On-Vehicle Service & Testing: Overview Subaru Outback BH

Torque Converter Clutch Specifications. Scheme 98

Oil Pump Specifications. Scheme 99

Transmission Control Element Specifications. Scheme 100

Transmission Gear Ratio Specifications. Scheme 101

Planetary Gear And Plate Specifications. Scheme 102

Selector Position Specifications. Scheme 103

Hydraulic Control And Lubrication Specifications. Scheme 104

Cooling And Harness Specifications. Scheme 105

Transfer Specifications. Scheme 106

Final Reduction Specifications. Scheme 107

Engine Brake Operation

1. Check the 3rd gear engine brake when shifting between D and 3rd range while driving in 4th gear of D range [50 to 60 km/h (31 to 37 MPH)].
2. Check the 2nd gear engine brake when shifting between 3 and 2 range while driving in the 3 range 3rd gear [40 to 50 km/h (25 to 31 MPH)].
3. Check the 1st gear engine brake when shifting between 2 and 1 range while driving in the 2 range 2nd gear [20 to 30 km/h ( 12 to 19 MPH)].

Lock-Up Function

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

P Range Operation

Stop the vehicle on an uphill grade of 5% or more and shift to P range. Check that the vehicle does not move when the parking brake is released.

General Information

The stall test is of extreme importance in diagnosing the condition of the automatic transmission and the engine. It should be conducted to measure the engine stall speeds in R and 2 ranges.

Purposes of the stall test

1. To check the operation of the automatic transmission clutch.
2. To check the operation of the torque converter clutch.
3. To check engine performance.

Scheme 108

1. Preparations before test: Check that throttle valve opens fully. Check that engine oil level is correct. Check that coolant level is correct. Check that ATF level is correct. Check that differential gear oil level is correct. Increase ATF temperature to 50 to 80°C (122 to 176°F) by idling the engine for approximately 30 minutes (with select lever set to "N" or "P").
2. Install an engine tachometer at a location visible from the driver's compartment and mark the stall speed range on the tachometer scale.
3. Place the wheel chocks at the front and rear of all wheels and engage the parking brake.
4. Move the manual linkage to ensure it operates properly, and shift the select lever to the 2 range.
5. While forcibly depressing the foot brake pedal, gradually depress the accelerator pedal until the engine operates at full throttle. (Scheme 108): Performing Stall Test
6. When the engine speed is stabilized, read that speed quickly and release the accelerator pedal.
7. Shift the select lever to Neutral, and cool down the engine by idling it for more than one minute.
8. Record the stall speed.
9. If stall speed in 2 range is higher than specifications, low clutch slipping and 2-4 brake slipping may occur. To identify it, conduct the same test as above in D range.
10. Perform the stall tests with the select lever in the R range. NOTE: Do not continue the stall test for MORE THAN FIVE SECONDS at a time (from closed throttle, fully open throttle to stall speed reading). Failure to follow this instruction causes the engine oil and ATF to deteriorate and the clutch and brake to be adversely affected. Be sure to cool down the engine for at least one minute after each stall test with the select lever set in the P or N range and with the idle speed lower than 1,200 rpm. If the stall speed is higher than the specified range, attempt to finish the stall test in as short a time as possible, in order to prevent the automatic transmission from sustaining damage. Stall speed (at sea level): Except OUTBACK: 2,100 - 2,600 rpm OUTBACK (2.5 L model): 2,200 - 2,700 rpm OUTBACK (3.0 L model): 2,000 - 3,500 rpm

Stall Test Diagram. Scheme 109

If the select lever is shifted while the engine is idling, there will be a certain time elapse or lag before the shock can be felt. This is used for checking the condition of the low clutch, reverse clutch, low & reverse brake and one-way clutch.

If the clutch or the brake shows a sign of slippage or shifting sensation is not correct, the line pressure should be checked.

1. Excessive shocks during upshifting or shifting takes place at a higher point than under normal circumstances, may be due to the line pressure being too high.
2. Slippage or inability to operate the vehicle may, in most cases, be due to loss of oil pressure for the operation of the clutch, brake or control valve.

