Continuously Variable Transmission: Diagnosis Subaru Outback BR

INSPECTION

Note. Stall test is extremely important in diagnosing the condition of CVT and engine. The test is necessary to measure the engine stall speeds in "R" and "D" range.

Purposes of the stall test

1. Operational check of forward clutch and reverse brake
2. Operational check of the torque converter assembly
3. Engine performance check

1. Place wheel chocks at the front and rear of all wheels and engage the electronic parking brake.
2. Turn the A/C OFF.
3. Using the Subaru Select Monitor, check if the throttle valve operates when you depress the accelerator pedal. Ref. to «READ CURRENT DATA FOR ENGINE (NORMAL MODE)»(ref-371914-S24953327312010091900000) , OPERATION, Subaru Select Monitor.
4. Check the engine oil level.
5. Check the coolant level.
6. Adjust the CVTF level. Ref. to «ADJUSTMENT»(ref-371903-S21010063132010091900000) , CVTF.
7. Increase the CVT temperature to 60 to 80°C (140 to 176°F) by idling the engine (with select lever set to "N" or "P" range).
8. Shift the select lever to "D" range.
9. Depress the accelerator pedal to the full while fully depressing the foot brake pedal with your left foot.
10. When the engine speed stabilizes, quickly record the engine speed and release accelerator pedal. Shift the select lever to "N" range. Let the engine idle for one minute or more to cool it down.
11. Shift to "R" range and perform the same stall test. NOTE: Do not perform a stall test for over 5 seconds at a time, (from closed throttle, fully open throttle to stall speed reading.) Failure to follow this instruction will cause the engine oil and CVTF to deteriorate and the clutch and brake to be adversely affected. Be sure to cool down the engine for at least one minute after each stall test with the select lever set in the "P" or "N" range and with the idle speed of 1,200 RPM or less. If the stall speed is higher than the specified range, attempt to finish the stall test in as short a time as possible, in order to prevent the CVT from sustaining damage. Stall speed standard: 2,400 - 3,100 RPM Stall test judgment

PROBABLE CAUSE CHART

Note. When the select lever is shifted while the engine is idling, there will be a certain time elapse or lag before shock is felt. This symptom helps to check the condition of forward clutch and reverse brake.

1. Perform the test at normal operation CVTF temperature of 60 - 80°C (140 - 176°F).
2. Be sure to allow one minute or more interval between tests.
3. Make three measurements and take the average value.

1. Apply the electronic parking brake.
2. Start the engine. Check the idling speed. (A/C OFF)
3. Shift the select lever from "N" to "D" range. Using a stop watch, measure the time elapsed from shifting the lever until the shock is felt. Time lag standard: 1.2 seconds or less If "N" --> "D" time lag is longer than specified: Secondary pressure (line pressure) is too low. Forward clutch worn Piston malfunction Control valve body malfunction Learning incomplete
4. In the same manner, measure the time lag when shifting "N" --> "R" range.

Time lag standard

1.5 seconds or less

If "N" --> "R" time lag is longer than specified

1. Secondary pressure (line pressure) is too low.
2. Reverse brake worn
3. Piston malfunction
4. Control valve body malfunction
5. Learning incomplete

Note. If the pulley and variator chain, clutch or brake show signs of slipping or shift feel is not correct, check the secondary pressure (line pressure). Connect Subaru Select Monitor to vehicle so as to measure the engine speed and actual secondary pressure (secondary pressure (line pressure)). 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.

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1. Remove the front wheel RH.
2. Lift up the vehicle.
3. Remove the plug for measuring secondary pressure (line pressure).
4. Attach ST1, ST2 and ST3 to transmission. ST1 18801AA000 OIL PRESSURE GAUGE ASSY ST2 18681AA000 PRESSURE GAUGE ADAPTER ST3 498897700 OIL PRESSURE ADAPTER SET NOTE: ST2 Used with genuine O-ring (part No. 806911080) attached to PRESSURE GAUGE ADAPTER.
5. Set the gauge so that it can be seen from the driver's seat.
6. Install the front wheel RH.
7. Using the Subaru Select Monitor, check if the throttle valve operates when you depress the accelerator pedal. Ref. to «READ CURRENT DATA FOR ENGINE (NORMAL MODE)»(ref-371914-S24953327312010091900000) , OPERATION, Subaru Select Monitor.
8. Check the engine oil level.
9. Check the coolant level. Ref. to «ENGINE COOLANT»(ref-371897-S22461305062010091900000) .
10. Adjust the CVTF level. Ref. to «ADJUSTMENT»(ref-371903-S21010063132010091900000) , CVTF.
11. Increase the CVT temperature to 60 to 80°C (140 to 176°F) by idling the engine (with select lever shift to "N" or "P" range).
12. Shift the select lever to "D" range.
13. Depress the accelerator pedal to the full while fully depressing the foot brake pedal with your left foot.
14. Immediately after the engine speed becomes steady, record the reading of the secondary pressure (line pressure), engine speed and actual secondary pressure on Subaru Select Monitor. And then release the accelerator pedal. Shift the select lever to "N" range. Let the engine idle for one minute or more to cool it down. NOTE: Do not continue the stall test for 5 seconds or more at a time (from fully closed throttle, fully open throttle to secondary pressure (line pressure) reading). Failure to follow this instruction will cause the engine oil and CVTF to deteriorate and the clutch and brake to be adversely affected. After performing the secondary pressure (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. Under each condition, check that the measured pressure matches almost totally with actual secondary pressure. When both measured pressure and actual secondary pressure are out of specification, judge as control valve malfunction. The value at stall is for reference because the pressure changes under different conditions or circumstances. The value at idling is steady because it is not affected by any condition or circumstance. SECONDARY PRESSURE CHART Secondary pressure (line pressure) standard Range Throttle Brake Secondary pressure (line pressure) (MPa (kgf/cm 2 , psi)) Stall D, R Full open ON 5 - 6 (51.0 - 61.2, 725 - 870) Idling P, N Full closed OFF 0.5 - 1.5 (5.1 -15.3,72 - 218)
15. Remove the ST and install the plug after measurement. NOTE: Use new O-rings. Tightening torque: 25 N.m (2.5 kgf-m, 18.4 ft-lb)

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1. Lift up the vehicle.
2. Remove the test plug.
3. Set the ST1, ST2 and ST3 to transmission. ST1 498575400 OIL PRESSURE GAUGE ASSY ST2 498897700 OIL PRESSURE ADAPTER SET ST3 18681AA000 PRESSURE GAUGE ADAPTER NOTE: ST3 Used with genuine O-ring (part No. 806911080) attached to PRESSURE GAUGE ADAPTER.
4. Lower the vehicle.
5. Connect the Subaru Select Monitor to the data link connector and read the current data.
6. Check the transfer clutch pressure as in secondary pressure (line pressure) test. Ref. to «SECONDARY PRESSURE (LINE PRESSURE) TEST»(ref-371903-S40869654772010091900000) . NOTE: Use Subaru Select Monitor for switching to FWD mode. Ref. to «AWD ON/OFF SWITCHING MODE»(ref-371903-S31068376682010091900000) . If no oil pressure is produced, if it does not change in AWD mode or if oil pressure is produced in FWD mode, there may be a problem in the control valve body. RANGE POSITION CHART Range position ON Duty ratio (%) Accelerator opening angle (%) Standard transfer clutch pressure kPa (kg/cm 2 , psi) AWD mode FWD mode Manual mode (2nd) 95 - 100 Fully opened (100) 1,000 - 1,200 (10.2 - 12.2, 145 - 174) - 60 Adjust ON Duty ratio to 60%. 400 - 700 (4.1 - 7.1, 58 - 102) - 0 Fully closed (0) - 0 (0, 0) N or P 0 Fully closed (0) 0
7. Remove the ST and install the plug after measurement. NOTE: Use new O-rings. Tightening torque: 25 N.m (2.5 kgf-m, 18.4 ft-lb)

