Automatic Transmission 5AT: Other Subaru Outback BR

OIL PUMP

OIL PUMP SPECIFICATIONS

TRANSMISSION CONTROL ELEMENT

TRANSMISSION CONTROL ELEMENT SPECIFICATIONS

TRANSMISSION GEAR RATIO

TRANSMISSION GEAR RATIO SPECIFICATIONS

PLANETARY GEAR AND PLATE

PLANETARY GEAR AND PLATE SPECIFICATIONS

SELECTOR POSITION

SELECTOR POSITION SPECIFICATIONS

TRANSFER

TRANSFER SPECIFICATIONS

FINAL REDUCTION GEAR

FINAL REDUCTION GEAR SPECIFICATIONS

RECOMMENDED GEAR OIL

RECOMMENDED GEAR OIL SPECIFICATIONS Lubrication oil Front differential oil capacity l (US qt, Imp qt) 1.3 - 1.5 (1.4 - 1.6, 1.1 - 1.3)

Scheme 141

Scheme 142

Tightening torque: N.m (kgf-m, ft-lb)

T1: 5(0.5, 3.7)

T2: 13 (1.3, 9.6)

T3: 20 (2.0, 14.8)

T4: 25 (2.5, 18.4)

T5: 40 (4.1, 29.5)

T6: 41 (4.2, 30.2)

T7: 45 (4.6, 33.2)

T8: 70 (7.1, 51.6)

T9: 90 (9.2, 66.4)

Scheme 143

Tightening torque: N.m (kgf-m, ft-lb)

T1: 10 (1.0, 7.4)

T2: 13 (1.3, 9.6)

Scheme 144

Scheme 145

Scheme 146

Scheme 147

Scheme 148

Tightening torque: N.m (kgf-m, ft-lb)

T: 7 (0.7, 5.2)

Scheme 149

Tightening torque: N.m (kgf-m, ft-lb)

T1: 25 (2.5, 18.4)

T2: 70 (7.1, 51.6)

Scheme 150

Tightening torque: N.m (kgf-m, ft-lb)

T1: 13(1.3, 9.6)

T2: 25 (2.5, 18.4)

T3: 70 (7.1, 51.6)

T4: 116 (11.8, 85.6)

Scheme 151

Tightening torque: N.m (kgf-m, ft-lb)

T1: 6 (0.6, 4.4)

T2: 7 (0.7, 5.2)

T3: 18 (1.8, 13.3)

T4: 25 (2.5, 18.4)

T5: Ref. to PARKING PAWL .

Scheme 152

Tightening torque: N.m (kgf-m, ft-lb)

T: 7.5 (0.8, 5.5)

Scheme 153

Tightening torque: N.m (kgf-m, ft-lb)

T1: 35 (3.6, 25.8)

T2: 40 (4.1, 29.5)

T3: 45 (4.6, 33.2)

T4: 75 (7.6, 55.3)

CAUTION

1. Wear appropriate work clothing, including a cap, protective goggles and protective shoes when performing any work.
2. Remove contamination including dirt and corrosion before removal, installation or disassembly.
3. Keep the disassembled parts in order and protect them from dust and dirt.
4. Until the oil pan is removed, do not place with the oil pan side facing up to prevent foreign matter from entering the valve body.
5. Before removal, installation or disassembly, be sure to clarify the failure. Avoid unnecessary removal, disassembly and replacement.
6. When disassembling the case and other light alloy parts, disassemble them by slightly tapping with a plastic hammer. Do not pry apart with screwdrivers or other tools.
7. Vehicle components are extremely hot after driving. Be wary of receiving burns from heated parts.
8. Use SUBARU genuine gear oil, grease or equivalent. Do not mix them of different grades or manufacturers.
9. Be sure to tighten bolts and nuts to the specified torque.
10. Place shop jacks or rigid racks at the specified points.
11. Apply gear oil onto sliding or revolving surfaces before installation.
12. Replace deformed or damaged snap rings with new parts.
13. Before installing O-rings or oil seals, apply sufficient amount of ATF fluid to avoid damage and deformation.
14. Be careful not to incorrectly install or fail to install O-rings, snap rings and other such parts.
15. Before securing a part on a vise, place cushioning material such as wood blocks, aluminum plate, or cloth between the part and the vise.
16. Avoid damaging the mating surface of the case.
17. Before applying liquid gasket, completely remove the old liquid gasket.

