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Automatic Transmission (5AT): Removal & Installation Subaru Outback BP рестайлинг

Automatic Trans 53 illustrations ~3254 words

INSTALLATION

  1. Install the rear vehicle speed sensor. Tightening torque: 7 N.m (0.7 kgf-m, 5.2 ft-lb)
  2. Connect the rear vehicle speed sensor connector.
  3. Install the transmission rear crossmember bolt. Tightening torque: 75 N.m (7.6 kgf-m, 55.3 ft-lb)
  4. Install the propeller shaft. < Ref. to «INSTALLATION»(ref-303075-S14670773772008102300000) , Propeller Shaft. >
  5. Install the heat shield cover.
  6. Install the center, rear exhaust pipes and the muffler. (Turbo model) < Ref. to «INSTALLATION»(ref-303072-S00349267932008102300000) , Center Exhaust Pipe . > < Ref. to «INSTALLATION»(ref-303072-S41302131562008102300000) , Rear Exhaust Pipe . > < Ref. to «INSTALLATION»(ref-303072-S11422866462008102300000) , Muffler . >
  7. Install the rear exhaust pipe and muffler. (Non-turbo model) < Ref. to «INSTALLATION»(ref-306933-S27723276652008122600000) , Rear Exhaust Pipe. > < Ref. to «INSTALLATION»(ref-306933-S10632792442008122600000) , Muffler. >
  8. Lower the vehicle.
  9. Pour ATF from the oil charge pipe. < Ref. to «REPLACEMENT»(ref-306924-S03871039702008122600000) , Automatic Transmission Fluid. >
  10. Check the level and leaks of ATF. < Ref. to «INSPECTION»(ref-306924-S39179730662008122600000) , Automatic Transmission Fluid. >

Scheme 566

Scheme 566: REMOVAL
Scheme 566: REMOVAL
  1. Remove the intercooler. (Turbo model) < Ref. to «REMOVAL»(ref-303068-S15667783702008102300000) , Intercooler. >
  2. Remove the air intake chamber. (Non-turbo model) < Ref. to «REMOVAL»(ref-306919-S12426210742008122600000) , Air Intake Chamber. >
  3. Lift up the vehicle.
  4. Disconnect the turbine speed sensor 1 connector.
  5. Remove the turbine speed sensor 1.
  1. Install the turbine speed sensor 1. Tightening torque: 7 N.m (0.7 kgf-m, 5.2 ft-lb)
  2. Connect the turbine speed sensor 1 connector.
  3. Lower the vehicle.
  4. Install the intercooler. (Turbo model) < Ref. to «INSTALLATION»(ref-303068-S14163859102008102300000) , Intercooler. >
  5. Install the air intake chamber. (Non-turbo model) < Ref. to «INSTALLATION»(ref-306919-S31904316202008122600000) , Air Intake Chamber. >

Scheme 567

Scheme 567: REMOVAL
Scheme 567: REMOVAL

Scheme 568

Scheme 568
Scheme 568

Scheme 569

Scheme 569
Scheme 569
  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 ATF drain plug to drain ATF. CAUTION: Immediately after the vehicle has been running or after idling for a long time, the ATF will be hot. Be careful not to burn yourself.
  6. Tighten the ATF drain plug. NOTE: Use a new gasket. Tightening torque: 20 N.m (2.0 kgf-m, 14.8 ft-lb)
  7. Remove the oil pan. CAUTION: Be sure to prevent the entering of dust and other foreign matters into 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. Disconnect the control valve connector and front vehicle speed sensor connector.
  12. Remove the control valve body. NOTE: The control valve body is replaced as an assembly only, because it is a non-disassembly part.