1. Line pressure measurement (under no load) CAUTION: Before measuring line pressure, jack-up all wheels. Maintain temperature of ATF at approximately 50°C (122°F) during measurement. (ATF will reach the above temperature after idling the engine for approximately 30 minutes with select lever in "N" or "P".)
2. Line pressure measurement (under heavy load) CAUTION: Before measuring line pressure, apply both foot and parking brakes with all wheels chocked (Same as for "stall" test conditions). Measure line pressure when select lever is in "R", "2" with engine under stall conditions. Measure line pressure within 5 seconds after shifting the select lever to each position. (If line pressure needs to be measured again, allow the engine to idle and then stop. Wait for at least one minute before measurement.) Maintain the temperature of ATF at approximately 50°C (122°F) during measurement. (ATF will reach the above temperature after idling the engine for approximately 30 minutes with the select lever in "N" or "P".)

Scheme 110

Scheme 111

Scheme 112

1. Temporarily attach the ST to a suitable place in the driver's compartment, remove the blind plug located in front of the toe board and pass the hose of the ST to the engine compartment. ST 498575400 OIL PRESSURE GAUGE ASSY (Scheme 110): Attaching Oil Pressure Gauge Assy
2. Remove the test plug and install ST instead. ST 498897200 OIL PRESSURE GAUGE ADAPTER (Scheme 111): Installing ST 498897200 Oil Pressure Gauge Adapter
3. Connect ST1 with ST2. ST1 498897200 OIL PRESSURE GAUGE ADAPTER ST2 498575400 OIL PRESSURE GAUGE ASSY
4. Check for duty ratio changes by opening and closing throttle valve using Subaru Select Monitor. Insert the cartridge to Subaru Select Monitor. See «PREPARATION TOOL»(ref-175581-S34279534152005042200000). (Scheme 112): Inserting The Cartridge To Subaru Select Monitor Connect Subaru Select Monitor to data link connector.
5. Check line pressure in accordance with the following chart.

Evaluating Line Pressure. Scheme 113

Scheme 114

Scheme 115

1. Except VTD model Check transfer clutch pressure in accordance with the following chart in the same manner as with line pressure. ST 498897700 OIL PRESSURE ADAPTER SET ST 498575400 OIL PRESSURE GAUGE ASSY AWD mode: "D" range FWD mode: "P" range, engine speed 2,000 rpm CAUTION: Before setting in FWD mode, install spare fuse on FWD mode switch. (Scheme 114): Locating Test Plug (Except VTD Model)
2. VTD model Check transfer clutch pressure in accordance with the following chart in the same manner as with line pressure. ST 498897700 OIL PRESSURE ADAPTER SET ST 498575400 OIL PRESSURE GAUGE ASSY (Scheme 115): Locating Test Plug (VTD Model)

Scheme 116

Scheme 117

1. Except VTD model 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 116): Evaluating, Except VTD Model
2. VTD model (Scheme 117): Evaluating VTD Model