GENERAL TOOL

GENERAL TOOL CHART

CONDITION CHECK

Note. When replacing ATF, check the inside condition of transmission body by inspecting the drained ATF.

FLUID CONDITION CHART

Scheme 154

Scheme 155

1. Park the vehicle on a level surface.
2. Remove the collector cover. NOTE: Follow the steps below when removing the collector cover. Pull up the two points at the rear (A). Pull up the two points at the front (B) while moving them forward.
3. Remove the oil level gauge and wipe it clean.
4. Reinsert the level gauge all the way. Make sure the level gauge is inserted correctly and in the proper orientation.
5. Remove the oil level gauge again, and check the level of differential gear oil. If the differential gear oil level is below "L" line, add oil to bring the level up to "F" line. NOTE: To prevent overfilling the differential gear oil, do not add oil above the "F" line.

Scheme 156

1. Lift up the vehicle.
2. Remove the differential gear oil drain plug using TORX® bit T70, and then drain differential gear oil. CAUTION: Immediately after the vehicle has been running or after idling for a long time, the differential gear oil will be hot. Be careful not to burn yourself. Be careful not to spill differential gear oil on the exhaust pipe to prevent it from emitting smoke or causing a fire. If differential gear oil is spilled on the exhaust pipe, wipe it off completely.
3. Tighten the differential gear oil drain plug using TORX® bit T70. NOTE: Use a new gasket. Tightening torque: 70 N.m (7.1 kgf-m, 51.6 ft-lb)
4. Lower the vehicle.
5. Pour gear oil into the level gauge hole. Recommended gear oil: Ref. to «RECOMMENDED GEAR OIL»(ref-371902-S36191986462010091900000) , SPECIFICATION, General Description. Gear oil capacity: 1.3 - 1.5 l (1.4 - 1.6 US qt, 1.1 - 1.3 Imp qt)
6. Check the level of differential gear oil. Ref. to «INSPECTION»(ref-371902-S42188848372010091900000) , Differential Gear Oil.

GENERAL PRECAUTION

Road tests should be conducted to properly diagnose the condition of automatic transmission.

Note. When performing the test, do not exceed posted speed limit.

D RANGE SHIFT FUNCTION

Check shifting between 1st <--> 2nd <--> 3rd <--> 4th <--> 5th while driving on normal city streets.

D RANGE SHIFT SHOCK

Check the shock level when shifting up during normal driving.

KICK-DOWN FUNCTION

Check kick-down for each gear. Check the shock level during kick-down at the same time.

LOCK-UP FUNCTION

When the accelerator is lightly depressed while driving on a flat road in lock-up range, check that RPM does not change abruptly.

OIL LEAKAGE

After the driving test, inspect for oil leaks from the transmission body.

MEASUREMENT

Note. If the clutch or brake shows a sign of slippage, or shifting interval is not correct, check the line pressure.

1. Excessive shock during up-shift may be due to the line pressure being too high.
2. In many cases, slippage or inability to operate the vehicle may be due to insufficient oil pressure for the operation of clutch, brake or control valve.

Scheme 157

1. Lift up the vehicle.
2. Remove the test plug and install the ST. ST 498897200 OIL PRESSURE ADAPTER
3. Set the ST1 and ST2. ST1 498897200 OIL PRESSURE ADAPTER ST2 498575400 OIL PRESSURE GAUGE ASSY
4. Lower the vehicle, and pull ST2, which were set in step 3 ), into the vehicle.
5. Connect the Subaru Select Monitor to the data link connector and read the current data. Ref. to «READ CURRENT DATA»(ref-371942-S06520178292010091900000) .
6. Perform the line pressure test. NOTE: Do not perform the line pressure test for 5 seconds or more at a time. Doing so will make the engine oil and ATF deteriorate and the clutch and brake to be adversely affected. After performing the line pressure test, be sure to cool down the engine for at least one minute with the select lever set in "P" or "N" range and with the idle speed at 1,200 RPM or less. Fully close or fully open the throttle valve in order to match the "P/L solenoid target pressure" displayed on the Subaru Select Monitor. THROTTLE OPENING ANGLE CHART Range of the select lever Throttle opening angle ATF temperature condition "P/L Solenoid Target Pressure" displayed on the Subaru Select Monitor kPa Standard line pressure kPa (kg/cm 2 , psi) 2nd gear of manual mode Full closed 45 - 55°C (113 - 131°F) 500 - 700 Target pressure: -10 - +190 (Target pressure: -0.10 - +1.94, Target pressure: -1.45 - +27.5) Full open 2,150 1,320 - 1,520 (13.46 - 15.50, 191.4 - 220.4) R Full open 2,150 1,660 - 1,860 (16.93 - 18.97, 240.7 - 269.7)
7. Remove the ST and install the test plug. Tightening torque: 13 N.m (1.3 kgf-m, 9.6 ft-lb)

