Automatic Transmission: Removal & Installation Subaru Outback BP

INSTALLATION

1. NON-TURBO MODEL When installing the rear vehicle speed sensor, refer to «INSTALLATION»(ref-208395-S10476214332005120700000) , Front Vehicle Speed Sensor.
2. TURBO MODEL 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 REMOVAL .

When installing the torque converter turbine speed sensor, refer to INSTALLATION .

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1. NON-TURBO MODEL Lift-up the vehicle. Clean the transmission exterior. 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) Remove the oil pan. Remove and clean the magnet. Remove the old gasket on the oil pan and transmission case completely. Disconnect each solenoid connector and remove ATF temperature sensor from control valve. Remove the control valve. NOTE: When removing the control valve body, be careful not to interfere with transfer duty solenoid wiring.
2. TURBO MODEL Set the vehicle on a lift. Disconnect the ground cable from battery. Lift-up the vehicle. Clean the transmission exterior. Remove the drain plug and gasket, and then drain ATF. Replace the gasket with a new one, and then tighten the drain plug. Tightening torque: 25 N.m (2.5 kgf.m, 18.1 ft.lb) Remove the oil pan. CAUTION: Be careful not to allow dirt or dust to get into the oil pan. Remove the magnet. Clean the magnet. Remove the liquid gasket completely from oil pan and transmission case. Remove the control valve connector. Remove the oil cooler pipe. Remove the control valve body. NOTE: Replace the control valve body as assembly, because the control valve body can not be disassembled.

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1. NON-TURBO MODEL Set the range select lever in "N" range. Install the control valve, ATF temperature sensor and ground connectors. Tightening torque: 8 N.m (0.8 kgf.m, 5.8 ft.lb) Connect all connectors. Attach the magnet at specified position. Apply proper amount of liquid gasket to the entire oil pan mating surface. Liquid gasket: THREE BOND 1217B (Part No. K0877YA020) Apply liquid gasket fully to three holes other than screw holes on transmission case. Liquid gasket: THREE BOND 1217B (Part No. K0877YA020) Install the oil pan by equally tightening the bolts. Tightening torque: 5 N.m (0.5 kgf.m, 3.6 ft.lb) Pour ATF from the oil charge pipe. Recommended fluid: Dexron III Fluid capacity: Fill the same amount of fluid drained from drain plug hole. Check the level of ATF. Refer to «AUTOMATIC TRANSMISSION FLUID»(ref-208395-S35776238372005120700000) .
2. TURBO MODEL Check the control valve body for dirt and dust. Install the control valve body and ground cable to transmission by tightening bolts evenly. Tightening torque: 8 N.m (0.8 kgf.m, 5.8 ft.lb) Attach the magnet at specified position of oil pan. Apply proper amount of liquid gasket to the entire oil pan mating surface. Liquid gasket: THREE BOND 1217B (Part No. K0877YA020) Apply liquid gasket fully to three holes other than screw holes on transmission case. Liquid gasket: THREE BOND 1217B (Part No. K0877YA020) Install the oil pan with tightening bolts evenly. Tightening torque: 5 N.m (0.5 kgf.m, 3.6 ft.lb) 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. Bleed the air from control valve. Refer to «AIR BLEEDING OF CONTROL VALVE»(ref-208395-S28802447402005120700000) . Check the level of ATF. Refer to «AUTOMATIC TRANSMISSION FLUID»(ref-208395-S35776238372005120700000) . Perform the advance operation of learning control. (TURBO model) Set the select lever to "P" range and apply parking brake, then lift-up the vehicle. Connect the SUBARU Select Monitor to vehicle. Using SUBARU Select Monitor, check that the DTC is not output. Select "Clear Memory - 2" on the Select Monitor. Refer to «OPERATION»(ref-208399-S13840447952005120700000) , Subaru Select Monitor. Using SUBARU Select Monitor, warm up the engine until the ATF temperature becomes within 60 to 90°C (140 to 194° F). Refer to «OPERATION»(ref-208399-S13840447952005120700000) , Subaru Select Monitor. Set the select lever to "R" range. Set the switches for headlights, air conditioner, rear defogger, etc. to OFF. Turn ignition switch to OFF, and wait for 30 seconds or more. Depress the brake pedal fully with left foot until learning promotion task is completed. Turn the ignition switch to ON. Confirm that the Select Monitor screen returns to normal. Set the select lever to "P" range, and then wait for more than three seconds. Set the select lever to "R" range, and then wait for more than three seconds. Set the select lever to "N" range, and then wait for more than three seconds. Set the select lever to "D" range, and then wait for more than three seconds. Set the select lever to "N" range, and then wait for more than three seconds. Slightly depress the accelerator pedal to full open. Slightly release the accelerator pedal to close. Start the engine. Set the select lever to "D" range. ATF temperature warning light in the combination meter blinks at 2 Hz. If ATF temperature warning light does not blink, repeat the procedure from step 4). Learning promotion task is completed when blinking of ATF temperature warning light in the combination meter changes from 2 to 0.5 Hz. NOTE: Repeat the procedure from step 4) if blinking of ATF temperature warning light changes from 2 Hz to 4 Hz. Set the select lever to "N" range, and turn the ignition switch to OFF. Set the select lever to "P" range to finish air bleeding.

