2 ft-lb)

REMOVAL

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

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

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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) to drain ATF. CAUTION: Directly after the vehicle has been running or the engine has been long idle running, the ATF is hot. Be careful not to burn yourself.
6. Perform replacement with a new gasket, and tighten the drain plug (ATF). Tightening torque: 25 N.m (2.5 kgf-m, 18.4 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 strainer tightening bolt, and remove control valve strainer from the control valve body.

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Scheme 283

1. Check the control valve body for dust and other foreign matter.
2. Attach a new control valve strainer to the control valve body. Apply ATF to the entire perimeter of the O-ring on the control valve strainer. CAUTION: When applying ATF, avoid adhesion of dust and foreign matter on the O-ring. Install the control valve strainer to the control valve body from the O-ring side. CAUTION: If the control valve strainer is pushed in at an angle, the O-ring may be damaged. Be sure to push in the control valve strainer straight to install. Tighten the three bolts. Tightening torque: 10 N.m (1.0 kgf-m, 7.4 ft-lb)
3. Attach the magnet at the specified position of the oil pan.
4. Apply proper amount of liquid gasket to the entire oil pan mating surface. Liquid gasket: THREE BOND 1217B (Part No. K0877YA020) or equivalent
5. Fill the 3 holes aside from the bolt holes in the transmission case, with liquid gasket. Liquid gasket: THREE BOND 1217B (Part No. K0877YA020) or equivalent
6. Install the oil pan by equally tightening the bolts. Tightening torque: 5 N.m (0.5 kgf-m, 3.7 ft-lb)
7. Fill ATF from the oil charge pipe. Ref. to «AUTOMATIC TRANSMISSION FLUID»(ref-357244-S28388939882010031100000) .
8. Bleed the air of control valve. Ref. to «PROCEDURE»(ref-357244-S28262219292010031100000) in Air Bleeding of Control Valve.
9. Check the ATF level. Ref. to «INSPECTION»(ref-357244-S25560399872010031100000) in Automatic Transmission Fluid.

1. 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)
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. NOTE: Install so that the hose is not folded over, excessively bent or twisted. Insert the hose to the specified position.
5. Install the heat shield cover. Tightening torque: 3 N.m (0.3 kgf-m, 2.2 ft-lb)
6. Install the under cover.
7. Install the battery.
8. Fill ATF. Ref. to «AUTOMATIC TRANSMISSION FLUID»(ref-357244-S28388939882010031100000) . 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) Ref. to «REMOVAL»(ref-357233-S01318946012010031100000) in Air Intake Chamber.
2. Remove the intercooler. (Turbo model) Ref. to «REMOVAL»(ref-357235-S29312200482010031100000) in Intercooler.
3. Remove the oil charge pipe, and then remove the O-ring from the flange side.

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1. 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)
2. Install the air intake chamber. (Non-turbo model) Ref. to «INSTALLATION»(ref-357233-S09562650492010031100000) in Air Intake Chamber.
3. Install the intercooler. (Turbo model)

Ref. to INSTALLATION in Inter-cooler.

1. Remove the transmission assembly from vehicle body. Ref. to «REMOVAL»(ref-357244-S28652167702010031100000) in Automatic Transmission Assembly.
2. Remove the extension case, and then remove the transfer clutch. Ref. to «REMOVAL»(ref-357244-S13918428892010031100000) in Extension Case. Ref. to «DISASSEMBLY»(ref-357244-S25073634272010031100000) in Extension Case.

Scheme 286

1. Select the thrust needle bearing. Ref. to «ADJUSTMENT»(ref-357244-S26059544462010031100000) in 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, 18.4 ft-lb)
4. Install the transmission assembly to the vehicle. Ref. to «INSTALLATION»(ref-357244-S02478580012010031100000) in Automatic Transmission Assembly.

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1. Remove the seal ring.
2. Remove the ball bearing using the ST and the press. ST 498077600 REMOVER
3. Using a flat tip screwdriver, etc. remove the snap ring, and take out the 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 PLIER ST2 398673600 COMPRESSOR ST3 398623600 SEAT
5. Apply compressed air to the rear drive shaft, to remove the transfer clutch piston.