Scheme 158

1. Lift up the vehicle.
2. Remove the bolts holding the heat shield cover, and move the heat shield cover to the rear.
3. Remove the test plug and install the ST. CAUTION: Be careful not to cut yourself on the heat shield cover when removing the test plugs and setting the ST. ST 498897800 OIL PRESSURE ADAPTER SET
4. Set the ST. ST 498575400 OIL PRESSURE GAUGE ASSY
5. Lower the vehicle, and pull ST, which were set in step 4 ), into the vehicle.
6. Connect the Subaru Select Monitor to the data link connector and read the current data. Ref. to «READ CURRENT DATA»(ref-371942-S06520178292010091900000) .
7. Perform the transfer clutch pressure test. NOTE: Do not perform the transfer clutch pressure test for 5 seconds or more at a time. Doing so will make the engine oil and ATF deteriorate and the clutch and brake to be adversely affected. After performing the transfer clutch pressure test, be sure to cool down the engine for at least one minute with the select lever set in the "P" or "N" range, and at an idle speed of 1,200 RPM or less. Adjust the throttle valve angle in order to obtain the "T/F solenoid target pressure" displayed on the Subaru Select Monitor. THROTTLE OPENING ANGLE CHART Range of the select lever Throttle opening angle ATF temperature condition "T/F Solenoid Target Pressure" displayed on the Subaru Select Monitor kPa Standard transfer clutch pressure kPa (kg/cm 2 , psi) 2nd gear of manual mode Full open 45 - 55°C (113 - 131°F) 1,200 990 - 1,190 (10.09 - 12.13, 143.5 - 172.5) Partial throttle 500 400 - 600 (4.08 - 6.12,58.0 - 87.0) N Full closed 0 0 - 50 (0 - 0.51,0 - 7.2)
8. Remove the ST and install the test plug. Tightening torque: 13 N.m (1.3 kgf-m, 9.6 ft-lb)
9. Install the heat shield cover. Ref. to «INSTALLATION»(ref-371913-S24263252922010091900000) , Heat Shield Cover.