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1. Set the vehicle on a lift.
2. Remove the front wheels.
3. Disconnect the ground cable from battery.
4. Remove the air intake duct. Ref. to «REMOVAL»(ref-371894-S28286124812010091900000) , Air Intake Duct.
5. Remove the air intake boot assembly. Ref. to «REMOVAL»(ref-371894-S06764648272010091900000) , Air Intake Boot.
6. Remove the ten clips and remove the grille bracket.
7. Disconnect the following connectors. Transmission harness connectors Transmission radio ground terminal
8. Separate the battery cable clip to remove the bracket.
9. Remove the starter. Ref. to «REMOVAL»(ref-371915-S27522616522010091900000) , Starter.
10. Remove the throttle body. Ref. to «REMOVAL»(ref-371892-S36593103462010091900000) , Throttle Body.
11. Remove the manifold absolute pressure sensor. Ref. to «REMOVAL»(ref-371892-S19593791942010091900000) , Manifold Absolute Pressure Sensor.
12. Remove the bolt and disconnect the engine harness connector.
13. Remove the engine harness connector from the engine hanger rear.
14. Remove the engine hanger rear.
15. Remove the service hole plug.
16. Install the engine hanger rear for turbo model. Part No. 10004AA180 Engine hanger rear Tightening torque: 16 N.m (1.6 kgf-m, 11.8 ft-lb)
17. Remove the four bolts combining the torque converter and drive plate while rotating the crank pulley a little at a time in the same direction as engine revolution. CAUTION: Be careful not to drop bolts into converter housing. Be careful not to damage the mounting bolts.
18. Make sure the torque converter moves freely by rotating with finger through the starter installation hole.
19. Attach the ST to the converter case. ST 498277200 Stopper set
20. After pulling off the cotter pin and removing the castle nut, use a puller to remove the tie-rod end from the knuckle arm.
21. Lift up the vehicle.
22. Remove the under cover.
23. Remove the center exhaust pipe. Ref. to «REMOVAL»(ref-371916-S36161192712010091900000) , Center Exhaust Pipe.
24. Remove the CVTF drain plug to drain CVTF. Ref. to «REPLACEMENT»(ref-371903-S22220435812010091900000) , CVTF.
25. Remove the heat shield cover.
26. Remove the snap pin and washer from shifter arm and remove the select cable from shifter arm.
27. Remove the plate assembly from the transmission case.
28. Drain differential gear oil. Ref. to «REPLACEMENT»(ref-371903-S01649799972010091900000) , Differential Gear Oil.
29. Remove the CVTF inlet hose and CVTF outlet hose.
30. Remove the universal joint. Ref. to «REMOVAL»(ref-371911-S09090447772010091900000) , Universal Joint.
31. Remove the propeller shaft. Ref. to «REMOVAL»(ref-371909-S33653701722010091900000) , Propeller Shaft.
32. Remove the stabilizer link.
33. Disconnect the lower arm ball joint and housing.
34. Pull out the front drive shaft from transmission using a crowbar.
35. Holding the joint of front drive shaft from transmission side, pull out the drive shaft from transmission with care not to stretch the boot.
36. Lower the vehicle.
37. Remove the nuts from left and right transmission mounting brackets.
38. Set the ST1 and ST2 to vehicle. ST1 99099AJ000 ENGINE HANGER ST2 99099AJ010 CHAIN BALANCER CAUTION: Set so that the chain sling does not hit the engine parts. Set the arms of ST (ENGINE HANGER) at the locations shown in the figure.
39. Remove the stopper rod.
40. Lift the engine slightly and remove the engine mounting bolts.
41. Remove the engine mounting nut and bolt to remove the engine mounting.
42. Temporarily install the ST by using two bolts. ST 41099AJ000 FRONT MOUNTING H4
43. Lift up the engine unit high enough to install the bolt and nut to vehicle. CAUTION: Do not lift up higher than enough level to install the ST to avoid damage to the hoses and pipes inside the engine room. NOTE: If it is difficult to pull out the stud bolt from transmission mounting bracket, shake the engine unit slightly while lifting up.
44. Tighten the attachment bolts at the engine side. Tightening torque: 25 N.m (2.5 kgf-m, 18.4 ft-lb)
45. Remove the ST (ENGINE HANGER).
46. Remove the left and right transmission mounting brackets. NOTE: First, remove the transmission mounting bracket on the right side of vehicle, and then tilt the engine unit to remove the left transmission mounting bracket.
47. Remove the four transmission connecting bolts.
48. Set the ST (ENGINE HANGER) again to loosen the chain sling.
49. Lift up the vehicle.
50. Set the transmission jack under the transmission.
51. Remove the rear crossmember.
52. Lower the transmission rear end (dust cover rear end). CAUTION: When lowering the transmission rear end, be careful not to let the converter case and steering mechanical parts contact each other. NOTE: Lower the transmission rear end by approx. 80 mm (3.1 in) (reference).
53. Rotate the handle of ST (ENGINE HANGER) to apply tension to the chain sling.
54. Remove the two transmission connecting bolts and two nuts (lower side).
55. Remove the transmission assembly. NOTE: Remove it while moving the transmission jack up and down so that the engine and transmission remain directly aligned.
56. Remove the cushion rubber.

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1. Attach the ST to converter case. ST 498277200 Stopper set
2. When completely overhauling the transmission, refill approx. 10 l (2.6 US qt, 8.8 lmp qt) of CVTF through the transmission right side plug, and install the plug. CAUTION: Always use specified CVTF or equivalent. Using other fluid except for specified or equivalent will cause malfunction. Ref. to «HYDRAULIC CONTROL AND LUBRICATION»(ref-371903-S28732902222010091900000) , SPECIFICATION, General Description. NOTE: Use a new gasket. Tightening torque: 25 N.m (2.5 kgf-m, 18.4 ft-lb)
3. Replace the front differential side retainer oil seal. Ref. to «REPLACEMENT»(ref-371903-S04387148892010091900000) , Differential Side Retainer Oil Seal. NOTE: Be sure to replace the differential side retainer oil seal with a new part whenever the front drive shaft is removed from the transmission.
4. Install the cushion rubber on the transmission. Tightening torque: 40 N.m (4.1 kgf-m, 29.5 ft-lb)
5. Mount the transmission onto the transmission jack.
6. Strike and bend the transmission hanger of transmission rear with a soft rubber hammer etc. so that it gets in contact with the transmission case. CAUTION: Do not apply extra overload or impact to the transmission case.
7. While lifting up the transmission gradually, install the transmission to the engine. CAUTION: This operation requires at least two persons. NOTE: Keep the engine level.
8. Install the two engine connecting bolts and two nuts (lower side). Tightening torque: 50 N.m (5.1 kgf-m, 36.9 ft-lb)
9. Secure the transmission rear crossmember to the vehicle body. Tightening torque: T1: 35 N.m (3.6 kgf-m, 25.8 ft-lb) T2: 75 N.m (7.6 kgf-m, 55.3 ft-lb)
10. Remove the transmission jack.
11. Lower the vehicle.
12. Remove the ST (ENGINE HANGER).
13. Install the four engine mounting bolts (upper side). Tightening torque: 50 N.m (5.1 kgf-m, 36.9 ft-lb)
14. Install the left and right transmission mounting brackets. NOTE: Install to the left side of vehicle first because the engine inclines to the left. Temporarily tighten one bolt arrowed in the figure. Tightening torque: 75 N.m (7.6 kgf-m, 55.3 ft-lb)
15. Set the ST1 to vehicle body and lift up the engine unit slightly. ST1 99099AJ000 ENGINE HANGER ST2 99099AJ010 CHAIN BALANCER CAUTION: Set so that the chain sling does not hit the engine parts. Set the arms of ST (ENGINE HANGER) at the locations shown in the figure.
16. Remove the bolts from ST (FRONT MOUNTING H4).
17. Remove the bolt and nut to remove ST (FRONT MOUNTING H4).
18. Temporarily attach the front engine mounting with bolts
19. Install the bolt and nut to the front engine mounting.
20. Tighten the bolt and nut of the front engine mounting. NOTE: Start tightening from the engine side bolt. 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)
21. Remove the ST (ENGINE HANGER and CHAIN SLING).
22. Install the stopper rod. Tightening torque: 36 N.m (3.7 kgf-m, 26.6 ft-lb)
23. Install the nut to the transmission mounting bracket. Tightening torque: 45 N.m (4.6 kgf-m, 51.6 ft-lb)
24. Remove the ST (STOPPER SET) from converter case.
25. Match the torque converter screw hole with drive plate hole to install the bolt. CAUTION: Do not drop the mounting bolt in the converter housing. Do not damage the mounting bolt. Tightening torque: 25 N.m (2.5 kgf-m, 18.4 ft-lb)
26. Install the remaining three bolts by rotating the crank pulley a little at a time in the same direction as engine revolution. Tightening torque: 25 N.m (2.5 kgf-m, 18.4 ft-lb)
27. Install the service hole.
28. Install the starter. Ref. to «INSTALLATION»(ref-371915-S06872456192010091900000) , Starter.
29. Lift up the vehicle.
30. Tighten the single mounting bolt of transmission mounting bracket. Tightening torque: 75 N.m (7.6 kgf-m, 55.3 ft-lb)
31. Set the ST to side retainer. ST 28399SA010 OIL SEAL PROTECTOR
32. Replace the circlip of the drive shaft with a new part.
33. Insert the front drive shaft spline section into transmission and remove the ST (OIL SEAL PROTECTOR).
34. Insert the drive shaft into the transmission securely by pressing the housing from outside of the vehicle.
35. Install the CVTF inlet hose and CVTF outlet hose. NOTE: Use the new CVTF inlet hose and CVTF outlet hose.
36. Insert the ball joint into housing and secure with bolt. Tightening torque: 50 N.m (5.1 kgf-m, 36.9 ft-lb) CAUTION: Do not apply grease to the tapered portion of ball stud. Before tightening, make sure the lower side of housing and stepped section of ball joint are in con tact.
37. Install the stabilizer link. Tightening torque: 60 N.m (6.1 kgf-m, 44.3 ft-lb)
38. Connect the tie-rod end and knuckle arm, and attach the castle nut. Tightening torque: 27 N.m (2.75 kgf-m, 19.9 ft-lb) CAUTION: When connecting, do not hit the cap at the bottom of tie-rod end with hammer.
39. After tightening the castle nut to the specified tightening torque, tighten it further within 60° until the cotter pin hole is aligned with slot in the nut. Fit the cotter pin into the nut, and then bend the pin to lock.
40. Install the propeller shaft. Ref. to «INSTALLATION»(ref-371909-S25688249532010091900000) , Propeller Shaft.
41. Install the universal joint. Ref. to «INSTALLATION»(ref-371911-S24455339282010091900000) , Universal Joint.
42. Install the plate assembly to transmission. Tightening torque: T: 25 N.m (2.5 kgf-m, 18.4 ft-lb)
43. Install the washer and snap pin to shifter arm.
44. Install the heat shield cover. Tightening torque: 18 N.m (1.8 kgf-m, 13.3 ft-lb)
45. Install the center exhaust pipe. Ref. to «INSTALLATION»(ref-371916-S02981401052010091900000) , Center Exhaust Pipe.
46. Install the under cover.
47. Lower the vehicle.
48. Remove the engine hanger rear for turbo model and install the engine hanger rear for non-turbo model. Tightening torque: T1: 16 N.m (1.6 kgf-m, 11.8 ft-lb) T2: 19 N.m (1.9 kgf-m, 14.0 ft-lb)
49. Install the engine harness connector to the engine hanger rear, and connect the harness connector, and install the harness connector bracket. Tightening torque: 7.5 N.m (0.76 kgf-m, 5.5 ft-lb)
50. Install the throttle body. Ref. to «INSTALLATION»(ref-371892-S39969274732010091900000) , Throttle Body.
51. Install the manifold absolute pressure sensor. Ref. to «INSTALLATION»(ref-371892-S40309739782010091900000) , Manifold Absolute Pressure Sensor.
52. Connect the following harness connectors. Transmission harness Transmission radio ground terminal Tightening torque: 13 N.m (1.3 kgf-m, 9.6 ft-lb)
53. Install the battery cable bracket, and install the battery cable clip to the bracket. Tightening torque: 7.5 N.m (0.76 kgf-m, 5.5 ft-lb)
54. Attach the grille bracket.
55. Install the air intake boot assembly. Ref. to «INSTALLATION»(ref-371894-S23105748052010091900000) , Air Intake Boot.
56. Install the air intake duct. Ref. to «INSTALLATION»(ref-371894-S07613473472010091900000) , Air Intake Duct.
57. Install the front wheels.
58. Connect the ground cable to battery.
59. Refill differential gear oil to adjust the differential gear oil amount. Ref. to «DIFFERENTIAL GEAR OIL»(ref-371903-S12079467962010091900000) .
60. Refill CVTF to adjust the CVTF amount. Ref. to «CVTF»(ref-371903-S30605479002010091900000) .
61. Perform the variator chain break-in. Ref. to «VARIATOR CHAIN BREAK-IN»(ref-371903-S38133595092010091900000) . CAUTION: Always execute the variator chain break-in at the replacement of the following. Variator chain replacement Primary pulley and secondary pulley replacement
62. Perform Clear Memory 2 operation. Ref. to «CLEAR MEMORY MODE»(ref-371930-S32672424632010091900000) .
63. Execute the learning control promotion. Ref. to «LEARNING CONTROL»(ref-371930-S40293120542010091900000) .
64. Execute the rear differential inspection mode. Ref. to «REAR DIFFERENTIAL INSPECTION MODE»(ref-371904-S05120778062010091900000) . CAUTION: Always execute the rear differential inspection mode at the replacement of the following. Replacement of transmission assembly Replacement of front differential hypoid gear set
65. Perform the road test to make sure there is no fault. Ref. to «INSPECTION»(ref-371903-S06649868052010091900000) , Road Test.