Scheme 570

Scheme 570: INSTALLATION
Scheme 570: INSTALLATION

Scheme 571

Scheme 571
Scheme 571

Scheme 572

Scheme 572
Scheme 572
  1. Check the control valve body for dust and other foreign matter.
  2. Install the control valve body to transmission by equally tightening the bolts. Tightening torque: 8 N.m (0.8 kgf-m, 5.8 ft-lb)
  3. Connect the control valve connector.
  4. Attach the magnet at the specified position of the oil pan.
  5. Apply liquid gasket to the oil pan. Liquid gasket: THREE BOND 1217B (Part No. K0877YA020)
  6. Install the oil pan by equally tightening the bolts. Tightening torque: 5 N.m (0.5 kgf-m, 3.7 ft-lb)
  7. Pour ATF through the oil charge pipe. Specified and recommended fluid: < Ref. to «SPECIFICATION»(ref-306924-S20295404442008122600000) , General Description. > Capacity: Fill with the same amount of ATF as drained.
  8. Check the ATF level. < Ref. to «AUTOMATIC TRANSMISSION FLUID»(ref-306924-S23554670732008122600000) . >
  9. Perform Clear Memory 2 operation. < Ref. to «CLEAR MEMORY MODE»(ref-306927-S29988651132008122600000) , OPERATION, Subaru Select Monitor. >
  10. Execute the learning control promotion. < Ref. to «GENERAL DESCRIPTION»(ref-306927-S03331440362008122600000) , Learning Control. >
  11. Perform the inspection at the end of repair work, and make sure there is no faulty as below; Excessive shift shock Oil leakage from the transmission body, etc. Occurrence of noise caused by interference etc.

REMOVAL

Note. The ATF filter is maintenance free.

Scheme 573

Scheme 573: REMOVAL
Scheme 573: REMOVAL

Scheme 574

Scheme 574
Scheme 574
  1. Disconnect the battery ground cable and remove the battery from the vehicle.
  2. Remove the harness securing bracket.
  3. Using the ST, remove the ATF filter. ST 498545400 OIL FILTER WRENCH
  1. Apply a thin coat of ATF to the oil seal part of new ATF filter.
  2. Install the ATF filter. Turn it by hand, being careful not to damage oil seal.
  3. 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: 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, 7.4) NOTE: Align the ST with the torque wrench while tightening the ATF filter. ST 498545400 OIL FILTER WRENCH
  4. Fill ATF.
  5. Inspect the level of ATF. < Ref. to «AUTOMATIC TRANSMISSION FLUID»(ref-306924-S23554670732008122600000) . >
  6. Install the harness securing bracket.
  7. Install the battery.

Install in the reverse order of removal.

Tightening torque

T1: 7.5 N.m (0.76 kgf-m, 5.5 ft-lb)

T2: 18 N.m (1.8 kgf-m, 13.3 ft-lb)

Scheme 575

Scheme 575: INSTALLATION
Scheme 575: INSTALLATION

Scheme 576

Scheme 576: REMOVAL
Scheme 576: REMOVAL

Scheme 577

Scheme 577
Scheme 577

Scheme 578

Scheme 578
Scheme 578

Scheme 579

Scheme 579
Scheme 579

Scheme 580

Scheme 580
Scheme 580
  1. Set the vehicle on a lift.
  2. Remove the battery.
  3. Lift up the vehicle.
  4. Remove the under cover.
  5. Remove the radiator under cover.
  6. 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.
  7. 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.
  8. Disconnect the ATF cooler pipe from frame.
  9. Remove the ATF inlet pipe and outlet pipe. NOTE: When disconnecting the outlet pipe, be careful not to lose the ball and spring used together with retaining screw.

Scheme 581

Scheme 581: INSTALLATION
Scheme 581: INSTALLATION
  1. Install the ATF inlet pipe and outlet pipe with new washers. NOTE: Use new bolts for the contact area of the converter case. Tightening torque: T1: 40 N.m (4.1 kgf-m, 29.5 ft-lb) T2: 38 N.m (5.9 kgf-m, 28.0 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 radiator under cover. Tightening torque: 4.9 N.m (0.5 kgf-m, 3.6 ft-lb)
  6. Install the under cover.
  7. Install the battery.
  8. Fill ATF. < Ref. to «AUTOMATIC TRANSMISSION FLUID»(ref-306924-S23554670732008122600000) . > NOTE: Make sure there are no ATF leaks in joints between the transmission, radiator, pipes, and hoses.
  1. Connect the air breather hose.
  2. Install the intercooler. (Turbo model) < Ref. to «INSTALLATION»(ref-303068-S14163859102008102300000) , Intercooler. >
  3. Install the air intake chamber. (Non-turbo model) < Ref. to «INSTALLATION»(ref-306919-S31904316202008122600000) , Air Intake Chamber. >
  1. Attach the selected reduction driven gear shim to end surface of reduction driven gear with vaseline. < Ref. to «ADJUSTMENT»(ref-306924-S40628917402008122600000) , Reduction Driven Gear. >
  2. Install the extension case. NOTE: Use a new gasket. Tightening torque: 25 N.m (2.5 kgf-m, 18.4 ft-lb)
  3. Install the rear vehicle speed sensor. Tightening torque: 7 N.m (0.7 kgf-m, 5.2 ft-lb)
  4. Connect the rear vehicle speed sensor connector.
  5. Install the transmission assembly. < Ref. to «INSTALLATION»(ref-306924-S06651075452008122600000) , Automatic Transmission Assembly. >