Scheme 159

Scheme 160

Scheme 161

Scheme 162

Scheme 163

Scheme 164

Scheme 165

Scheme 166

Scheme 167

Scheme 168

Scheme 169

Scheme 170

Scheme 171

Scheme 172

Scheme 173

Scheme 174

Scheme 175

Scheme 176

Scheme 177

Scheme 178

Scheme 179

Scheme 180

Scheme 181

Scheme 182

Scheme 183

Scheme 184

1. Set the vehicle on a lift.
2. Remove the front wheels.
3. Fully open the front hood.
4. Disconnect the ground cable from battery.
5. Remove the collector cover. NOTE: Follow the steps below when removing the collector cover. Pull up the two points at the rear (A). Pull up the two points at the front (B) while moving them forward.
6. Remove the air intake duct. Ref. to «REMOVAL»(ref-371896-S20541353172010091900000) , Air Intake Duct.
7. Remove the 10 clips and detach the grille bracket.
8. Remove the air intake boot. Ref. to «REMOVAL»(ref-371896-S05520593882010091900000) , Air Intake Boot.
9. Disconnect the following connectors.
10. Disconnect the ground cable.
11. Remove the air breather hose. Ref. to «REMOVAL»(ref-371902-S25450391842010091900000) , Air Breather Hose.
12. Remove the starter. Ref. to «REMOVAL»(ref-371915-S27522616522010091900000) , Starter.
13. Remove the engine hanger rear.
14. Separate the torque converter from drive plate. CAUTION: Be careful not to drop bolts into converter housing. Be careful not to damage the mounting bolts. Remove the service hole plug. Remove the bolts which hold torque converter to drive plate. Remove the four bolts by rotating the crank pulley a little at a time. Make sure the torque converter moves freely by rotating with finger through the starter installation hole.
15. Attach the ST to the converter case. ST 498277200 STOPPER SET
16. Attach the ST to the engine. Tightening torque: 19 N.m (1.9 kgf-m, 14.0 ft-lb) ST 18360AA020 HANGER
17. Lift up the vehicle.
18. Remove the under cover. Ref. to «REMOVAL»(ref-371913-S09538241932010091900000) , Front Under Cover.
19. Remove the front and rear exhaust pipes. Ref. to «REMOVAL»(ref-371938-S37097172362010091900000) , Front Exhaust Pipe. Ref. to «REMOVAL»(ref-371938-S08736757402010091900000) , Rear Exhaust Pipe.
20. Remove the heat shield cover.
21. Remove the steering shaft universal joint. Ref. to «REMOVAL»(ref-371911-S09090447772010091900000) , Universal Joint.
22. Remove the ATF drain plug to drain ATF.
23. Remove the oil charge pipe.
24. Disconnect the connector from turbine speed sensor 1.
25. Remove the turbine speed sensor 1 connector mounting bolt and rotate the sensor by 180°. CAUTION: Failure to follow this procedure may cause the interference between vehicle body and sensor while removing/installing transmission, and resulting in damage.
26. Remove the propeller shaft. Ref. to «REMOVAL»(ref-371909-S33653701722010091900000) , Propeller Shaft.
27. Remove the select cable. Ref. to «REMOVAL»(ref-371931-S28533952912010091900000) , Select Cable.
28. Disconnect the ATF cooler inlet and outlet hose from the ATF cooler inlet and outlet pipe.
29. Remove the front stabilizer bracket. Ref. to «REMOVAL»(ref-371907-S03605187482010091900000) , Front Stabilizer.
30. Remove the bolts which secure front ball joint to the housing. Ref. to «REMOVAL»(ref-371907-S07837666632010091900000) , Front Ball Joint.
31. Pull out the drive shaft from transmission.
32. Lower the vehicle.
33. Remove the nuts connecting the engine mounting and the transmission main mounting bracket.
34. Remove the radiator upper brackets.
35. Set the ST on the vehicle and hang the engine. CAUTION: Set the ST so that the chain does not contact the sensor and other parts while hanging the engine. Set the arms of ST (ENGINE HANGER) at the locations shown in the figure. ST1 99099AJ000 SPECIAL TOOL ENGINE HANGER ST2 99099AJ010 SPECIAL TOOL CHAIN BALANCER GENERAL TOOL Sling chain GENERAL TOOL Screw shackle
36. Lift the radiator by approximately 30 mm and remove the front cushion rubber. NOTE: The front cushion rubber cannot be removed from the vehicle unless the radiator is lifted due to a small clearance between the radiator and engine. Lift the radiator up and keep the position with cloth or other material placed under the radiator.
37. Attach the ST with the front cushion rubber mounting bolts and nuts. CAUTION: Do not tighten the nuts on the engine mount excessively, or the engine mounting bracket may be deformed. Tightening torque: 25 N.m (2.5 kgf-m, 18.4 ft-lb) ST 41099AJ010 SPECIAL TOOL H6
38. Remove the ST (ENGINE HANGER). NOTE: Operation is less efficient with the ST (ENGINE HANGER) attached. Remove it temporarily.
39. Remove the transmission main mounting bracket.
40. Remove the transmission mounting bolt (upper side).
41. Attach the ST (ENGINE HANGER) again.
42. Lift up the vehicle.
43. Set the transmission jack under the transmission.
44. Remove the rear crossmember from the vehicle.
45. Remove the transmission mounting bolt and nut (lower side).
46. Remove the transmission.
47. Remove the rear crossmember and cushion rubber from the transmission.