1. Check the crossmember for bends or damage.
2. Check that the cushion rubber is not stiff, cracked or otherwise damaged.

Check for leakage of CVTF from the joint section of transmission and propeller shaft. If a leak is found, inspect the propeller shaft and replace the oil seal.

Check for leakage of gear oil from differential side retainer oil seal part. If there is an oil leak, inspect the front drive shaft and replace the oil seal.

When the driving condition or starter motor operation is improper, first check the shift linkage for improper operation. If the shift linkage is functioning properly, check the inhibitor switch.

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1. Remove the air intake boot assembly. Ref. to «REMOVAL»(ref-371894-S06764648272010091900000) , Air Intake Boot.
2. Disconnect the inhibitor harness connector.
3. Check for continuity in inhibitor switch circuit by shifting the select lever in "P", "R", "N" and "D" respectively. NOTE: Check that there is no continuity in the ignition circuit when the select lever is in the "R" and "D" ranges. When inhibitor switch is normal, check there is no poor contact in vehicle side connector and no open circuit in harness. TCM SPECIFICATIONS Signal sent to TCM Range Terminal No. P 4 - 3 R 4 - 2 N 4 - 1 D 4 - 8 Starter circuit P/N 12 - 11 Back-up light circuit R 10 - 9
4. Check that there is continuity at equal points when the select lever is tilted 1.5° in both directions from the "N" range. If there is continuity in only one direction or in other points, adjust the inhibitor switch. Ref. to «ADJUSTMENT»(ref-371903-S27483843862010091900000) , Inhibitor Switch.
5. Repeat the above inspection in other gear ranges. If there is fault, adjust the inhibitor switch and select cable. Ref. to «ADJUSTMENT»(ref-371903-S27483843862010091900000) , Inhibitor Switch. Ref. to «ADJUSTMENT»(ref-371903-S27483843862010091900000) , Select Cable.

Scheme 284

1. Shift the select lever to "N" range.
2. Loosen the two bolts holding the inhibitor switch.
3. Insert the ST vertically into the holes of the shifter arm and switch body. ST 499267300 STOPPER PIN
4. Tighten the two bolts holding the inhibitor switch. Tightening torque: 5 N.m (0.5 kgf-m, 3.7 ft-lb)
5. Repeat the inspection of the inhibitor switch. If the inhibitor switch is determined to be "faulty", replace it.

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1. Set the vehicle on a lift.
2. Shift the select lever to "N" range.
3. Disconnect the ground cable from battery.
4. Lift up the vehicle.
5. Remove the center exhaust pipe. Ref. to «REMOVAL»(ref-371916-S36161192712010091900000) , Center Exhaust Pipe.
6. Remove the snap pin and washer from the shifter arm.
7. Using the ST, remove the spring pin and shifter arm. ST 398791600 REMOVER
8. Remove the inhibitor harness connector from inhibitor switch.
9. Remove the two inhibitor switch securing bolts.
10. Remove the inhibitor switch from the transmission case.

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1. Install the inhibitor switch to the transmission case temporarily.
2. Connect the inhibitor harness connector to the inhibitor switch.
3. Install the shifter arm and fix with the spring pin. NOTE: Use new spring pin.
4. Shift the shifter arm to "N" range.
5. Install the ST vertically in the cutout of shifter arm and the hole of switch body. ST 499267300 STOPPER PIN
6. Tighten the two bolts holding the inhibitor switch. Tightening torque: 5 N.m (0.5 kgf-m, 3.7 ft-lb)
7. Install the select cable to the shifter arm.
8. Install the washer and snap pin to the shifter arm.
9. Install the center exhaust pipe. Ref. to «INSTALLATION»(ref-371916-S02981401052010091900000) , Center Exhaust Pipe.
10. Lower the vehicle.
11. Connect the ground cable to battery.
12. Check the inhibitor switch. Ref. to «INSPECTION»(ref-371903-S03024702892010091900000) , Inhibitor Switch.

1. Check each part for damage or dust.
2. Check oil strainer for clogging.
3. Measure the resistance of each solenoid.

Note. Measurement should be performed at a temperature of 20°C (68°F).

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SOLENOID SPECIFICATIONS

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1. Remove the transmission from the vehicle. Ref. to «REMOVAL»(ref-371903-S11094350542010091900000) , Automatic Transmission Assembly.
2. Remove the transmission harness ground terminal and remove the harness connectors from front wheel speed sensor and secondary speed sensor.
3. Remove the harness connectors from inhibitor switch, primary speed sensor and secondary pressure sensor.
4. Remove the transmission harness stay.
5. Remove transmission harness connector and inhibitor harness connector from harness stay.
6. Remove the control valve body. Ref. to «REMOVAL»(ref-371903-S31374286982010091900000) , Control Valve Body.
7. Remove the mounting bolt to pull out the bushing of transmission harness from transmission case round hole.
8. Remove the harness clip from transmission assembly.

1. Visually check the harness and connector for damage or crack.
2. Check the harness terminal for rust, disconnection or poor contact.
3. Check the continuity between harness terminals and oil temperature sensor.

Note. Refer to WIRING ARTICLE for transmission harness terminal and oil temperature sensor terminal. Ref. to TRANSMISSION , WIRING DIAGRAM, CVT Control System .

Harness continuity standard

Less than 1 ohms

Oil temperature sensor standard

Approx. 2.6 kohms (at 20°C)

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1. Disconnect the ground cable from battery.
2. Remove the instrument panel lower cover. Ref. to «REMOVAL»(ref-371913-S16002500292010091900000) , Instrument Panel Lower Cover.
3. Remove the bulkhead harness connector from TCM.
4. Remove the TCM. NOTE: Replace TCM and bracket as a set.

Repair or replace any faulty hoses, pipes, clamps, and washers found in the inspection below.

1. Check for CVTF leaks in joints between the transmission, radiator, CVTF oil cooler (OUTBACK model), pipes, and hoses.
2. Check the clamp for deformation.
3. Lightly bend the hose and check for cracks in the surface or other damages.
4. Pinch the hose with your fingers and check for poor elasticity. Also check for poor elasticity in the parts where the clamp was installed by pressing with your fingernail.
5. Check for peeling, cracks, and deformation at the tip of the hose.

Check that the CVTF oil cooler has no deformation, cracks or other damages.

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1. Remove the air intake boot assembly. Ref. to «REMOVAL»(ref-371894-S06764648272010091900000) , Air Intake Boot.
2. Remove the two air breather hoses.
3. Remove the oil cap.

Scheme 297

1. Check the hose for peeling, crack or clogging.
2. Check the oil cap is not cracked or clogged.
3. Check O-ring of oil cap is not damaged.

Scheme 298

1. Remove the transmission assembly from the vehicle. Ref. to «REMOVAL»(ref-371903-S11094350542010091900000) , Automatic Transmission Assembly.
2. Set the ST. ST 498497100 CRANKSHAFT STOPPER
3. Remove the drive plate.

Check the drive cable for damage.

1. Check the protrusion of torque converter center (front boss) is not deformed or damaged.
2. Check the ring gear and exterior for break or damage.

1. Check there is no leak of CVTF from the joint between extension case and intermediate case.
2. Check there is no damage or cracks on the extension case.