Scheme 582

Scheme 582: DISASSEMBLY
Scheme 582: DISASSEMBLY

Scheme 583

Scheme 583
Scheme 583
  1. Take out the transfer clutch and multi-plate clutch hub assembly by lightly tapping the end of rear drive shaft. NOTE: Be careful not to damage the oil seal of the extension.
  2. Remove the snap ring using the ST and press. ST 18762AA000 COMPRESSOR SPECIAL TOOL
  3. Remove the clutch piston by applying compressed air.
  4. Remove the dust cover from extension case.
  5. Remove the oil seal from the extension case.

Scheme 584

Scheme 584: ASSEMBLY
Scheme 584: ASSEMBLY
  1. Press-fit the new oil seal using ST and the press. ST 498057300 INSTALLER
  2. Press-fit the dust cover.
  3. Insert the transfer clutch assembly, spring retainer, return spring and clutch spring retainer.
  4. Using the ST and compressor, install the snap ring. ST 18762AA000 COMPRESSOR SPECIAL TOOL
  5. Install the transfer clutch. < Ref. to «INSTALLATION»(ref-306924-S29839959572008122600000) , Transfer Clutch. >
  6. Install the multi-plate hub assembly.
  1. Remove the transmission assembly from vehicle body. < Ref. to «REMOVAL»(ref-306924-S37789396842008122600000) , Automatic Transmission Assembly. >
  2. Remove the extension case, and then remove the transfer clutch. < Ref. to «REMOVAL»(ref-306924-S29155680122008122600000) , Extension Case. >, < Ref. to «DISASSEMBLY»(ref-306924-S07221819922008122600000) , Extension Case. >
  1. Select the rear drive shaft shim. < Ref. to «ADJUSTMENT»(ref-306924-S29086251462008122600000) , Transfer Clutch. >
  2. Select driven plate No. 3. < Ref. to «ADJUSTMENT»(ref-306924-S29086251462008122600000) , Transfer Clutch. >
  3. Install the extension case. < Ref. to «INSTALLATION»(ref-306924-S16911151992008122600000) , Extension Case. >
  4. Install the transmission assembly to the vehicle. < Ref. to «INSTALLATION»(ref-306924-S06651075452008122600000) , Automatic Transmission Assembly. >
  1. Remove the transmission assembly from vehicle body. < Ref. to «REMOVAL»(ref-306924-S37789396842008122600000) , Automatic Transmission Assembly. >
  2. Remove the rear vehicle speed sensor, and then remove the extension case. < Ref. to «REMOVAL»(ref-306924-S29155680122008122600000) , Extension Case. >
  3. Pull out the rear driveshaft from center differential assembly.
  4. Remove the drive plate and driven plate.
  1. Select the shim. < Ref. to «ADJUSTMENT»(ref-306924-S29086251462008122600000) , Transfer Clutch. >
  2. Install drive plate and driven plate.
  3. Insert the rear driveshaft into the center differential assembly.
  4. Combine the extension case, and then install the rear vehicle speed sensor. < Ref. to «INSTALLATION»(ref-306924-S16911151992008122600000) , Extension Case. >
  5. Install the transmission assembly to the vehicle. < Ref. to «INSTALLATION»(ref-306924-S06651075452008122600000) , Automatic Transmission Assembly. >

Scheme 585

Scheme 585: DISASSEMBLY
Scheme 585: DISASSEMBLY

Scheme 586

Scheme 586
Scheme 586
  1. Using a press, remove the revolution gear.
  2. Using a press, remove the front and rear side ball bearings and clutch hub.
  1. Set the range select lever to the "P" range.
  2. Use a plastic hammer to install reduction driven gear assembly.
  3. Select the reduction gear shims. < Ref. to «ADJUSTMENT»(ref-306924-S40628917402008122600000) , Reduction Driven Gear. >
  4. Join the transmission case and the extension case, and then install the rear vehicle speed sensor. < Ref. to «INSTALLATION»(ref-306924-S16911151992008122600000) , Extension Case. >
  5. Install the transmission assembly to the vehicle. < Ref. to «INSTALLATION»(ref-306924-S06651075452008122600000) , Automatic Transmission Assembly. >