Scheme 185

Scheme 186

Scheme 187

Scheme 188

Scheme 189

Scheme 190

Scheme 191

Scheme 192

Scheme 193

Scheme 194

Scheme 195

Scheme 196

1. Replace the front differential side retainer oil seal. Remove the oil seal by using flat tip screwdriver etc. Using the ST, install the oil seal by lightly tapping with a plastic hammer. NOTE: Use a new oil seal. Check the identification marks (L, R) during installation not to mix up the oil seal RH and LH. Apply gear oil to the oil seal lips. Be sure to replace the differential side retainer oil seal whenever the front drive shaft is removed from the transmission. ST 18675AA000 DIFFERENTIAL SIDE OIL SEAL INSTALLER
2. Attach the ST to converter case. ST 498277200 STOPPER SET
3. Install the rear crossmember and cushion rubber to the transmission. Tightening torque: T1: 35 N.m (3.6 kgf-m, 25.8 ft-lb) T2: 40 N.m (4.1 kgf-m, 29.5 ft-lb)
4. Tap the transmission hanger in the rear side of transmission with a rubber hammer to bend it until it is in close contact with the transmission case. CAUTION: Do not apply excessive load or impact to the transmission case.
5. While lifting up the transmission gradually using transmission jack, install the transmission to the engine.
6. Install the engine mounting bolt and nut (lower side). Tightening torque: 50 N.m (5.1 kgf-m, 36.9 ft-lb)
7. Install the transmission rear crossmember. Tightening torque: 75 N.m (7.6 kgf-m, 55.3 ft-lb)
8. Remove the transmission jack.
9. Lower the vehicle.
10. Install the engine mounting bolt (upper side). Tightening torque: 50 N.m (5.1 kgf-m, 36.9 ft-lb)
11. Remove the ST (ENGINE HANGER).
12. Install the transmission main mounting bracket. Tightening torque: 75 N.m (7.6 kgf-m, 55.3 ft-lb)
13. Attach the ST (ENGINE HANGER) again.
14. Remove the ST and install the front cushion rubber. Lift the radiator by approximately 30 mm and install the front cushion rubber. NOTE: The front cushion rubber cannot be installed to the vehicle unless the radiator is lifted due to a small clearance between the radiator and engine. Lift the radiator up and keep the position with cloth or other material placed under the radiator. Tightening torque: T1:25 N.m (2.5 kgf-m, 18.4 ft-lb) T2:45 N.m (4.6 kgf-m, 33.2 ft-lb) Install the radiator upper brackets. Tightening torque: 12 N.m (1.2 kgf-m, 8.9 ft-lb)
15. Remove the ST from the vehicle.
16. Tighten the nuts connecting the engine mounting and the transmission main mounting bracket. Tightening torque: 45 N.m (4.6 kgf-m, 33.2 ft-lb)
17. Remove the ST from converter case.
18. Install the torque converter to drive plate. CAUTION: Be careful not to drop bolts into converter housing. Be careful not to damage the mounting bolts. Install the bolts which connect the torque converter and drive plate. Install all four bolts by rotating the crank pulley a little at a time. Install the service hole plug. Tightening torque: 25 N.m (2.5 kgf-m, 18.4 ft-lb)
19. Install the starter. Ref. to «INSTALLATION»(ref-371915-S06872456192010091900000) , Starter.
20. Lift up the vehicle.
21. Set the ST to side retainer. ST 28399SA010 OIL SEAL PROTECTOR
22. Install the front drive shaft into the transmission. Ref. to «INSTALLATION»(ref-371909-S19257939972010091900000) , Front Drive Shaft.
23. Connect the ATF cooler inlet and outlet hose to the ATF cooler inlet and outlet pipe.
24. Insert the ball joint into housing. Ref. to «INSTALLATION»(ref-371907-S13591955662010091900000) , Front Ball Joint.
25. Install the front stabilizer bracket. Ref. to «INSTALLATION»(ref-371907-S24289471772010091900000) , Front Stabilizer.
26. Install the propeller shaft. Ref. to «INSTALLATION»(ref-371909-S25688249532010091900000) , Propeller Shaft.
27. Install the select cable. Ref. to «INSTALLATION»(ref-371931-S15423923542010091900000) , Select Cable.
28. Rotate the turbine speed sensor 1 by 180° and then restore it to the original position to install. Then, connect the connector. Tightening torque: 7 N.m (0.7 kgf-m, 5.2 ft-lb)
29. Install the oil charge pipe. NOTE: Use new gaskets and O-rings. Tightening torque: 38 N.m (3.9 kgf-m, 28.0 ft-lb)
30. Install the steering shaft universal joint. Ref. to «INSTALLATION»(ref-371911-S24455339282010091900000) , Universal Joint.
31. Install the heat shield cover. Ref. to «INSTALLATION»(ref-371913-S24263252922010091900000) , Heat Shield Cover.
32. Install the front and rear exhaust pipe. Ref. to «INSTALLATION»(ref-371938-S05858096482010091900000) , Front Exhaust Pipe. Ref. to «INSTALLATION»(ref-371938-S01176927902010091900000) , Rear Exhaust Pipe.
33. Install the under cover. Ref. to «INSTALLATION»(ref-371913-S15712020302010091900000) , Front Under Cover.
34. Lower the vehicle.
35. Remove the ST and install the engine hanger rear. Tightening torque: 19 N.m (1.9 kgf-m, 14.0 ft-lb)
36. Connect the following connectors.
37. Install the ground cable. Tightening torque: 13 N.m (1.3 kgf-m, 9.6 ft-lb)
38. Pour ATF from the oil charge pipe. Ref. to «AUTOMATIC TRANSMISSION FLUID»(ref-371902-S14762472072010091900000) .
39. Install the air breather hose. Ref. to «INSTALLATION»(ref-371902-S15173255992010091900000) , Air Breather Hose.
40. Install the air intake boot. Ref. to «INSTALLATION»(ref-371896-S02881003482010091900000) , Air Intake Boot.
41. Attach the grille bracket.
42. Install the air intake duct. Ref. to «INSTALLATION»(ref-371896-S14011537962010091900000) , Air Intake Duct.
43. Install the collector cover.
44. Connect the ground cable to battery.
45. Perform Clear Memory 2 operation. Ref. to «CLEAR MEMORY MODE»(ref-371942-S04843487322010091900000) .
46. Perform learning operation. Ref. to «LEARNING CONTROL»(ref-371942-S05358684462010091900000) .
47. 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.