1. Check each part for crack, damage or dust.
2. Check the ball bearing for smooth rotation.
3. Check the ball bearing for excessive looseness.

1. Inspect the drive plate facing for wear and damage.
2. Driven plate for discoloration (burned color)
3. Make sure the snap ring is not worn and the return spring has no permanent distortion, damage, or deformation.
4. Check the lip seal for damage.
5. Inspect the extension end play, and adjust it to within the standard value. Ref. to «ADJUSTMENT»(ref-371903-S33787784872010091900000) , Transfer Clutch.

1. Before measuring clearance "A" between snap ring and retaining plate, place same thickness shims on both sides to prevent the retaining plate from tilting.
2. When clearance "A" exceeds the limit for use, replace the drive plate and driven plate as a set, and select the pressure plate within the initial specified value. Initial standard: 0.7 - 1.1 mm (0.028 - 0.043 in) Limit thickness: 1.6 mm (0.063 in)
3. Check for tight corner braking phenomenon when the vehicle is moved forward with the steering fully turned. If tight corner braking occurs, perform the following procedures. With the steering wheel held at fully turned position, drive the vehicle in "D" range and with vehicle speed at approx. 5 km/h (3 MPH) in both clockwise and counterclockwise directions for approx. ten times each, while repeating acceleration and braking intermittently. If the tight corner braking phenomenon still persists, drive the vehicle again in a circle for several laps.

1. Check the ball bearing for smooth rotation.
2. Check the ball bearing for excessive looseness.
3. Make sure the gear is not broken or damaged.

Scheme 299

Scheme 300

1. Measure depth "A" from the ST upper face to the ball bearing catch surface. ST 398643600 GAUGE
2. Measure height "B" from the ST to the end of the ball bearing outer ring. ST 398643600 GAUGE
3. Obtain the thickness of shim using the following formula to select none to two shims. T mm = (A - 15) - (B + 15) - (0.05 - 0.25) [T in = (A - 0.591) - (B + 0.591) - (0.002 - 0.01)] T: Shim thickness A: Depth from the ST upper face to the ball bearing catch surface B: Height from the ST to the end of the ball bearing outer ring 15 mm (0.591 in): Thickness of ST 0.05 - 0.25 mm (0.002 - 0.01 in): Clearance

SHIM SPECIFICATIONS

Scheme 301

1. Remove the transmission assembly from the vehicle. Ref. to «REMOVAL»(ref-371903-S11094350542010091900000) , Automatic Transmission Assembly.
2. Shift the range select lever to "N" range.
3. Remove the extension case. Ref. to «REMOVAL»(ref-371903-S18410168992010091900000) , Extension Case.
4. Remove the parking pawl shaft, return spring and parking pawl.

Scheme 302

1. Set the range select lever to the "N" range.
2. Install the parking pawl shaft, return spring and parking pawl. NOTE: Make sure the return spring sticks out of parking pawl.
3. Install the extension case. Ref. to «INSTALLATION»(ref-371903-S05160737982010091900000) , Extension Case.
4. Install the transmission assembly to the vehicle. Ref. to «INSTALLATION»(ref-371903-S31862939282010091900000) , Automatic Transmission Assembly.

1. Check the parking pawl for breakage or damage.
2. Check the return spring for fatigue.

Scheme 303

Scheme 304

Scheme 305

1. Remove the transmission assembly from vehicle body. Ref. to «REMOVAL»(ref-371903-S11094350542010091900000) , Automatic Transmission Assembly.
2. Remove the extension case. Ref. to «REMOVAL»(ref-371903-S18410168992010091900000) , Extension Case.
3. Remove the rear drive shaft. Ref. to «REMOVAL»(ref-371903-S20465131602010091900000) , Rear Drive Shaft.
4. Remove the transfer clutch assembly. Ref. to «REMOVAL»(ref-371903-S12564414742010091900000) , Transfer Clutch.
5. Remove the transfer reduction driven gear assembly. Ref. to «REMOVAL»(ref-371903-S41327781802010091900000) , Transfer Reduction Driven Gear.
6. Remove the intermediate case. NOTE: The total number of intermediate case mounting bolts is 14. Inside the transmission is a single bolt (arrowed).
7. Remove the CVTF filter.
8. Remove the O-ring from the transmission case.

Scheme 306

1. Clean the mating surface of oil pan and transmission case.
2. Install the CVTF filter. NOTE: Apply CVTF to the O-ring.
3. Install the O-ring to the transmission case. NOTE: Use new O-rings. Apply CVTF to the O-ring.
4. Apply liquid gasket to intermediate case seamlessly. Liquid gasket: THREE BOND 1215 (Part No. 004403007) or equivalent
5. Install the intermediate case to the transmission case. NOTE: Make sure to install the arrowed bolt. Tightening torque: 25 N.m (2.5 kgf-m, 18.4 ft-lb)
6. Install the transfer reduction driven gear assembly. Ref. to «INSTALLATION»(ref-371903-S30695490442010091900000) , Transfer Reduction Driven Gear.
7. Install the transfer clutch assembly. Ref. to «INSTALLATION»(ref-371903-S21370970802010091900000) , Transfer Clutch.
8. Install the rear drive shaft. Ref. to «INSTALLATION»(ref-371903-S32738999372010091900000) , Rear Drive Shaft.
9. Install the extension case. Ref. to «INSTALLATION»(ref-371903-S05160737982010091900000) , Extension Case.
10. Install the transmission to vehicle. Ref. to «INSTALLATION»(ref-371903-S31862939282010091900000) , Automatic Transmission Assembly.

Scheme 307

1. Remove the CVTF filler plug.
2. Remove all plugs from intermediate case.
3. Remove the reverse brake assembly. Ref. to «DISASSEMBLY»(ref-371903-S01773001222010091900000) , Reverse Brake Assembly.

1. Check the intermediate case for fissures, cracks or damage.
2. Check for leakage of CVTF from the connections between intermediate case and transmission case, and between intermediate case and extension case.

1. Check if a large quantity of wear debris or metal particles are in CVTF and CVTF filter.
2. Check for broken part or damaged O-ring.

1. Inspect the drive plate facing for wear and damage.
2. Check the driven plate for discoloration (burnt color).
3. Check for worn snap ring, fatigue or damaged return spring or deformed spring retainer.
4. Make sure the clearance between retaining plate and snap ring of reverse brake is within the limit. If it exceeds the limit, replace with a new drive plate and select and adjust the retaining plate within the initial standard value. Ref. to «ASSEMBLY»(ref-371903-S14571259312010091900000) , Reverse Brake Assembly.

Scheme 308

Scheme 309

1. Remove the transmission from the vehicle. Ref. to «REMOVAL»(ref-371903-S11094350542010091900000) , Automatic Transmission Assembly.
2. Remove the extension case. Ref. to «REMOVAL»(ref-371903-S18410168992010091900000) , Extension Case.
3. Remove the rear drive shaft. Ref. to «REMOVAL»(ref-371903-S20465131602010091900000) , Rear Drive Shaft.
4. Remove the transfer clutch assembly. Ref. to «REMOVAL»(ref-371903-S12564414742010091900000) , Transfer Clutch.
5. Remove the transfer reduction driven gear. Ref. to «REMOVAL»(ref-371903-S41327781802010091900000) , Transfer Reduction Driven Gear.
6. Remove the intermediate case. Ref. to «REMOVAL»(ref-371903-S09838808512010091900000) , Intermediate Case.
7. Remove the thrust needle bearing.
8. Remove the forward clutch assembly.
9. Remove the washer.

Scheme 310

Scheme 311

1. Select a washer. Ref. to «ADJUSTMENT»(ref-371903-S01200888442010091900000) , Forward Clutch Assembly.
2. Install the selected washer.
3. Install the forward clutch assembly.
4. Install the thrust needle bearing. NOTE: Install the thrust needle bearing in the correct direction.
5. Install the intermediate case. Ref. to «INSTALLATION»(ref-371903-S03316523282010091900000) , Intermediate Case.
6. Install the transfer reduction driven gear assembly. Ref. to «INSTALLATION»(ref-371903-S30695490442010091900000) , Transfer Reduction Driven Gear.
7. Install the transfer clutch assembly. Ref. to «INSTALLATION»(ref-371903-S21370970802010091900000) , Transfer Clutch.
8. Install the rear drive shaft. Ref. to «INSTALLATION»(ref-371903-S32738999372010091900000) , Rear Drive Shaft.
9. Install the extension case. Ref. to «INSTALLATION»(ref-371903-S05160737982010091900000) , Extension Case.
10. Install the transmission to vehicle. Ref. to «INSTALLATION»(ref-371903-S31862939282010091900000) , Automatic Transmission Assembly.

Scheme 312

Scheme 313

Scheme 314

Scheme 315

Scheme 316

Scheme 317

Scheme 318

Scheme 319

Scheme 320

Scheme 321

Scheme 322

Scheme 323

1. Remove the planetary carrier assembly.
2. Remove the thrust needle bearing.
3. Remove the snap ring. NOTE: Two same snap rings are used in forward clutch assembly. Use marking or labeling for measurement of the snap ring thickness when selecting the retaining plate.
4. Remove the internal gear.
5. Remove the sun gear.
6. Remove the washer.
7. Remove the thrust needle bearing.
8. Remove the snap ring.
9. Remove the retaining plate, drive plate, driven plate and dish plate.
10. Using the ST, remove the snap ring. ST 18762AA000 COMPRESSOR SPECIAL TOOL
11. Remove the forward clutch piston seal.
12. Remove the return spring.
13. Remove the forward clutch piston by blowing compressed air intermittently from end of forward clutch drum.