Scheme 587

Scheme 587: DISASSEMBLY
Scheme 587: DISASSEMBLY

Scheme 588

Scheme 588
Scheme 588

Scheme 589

Scheme 589
Scheme 589

Scheme 590

Scheme 590
Scheme 590
  1. Remove the ball bearing from reduction driven gear using ST. ST 498077300 REMOVER
  2. Remove the ball bearing on the reverse side with the same procedure as step 1 ). ST 498077300 REMOVER
  3. Remove the snap ring of the parking gear.
  4. Using the ST, remove the parking gear. ST 18767AA000 REMOVER

Scheme 591

Scheme 591: ASSEMBLY
Scheme 591: ASSEMBLY

Scheme 592

Scheme 592
Scheme 592

Scheme 593

Scheme 593
Scheme 593
  1. Using the ST, install the parking gear. ST 499755602 PRESS
  2. Install the snap ring.
  3. Install the new ball bearing to reduction driven gear using press. ST 18654AA000 INSTALLER
  4. Install the ball bearing on the reverse side with the same procedure as step 3 ). ST 18654AA000 INSTALLER
  1. Install the center differential assembly with the shim (s). NOTE: Press-fit it to the bottom of bearing shoulder completely.
  2. Insert the rear drive shaft. < Ref. to «INSTALLATION»(ref-306924-S00536473852008122600000) , Rear Drive Shaft. >
  3. Join the transmission case and the extension case, and then install the rear vehicle speed sensor. < Ref. to «INSTALLATION»(ref-306924-S16911151992008122600000) , Extension Case. >
  4. Install the transmission assembly to the vehicle. < Ref. to «INSTALLATION»(ref-306924-S06651075452008122600000) , Automatic Transmission Assembly. >

Scheme 594

Scheme 594: DISASSEMBLY
Scheme 594: DISASSEMBLY

Scheme 595

Scheme 595
Scheme 595

Scheme 596

Scheme 596
Scheme 596

Scheme 597

Scheme 597
Scheme 597
  1. Remove the seal ring.
  2. Using a press and ST, remove the ball bearing. ST 498077600 REMOVER
  3. Remove the snap ring, and pull out the shaft from center differential assembly.
  4. Remove the thrust washers, pinion gears and washers from center differential assembly.
  5. Pull out the intermediate shaft and thrust bearing.

Scheme 598

Scheme 598: ASSEMBLY
Scheme 598: ASSEMBLY
  1. Install the thrust washer onto intermediate shaft.
  2. Install the thrust bearing onto intermediate shaft.
  3. Install the pinion gears and washers.
  4. Insert the shaft into the center differential assembly.
  5. Install the snap ring.
  6. Using a press, install a new ball bearing into the center differential assembly. ST 498077000 REMOVER
  7. Apply vaseline onto the seal ring outer surface and shaft grooves.
  8. Install a new seal ring.
  1. Secure the oil pump cover. Tightening torque: 41 N.m (4.2 kgf-m, 30.2 ft-lb)
  2. Install the converter case assembly to the transmission case assembly. < Ref. to «INSTALLATION»(ref-306924-S16295455252008122600000) , Converter Case. >
  3. Install the transmission harness connector to the stay.
  4. Install the ATF cooler pipe. < Ref. to «INSTALLATION»(ref-306924-S30885151132008122600000) , ATF Cooler Pipe and Hose. >
  5. Install the oil charge pipe together with an O-ring. < Ref. to «INSTALLATION»(ref-306924-S11223598222008122600000) , Oil Charge Pipe. >
  6. Install the torque converter assembly. < Ref. to «INSTALLATION»(ref-306924-S12776292312008122600000) , Torque Converter Assembly. >
  7. Install the transmission assembly to the vehicle. < Ref. to «INSTALLATION»(ref-306924-S06651075452008122600000) , Automatic Transmission Assembly. >

Scheme 599

Scheme 599: FRONT BRAKE
Scheme 599: FRONT BRAKE

Scheme 600

Scheme 600
Scheme 600

Scheme 601

Scheme 601
Scheme 601
  1. Remove the snap ring.
  2. Remove the retainer plate, drive plate and driven plate.
  3. Using the ST1, ST2 and ST3, remove the snap ring. ST1 18762AA000 COMPRESSOR SPECIAL TOOL ST2 18765AA000 COMPRESSOR SUPPORT ST3 18763AA000 COMPRESSOR SHAFT
  4. Remove the retainer and return spring.
  5. Remove the front brake piston using compressed air.
  6. Remove the D-ring from front brake piston.