Scheme 197

1. Disconnect the ground cable from battery.
2. Lift up the vehicle.
3. Remove the under cover. Ref. to «REMOVAL»(ref-371913-S09538241932010091900000) , Front Under Cover.
4. Remove the front exhaust pipe. Ref. to «REMOVAL»(ref-371938-S37097172362010091900000) , Front Exhaust Pipe.
5. Remove the heat shield cover.
6. Set the transmission jack under transmission. Make sure that the support plate of transmission jack does not touch the oil pan.
7. Remove the transmission rear crossmember.
8. Remove the rear cushion rubber.

TRANSMISSION REAR CROSSMEMBER & REAR CUSHION RUBBER

1. Install the rear cushion rubber. Tightening torque: T1:35 N.m (3.6 kgf-m, 25.8 ft-lb) T2:40 N.m (4.1 kgf-m, 29.5 ft-lb)
2. Install the crossmember. Tightening torque: 75 N.m (7.6 kgf-m, 55.3 ft-lb)
3. Remove the transmission jack.
4. Install the heat shield cover. Ref. to «INSTALLATION»(ref-371913-S24263252922010091900000) , Heat Shield Cover.
5. Install the front exhaust pipe. Ref. to «INSTALLATION»(ref-371938-S05858096482010091900000) , Front Exhaust Pipe.
6. Install the under cover. Ref. to «INSTALLATION»(ref-371913-S15712020302010091900000) , Front Under Cover.
7. Lower the vehicle.
8. Connect the ground cable to battery.

Check crossmember for bends or damage. Check that there are no cracks, hardening, or damage on cushion rubbers.

FRONT BRAKE

Check the following items.

1. Drive plate facing for wear or damage
2. Snap ring for wear, return spring for damage, and retainer for damage
3. Piston for damage
4. D-ring for damage

Check the following items.