Scheme 324

Scheme 325

Scheme 326

Scheme 327

Scheme 328

Scheme 329

Scheme 330

Scheme 331

Scheme 332

1. Install the forward clutch piston to forward clutch drum. NOTE: Apply CVTF to the seal of forward clutch piston. Insert it all the way to the end.
2. Install the return spring.
3. Install the forward clutch piston seal. NOTE: Apply CVTF to the sealing area of forward clutch piston seal.
4. Compress the return spring using the ST to install the snap ring. ST 18762AA000 COMPRESSOR SPECIAL TOOL
5. Measure thickness "A" of the retaining plate installed.
6. Measure thickness "B" of internal gear on the workbench.
7. Measure thickness "C" of labelled or marked snap ring.
8. Install the dish plate, drive plate, driven plate and retaining plate.
9. Install the snap ring at the location (upper groove) indicated in the figure.
10. Measure depth "D" of snap ring and retaining plate while lifting the snap ring.
11. Calculate clearance "T" from internal gear to retaining plate with the obtained value from step 5) through step 10). Formula: T mm (in) = D - A - B - C
12. If the value "T" obtained from step 11) exceeds the limit for use, replace the drive plate and driven plate with new parts and select the retaining plate within the initial standard value. Initial standard: 1.2 - 1.6 mm (0.047 - 0.063 in) Limit thickness: 2.4 mm (0.09 in) RETAINING PLATE SPECIFICATIONS Retaining plate Item number Thickness mm (in) 31567AB670 3.2 (0.126) 31567AB660 3.0 (0.118) 31567AB650 2.8 (0.110) 31567AB640 2.6 (0.102)
13. Remove the snap ring.
14. Replace with the selected retaining plate.
15. Install the snap ring to the lower groove.
16. Install the thrust needle bearing. NOTE: Install the thrust needle bearing in the correct direction.
17. Install the washer.
18. Install the sun gear.
19. Install the internal gear.
20. Install the snap ring.
21. Install the thrust needle bearing. NOTE: Make sure to install in the right direction.
22. Install the planetary carrier assembly.

1. Check the forward clutch drum, internal gear, sun gear and forward clutch piston lip for wear or damage.
2. Inspect the drive plate facing for wear and damage.
3. Check the driven plate for discoloration (burnt color).
4. Check for worn snap ring, fatigue or damaged return spring or deformed spring retainer.
5. Make sure the clearance between retaining plate and internal gear of forward clutch is within the limit. If it exceeds the standard, replace the forward clutch assembly. Ref. to «ASSEMBLY»(ref-371903-S00355700832010091900000) , Forward Clutch Assembly.

Scheme 333

Scheme 334

1. Measure depth "A" from the ST upper face to the washer catch surface. ST 398643600 GAUGE
2. Install the forward clutch assembly to intermediate case.
3. Setting the ST, measure height "B" from the ST upper side to the immediate case mating surface. ST 499575600 GAUGE
4. Obtain the thickness of washer using the following formula. Calculation formula: T (mm) = (A - 15) - (B - 15) - (0.35 - 0.70) [T (in) = (A - 0.591) - (B - 0.591) - (0.014 - 0.028)] T: Washer thickness A: Depth from the ST upper face to the washer catch surface B: Height from the upper surface of the ST to the mating surface of the intermediate case 15 mm (0.591 in): Thickness of ST 0.35 - 0.70 mm (0.014 - 0.028 in): Clearance
5. Select the washer matching value "T" obtained from step 4).

WASHER SPECIFICATIONS

Scheme 335

Scheme 336

1. Remove the transmission from the vehicle. Ref. to «REMOVAL»(ref-371903-S11094350542010091900000) , Automatic Transmission Assembly.
2. Remove the extension case. Ref. to «REMOVAL»(ref-371903-S18410168992010091900000) , Extension Case.
3. Remove the rear drive shaft. Ref. to «REMOVAL»(ref-371903-S20465131602010091900000) , Rear Drive Shaft.
4. Remove the transfer clutch assembly. Ref. to «REMOVAL»(ref-371903-S12564414742010091900000) , Transfer Clutch.
5. Remove the transfer reduction driven gear assembly. Ref. to «REMOVAL»(ref-371903-S41327781802010091900000) , Transfer Reduction Driven Gear.
6. Remove the intermediate case. Ref. to «REMOVAL»(ref-371903-S09838808512010091900000) , Intermediate Case.
7. Remove the forward clutch assembly. Ref. to «REMOVAL»(ref-371903-S15268192012010091900000) , Forward Clutch Assembly.
8. Remove the snap ring.
9. Remove the reduction driven gear assembly.
10. Remove the straight pin.

Scheme 337

1. Check the ball bearing for smooth rotation.
2. Check the ball bearing for excessive looseness.
3. Check the reduction driven gear for breakage or damage.
4. Check the clearance between snap ring and transmission case and replace the snap ring as necessary.

Scheme 338

1. Measure clearance "A" between snap ring and transmission case. Specification: 0.05 - 0.25 mm (0.002 - 0.01 in)
2. If clearance "A" is out of standard, select the snap ring within standard.

SNAP RING SPECIFICATIONS

Scheme 339

Scheme 340

Scheme 341

1. Remove the transmission assembly from vehicle body. Ref. to «REMOVAL»(ref-371903-S11094350542010091900000) , Automatic Transmission Assembly.
2. Remove the oil pan and control valve body. Ref. to «REMOVAL»(ref-371903-S31374286982010091900000) , Control Valve Body.
3. Remove the inhibitor switch. Ref. to «REMOVAL»(ref-371903-S30952394702010091900000) , Inhibitor Switch.
4. Remove the spring pin. NOTE: Prevent the spring pin from dropping in the transmission using paper towel etc.
5. Remove the bolt and remove the range select lever, manual plate and parking rod. NOTE: Do not damage the lip of oil seal press-fitted in the case.
6. Remove the detent spring.

Scheme 342

1. Install the detent spring to the transmission case. Tightening torque: 7 N.m (0.7 kgf-m, 5.2 ft-lb)
2. Install the manual plate, parking rod, range select lever and bolt. Tightening torque: 7 N.m (0.7 kgf-m, 5.2 ft-lb)
3. Install the spring pin. NOTE: Use new spring pin.
4. Install the inhibitor switch. Ref. to «INHIBITOR SWITCH»(ref-371903-S33289987982010091900000) .
5. Adjust the inhibitor switch. Ref. to «INHIBITOR SWITCH»(ref-371903-S33289987982010091900000) .
6. Install the control valve body and oil pan. Ref. to «INSTALLATION»(ref-371903-S03125368572010091900000) , Control Valve Body.
7. Install the transmission assembly to the vehicle. Ref. to «INSTALLATION»(ref-371903-S31862939282010091900000) , Automatic Transmission Assembly.

Make sure that the manual lever and detent spring are not worn or otherwise damaged.

Scheme 343

Scheme 344

Scheme 345

1. Remove the transmission assembly from the vehicle. Ref. to «REMOVAL»(ref-371903-S11094350542010091900000) , Automatic Transmission Assembly.
2. Remove the air breather hose. Ref. to «REMOVAL»(ref-371903-S42539743082010091900000) , Air Breather Hose.
3. Remove the transmission harness. Ref. to «REMOVAL»(ref-371903-S40361978382010091900000) , Transmission Harness.
4. Remove the secondary speed sensor. Ref. to «REMOVAL»(ref-371903-S21026472492010091900000) , Secondary Speed Sensor.
5. Remove the inhibitor switch. Ref. to «REMOVAL»(ref-371903-S30952394702010091900000) , Inhibitor Switch.
6. Remove the CVTF inlet pipe and CVTF outlet pipe. Ref. to «REMOVAL»(ref-371903-S18940302922010091900000) , CVTF Cooler Pipe and Hose.
7. Remove the extension case. Ref. to «REMOVAL»(ref-371903-S18410168992010091900000) , Extension Case.
8. Remove the rear drive shaft. Ref. to «REMOVAL»(ref-371903-S20465131602010091900000) , Rear Drive Shaft.
9. Remove the transfer clutch assembly. Ref. to «REMOVAL»(ref-371903-S12564414742010091900000) , Transfer Clutch.
10. Remove the transfer reduction driven gear assembly. Ref. to «REMOVAL»(ref-371903-S41327781802010091900000) , Transfer Reduction Driven Gear.
11. Remove the intermediate case. Ref. to «REMOVAL»(ref-371903-S09838808512010091900000) , Intermediate Case.
12. Remove the forward clutch assembly. Ref. to «REMOVAL»(ref-371903-S15268192012010091900000) , Forward Clutch Assembly.
13. Remove the reduction driven gear. Ref. to «REMOVAL»(ref-371903-S17527593052010091900000) , Reduction Driven Gear.
14. Remove the oil pan and control valve body. Ref. to «REMOVAL»(ref-371903-S31374286982010091900000) , Control Valve Body. NOTE: When removing the control valve body, also remove the pressure pipe If it is attached on the case.
15. Remove the CVTF pipe using a tire lever etc. NOTE: Remove by hooking the stepped portion of CVTF pipe with a tire lever etc.
16. Remove the transmission case. NOTE: The total number of transmission case mounting bolts is 15.
17. Remove the O-ring of lubrication pipe.
18. Remove the control device system. Ref. to «REMOVAL»(ref-371903-S18623712502010091900000) , Transmission Control Device.

