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Automatic Transmission 5AT: Removal & Installation Subaru Outback BR

Automatic Trans 45 illustrations ~2516 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 heat shield cover. Ref. to «INSTALLATION»(ref-371913-S24263252922010091900000) , Heat Shield Cover.
  4. Tighten the bolts which connect the front exhaust pipe and rear exhaust pipe. Tightening torque: 18 N.m (1.8 kgf-m, 13.3 ft-lb)
  5. Lower the vehicle.

Scheme 84

Scheme 84: REMOVAL
Scheme 84: REMOVAL
  1. Disconnect the ground cable from battery.
  2. Lift up the vehicle.
  3. Remove the front exhaust pipe. Ref. to «REMOVAL»(ref-371938-S37097172362010091900000) , Front Exhaust Pipe.
  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. Install the front exhaust pipe. Ref. to «INSTALLATION»(ref-371938-S05858096482010091900000) , Front Exhaust Pipe.
  4. Lower the vehicle.
  5. Connect the ground cable to battery.

Scheme 85

Scheme 85: REMOVAL
Scheme 85: REMOVAL

Scheme 86

Scheme 86
Scheme 86

Scheme 87

Scheme 87
Scheme 87
  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: Directly after the vehicle has been running or the engine has been long idle running, the ATF is 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 88

Scheme 88: INSTALLATION
Scheme 88: INSTALLATION

Scheme 89

Scheme 89
Scheme 89
  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, 5.9 ft-lb)
  3. Connect the control valve connector and front vehicle speed sensor 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) or equivalent
  6. Install the oil pan by equally tightening the bolts. Tightening torque: 5 N.m (0.5 kgf-m, 3.7 ft-lb)
  7. Lower the vehicle.
  8. Connect the ground cable to battery.
  9. Pour ATF through the oil charge pipe. Ref. to «AUTOMATIC TRANSMISSION FLUID»(ref-371902-S14762472072010091900000) .
  10. Check the ATF level. Ref. to «INSPECTION»(ref-371902-S33705940982010091900000) , Automatic Transmission Fluid.
  11. Perform Clear Memory 2 operation. Ref. to «CLEAR MEMORY MODE»(ref-371942-S04843487322010091900000) .
  12. Perform learning operation. Ref. to «LEARNING CONTROL»(ref-371942-S05358684462010091900000) .
  13. 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.
  1. Connect the air breather hose.
  2. Install the air intake boot. Ref. to «INSTALLATION»(ref-371896-S02881003482010091900000) , Air Intake Boot.
  3. Install the collector cover.

REMOVAL

  1. Remove the transmission assembly. Ref. to «REMOVAL»(ref-371902-S37686204272010091900000) , Automatic Transmission Assembly.
  2. Disconnect the rear vehicle speed sensor connector.
  3. Remove the rear vehicle speed sensor.
  4. Remove the extension case.
  1. Attach the selected reduction driven gear shim to end surface of reduction driven gear with vaseline. Ref. to «ADJUSTMENT»(ref-371902-S36277079342010091900000) , 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-371902-S14197603732010091900000) , Automatic Transmission Assembly.

Scheme 90

Scheme 90: DISASSEMBLY
Scheme 90: DISASSEMBLY

Scheme 91

Scheme 91
Scheme 91
  1. Take out the transfer clutch and rear drive shaft 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. Supply compressed air to remove the clutch piston.
  4. Remove the dust cover from extension case.
  5. Remove the oil seal from the extension case.

Scheme 92

Scheme 92: ASSEMBLY
Scheme 92: ASSEMBLY

Scheme 93

Scheme 93
Scheme 93
  1. Press-fit the oil seal using the ST and press. NOTE: Use a new oil seal. 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-371902-S11881166012010091900000) , Transfer Clutch.
  6. Install the rear drive shaft.
  1. Remove the transmission assembly from vehicle body. Ref. to «REMOVAL»(ref-371902-S37686204272010091900000) , Automatic Transmission Assembly.
  2. Remove the extension case, and then remove the transfer clutch. Ref. to «REMOVAL»(ref-371902-S41849151192010091900000) , Extension Case. Ref. to «DISASSEMBLY»(ref-371902-S04856099652010091900000) , Extension Case.
  1. Select the rear drive shaft shim. Ref. to «ADJUSTMENT»(ref-371902-S39559671762010091900000) , Transfer Clutch.
  2. Select driven plate No. 3 Ref. to «ADJUSTMENT»(ref-371902-S39559671762010091900000) , Transfer Clutch.
  3. Install the extension case. Ref. to «INSTALLATION»(ref-371902-S13329184862010091900000) , Extension Case.
  4. Install the transmission assembly to the vehicle. Ref. to «INSTALLATION»(ref-371902-S14197603732010091900000) , Automatic Transmission Assembly.
  1. Remove the transmission assembly from the vehicle. Ref. to «REMOVAL»(ref-371902-S37686204272010091900000) , Automatic Transmission Assembly.
  2. Remove the rear vehicle speed sensor, and then remove the extension case. Ref. to «REMOVAL»(ref-371902-S41849151192010091900000) , Extension Case.
  3. Pull out the rear driveshaft from center differential assembly.
  4. Remove the drive plate and driven plate.
  1. Select shims. Ref. to «ADJUSTMENT»(ref-371902-S39559671762010091900000) , Transfer Clutch.
  2. Install the 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-371902-S13329184862010091900000) , Extension Case.
  5. Install the transmission assembly to the vehicle. Ref. to «INSTALLATION»(ref-371902-S14197603732010091900000) , Automatic Transmission Assembly.