Scheme 602

Scheme 602: OIL PUMP
Scheme 602: OIL PUMP
  1. Take out the oil pump housing.
  2. Take out the oil pump body.

Scheme 603

Scheme 603: FRONT BRAKE
Scheme 603: FRONT BRAKE

Scheme 604

Scheme 604
Scheme 604
  1. Apply ATF to D-ring, and then install it to the front brake piston.
  2. Install the front brake piston to oil pump cover. NOTE: Install by aligning the "arrow " mark on front brake piston surface with the oil pump cover rib.
  3. Install the retainer and return spring.
  4. Install the front brake piston assembly using ST1, ST2 and ST3. ST1 18762AA000 COMPRESSOR SPECIAL TOOL ST2 18765AA000 COMPRESSOR SUPPORT ST3 18763AA000 COMPRESSOR SHAFT
  5. Install the genuine driven plate instead of retainer plate, and temporarily assemble the drive plate and driven plate. Part No. 31536AA290 DRIVEN PLATE
  6. Install the snap ring.
  7. Measure the clearance between retainer plate and snap ring, and then select the suitable retainer plate from table. Front brake clearance specification: 0.7 - 1.1 mm (0.028 - 0.043 in) FRONT BRAKE RETAINER PLATE REFERENCE Front brake retainer plate Part number Thickness mm (in) 31567AB130 3.4 (0.134) 31567AB140 3.6 (0.142) 31567AB150 3.8 (0.150) 31567AB160 4.0 (0.157)
  8. Remove the snap ring, replace the drive plate used in measurement of clearance with the retainer plate, and then reassemble.

Scheme 605

Scheme 605: OIL PUMP
Scheme 605: OIL PUMP
  1. Apply ATF to oil pump assembly, and then install it to oil pump housing.
  2. Install the O-ring to oil pump cover.
  3. Install the oil pump housing to the oil pump cover. Tightening torque: 10 N.m (1.0 kgf-m, 7.4 ft-lb)
  1. Assemble the drive pinion assembly to oil pump cover. NOTE: Be careful not to bend the shim. Tightening torque: 70 N.m (7.1 kgf-m, 51.6 ft-lb)
  2. Adjust the tooth contact between drive pinion shaft assembly and the front differential side gear. < Ref. to «ADJUSTMENT»(ref-306924-S33882513282008122600000) , Drive Pinion Shaft Assembly. >
  3. Join the converter case with the transmission case. < Ref. to «INSTALLATION»(ref-306924-S16295455252008122600000) , Converter Case. >
  4. Install the transmission harness connector to the stay.
  5. Install the ATF cooler pipe. < Ref. to «INSTALLATION»(ref-306924-S30885151132008122600000) , ATF Cooler Pipe and Hose. >
  6. Install the oil charge pipe with O-ring.
  7. Install the torque converter assembly. < Ref. to «INSTALLATION»(ref-306924-S12776292312008122600000) , Torque Converter Assembly. >
  8. Install the transmission assembly to the vehicle. < Ref. to «INSTALLATION»(ref-306924-S06651075452008122600000) , Automatic Transmission Assembly. >

Scheme 606

Scheme 606: DISASSEMBLY
Scheme 606: DISASSEMBLY

Scheme 607

Scheme 607
Scheme 607

Scheme 608

Scheme 608
Scheme 608
  1. Flatten the lock nut tab, and then remove the lock nut while holding the rear spline part of the shaft using ST1 and ST2. Pull out the drive pinion collar. ST1 18667AA010 HOLDER ST2 499787700 WRENCH ST3 499787500 ADAPTER
  2. Remove the O-ring.
  3. Separate the roller bearing and outer race from shaft using a press.
  4. Separate the front roller bearing from shaft using a press and ST. ST 498517000 REPLACER