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1. Install the transfer clutch piston.
2. Install the return spring to transfer clutch piston.
3. Apply ATF to the lip of transfer clutch piston seal, then install.
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 driven plate, drive plate, retaining plate and snap ring.
8. Apply compressed air to see if the assembled parts move smoothly.
9. Check the clearance between the snap ring and retaining plate. Ref. to «INSPECTION»(ref-357244-S30689502292010031100000) in 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 302

1. Remove the transmission assembly from the vehicle. Ref. to «REMOVAL»(ref-357244-S28652167702010031100000) in Automatic Transmission Assembly.
2. Remove the rear vehicle speed sensor, and separate the extension case from transmission case. Ref. to «REMOVAL»(ref-357244-S13918428892010031100000) in Extension Case.
3. Remove the reduction driven gear. Ref. to «REMOVAL»(ref-357244-S30056105302010031100000) in Reduction Driven Gear.
4. Using the ST, extract the reduction drive gear assembly.

ST1 499737100 PULLER SET

ST2 899524100 PULLER SET

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Scheme 304

1. Install the reduction drive gear assembly. NOTE: Press-fit it to the bottom of bearing shoulder completely.
2. Install the reduction driven gear. Ref. to «INSTALLATION»(ref-357244-S25128206772010031100000) in Reduction Driven Gear.
3. Join the transmission case and the extension case, and then install the rear vehicle speed sensor. Ref. to «INSTALLATION»(ref-357244-S38397958152010031100000) in Extension Case.
4. Install the transmission assembly to the vehicle. Ref. to «INSTALLATION»(ref-357244-S02478580012010031100000) in Automatic Transmission Assembly.

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Scheme 307

1. Take out the seal ring.
2. Remove the ball bearing using ST. ST 498077600 REMOVER
3. Apply vaseline to the outer surface of seal ring and shaft groove.

1. Remove the transmission assembly from vehicle body. Ref. to «REMOVAL»(ref-357244-S28652167702010031100000) in Automatic Transmission Assembly.
2. Remove the rear wheel speed sensor, and separate the extension case from transmission case. Ref. to «REMOVAL»(ref-357244-S13918428892010031100000) in Extension Case.
3. Remove the reduction drive gear. Ref. to «REMOVAL»(ref-357244-S16396160072010031100000) in Reduction Drive Gear.
4. Remove the parking pawl, return spring and shaft.

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Scheme 309

1. Install the parking pawl, return spring and shaft.
2. Install the reduction drive gear. Ref. to «INSTALLATION»(ref-357244-S12190902592010031100000) in Reduction Drive Gear.
3. Install the rear vehicle speed sensor and extension case. Ref. to «INSTALLATION»(ref-357244-S38397958152010031100000) in Extension Case.
4. Install the transmission assembly to the vehicle. Ref. to «INSTALLATION»(ref-357244-S02478580012010031100000) in Automatic Transmission Assembly.

1. Remove the transmission assembly from vehicle body. Ref. to «REMOVAL»(ref-357244-S28652167702010031100000) in Automatic Transmission Assembly.
2. Pull out the torque converter clutch assembly. Ref. to «REMOVAL»(ref-357244-S10608289762010031100000) in 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. Ref. to «REMOVAL»(ref-357244-S36826719922010031100000) in Air Breather Hose.
7. Remove the oil charge pipe. Ref. to «REMOVAL»(ref-357244-S11586835642010031100000) in Oil Charge Pipe.
8. Remove the ATF inlet and outlet pipes. Ref. to «REMOVAL»(ref-357244-S07030250202010031100000) in ATF Cooler Pipe and Hose.
9. Separate the converter case and transmission case. Ref. to «REMOVAL»(ref-357244-S13290346142010031100000) in Converter Case.
10. Separate the transmission case and extension case section. Ref. to «REMOVAL»(ref-357244-S13918428892010031100000) in Extension Case.
11. Remove the reduction drive gear. Ref. to «REMOVAL»(ref-357244-S16396160072010031100000) in Reduction Drive Gear.
12. Remove the reduction driven gear. Ref. to «REMOVAL»(ref-357244-S30056105302010031100000) in Reduction Driven Gear.
13. Remove the drive pinion shaft mounting bolt and remove the drive shaft assembly from oil pump housing.

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Scheme 311

1. Assemble the drive pinion shaft 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. Ref. to «INSTALLATION»(ref-357244-S02121612852010031100000) in Converter Case.
3. Install the reduction driven gear. Ref. to «INSTALLATION»(ref-357244-S25128206772010031100000) in Reduction Driven Gear.
4. Install the reduction drive gear. Ref. to «INSTALLATION»(ref-357244-S12190902592010031100000) in Reduction Drive Gear.
5. Join the transmission case and the extension case, and then install the rear vehicle speed sensor. Ref. to «INSTALLATION»(ref-357244-S38397958152010031100000) in Extension Case.
6. Insert the inhibitor switch connector and transmission harness connector onto the stay.
7. Install the air breather hose. Ref. to «INSTALLATION»(ref-357244-S39475366072010031100000) in Air Breather Hose.
8. Install the ATF inlet and outlet pipes. Ref. to «INSTALLATION»(ref-357244-S17502157812010031100000) in ATF Cooler Pipe and Hose.
9. Install the oil charge pipe with 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. Ref. to «INSTALLATION»(ref-357244-S41481035742010031100000) in Torque Converter Clutch Assembly.
12. Install the transmission assembly to the vehicle. Ref. to «INSTALLATION»(ref-357244-S02478580012010031100000) in Automatic Transmission Assembly.