Scheme 94

Scheme 94: DISASSEMBLY
Scheme 94: DISASSEMBLY

Scheme 95

Scheme 95
Scheme 95
  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-371902-S36277079342010091900000) , Reduction Driven Gear.
  4. Join the transmission case and the extension case, and then install the rear vehicle speed sensor. Ref. to «INSTALLATION»(ref-371902-S13329184862010091900000) , Extension Case.
  5. Install the transmission assembly to the vehicle. Ref. to «INSTALLATION»(ref-371902-S14197603732010091900000) , Automatic Transmission Assembly.

Scheme 96

Scheme 96: DISASSEMBLY
Scheme 96: DISASSEMBLY

Scheme 97

Scheme 97
Scheme 97

Scheme 98

Scheme 98
Scheme 98

Scheme 99

Scheme 99
Scheme 99
  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 100

Scheme 100: ASSEMBLY
Scheme 100: ASSEMBLY

Scheme 101

Scheme 101
Scheme 101

Scheme 102

Scheme 102
Scheme 102
  1. Using the ST, install the parking gear. ST 499755602 PRESS
  2. Install the snap ring.
  3. Install the ball bearing to the reduction driven gear using a press. NOTE: Use a new ball bearing. 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-371902-S10707959732010091900000) , Rear Drive Shaft.
  3. Join the transmission case and the extension case, and then install the rear vehicle speed sensor. Ref. to «INSTALLATION»(ref-371902-S13329184862010091900000) , Extension Case.
  4. Install the transmission assembly to the vehicle. Ref. to «INSTALLATION»(ref-371902-S14197603732010091900000) , Automatic Transmission Assembly.

Scheme 103

Scheme 103: DISASSEMBLY
Scheme 103: DISASSEMBLY

Scheme 104

Scheme 104
Scheme 104

Scheme 105

Scheme 105
Scheme 105

Scheme 106

Scheme 106
Scheme 106
  1. Remove the seal ring.
  2. Remove the ball bearing using the ST and the press. ST 498077600 REMOVER
  3. Remove the snap ring, and pull out the pinion shaft from center differential assembly.
  4. Remove the pinion gear and washers from center differential assembly.
  5. Pull out the intermediate shaft and thrust bearing.

Scheme 107

Scheme 107: ASSEMBLY
Scheme 107: ASSEMBLY

Scheme 108

Scheme 108
Scheme 108
  1. Install the thrust bearing onto intermediate shaft.
  2. Insert the intermediate shaft into the center differential assembly.
  3. Install the pinion gears and washers.
  4. Insert the pinion shaft into the center differential assembly. NOTE: Insert the pinion shaft with the side with the plug side facing the front side (gear side). After inserting the pinion shaft, adjust its position so that the cutout portion on the front side is on the inner side.
  5. Install the snap ring.
  6. Using a press, press-fit the ball bearing into the center differential assembly. NOTE: Use a new ball bearing. 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-371902-S01601256022010091900000) , Torque Converter Assembly.
  3. Install the transmission harness connector to the stay.
  4. Install the ATF cooler pipe. Ref. to «INSTALLATION»(ref-371902-S42933691982010091900000) , ATF Cooler Pipe and Hose.
  5. Install the torque converter assembly. Ref. to «INSTALLATION»(ref-371902-S01601256022010091900000) , Torque Converter Assembly.
  6. Install the transmission assembly to the vehicle. Ref. to «INSTALLATION»(ref-371902-S14197603732010091900000) , Automatic Transmission Assembly.

Scheme 109

Scheme 109: FRONT BRAKE
Scheme 109: FRONT BRAKE

Scheme 110

Scheme 110
Scheme 110

Scheme 111

Scheme 111
Scheme 111
  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 112

Scheme 112: OIL PUMP
Scheme 112: OIL PUMP
  1. Take out the oil pump housing.
  2. Take out the oil pump body.

