Automatic Transmission (4AT): Removal & Installation — Subaru Outback BP рестайлинг (2006-2009)

INSTALLATION

Install in the reverse order of removal.

Note. Replace the O-ring with a new part.

Tightening torque

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

REMOVAL

For removal procedure of the torque converter turbine speed sensor, refer to REMOVAL , Front Vehicle Speed Sensor.

For installation procedure of the torque converter turbine speed sensor, refer to INSTALLATION , Front Vehicle Speed Sensor.

Scheme 361

Scheme 361: REMOVAL

Scheme 362

Scheme 363

Scheme 364

Scheme 365

Scheme 366

Set the vehicle on a lift.
Disconnect the ground cable from the battery.
Lift up the vehicle.
Clean the transmission exterior.
Remove the drain plug (ATF) to drain the ATF. CAUTION: After running the engine or after idling for a long time, the ATF is hot. Be careful not to burn yourself.
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)
Remove the oil pan. CAUTION: Be careful not to allow foreign matter such as dust or dirt to enter the oil pan.
Remove the magnet.
Clean the magnet.
Completely remove the remaining liquid gasket on the transmission case and oil pan.
Disconnect the control valve connector.
Remove the oil cooler pipe.
Remove the control valve body. NOTE: The control valve body is replaced as an assembly only, because it is a non-disassembly part.

Scheme 367

Check the control valve body for dust and other foreign matter.
Temporarily install the control valve body and ground cable to the transmission, then install the oil cooler pipe. Tightening torque: 8 N.m (0.8 kgf-m, 5.8 ft-lb)
Tighten the bolts equally. Tightening torque: 8 N.m (0.8 kgf-m, 5.8 ft-lb)
Connect the control valve connector.
Attach the magnet at the specified position of the oil pan.
Apply proper amount of liquid gasket to the entire oil pan mating surface. Liquid gasket: THREE BOND 1217B (Part No. K0877YA020) or equivalent
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
Install the oil pan by equally tightening the bolts. Tightening torque: 5 N.m (0.5 kgf-m, 3.6 ft-lb)
Fill ATF from the oil charger pipe. Recommended fluid: SUBARU ATF HP Substitute fluid: Idemitsu "ATF HP", Castrol "Transmax J", Pennzoll-Quaker State "Pennzoil ATF-J" Capacity: Fill with the same amount of ATF as drained.
Bleed the air of control valve body. < Ref. to «AIR BLEEDING OF CONTROL VALVE»(ref-306923-S32258280342008122600000) . >
Check the ATF level. < Ref. to «AUTOMATIC TRANSMISSION FLUID»(ref-306923-S07188944182008122600000) . >
Execute the learning control promotion. < Ref. to «FACILITATION OF LEARNING CONTROL»(ref-306922-S36203919282008122600000) , OPERATION, Subaru Select Monitor. >

Note. The ATF filter is maintenance free.

Scheme 368

Scheme 368: REMOVAL

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

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, 10.1 ft-lb) [Required torque setting] T2: Tightening torque L1: ST length 78 mm (3.07 in) L2: Torque wrench length Example: TORQUE WRENCH LENGTH SPECIFICATION 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: Attach ST to the torque wrench as straight as possible. ST 498545400 OIL FILTER WRENCH
Fill the ATF.
Inspect the level of ATF. < Ref. to «AUTOMATIC TRANSMISSION FLUID»(ref-306923-S07188944182008122600000) . >

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.
Install the under cover.
Install the battery.
Fill the ATF. < Ref. to «AUTOMATIC TRANSMISSION FLUID»(ref-306923-S07188944182008122600000) . > NOTE: Make sure there are no ATF leaks in joints between the transmission, radiator, pipes, and hoses.