1. Oil pump cover and oil seal for breakage or damage
2. Oil pump body for scratch or damage

Scheme 198

Scheme 199

1. Check the seal ring and oil seal for breaks and damage.
2. Check other parts for dents or faults.
3. Oil pump rotor assembly selection Tip clearance Install the inner rotor and outer rotor to oil pump housing. With rotor gears facing each other, measure the crest-to-crest clearance. Tip clearance: 0.02 - 0.15 mm (0.0008 - 0.0059 in) Side clearance Set a depth gauge to oil pump housing, then measure the oil pump housing-to-rotor clearance. Side clearance: 0.02 - 0.045 mm (0.0008 - 0.0018 in) If the depth and/or side clearance are not within the specification, replace the rotor assembly. OIL PUMP ROTOR ASSEMBLY SPECIFICATIONS Oil pump rotor assembly Part No. Thickness mm (in) 15008AA130 11.37 - 11.38 (0.4476 - 0.4480) 15008AA140 11.38 - 11.39 (0.4480 - 0.4484) 15008AA150 11.39 - 11.40 (0.4484 - 0.4488) Check the total end play and adjust it to be within specifications. Ref. to «ADJUSTMENT»(ref-371902-S27804520132010091900000) , AT Main Case.

Scheme 200

1. Remove the transmission assembly from the vehicle. Ref. to «REMOVAL»(ref-371902-S37686204272010091900000) , Automatic Transmission Assembly.
2. Pull out the torque converter assembly. Ref. to «REMOVAL»(ref-371902-S04595510652010091900000) , Torque Converter Assembly.
3. Remove the transmission harness connector from stay.
4. Remove the ATF inlet and outlet pipes. Ref. to «REMOVAL»(ref-371902-S13421677622010091900000) , ATF Cooler Pipe and Hose.
5. Separate the converter case and transmission case. Ref. to «REMOVAL»(ref-371902-S41955636532010091900000) , Converter Case.
6. Remove the drive pinion shaft mounting bolts, and then remove the drive pinion shaft assembly from oil pump cover.
7. Remove the oil pump cover from AT main case. Ref. to «OIL PUMP COVER»(ref-371902-S28735165422010091900000) .

SIDE RETAINER

Note. After adjusting the drive pinion backlash and tooth contact, remove and install the oil seal and O-ring.

Scheme 201

Scheme 202

Scheme 203

Scheme 204

Scheme 205

1. Remove the O-ring.
2. Remove the oil seal.
3. Remove the split pin, and then remove the claw. ST 398527700 PULLER ASSY
4. Attach two claws to the outer race, and set the ST to side retainer. ST 398527700 PULLER ASSY
5. Restore the removed claws to original position, and install the pin and split pin.
6. Hold the shaft of ST to avoid removing from side retainer, and then remove the bearing outer race. NOTE: Replace the bearing inner and outer races as a single unit. ST 398527700 PULLER ASSY

Scheme 206

Scheme 207

Scheme 208

1. Install the washer, differential bevel gear and differential bevel pinion in the differential case (RH). Insert the pinion shaft.
2. Attach the straight pin in the reverse direction.
3. Install the washer and differential bevel gear to differential case (LH). Put the differential case (LH) on the differential case (RH), and assemble the two differential cases.
4. Install the hypoid driven gear and secure by tightening the bolt. Tightening torque: 70 N.m (7.1 kgf-m, 51.6 ft-lb)
5. Measurement of backlash (Selection of washer) Install the SUBARU genuine axle shaft to differential case. Part No. 38415AA070 Axle shaft Measure the gear backlash using ST1 and ST2, and then insert the ST2 through the access window of differential case. NOTE: Measure the backlash by applying a differential bevel pinion tooth between two differential bevel gear teeth. When measuring, fix the differential bevel pinion gear in place with a screwdriver covered with waste cloth, or a similar tool. Standard: 0.13 - 0.18 mm (0.0051 - 0.0071 in) ST1 498247001 MAGNET BASE ST2 498247100 DIAL GAUGE If the backlash is not within specification, select a washer from the table below. WASHER SPECIFICATIONS Washer Part No. Thickness mm (in) 803038021 0.95 (0.037) 803038022 1.00 (0.039) 803038023 1.05 (0.041)
6. Using the ST, install the taper roller bearing. ST 398487700 DRIFT

Note. Install the oil seal and O-ring of side retainer after the adjustment of backlash and tooth contact.

Scheme 209

1. Install the bearing outer race to side retainer.
2. Using the ST, install the oil seal. NOTE: Use a new oil seal. Apply gear oil to the oil seal lips, and install the oil seal while being careful not to deform the lip. Check the identification marks (L, R) during installation not to mix up the oil seal RH and LH. ST 18675AA000 DIFFERENTIAL SIDE OIL SEAL INSTALLER
3. Install a new O-ring.