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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 bolt lengths 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 bolt lengths 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 bolt lengths 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 the lower separate plate to lower valve body.
9. Temporarily assemble the 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 the bolts and nuts. 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. 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. Dropping resistor is installed except VDC or SPORT shift and U5 model.

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1. Disconnect the ground cable from battery.
2. Remove the air intake duct. 2.5 L model Refer to «REMOVAL»(ref-208359-S22811893822005120700000) , Air Cleaner Case. 3.0 L model Refer to «REMOVAL»(ref-208384-S10767206552005120700000) , Air Intake Duct.
3. Disconnect the connector from dropping resistor.
4. Remove the dropping resistor.

Install in the reverse order of removal.

1. Tightening torque: 13 N.m (1.3 kgf.m, 10 ft.lb)

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1. EXCEPT 3.0 L MODEL AND U5 MODEL Set the vehicle on a lift. Remove battery and washer tank. Lift-up the vehicle. Remove the under cover. Disconnect 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. Disconnect 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. Remove ATF cooler pipe from frame. Remove the oil cooler inlet and outlet pipes. NOTE: When removing outlet pipe, be careful not to lose ball and spring used with retaining screw.
2. 3.0 L Model and U5 model Set the vehicle on a lift. Remove battery and washer tank. Lift-up the vehicle. Remove the under cover. Disconnect 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. Disconnect ATF cooler hoses from transmission. 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. Remove front left mud guard. Refer to «REMOVAL»(ref-216282-S31390955912006011800000) , Mud Guard. Disconnect ATF cooler hoses from ATF filter. 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. Remove AT cooler pipe from frame. Remove the oil cooler inlet and outlet pipes. NOTE: When removing outlet pipe, be careful not to lose ball and spring used with retaining screw.

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1. EXCEPT 3.0 L MODEL AND U5 MODEL Install the oil cooler outlet and inlet pipes. NOTE: Be sure to use a new aluminum 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) Install ATF cooler pipe to frame. Connect 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. Connect ATF cooler hose to 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. Install the under cover. Install battery and washer tank. Fill ATF. Refer to «AUTOMATIC TRANSMISSION FLUID»(ref-208395-S35776238372005120700000) . NOTE: Make sure there are no ATF leaks in joints between the transmission, radiator, pipes, and hoses.
2. 3.0 L MODEL Install the oil cooler outlet and inlet pipes. NOTE: Be sure to use a new aluminum 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) Install ATF cooler pipe to frame. Connect ATF cooler hose to transmission. NOTE: Install so that the hose is not folded over, excessively bent, or twisted. Be careful to insert the hose to the specified position. Connect ATF cooler hoses from ATF filter. NOTE: Install so that the hose is not folded over, excessively bent, or twisted. Be careful to insert the hose to the specified position. Connect ATF cooler hoses from radiator. NOTE: Install so that the hose is not folded over, excessively bent, or twisted. Be careful to insert the hose to the specified position. Install front left mud guard. Refer to «INSTALLATION»(ref-216282-S08231901382006011800000) , Mud Guard. Install the under cover. Install battery and washer tank. Fill ATF. Refer to «AUTOMATIC TRANSMISSION FLUID»(ref-208395-S35776238372005120700000) . NOTE: Make sure there are no ATF leaks in joints between the transmission, radiator pipes and hoses.