Scheme 609

Scheme 609: ASSEMBLY
Scheme 609: ASSEMBLY

Scheme 610

Scheme 610
Scheme 610

Scheme 611

Scheme 611
Scheme 611

Scheme 612

Scheme 612
Scheme 612

Scheme 613

Scheme 613
Scheme 613
  1. Measure the dimension "A" of the drive pinion shaft. ST 398643600 GAUGE
  2. Using a press, press-fit the new roller bearing into the specified position. NOTE: If excessive force is applied to roller bearing, the roller bearing will not turn easily.
  3. After fitting a new O-ring to the shaft, attach the drive pinion collar to the shaft.
  4. Tighten the new lock nuts using ST1, ST2 and ST3. Use the calculation below to calculate the tightening torque. 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: TIGHTENING TORQUE REFERENCE 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 18667AA010 HOLDER ST2 499787700 WRENCH ST3 499787500 ADAPTER NOTE: Attach ST2 to torque wrench as straight as possible.
  5. 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 - 38.1N (0.776 - 3.88 kgf, 1.7 - 8.6 lb)
  6. Crimp the locknut in 2 locations.
  7. Measure the dimension "B" of the drive pinion shaft. ST 398643600 GAUGE
  8. Calculate the thickness "t" (mm) of the drive pinion shim. t = 6.5±0.0625 - (B - A)
  9. Select three or less shims from following table. DRIVE PINION SHIM REFERENCE Drive pinion shim Part number Thickness mm (in) 31451AA180 0.150 (0.0059) 31451AA190 0.175 (0.0069) 31451AA200 0.200 (0.0079) 31451AA210 0.225 (0.0089) 31451AA220 0.250 (0.0098) 31451AA230 0.275 (0.0108)
  1. Remove the transmission assembly from vehicle body. < Ref. to «REMOVAL»(ref-306924-S37789396842008122600000) , Automatic Transmission Assembly. >
  2. Pull out the torque converter assembly. < Ref. to «REMOVAL»(ref-306924-S27511869232008122600000) , Torque Converter Assembly. >
  3. Remove the transmission harness connector from stay.
  4. Remove the oil charge pipe. < Ref. to «REMOVAL»(ref-306924-S36410707882008122600000) , Oil Charge Pipe. >
  5. Remove the ATF inlet and outlet pipes. < Ref. to «REMOVAL»(ref-306924-S38540553782008122600000) , ATF Cooler Pipe and Hose. >
  6. Separate the converter case from the transmission case. < Ref. to «REMOVAL»(ref-306924-S15315503632008122600000) , Converter Case. >
  7. Remove the differential side retainers using ST. ST 18630AA010 WRENCH COMPL RETAINER NOTE: Hold the differential case assembly by hand to avoid damaging the retainer mounting hole of the converter case.
  8. Remove the differential assembly while being careful not to damage the attachment part of retainer.

Scheme 614

Scheme 614: INSTALLATION
Scheme 614: INSTALLATION

Scheme 615

Scheme 615
Scheme 615
  1. When installing the front differential assembly to case, be careful not to damage the inside of case (particularly, the differential side retainer mating surface).
  2. Install the O-ring to left and right side retainer.
  3. Using the ST, install the side retainer. < Ref. to «INSTALLATION»(ref-306924-S24437936132008122600000) , Front Differential Assembly. > ST 18630AA010 WRENCH COMPL RETAINER
  4. Adjust the backlash of the front differential. < Ref. to «ADJUSTMENT»(ref-306924-S22677262462008122600000) , Front Differential Assembly. >
  5. Install the lock plate. Tightening torque: 25 N.m (2.5 kgf-m, 18.4 ft-lb)
  6. Install the converter case to the transmission case. < Ref. to «INSTALLATION»(ref-306924-S16295455252008122600000) , Converter Case. >
  7. Install the transmission harness connector to the stay.
  8. Install the ATF cooler pipe. < Ref. to «INSTALLATION»(ref-306924-S30885151132008122600000) , ATF Cooler Pipe and Hose. >
  9. Install the oil charge pipe together with an O-ring. < Ref. to «INSTALLATION»(ref-306924-S11223598222008122600000) , Oil Charge Pipe. >
  10. Install the torque converter assembly. < Ref. to «INSTALLATION»(ref-306924-S12776292312008122600000) , Toque Converter Assembly. >
  11. Install the transmission assembly to the vehicle. < Ref. to «INSTALLATION»(ref-306924-S06651075452008122600000) , Automatic Transmission Assembly. >

Scheme 616

Scheme 616: DIFFERENTIAL CASE ASSEMBLY
Scheme 616: DIFFERENTIAL CASE ASSEMBLY

Scheme 617

Scheme 617
Scheme 617

Scheme 618

Scheme 618
Scheme 618
  1. Remove the taper roller bearing using the ST and a 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 case (RH) and case (LH).
  3. Pull out the straight pin and shaft, and then remove the differential bevel gear, washer and differential bevel pinion.

More articles — Automatic Transmission (5AT)