Scheme 118

Scheme 119

Scheme 120

Scheme 121

Scheme 122

Scheme 123

Scheme 124

Scheme 125

Scheme 126

Scheme 127

Scheme 128

Scheme 129

Scheme 130

Scheme 131

Scheme 132

Scheme 133

Scheme 134

Scheme 135

Scheme 136

Scheme 137

1. Open front hood fully, and support with stay.
2. Disconnect battery ground terminal.
3. Remove air intake duct and cleaner case.
4. Remove air cleaner case stay. (Scheme 118): Removing Air Cleaner Case Stay
5. Disconnect the following connectors. Oxygen sensor connector (Scheme 119): Disconnecting Oxygen Sensor Connector Transmission harness connector (Scheme 120): Disconnecting Transmission Harness Connector Transmission ground terminal
6. Remove starter.
7. Remove pitching stopper. (Scheme 121): Removing Pitching Stopper
8. Separate torque converter clutch from drive plate. Remove service hole plug. Remove bolts which hold torque converter clutch to drive plate. While rotating the engine, remove other bolts using ST. CAUTION: Be careful not to drop bolts into torque converter clutch housing. ST 499977100 CRANK PULLEY WRENCH (Scheme 122): Identifying ST 499977100 Crank Pulley Wrench
9. Install ST to torque converter clutch case. See 9. ST 498277200 STOPPER SET (Scheme 123): Installing ST To Torque Converter Clutch Case
10. Remove ATF level gauge. CAUTION: Plug opening to prevent entry of foreign particles into transmission fluid. (Scheme 124): Remove ATF Level Gauge
11. Set ST. NOTE: Also is available Part No. 927670000. ST 41099AA020 ENGINE SUPPORT ASSY (Scheme 125): Identifying ST 41099AA020 Engine Support Assy
12. Remove bolt which holds right upper side of transmission to engine. (Scheme 126): 2.5 L Model (Scheme 127): 3.0 L Model
13. Remove under cover.
14. Disconnect connector from rear oxygen sensor. (Scheme 128): Disconnect Connector From Rear Oxygen Sensor
15. Remove front and center exhaust pipes.
16. Remove rear exhaust pipe and muffler assembly.
17. Remove heat shield cover. (Scheme 129): Removing Heat Shield Cover
18. Drain ATF. (Scheme 130): Draining ATF
19. Disconnect ATF cooler hoses from pipes of transmission side, and remove ATF level gauge guide. (Scheme 131): Disconnect ATF Cooler Hoses
20. Remove propeller shaft. See «PROPELLER SHAFT»(ref-175738-S22787743532005042600000)..
21. Remove shift select cable. See «SELECT CABLE»(ref-175339-S32654481672005042000000).
22. Remove bolts which install stabilizer clamps onto crossmember. (Scheme 132): Remove Bolts
23. Remove front drive shafts from transmission. See «REMOVAL, DISASSEMBLY, REASSEMBLY & INSTALLATION»(ref-166806-S20324547732004092900000).
24. Remove nuts which hold lower side of transmission to engine. (Scheme 133): 2.5 L Model (Scheme 134): 3.0 L Model
25. Place transmission jack under transmission. CAUTION: Always support transmission case with a transmission jack. On AT vehicles, make sure that the support plates of transmission jack don't touch the oil pan. (Scheme 135): Placing Transmission Jack Under Transmission
26. Remove transmission rear crossmember from vehicle. (Scheme 136): Removing Transmission Rear Crossmember
27. Remove transmission. CAUTION: Move transmission and torque converter as a unit away from engine. (Scheme 137): Removing Transmission
28. Separate transmission assembly and rear cushion rubber.