REVERSE BRAKE

Check the following items.

1. Snap ring for wear, return spring for breakage, and spring retainer for deformation
2. Lip seal and D-ring for damage
3. Piston operation
4. Piston stroke

Scheme 210

Scheme 211

Scheme 212

1. Using the ST, measure the height "A" from the AT main case mating surface to convex surface of oil pump cover. ST 499575400 GAUGE
2. Using the ST, measure the depth "B" from the convex surface of oil pump cover to thrust bearing transferring surface. ST 499575400 GAUGE
3. Calculate the measured value from step 1 ) and 2 ), and then set the calculated value as "C". Calculation formula: C = A - B
4. Using the ST, measure the depth "D" from the AT main case mating surface to thrust bearing transferring surface of front sun gear. ST 499575400 GAUGE
5. Set the value as "E" which subtract the thickness of ST (499575400 GAUGE) from the measured value on step 4 ). Calculation: E (mm) = D - 15 [E (in) = D - 0.59]
6. Calculation formula: Select one thrust bearing from the table to adjust clearance within 0.25 - 0.55 mm (0.0098 - 0.0217 in). When clearances are 0.25 mm (0.0098 in): T (mm) = E - C + 0.03 [T (in) = E-C + 0.0012] When clearances are 0.55 mm (0.0217 in): T (mm) = E - C + 0.27 [T (in) = E-C + 0.0106] T: Thrust bearing thickness C: Distance from oil pump cover mating surface to rear end of oil pump cover E: Depth from mating surface of AT main case to bearing surface of front sun gear NOTE: Calculation formula for "T" above is applied when measuring with the ST (499575400 GAUGE). In the calculation without using ST, substitute the thickness of collar used to calculate the value "E" on step 5 ). THRUST BEARING SPECIFICATIONS Thrust bearing Part No. Thickness mm (in) 806548020 3.2 (0.126) 606548030 3.4 (0.134) 806548040 3.6 (0.142) 806548050 3.8 (0.150) 806548060 4.0 (0.157) 806548070 4.2 (0.165)

Scheme 213

Scheme 214

Scheme 215

1. Remove the transmission assembly from the vehicle. Ref. to «REMOVAL»(ref-371902-S37686204272010091900000) , Automatic Transmission Assembly.
2. Pull out the torque converter assembly. Ref. to «REMOVAL»(ref-371902-S04595510652010091900000) , Torque Converter Assembly.
3. Lift up the lever on the rear side of transmission harness connector, and then disconnect it from the stay.
4. Wrap vinyl tape around the nipple attached to the air breather hose.
5. Remove the transmission hanger COMPL.
6. Remove the control valve body assembly. Ref. to «REMOVAL»(ref-371902-S36943346192010091900000) , Control Valve Body.
7. Pull out the straight pin of manual plate.
8. Remove the bolts securing range select lever, and then remove the select lever, manual plate and parking rod. NOTE: Be careful not to damage the lips of press-fitted oil seal in the case.
9. Remove the detent spring.

Scheme 216

Scheme 217

1. Install the detent spring to the transmission case. Tightening torque: 7 N.m (0.7 kgf-m, 5.2 ft-lb)
2. Insert the range select lever, and tighten the bolts. Tightening torque: 6 N.m (0.6 kgf-m, 4.4 It-lb)
3. Insert the manual plate and parking rod.
4. Insert the straight pin to the manual plate.
5. Install the oil pan and the control valve body assembly. Ref. to «INSTALLATION»(ref-371902-S20954234102010091900000) , Control Valve Body.
6. Install the transmission hanger COM PL. Tightening torque: 41 N.m (4.2 kgf-m, 30.2 ft-lb)
7. Insert the transmission connector to the stay.
8. Install the air breather hose. Ref. to «INSTALLATION»(ref-371902-S15173255992010091900000) , Air Breather Hose.
9. Install the torque converter assembly. Ref. to «INSTALLATION»(ref-371902-S01601256022010091900000) , Torque Converter Assembly>
10. Install the transmission assembly to the vehicle. Ref. to «INSTALLATION»(ref-371902-S14197603732010091900000) , Automatic Transmission Assembly.