Scheme 113

Scheme 113: FRONT BRAKE
Scheme 113: FRONT BRAKE

Scheme 114

Scheme 114
Scheme 114
  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 "↑" 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 drive plate and driven plate.
  6. Install the snap ring.
  7. Measure the clearance between the retaining plate and snap ring. If the value exceeds the specification, replace the drive plate and driven plate as a set and select the retaining plate so that the value is within the specification. Front brake clearance specification: 0.7 - 1.1 mm (0.028 - 0.043 in) FRONT BRAKE RETAINING PLATE SPECIFICATIONS Front brake retaining plate Part No. Thickness mm (in) 31567AB130 3.4 (0.134) 31567AB140 3.6 (0.142) 31567AB150 3.8 (0.150) 31567AB160 4.0 (0.157)

Scheme 115

Scheme 115: OIL PUMP
Scheme 115: 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-371902-S21489317092010091900000) , Drive Pinion Shaft Assembly.
  3. Join the converter case with the transmission case. Ref. to «INSTALLATION»(ref-371902-S36953341792010091900000) , Converter Case.
  4. Install the transmission harness connector to the stay.
  5. Install the ATF cooler pipe. Ref. to «INSTALLATION»(ref-371902-S42933691982010091900000) , ATF Cooler Pipe and Hose.
  6. Install the torque converter assembly. Ref. to «INSTALLATION»(ref-371902-S01601256022010091900000) , Torque Converter Assembly.
  7. Install the transmission assembly to the vehicle. Ref. to «INSTALLATION»(ref-371902-S14197603732010091900000) , Automatic Transmission Assembly.

Scheme 116

Scheme 116: DISASSEMBLY
Scheme 116: DISASSEMBLY

Scheme 117

Scheme 117
Scheme 117

Scheme 118

Scheme 118
Scheme 118
  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 the shaft using a press and the ST. ST 498517000 REPLACER

Scheme 119

Scheme 119: ASSEMBLY
Scheme 119: ASSEMBLY

Scheme 120

Scheme 120
Scheme 120

Scheme 121

Scheme 121
Scheme 121

Scheme 122

Scheme 122
Scheme 122

Scheme 123

Scheme 123
Scheme 123
  1. Measure the dimension "A" of 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. Calculate the tightening torque using following formula. T2 = L2/(L1 + L2) x T1 T1: 116 N.m (11.8 kgf-m, 85.6 ft-lb) [Required torque setting] T2: Tightening torque L1: ST2 length 0.072 m (2.83 in) L2: Torque wrench length Example: TIGHTENING TORQUE Torque wrench length m (in) Tightening torque N.m (kgf-m, ft-lb) 0.4 (15.75) 98 (10.0,72.3) 0.45 (17.72) 100 (10.2,73.8) 0.5 (19.69) 101 (10.3,74.5) 0.55 (21.65) 102 (10.4,75.2) 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 (0.775 - 3.88 kgf, 1.7 - 8.6 lbf)
  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 (in) of the drive pinion shim. t = 6.5±0.0625 (0.256±0.0025) - (B - A)
  9. Select three or less shims from following table. DRIVE PINION SHIM SPECIFICATIONS Drive pinion shim Part No. 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 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 from the transmission case. Ref. to «REMOVAL»(ref-371902-S41955636532010091900000) , Converter Case.
  6. Remove the differential side retainers using ST. NOTE: Hold the differential case assembly by hand to avoid damaging the differential side retainer mounting hole of the converter case. ST 18630AA010 WRENCH COMPL RETAINER
  7. Remove the front differential assembly while being careful not to damage the attachment part of the retainer.

Scheme 124

Scheme 124: INSTALLATION
Scheme 124: INSTALLATION

Scheme 125

Scheme 125
Scheme 125
  1. When installing the front differential assembly to the 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 retainers.
  3. Using the ST, install the side retainer. Ref. to «ADJUSTMENT»(ref-371902-S18432784062010091900000) , Front Differential Assembly. ST 18630AA010 WRENCH COMPL RETAINER
  4. Adjust the backlash of the front differential. Ref. to «ADJUSTMENT»(ref-371902-S18432784062010091900000) , 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-371902-S36953341792010091900000) , Converter Case.
  7. Install the transmission harness connector to the stay.
  8. Install the ATF cooler pipe. Ref. to «INSTALLATION»(ref-371902-S42933691982010091900000) , ATF Cooler Pipe and 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.

Scheme 126

Scheme 126: DIFFERENTIAL CASE ASSEMBLY
Scheme 126: DIFFERENTIAL CASE ASSEMBLY

Scheme 127

Scheme 127
Scheme 127

Scheme 128

Scheme 128
Scheme 128
  1. Remove the taper roller bearing using the ST and the 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.

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