Scheme 138

Scheme 139

Scheme 140

Scheme 141

Scheme 142

Scheme 143

Scheme 144

Scheme 145

Scheme 146

Scheme 147

Scheme 148

Scheme 149

Scheme 150

Scheme 151

Scheme 152

Scheme 153

1. Install rear cushion rubber to transmission assembly. Tightening torque: 38 N.m (3.9 kgf-m, 28 ft-lb)
2. Install ST to torque converter clutch case. ST 498277200 STOPPER SET (Scheme 138): Installing ST To Torque Converter Clutch Case
3. Install transmission onto engine. Gradually raise transmission with transmission jack. (Scheme 139): Install Transmission Onto Engine Engage them at splines.
4. Install transmission rear crossmember. Tightening torque: T1: 35 N.m (3.6 kgf-m, 26 ft-lb) T2: 75 N.m (7.6 kgf-m, 55 ft-lb) (Scheme 140): Installing Transmission Rear Crossmember
5. Take off transmission jack.
6. Tighten nuts which hold lower side of transmission to engine. Tightening torque: 50 N.m (5.1 kgf-m, 36.9 ft-lb) (Scheme 141): 2.5 L Model (Scheme 142): 3.0 L Model
7. Connect engine and transmission. Remove ST from torque converter clutch case. NOTE: Be careful not to drop the ST into the torque converter clutch case when removing ST. ST 498277200 STOPPER SET Install starter. Tighten bolt which holds right upper side of transmission to engine. Tightening torque: 50 N.m (5.1 kgf-m, 36.9 ft-lb) (Scheme 143): 2.5 L Model (Scheme 144): 3.0 L Model
8. Install torque converter clutch to drive plate. Tighten bolts which hold torque converter clutch to drive plate. Tighten other bolts while rotating the engine by using ST. CAUTION: Be careful not to drop bolts into torque converter clutch housing. ST 499977100 CRANK PULLEY WRENCH Tightening torque: 25+/-2 N.m (2.5+/-0.2 kgf-m, 18.1+/-1.4 ft-lb) (Scheme 145): Tightening Bolts Which Hold Torque Converter & Additional Bolts With ST 499977100 Crank Pulley Wrench Clog plug onto service hole.
9. Remove ST. (Scheme 146): Removing ST
10. Install pitching stopper. Tightening torque: T1: 50 N-m (5.1 kgf-m, 37 ft-Ib) T2: 58 N-m (5.9 kgf-m, 43 ft-Ib) (Scheme 147): Installing Pitching Stopper
11. Install front drive shafts into transmission. Lift-up the vehicle. Install front drive shaft into transmission. Drive spring pin into chamfered hole of drive shaft. CAUTION: Always use a new spring pin. (Scheme 148): Installing Front Drive Shaft Install ball joints of lower arm into knuckle arm of housing, and tighten installing bolts. Tightening torque: 49 N-m (5.0 kgf-m, 36 ft-Ib) (Scheme 149): Installing Ball Joints
12. Install stabilizer clamps onto front crossmember. Tightening torque: 25 N-m (2.5 kgf-m, 18.1 ft-Ib) (Scheme 150): Install Stabilizer Clamps
13. Install shift select cable onto select lever. See «SELECT CABLE»(ref-175339-S32654481672005042000000).
14. Install ATF level gauge guide, and connect ATF cooler hoses to pipe. (Scheme 151): Installing ATF Level Gauge Guide & Connecting ATF Cooler Hose
15. Install propeller shaft. See «REMOVAL, DISASSEMBLY, REASSEMBLY & INSTALLATION»(ref-166806-S20324547732004092900000).
16. Install heat shield cover. (Scheme 152): Install Heat Shield Cover
17. Install rear exhaust pipe to muffler.
18. Install front exhaust pipe and center exhaust pipe.
19. Install under cover.
20. Install ATF level gauge. (Scheme 153): Installing ATF Level Gauge
21. Connect the following connectors. Transmission harness connectors Transmission ground terminal Oxygen sensor connector
22. Connect the following cables. Cruise control cable (With cruise control vehicles)
23. Install air cleaner case stay. Tightening torque: 16 N-m (1.6 kgf-m, 11.6 ft-Ib)
24. Install air cleaner case.
25. Connect battery ground cable.
26. Fill ATF up to the middle of the "COLD" side on level gauge by using the gauge hole. Recommended fluid: Dexron III type automatic transmission fluid Fluid capacity: 9.3 - 9.6 l (9.8 - 10.1 US qt, 8.2 - 8.4 Imp qt)
27. Take off vehicle from lift arms.
28. Check select lever operation. See «Inhibitor Switch»(ref-175581-S35552029852005042200000).
29. Run the vehicle until the ATF temperature rises from 60 to 80°C (140 to 176°F) and check the ATF level of the "HOT" side on level gauge.
30. Check the vehicle on the road tester. See «Road Test»(ref-175581-S37523360162005042200000).

Scheme 154

1. Disconnect battery ground terminal.
2. Remove the air intake duct and cleaner case.
3. Remove the pitching stopper. (Scheme 154): Removing The Pitching Stopper

Scheme 155

Scheme 156

Scheme 157

1. Disconnect battery ground terminal.
2. Jack-up vehicle and support it with sturdy racks.
3. Remove the front center, rear exhaust pipes and muffler. CAUTION: When removing exhaust pipes, be careful each exhaust pipe does not drop out.
4. Remove the heat shield cover. (Scheme 155): Removing The Heat Shield Cover
5. Set the transmission jack under the transmission. CAUTION: Always support transmission case with a transmission jack. On AT vehicle, make sure that the support plates of transmission jack don't touch the oil pan. (Scheme 156): Setting The Transmission Jack Under The Transmission
6. Remove the crossmember. (Scheme 157): Removing The Crossmember
7. Remove the rear cushion rubber.

Scheme 158

1. Install the pitching stopper. Tightening torque: T1: 50 N-m (5.1 kgf-m, 37 ft-Ib) T2: 58 N-m (5.9 kgf-m, 43 ft-Ib) (Scheme 158): Installing The Pitching Stopper
2. Install the air intake duct and cleaner case.

Scheme 159

1. Install the rear cushion rubber. Tightening torque: 38 N-m (3.9 kgf-m, 28 ft-Ib)
2. Install the crossmember. Tightening torque: T1: 35 N-m (3.6 kgf-m, 26 ft-Ib) T2: 75 N-m (7.6 kgf-m, 55 ft-Ib) (Scheme 159): Installing The Crossmember
3. Remove the transmission jack.
4. Install the heat shield cover.
5. Install the front center, rear exhaust pipes and the muffler.