Scheme 346

Scheme 347

Scheme 348

Scheme 349

1. Clean the mating surface of transmission case and converter case.
2. Install the control device system. Ref. to «INSTALLATION»(ref-371903-S05132611792010091900000) , Transmission Control Device.
3. Install the O-ring to the lubrication pipe. NOTE: Use new O-rings. Apply CVTF to the O-ring.
4. Make sure the lubrication pipe and support rod are in vertical position.
5. Apply liquid gasket seamlessly to the mating surface of transmission case. Liquid gasket: THREE BOND 1215 (Part No. 004403007) or equivalent
6. Install the transmission case. CAUTION: If the transmission case gets in contact with the lubrication pipe and support rod, do not install the transmission case forcibly. NOTE: Install while checking the lubrication pipe and support rod is being inserted properly into transmission case. If installing the transmission is difficult, check if the lubrication pipe and support rod are bent. The total number of transmission case mounting bolts is 15. Tightening torque: 41 N.m (4.2 kgf-m, 30.2 ft-lb)
7. Install the O-ring to CVTF pipe. NOTE: Use new O-rings.
8. The smaller opening of CVTF pipe should be inserted to transmission. NOTE: After installing, make sure the CVTF pipe does not stick out of transmission case.
9. Install the reduction driven gear. Ref. to «INSTALLATION»(ref-371903-S20267797932010091900000) , Reduction Driven Gear.
10. Install the forward clutch assembly. Ref. to «INSTALLATION»(ref-371903-S36652881282010091900000) , Forward Clutch Assembly.
11. Install the intermediate case. Ref. to «INSTALLATION»(ref-371903-S03316523282010091900000) , Intermediate Case.
12. Install the transfer reduction driven gear assembly. Ref. to «INSTALLATION»(ref-371903-S30695490442010091900000) , Transfer Reduction Driven Gear.
13. Install the transfer clutch assembly. Ref. to «INSTALLATION»(ref-371903-S21370970802010091900000) , Transfer Clutch.
14. Install the rear drive shaft. Ref. to «INSTALLATION»(ref-371903-S21370970802010091900000) , Transfer Clutch.
15. Install the extension case. Ref. to «INSTALLATION»(ref-371903-S05160737982010091900000) , Extension Case.
16. Install the CVTF inlet pipe and CVTF outlet pipe. Ref. to «INSTALLATION»(ref-371903-S04276710012010091900000) , CVTF Cooler Pipe and Hose.
17. Install the inhibitor switch. Ref. to «INSTALLATION»(ref-371903-S09739422292010091900000) , Inhibitor Switch.
18. Install the secondary speed sensor. Ref. to «INSTALLATION»(ref-371903-S11907302472010091900000) , Secondary Speed Sensor.
19. Install the transmission harness. Ref. to «INSTALLATION»(ref-371903-S11130017622010091900000) , Transmission Harness.
20. Install the control valve body and oil pan. Ref. to «INSTALLATION»(ref-371903-S03125368572010091900000) , Control Valve Body.
21. Install the air breather hose. Ref. to «INSTALLATION»(ref-371903-S20333854442010091900000) , Air Breather Hose.
22. Install the transmission assembly to the vehicle. Ref. to «INSTALLATION»(ref-371903-S31862939282010091900000) , Automatic Transmission Assembly.

Scheme 350

Scheme 351

Scheme 352

Scheme 353

Scheme 354

Scheme 355

Scheme 356

Scheme 357

1. Remove all plugs from the transmission case.
2. Remove the lubrication pipe.
3. Remove the oil seal using a screwdriver wrapped with cloth etc.
4. Remove the ball bearing from reduction driven gear using ST. ST 398527700 PULLER ASSY
5. Remove the snap ring on primary pulley side.
6. Using the ST, remove the roller bearing on primary pulley side. NOTE: Warm up the bearing area of transmission case using a drier or heat gun. ST 398527700 PULLER ASSY
7. Remove the snap ring on secondary pulley side.
8. Using the ST, remove the roller bearing on secondary pulley side. NOTE: Warm up the bearing area of transmission case using a drier or heat gun. ST 398527700 PULLER ASSY

Scheme 358

Scheme 359

Scheme 360

Scheme 361

1. Using the ST, install the oil seal. ST 18657AA000 INSTALLER
2. Using ST1 and ST2, install the ball bearing on the reduction gear side. NOTE: Use a new ball bearing. ST1 398177700 INSTALLER ST2 499755602 PRESS SNAP RING
3. Using ST1 and ST2, install the roller bearing on primary pulley side. NOTE: Use a new roller bearing. Make adjustment so that PRESS gets in contact with the center of ST2. ST1 398177700 INSTALLER ST2 20299AG010 PRESS SNAP RING
4. Install the snap ring on primary pulley side. NOTE: Use new snap rings.
5. Using ST1 and ST2, install the roller bearing on secondary pulley side. NOTE: Use a new roller bearing. Make adjustment so that PRESS gets in contact with the center of ST2. ST1 398177700 INSTALLER ST2 499755602 PRESS SNAP RING
6. Install the snap ring on secondary pulley side. NOTE: Use new snap rings.
7. Install all plugs. NOTE: Use new gaskets and O-rings. Tightening torque: T1: 13 N.m (1.3 kgf-m, 9.6 ft-lb) T2: 25 N.m (2.5 kgf-m, 18.4 ft-lb) T3: 35 N.m (3.5 kgf-m, 25.8 ft-lb)
8. Install the lubrication pipe and O-ring. NOTE: Use new O-rings. Apply CVTF to the O-ring. Tightening torque: 16 N.m (1.6 kgf-m, 11.8 ft-lb)

1. Check the transmission case for damage.
2. Check for leakage of CVTF from the connection between converter case and transmission case.
3. Check for leakage of CVTF from the connection between intermediate case and transmission case.
4. Check the lubrication pipe for bend or damage.
5. Check the ball bearing for smooth rotation.
6. Check the bearing for seizure or wear.
7. Apply CVTF to ball bearing and rotate the ball bearing to check for noise or dragging etc.

1. Check the surface of primary and secondary pulley cones for damage or wear.
2. Check the primary and secondary pulley for damage.
3. Check the bearing for seizure or wear.
4. Apply CVTF to bearing and rotate the bearing to check for noise or dragging etc.

Scheme 362

Scheme 363

1. Measure depth "Lp" from the ST upper face to the primary pulley bearing catch surface at several points and calculate the average. ST 499575400 GAUGE
2. Measure height "Ls" from the drive pinion retainer upper face to the secondary pulley bearing catch surface at several points and calculate the average. ST 499575400 GAUGE
3. Calculate the following formula. Calculation formula: T (mm) = B + (Lp-Ls) + 31.601 - A [T (in) = B + (Lp - Ls) + 1.224 - A] T: Pulley alignment A: Specified primary pulley dimension B: Specified secondary pulley dimension Lp: Depth from the ST upper face to the primary pulley bearing catch surface Ls: Depth from the ST upper face to the secondary pulley bearing catch surface 15 mm (0.591 in): Thickness of ST 31.601 mm (1.224 in): Constant SHIM THICKNESS CHART Pulley alignment T mm (in) Shim thickness mm (in) 0.050 - 0.150 (0.002 - 0.006) 0.1 (0.004) 0.151 - 0.250 (0.006 - 0.01) 0.2 (0.008) 0.251 - 0.350 (0.01 - 0.014) 0.3 (0.012) 0.351 - 0.450 (0.014 - 0.018) 0.4 (0.016) 0.451 - 0.550 (0.018 - 0.022) 0.5 (0.020) 0.551 - 0.650 (0.022 - 0.026) 0.6 (0.024) 0.651 - 0.750 (0.026 - 0.030) 0.7 (0.028) 0.751 - 0.850 (0.030 - 0.033) 0.8 (0.031) 0.851 - 0.950 (0.033 - 0.037) 0.9 (0.035)
4. Select one to two shims so that the total thickness meets the value obtained from step 3). SHIM THICKNESS CHART Part number Shim thickness mm (in) 32451AA000 0.1 (0.004) 32451AA010 0.2 (0.008) 32451AA020 0.3 (0.012) 32451AA030 0.4 (0.016) 32451AA040 0.5 (0.020)

Scheme 364

Scheme 365

Scheme 366

Scheme 367

1. Clean the mating surface of current drive pinion retainer and converter case.
2. Measure and record the shim thickness that is attached on the current converter case.
3. Using the current drive pinion retainer, measure depth "Lp1" from the ST upper face to the primary pulley bearing catch surface at several points and calculate the average. ST 499575400 GAUGE
4. Using the current drive pinion retainer or current converter case, measure depth "Ls1" from the ST upper face to the secondary pulley bearing catch surface at several points and calculate the average. ST 499575400 GAUGE
5. Calculate the "LD1" using the following formula and record it. Calculation formula: LD1 mm (in) = Lp1 - Ls1 LD1: Height from the primary pulley bearing catch surface to the secondary pulley bearing catch surface Lp1: Depth from the ST upper face to the primary pulley bearing catch surface Ls1: Depth from the ST upper face to the secondary pulley bearing catch surface
6. Using the new drive pinion retainer or new converter case, measure depth "Lp2" from the ST upper face to the primary pulley bearing catch surface at several points and calculate the average. ST 499575400 GAUGE
7. Using the new drive pinion retainer or new converter case, measure depth "Ls2" from the ST upper face to the secondary pulley bearing catch surface at several points and calculate the average. ST 499575400 GAUGE
8. Calculate the "LD2" using the following formula and record it. Calculation formula: LD2 mm (in) = Lp2 - Ls2 LD2: Height from the primary pulley bearing catch surface to the secondary pulley bearing catch surface Lp2: Depth from the ST upper face to the primary pulley bearing catch surface Ls2: Depth from the ST upper face to the secondary pulley bearing catch surface
9. Calculate the recorded values of "LD1" and "LD2" to obtain the positive number to select the shims. Calculation formula: T1 mm (in) = LD1 - LD2 or T2 mm (in) = LD2 - LD1 T1, T2: Difference between new drive pinion retainer or new converter case and current drive pinion retainer or current converter case LD1: Calculated value of current drive pinion retainer or current converter case LD2: Calculated value of new drive pinion retainer or new converter case

SHIM SPECIFICATIONS

SHIM SPECIFICATIONS

SHIM THICKNESS CHART

Check the variator chain for damage and wear.