1. Remove the transmission assembly from vehicle. Refer to «REMOVAL»(ref-208395-S27755175932005120700000) .
2. Remove the extension case and remove the transfer clutch. Refer to «REMOVAL»(ref-208395-S34269959682005120700000) and «REMOVAL»(ref-208395-S34269959682005120700000) .

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1. Select the thrust needle bearing. Refer to «ADJUSTMENT»(ref-208395-S20752087092005120700000) .
2. Install the transfer clutch assembly to the case.
3. Tighten bolts to secure the case. Tightening torque: 25 N.m (2.5 kgf.m, 18.1 ft.lb)
4. Install the transmission assembly to vehicle. Refer to «INSTALLATION»(ref-208395-S37442351082005120700000) .

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1. Remove the seal ring.
2. Using a press and ST, remove the ball bearing.
3. Remove the snap ring, and take out the pressure plate, drive plates, and driven plates.
4. Remove the snap ring with ST1, ST2 and ST3, and take out the return spring and transfer clutch piston seal.
5. Apply compressed air to the rear drive shaft to remove the piston.

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1. Install the transfer clutch piston.
2. Install return spring to transfer piston.
3. Install transfer clutch piston seal.
4. Install ST to rear drive shaft. ST 499257300 SNAP RING OUTER GUIDE
5. Install snap ring to ST.
6. Using ST1 and ST2, install snap ring to rear drive shaft.
7. Install the driven plates, drive plates, pressure plate and snap ring.
8. Apply compressed air to see if the assembled parts move smoothly.
9. Check clearance between snap ring and pressure plate. Refer to «INSPECTION»(ref-208395-S39284175112005120700000) .
10. Press-fit a new ball bearing with ST.
11. Coat a new seal ring with vaseline, and install it in the seal ring groove of the shaft. NOTE: Do not expand the seal ring excessively when installing.
12. Install the transfer clutch assembly without damaging seal ring.

Remove multi-plate clutch following the same instructions as for the extension case. Refer to REMOVAL .

Install multi-plate clutch following the same instructions as for the extension case. Refer to INSTALLATION .

1. Select the appropriate shim. .
2. Install drive plate and driven plate.
3. Insert rear driveshaft into the center differential assembly.
4. Join transmission case and extension case. Install rear wheel speed sensor. Refer to «INSTALLATION»(ref-208395-S01684578102005120700000) .
5. Install transmission assembly. Refer to «INSTALLATION»(ref-208395-S37442351082005120700000) .

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

1. Remove the transmission assembly from the vehicle. Refer to «REMOVAL»(ref-208395-S27755175932005120700000) .
2. Remove rear vehicle speed sensor, and separate the transmission case and extension case. Refer to «REMOVAL»(ref-208395-S34269959682005120700000) .
3. Remove the reduction driven gear. Refer to «REMOVAL»(ref-208395-S24947878792005120700000) .
4. Using ST, extract the reduction drive gear. ST1 499737000 PULLER ST2 899524100 PULLER SET

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1. Install the reduction drive gear assembly. NOTE: Install it fully into position until the bearing shoulder bottoms.
2. Install the reduction driven gear. Refer to «INSTALLATION»(ref-208395-S20613010722005120700000) .
3. Combine the transmission case with the extension case, and install rear vehicle speed sensor. Refer to «INSTALLATION»(ref-208395-S01684578102005120700000) .
4. Install the transmission assembly to the vehicle. Refer to «INSTALLATION»(ref-208395-S37442351082005120700000) .

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1. Take out the seal rings.
2. Using ST, remove the ball bearing. ST 498077600 REMOVER
3. Using a press, remove the reduction drive gear.

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1. Press-fit the reduction drive gear to the shaft.
2. Press-fit a new ball bearing to the reduction drive gear.
3. Apply vaseline to the outer surface of seal ring and shaft groove.
4. Attach a new seal rings.