Remove the transmission assembly from vehicle body. < Ref. to «REMOVAL»(ref-306923-S38561231092008122600000) , Automatic Transmission Assembly. >
Remove the extension case, and then remove the transfer clutch. < Ref. to «REMOVAL»(ref-306923-S12949428832008122600000) , Extension Case. > < Ref. to «DISASSEMBLY»(ref-306923-S12297037672008122600000) , Extension Case. >

Scheme 369

Scheme 369: INSTALLATION

Select the thrust needle bearing. < Ref. to «ADJUSTMENT»(ref-306923-S31207895682008122600000) , 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. < Ref. to «INSTALLATION»(ref-306923-S41850346902008122600000) , Automatic Transmission Assembly. >

Scheme 370

Scheme 370: DISASSEMBLY

Scheme 371

Scheme 372

Scheme 373

Scheme 374

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 pressure plate, 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 375

Scheme 375: ASSEMBLY

Scheme 376

Scheme 377

Scheme 378

Scheme 379

Scheme 380

Scheme 381

Scheme 382

Scheme 383

Scheme 384

Scheme 385

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, pressure plate, retaining plate and snap ring.
Apply compressed air to see if the assembled parts move smoothly.
Check clearance between the snap ring and pressure plate. < Ref. to «INSPECTION»(ref-306923-S26615414092008122600000) , 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 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.

Remove the multi-plate clutch in the same manner as the extension case. < Ref. to REMOVAL , Extension Case. >

Install the multi-plate clutch in the same manner as the extension case. < Ref. to INSTALLATION , Extension Case. >

Select shims. < Ref. to «VTD MODEL»(ref-306923-S41391457602008122600000) , Transfer Clutch. >
Install drive plate and driven plate.
Insert the rear drive shaft into the center differential assembly.
Join the transmission case and the extension case, and then install the rear vehicle speed sensor. < Ref. to «INSTALLATION»(ref-306923-S16842233012008122600000) , Extension Case. >
Install the transmission assembly to the vehicle. < Ref. to «INSTALLATION»(ref-306923-S41850346902008122600000) , Automatic Transmission Assembly. >

Scheme 386

Scheme 386: DISASSEMBLY

Scheme 387

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

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 (4.0 kgf-m, 29.5 ft-lb)
Join the torque converter case with the transmission case. < Ref. to «INSTALLATION»(ref-306923-S03996898592008122600000) , Converter Case. >
Install the reduction driven gear. < Ref. to «INSTALLATION»(ref-306923-S18552244392008122600000) , Reduction Driven Gear. >
Install the reduction drive gear. (MP-T model) < Ref. to «INSTALLATION»(ref-306923-S40267898042008122600000) , Reduction Drive Gear. >
Install the center differential carrier. (VTD model) < Ref. to «INSTALLATION»(ref-306923-S06871127112008122600000) , Center Differential Carrier. >
Join the transmission case and the extension case, and then install the rear vehicle speed sensor. < Ref. to «INSTALLATION»(ref-306923-S16842233012008122600000) , Extension Case. >
Insert the inhibitor switch and transmission harness connector to the stay.
Install the air breather hose. < Ref. to «INSTALLATION»(ref-306923-S25363629592008122600000) , Air Breather Hose. >
Install the ATF inlet and outlet pipes. < Ref. to «INSTALLATION»(ref-306923-S41459136272008122600000) , ATF Cooler Pipe and Hose. >
Install the oil charge pipe with O-ring.
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)
Install the torque converter assembly. < Ref. to «INSTALLATION»(ref-306923-S38519732182008122600000) , Torque Converter Assembly. >
Install the transmission assembly to the vehicle. < Ref. to «INSTALLATION»(ref-306923-S41850346902008122600000) , Automatic Transmission Assembly. >

Scheme 388

Scheme 388: DISASSEMBLY

Scheme 389

Scheme 390

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
Remove the O-ring.
Separate the rear roller bearing and outer race from the drive pinion shaft using a press.
Separate the front roller bearing from the drive pinion shaft using a press and the ST. ST 498517000 REPLACER