Scheme 368

Scheme 369

Scheme 370

1. Remove the transmission assembly from the vehicle. Ref. to «REMOVAL»(ref-371903-S11094350542010091900000) , Automatic Transmission Assembly.
2. Remove the air breather hose. Ref. to «REMOVAL»(ref-371903-S42539743082010091900000) , Air Breather Hose.
3. Remove the oil pan and control valve body. Ref. to «REMOVAL»(ref-371903-S31374286982010091900000) , Control Valve Body.
4. Remove the transmission harness. Ref. to «REMOVAL»(ref-371903-S40361978382010091900000) , Transmission Harness.
5. Remove the extension case. Ref. to «REMOVAL»(ref-371903-S18410168992010091900000) , Extension Case.
6. Remove the rear drive shaft. Ref. to «REMOVAL»(ref-371903-S20465131602010091900000) , Rear Drive Shaft.
7. Remove the transfer clutch assembly. Ref. to «REMOVAL»(ref-371903-S12564414742010091900000) , Transfer Clutch.
8. Remove the transfer reduction driven gear assembly. Ref. to «REMOVAL»(ref-371903-S41327781802010091900000) , Transfer Reduction Driven Gear.
9. Remove the intermediate case. Ref. to «REMOVAL»(ref-371903-S09838808512010091900000) , Intermediate Case.
10. Remove the forward clutch assembly. Ref. to «REMOVAL»(ref-371903-S15268192012010091900000) , Forward Clutch Assembly.
11. Remove the reduction driven gear. Ref. to «REMOVAL»(ref-371903-S17527593052010091900000) , Reduction Driven Gear.
12. Remove the transmission case. Ref. to «REMOVAL»(ref-371903-S16674758132010091900000) , Transmission Case.
13. Remove the primary pulley, secondary pulley and variator chain. Ref. to «REMOVAL»(ref-371903-S30531158412010091900000) , Primary Pulley and Secondary Pulley.
14. Using the ST, remove the drive pinion retainer and lubrication pipe. ST 18270KA020 SOCKET (E20)
15. Remove the O-ring.
16. Remove the oil pump.
17. Remove the O-ring.

Scheme 371

Scheme 372

Scheme 373

Scheme 374

1. Clean the mating surface of drive pinion retainer and converter case.
2. Adjust the backlash and tooth contact between drive pinion shaft assembly and the front differential side gear. Ref. to «ADJUSTMENT»(ref-371903-S01674983312010091900000) , Drive Pinion Shaft Assembly.
3. Install the O-ring for oil pump to drive pinion retainer. NOTE: Use new O-rings. Apply CVTF to the O-ring.
4. Install the oil pump. NOTE: Apply CVTF to the bolt. Tightening torque: 8.5 N.m (0.9 kgf-m, 6.3 ft-lb)
5. Apply liquid gasket seamlessly to the mating surface of drive pinion retainer. NOTE: Be careful not to block the arrowed hole when applying liquid gasket. Liquid gasket: THREE BOND 1215 (Part No. 004403007) or equivalent
6. Install the O-ring to the lubrication pipe. NOTE: Use new O-rings. Apply CVTF to the O-ring.
7. Install the drive pinion retainer and lubrication pipe to converter case and tighten the bolt using the ST. ST 18270KA020 SOCKET (E20) NOTE: Do not confuse the three different-length bolts when installing. Tightening torque: 43 N.m (4.4 kgf-m, 31.7 ft-lb)
8. Install the primary pulley, secondary pulley and variator chain. Ref. to «INSTALLATION»(ref-371903-S36883906552010091900000) , Primary Pulley and Secondary Pulley.
9. Install the transmission case. Ref. to «INSTALLATION»(ref-371903-S27250346402010091900000) , Transmission Case.
10. Install the forward clutch assembly. Ref. to «INSTALLATION»(ref-371903-S36652881282010091900000) , Forward Clutch Assembly.
11. Install the intermediate case. Ref. to «INSTALLATION»(ref-371903-S03316523282010091900000) , Intermediate Case.
12. Install the transfer reduction driven gear assembly. Ref. to «INSTALLATION»(ref-371903-S30695490442010091900000) , Transfer Reduction Driven Gear.
13. Install the transfer clutch assembly. Ref. to «INSTALLATION»(ref-371903-S21370970802010091900000) , Transfer Clutch.
14. Install the rear drive shaft. Ref. to «INSTALLATION»(ref-371903-S32738999372010091900000) , Rear Drive Shaft.
15. Install the extension case. Ref. to «INSTALLATION»(ref-371903-S05160737982010091900000) , Extension Case.
16. Install the transmission harness. Ref. to «INSTALLATION»(ref-371903-S11130017622010091900000) , Transmission Harness.
17. Install the oil pan and control valve body. Ref. to «INSTALLATION»(ref-371903-S03125368572010091900000) , Control Valve Body.
18. Install the air breather hose. Ref. to «INSTALLATION»(ref-371903-S20333854442010091900000) , Air Breather Hose.
19. Install the transmission assembly to the vehicle. Ref. to «INSTALLATION»(ref-371903-S31862939282010091900000) , Automatic Transmission Assembly.

Scheme 375

Scheme 376

Scheme 377

Scheme 378

Scheme 379

1. Remove the drive pinion assembly.
2. Flatten the tab of the lock nut.
3. Using ST1 and ST2, fix at the spline portion of drive pinion shaft to remove the lock nut. ST1 18620AA000 WRENCH ST2 18667AA010 HOLDER
4. Remove the taper roller bearing and outer race from drive pinion shaft.
5. Separate the front roller bearing from the drive pinion shaft using the ST. ST 498077000 REMOVER
6. Remove the two oil seals using a screwdriver wrapped with cloth etc. CAUTION: Do not damage the fitting surface of drive pinion bearing.
7. Remove the plug from drive pinion retainer.

Scheme 380

Scheme 381

Scheme 382

Scheme 383

Scheme 384

Scheme 385

Scheme 386

1. Install the O-ring to plug and install the plug to drive pinion retainer. NOTE: Use new O-rings. Apply CVTF to the O-ring. Tightening torque: 25 N.m (2.5 kgf-m, 18.4 ft-lb)
2. Using the ST, install the oil seal to drive pinion retainer. NOTE: Apply CVTF to the oil seal press-fitting surface and lip. Install the oil seal in the correct direction. Pulley side ST 18657AA020 OIL SEAL INSTALLER Front differential side ST 499277100 INSTALLER
3. Measure the dimension "A" of drive pinion shaft. ST 398643600 GAUGE
4. Press-fit the new inner bearing inner race using the ST. ST 499277200 INSTALLER
5. Press-fit the new outer bearing outer race and inner bearing inner race. CAUTION: Damage may result if too much force is applied to the roller bearing. NOTE: Press in to a position where the bearing rotates smoothly without play.
6. Tighten a new lock nut using the ST. Using the following formula, calculate the torque for a torque wrench. T2 = L2/(L1 + L2) x T1 T1:130 N.m (13.3 kgf-m, 95.9 ft-lb) [Required torque setting] T2: Tightening torque L1: ST1 length 0.1 m (3.94 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) 104 (10.6, 76.7) 0.45 (17.72) 106 (10.8, 78.2) 0.5 (19.69) 108 (11.0, 79.7) 0.55 (21.65) 110 (11.2, 81.1) ST1 18620AA000 WRENCH ST2 18667AA010 HOLDER NOTE: Tighten the lock nut while directly aligning ST1 and torque wrench.
7. Apply differential gear oil to roller of bearing and rotate the bearing several times.
8. 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: 11.6 - 34.7 N (1.2 - 3.5 kgf, 2.6 - 7.8 lb)
9. Crimp the lock nut in 2 locations.
10. Measure the dimension "B" of the drive pinion shaft. ST 398643600 GAUGE
11. Obtain thickness "t" mm (in) of the drive pinion shim. t = 6.55±0.1225 - (B-A)
12. Select three or less shims from following table. DRIVE PINION SHIM SPECIFICATIONS 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) 31451AA240 0.300 (0.0118)
13. Install the shims selected for drive pinion retainer and drive pinion shaft assembly. NOTE: Be careful not to bend the shim. Tightening torque: 70 N.m (7.1 kgf-m, 51.6 ft-lb)

1. Make sure that all component parts are free of scratches, holes and other faults.
2. Check the tooth contact. Ref. to «ADJUSTMENT»(ref-371903-S01674983312010091900000) , Drive Pinion Shaft Assembly.
3. Check the bearing preload of drive pinion shaft.