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1. Flatten the lock nut tab, 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 rear 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

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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. CAUTION: Damage may result if too much force is applied to the roller bearing.
3. After applying ATF to a new O-ring and attaching it 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 a new lock nut using the ST. 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, 85.6 ft-lb) [Required torque setting] T2: Tightening torque L1: ST2 length 0.072 m (2.83 in) L2: Torque wrench length Example: TORQUE REFERENCE CHART 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 (10.2,73.8) 0.5 (19.69) 101 (10.3,74.5) 0.55 (21.65) 102 (10.4,75.2) 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: 7.6 - 38.1 N (0.775 - 3.88 kgf, 1.7 - 8.6 lb)
7. Crimp the locknut in 2 locations.
8. Measure the dimension "B" of the drive pinion shaft. ST 398643600 GAUGE
9. Calculate the thickness "t" mm (in) of the drive pinion shim. t = 6.5±0.0625 (0.256±0.0025) - (B - A)
10. Select three or less shims from following table. DRIVE PINION SHIM REFERENCE CHART 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 the vehicle. Ref. to «REMOVAL»(ref-357244-S28652167702010031100000) in Automatic Transmission Assembly.
2. Pull out the torque converter clutch assembly. Ref. to «REMOVAL»(ref-357244-S10608289762010031100000) in Torque Converter Clutch Assembly.
3. Remove the input shaft.
4. Lift up the lever on the rear side of transmission harness connector, and then remove it from the stay.
5. Remove the inhibitor switch connector from the stay.
6. Remove the oil charge pipe. Ref. to «REMOVAL»(ref-357244-S11586835642010031100000) in Oil Charge Pipe.
7. Remove the ATF inlet and outlet pipes. Ref. to «REMOVAL»(ref-357244-S07030250202010031100000) in ATF Cooler Pipe and Hose.
8. Separate the converter case from the transmission case. Ref. to «REMOVAL»(ref-357244-S13290346142010031100000) in Converter Case.
9. Remove the seal pipe.
10. Remove the differential side retainers using ST. ST 18630AA010 WRENCH COMPL RETAINER NOTE: ST WRENCH ASSEMBLY (499787000) can also be used. Hold the differential case assembly by hand to avoid damaging the retainer mounting hole of the converter case.
11. Remove the front differential assembly while being careful not to damage the attachment part of the retainer.

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1. Install the front differential assembly to the converter case. NOTE: Be careful not to damage the inside of the converter case (especially the mating surface of the differential side retainer).
2. Install the O-ring to left and right side differential retainers.
3. Install the differential side retainers using ST. Ref. to «ADJUSTMENT»(ref-357244-S20568824732010031100000) in Front Differential Assembly. ST 18630AA010 WRENCH COMPL RETAINER NOTE: ST WRENCH ASSEMBLY (499787000) can also be used.
4. Adjust the backlash of the front differential. Ref. to «ADJUSTMENT»(ref-357244-S20568824732010031100000) in Front Differential Assembly.
5. Install the lock plate. Tightening torque: 25 N.m (2.5 kgf-m, 18.4 ft-lb)
6. Install new seal pipe to converter case.
7. Install the converter case to the transmission case. Ref. to «INSTALLATION»(ref-357244-S02121612852010031100000) in Converter Case.
8. Insert the inhibitor switch connector and transmission harness connector onto the stay.
9. Install the ATF cooler pipe. Ref. to «INSTALLATION»(ref-357244-S17502157812010031100000) in ATF Cooler Pipe and Hose.
10. Install the oil charge pipe together with an O-ring. Ref. to «INSTALLATION»(ref-357244-S40766461582010031100000) , Oil Charge 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. Ref. to «INSTALLATION»(ref-357244-S41481035742010031100000) in Torque Converter Clutch Assembly.
13. Install the transmission assembly to the vehicle. Ref. to «INSTALLATION»(ref-357244-S02478580012010031100000) in Automatic Transmission Assembly.

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Scheme 326

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

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