Scheme 391

Scheme 391: ASSEMBLY

Scheme 392

Scheme 393

Scheme 394

Scheme 395

Measure the dimension "A" of the drive pinion shaft. ST 398643600 GAUGE
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.
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.
Install the lock washer to drive pinion shaft in the proper direction.
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, 85.3 ft-lb) [Required torque setting] T2: Tightening torque L1: ST2 length 0.072 m (2.83 in) L2: Torque wrench length Example: TORQUE SPECIFICATION Torque wrench length m (in) Tightening torque N.m (kgf-m, ft-lb) 0.4 (15.75) 98 (10.0, 72) 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) ST1 498937110 HOLDER ST2 499787700 WRENCH ST3 499787500 ADAPTER NOTE: Attach ST2 to torque wrench as straight as possible.
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 (0.776 - 3.88 kgf, 1.7 - 8.6 lb)
Crimp the locknut in two locations.
Measure the dimension "B" of the drive pinion shaft. ST 398643600 GAUGE
Calculate the thickness T (mm) of the drive pinion shim. t = 6.5 ± 0.0625 - (B - A)
Select three or less shims from following table. THICKNESS CHART Drive pinion shim Part number 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)

Remove the transmission assembly from vehicle body. < Ref. to «REMOVAL»(ref-306923-S38561231092008122600000) , Automatic Transmission Assembly. >
Pull out the torque converter assembly. < Ref. to «REMOVAL»(ref-306923-S06826541512008122600000) , Torque Converter Assembly. >
Remove the input shaft.
Lift up the lever on the rear side of transmission harness connector, and then remove it from the stay.
Remove the inhibitor switch from the stay.
Remove the oil charge pipe. < Ref. to «REMOVAL»(ref-306923-S04356908172008122600000) , Oil Charge Pipe. >
Remove the ATF inlet and outlet pipes. < Ref. to «REMOVAL»(ref-306923-S02307713372008122600000) , ATF Cooler Pipe and Hose. >
Separate the converter case from the transmission case. < Ref. to «REMOVAL»(ref-306923-S01660228282008122600000) , Converter Case. >
Remove the seal pipe.
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.
Remove the front differential assembly while being careful not to damage the attachment part of the retainer.

Scheme 396

Scheme 396: installation

Scheme 397

Scheme 398

Scheme 399

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).
Install the O-ring to left and right side differential retainers.
Install the differential side retainers using the ST. < Ref. to «ADJUSTMENT»(ref-306923-S11712879782008122600000) , Front Differential Assembly. > ST 18630AA010 WRENCH COMPL RETAINER NOTE: ST WRENCH ASSEMBLY (499787000) can also be used.
Adjust the backlash of the front differential. < Ref. to «ADJUSTMENT»(ref-306923-S11712879782008122600000) , Front Differential Assembly. >
Install the lock plate. Tightening torque: 25 N.m (2.5 kgf-m, 18.4 ft-lb)
Install new seal pipe to converter case.
Install the converter case to the transmission case. < Ref. to «INSTALLATION»(ref-306923-S03996898592008122600000) , Converter Case. >
Insert the inhibitor switch and transmission harness connector to the stay.
Install the ATF cooler pipe. < Ref. to «INSTALLATION»(ref-306923-S41459136272008122600000) , ATF Cooler Pipe and Hose. >
Install the oil charge pipe together with an O-ring. < Ref. to «INSTALLATION»(ref-306923-S06307616812008122600000) , Oil Charge Pipe. >
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)
Install the torque converter assembly. < Ref. to «INSTALLATION»(ref-306923-S38519732182008122600000) , Torque Converter Assembly. >
Install the transmission assembly to the vehicle. < Ref. to «INSTALLATION»(ref-306923-S41850346902008122600000) , Automatic Transmission Assembly. >

Scheme 400

Scheme 400: DIFFERENTIAL CASE ASSEMBLY

Scheme 401

Scheme 402

Remove the taper roller bearing using the ST and a press. ST 498077000 REMOVER
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).
Pull out the straight pin and pinion shaft, then remove the differential bevel gear, washer and differential bevel pinion.

Automatic Transmission (4AT): Removal & Installation Subaru Outback BP рестайлинг