Starting torque

11.6 - 34.7 N (1.2 - 3.5 kgf, 2.6- 7.8 lb)

Scheme 387

Scheme 388

Scheme 389

Scheme 390

Scheme 391

Scheme 392

Scheme 393

Scheme 394

Scheme 395

1. Remove the liquid gasket from the mating surface completely.
2. Using the ST, install the drive pinion retainer to converter case. ST1 18270KA020 SOCKET (E20) NOTE: Do not confuse the three different-length bolts when installing. Tightening torque: 43 N.m (4.4 kgf-m, 31.7 ft-lb)
3. Rotate the drive pinion several times using ST1 and ST2. ST1 18667AA010 HOLDER ST2 499787700 WRENCH
4. Adjust the drive pinion and hypoid driven gear backlash. Ref. to «ADJUSTMENT»(ref-371903-S40067064972010091900000) , Front Differential Assembly.
5. Using the ST, remove the drive pinion retainer from converter case. ST1 18270KA020 SOCKET (E20)
6. Apply lead-free red dye evenly on the both sides of three to four teeth of the hypoid driven gear. Then install the drive pinion retainer and rotate the drive pinion in both directions several times. Remove the drive pinion retainer and check the tooth contact pattern. If the teeth contact is inappropriate, adjust the backlash or thickness of the shim. Ref. to «ADJUSTMENT»(ref-371903-S40067064972010091900000) , Front Differential Assembly. NOTE: After correction, wipe off the lead-free red dye. Correct tooth contact Check item: Tooth contact surface is slightly shifted toward the toe side under a no-load condition. (When driving, it moves towards the heel side. Face contact Check item: Backlash is too large Contact pattern Corrective action: Increase thickness of pinion height adjusting washer according to the procedure for bringing drive pinion close to hypoid driven gear side. Flank contact Check item: Backlash is too small Contact pattern Corrective action: Reduce the thickness of pinion height adjusting washer according to the procedure for bringing drive pinion away from hypoid driven gear. Toe contact (inside contact) Check item: Teeth contact area is too small Contact pattern Corrective action: Reduce the thickness of pinion height adjusting washer according to the procedure for bringing drive pinion away from hypoid driven gear side. Heel contact (outside end contact) Check item: Teeth contact area is too small. Contact pattern Corrective action: Increase thickness of pinion height adjusting washer according to the procedures for moving the drive pinion closer to the hypoid driven gear.
7. If tooth contact is correct, mark the differential side retainer position and loosen. After fitting a new O-ring and oil seal, screw in the differential side retainer to the marked position.
8. Tighten the lock plate with specified torque. Tightening torque: 25 N.m (2.5 kgf-m, 18.4 ft-lb)

Scheme 396

Scheme 397

1. Remove the transmission assembly from the vehicle. Ref. to «REMOVAL»(ref-371903-S11094350542010091900000) , Automatic Transmission Assembly.
2. Remove the air breather hose. Ref. to «REMOVAL»(ref-371903-S42539743082010091900000) , Air Breather Hose.
3. Remove the oil pan and control valve body. Ref. to «REMOVAL»(ref-371903-S31374286982010091900000) , Control Valve Body.
4. Remove the transmission harness. Ref. to «REMOVAL»(ref-371903-S40361978382010091900000) , Transmission Harness.
5. Remove the extension case. Ref. to «REMOVAL»(ref-371903-S18410168992010091900000) , Extension Case.
6. Remove the rear drive shaft. Ref. to «REMOVAL»(ref-371903-S20465131602010091900000) , Rear Drive Shaft.
7. Remove the transfer clutch assembly. Ref. to «REMOVAL»(ref-371903-S12564414742010091900000) , Transfer Clutch.
8. Remove the transfer reduction driven gear assembly. Ref. to «REMOVAL»(ref-371903-S41327781802010091900000) , Transfer Reduction Driven Gear.
9. Remove the intermediate case. Ref. to «REMOVAL»(ref-371903-S09838808512010091900000) , Intermediate Case.
10. Remove the forward clutch assembly. Ref. to «REMOVAL»(ref-371903-S15268192012010091900000) , Forward Clutch Assembly.
11. Remove the reduction driven gear. Ref. to «REMOVAL»(ref-371903-S17527593052010091900000) , Reduction Driven Gear.
12. Remove the transmission case. Ref. to «REMOVAL»(ref-371903-S16674758132010091900000) , Transmission Case.
13. Remove the primary pulley, secondary pulley and variator chain. Ref. to «REMOVAL»(ref-371903-S30531158412010091900000) , Primary Pulley and Secondary Pulley.
14. Remove the drive pinion shaft assembly. Ref. to «REMOVAL»(ref-371903-S24707370692010091900000) , Drive Pinion Shaft Assembly.
15. Remove the lock plates on both sides.
16. Remove the differential side retainers using ST. ST 18658AA020 WRENCH COMPL RETAINER NOTE: Support the differential case assembly by hand to avoid damaging the retainer mounting hole of the converter case. When keeping the retainers aside, use labels etc. to avoid confusing the left and right.
17. Remove the front differential assembly while being careful not to damage the attachment part of the retainer.
18. Remove the oil seals and O-rings from both differential side retainers. Ref. to «SIDE RETAINER»(ref-371903-S40178576132010091900000) , DISASSEMBLY, Front Differential Assembly.

Scheme 398

1. Install the front differential assembly to the converter case. NOTE: Be careful not to damage the inside of the case (especially the mating surface of the differential side retainers).
2. Temporarily install the differential side retainers using ST. ST 18658AA020 WRENCH COMPL RETAINER
3. Adjust the backlash of the front differential. Ref. to «ADJUSTMENT»(ref-371903-S40067064972010091900000) , Front Differential Assembly.
4. Inspect and adjust the tooth contact. Ref. to «ADJUSTMENT»(ref-371903-S01674983312010091900000) , Drive Pinion Shaft Assembly.
5. Remove the differential side retainers and install the O-rings and oil seals. Ref. to «SIDE RETAINER»(ref-371903-S35481030722010091900000) , ASSEMBLY, Front Differential Assembly. NOTE: Record how many turns were needed to remove. Use new O-rings and oil seals.
6. Install the differential side retainers using ST. NOTE: When attaching, turn the differential side retainer by the same number of turns it took to remove, and align the marks. ST 18658AA020 WRENCH COMPL RETAINER
7. Install the lock plate. Tightening torque: 25 N.m (2.5 kgf-m, 18.4 ft-lb)
8. Install the drive pinion shaft assembly. Ref. to «INSTALLATION»(ref-371903-S26963116062010091900000) , Drive Pinion Shaft Assembly.
9. Install the primary pulley, secondary pulley and variator chain. Ref. to «INSTALLATION»(ref-371903-S36883906552010091900000) , Primary Pulley and Secondary Pulley.
10. Install the transmission case. Ref. to «INSTALLATION»(ref-371903-S27250346402010091900000) , Transmission Case.
11. Install the forward clutch assembly. Ref. to «INSTALLATION»(ref-371903-S36652881282010091900000) , Forward Clutch Assembly.
12. Install the intermediate case. Ref. to «INSTALLATION»(ref-371903-S03316523282010091900000) , Intermediate Case.
13. Install the transfer reduction driven gear assembly. Ref. to «INSTALLATION»(ref-371903-S30695490442010091900000) , Transfer Reduction Driven Gear.
14. Install the transfer clutch assembly. Ref. to «INSTALLATION»(ref-371903-S21370970802010091900000) , Transfer Clutch.
15. Install the rear drive shaft. Ref. to «INSTALLATION»(ref-371903-S32738999372010091900000) , Rear Drive Shaft.
16. Install the extension case. Ref. to «INSTALLATION»(ref-371903-S05160737982010091900000) , Extension Case.
17. Install the transmission harness. Ref. to «INSTALLATION»(ref-371903-S11130017622010091900000) , Transmission Harness.
18. Install the control valve body and oil pan. Ref. to «INSTALLATION»(ref-371903-S03125368572010091900000) , Control Valve Body.
19. Install the air breather hose. Ref. to «INSTALLATION»(ref-371903-S20333854442010091900000) , Air Breather Hose.
20. Install the transmission assembly to the vehicle. Ref. to «INSTALLATION»(ref-371903-S31862939282010091900000) , Automatic Transmission Assembly.

Scheme 399

Scheme 400

Scheme 401

Scheme 402

Scheme 403

Scheme 404

1. Remove the taper roller bearing using the ST. ST 498077000 REMOVER
2. Remove the hypoid driven gear mounting bolt using the ST. ST 18270KA020 SOCKET (E20)
3. Remove the differential case (LH).
4. Remove the differential bevel gear and washer from differential case.
5. Remove the straight pin.
6. Remove the pinion shaft, then remove the differential bevel gear, washer and differential bevel pinion

1. Check each component for scratches, damage or other faults.
2. Inspect the backlash of the pinion gear. Specification: 0.13 - 0.18 mm (0.0051 - 0.0071 in)
3. Measure the hypoid gear backlash, and then adjust it to be within specification. Ref. to «ADJUSTMENT»(ref-371903-S40067064972010091900000) , Front Differential Assembly.

Scheme 405

Scheme 406

Scheme 407

Scheme 408

1. Using the ST, screw-in the retainer until resistance is felt. NOTE: RH side should be screwed-in more than LH side. ST 18658AA020 WRENCH COMPL RETAINER
2. Remove the remaining liquid gasket from the mating surface completely.
3. Using the ST, install the drive pinion assembly to converter case. ST1 18270KA020 SOCKET (E20) NOTE: Do not confuse the three different-length bolts when installing. Tightening torque: 43 N.m (4.4 kgf-m, 31.7 ft-lb)
4. Rotate the drive pinion shaft more than ten times using ST1 and ST2. ST1 18667AA010 HOLDER ST2 499787700 Wrench
5. While rotating the pinion shaft, keep tightening the retainer LH, and loosening the retainer RH until the pinion shaft no longer be turned. When pinion shaft no longer turns, backlash is "zero".
6. After the "zero" state is established, loosen the retainer LH by 3 notches and secure it with the lock plate. Loosen the retainer RH and retighten until it stops. Rotate the drive pinion 2 or 3 times. Tighten the retainer RH further 1 -3/4 notches. This sets the preload. Finally, secure the retainer with its lock plate. NOTE: Turning the retainer by every one tooth changes the backlash approx. 0.05 mm (0.0020 in).
7. Insert the two Subaru genuine axle shaft into differential case. Part No. 38415AA070 Axle shaft
8. Wrap the drive shaft pinion shaft with cloth and pinch with vise pliers. Install the installation bolt into the bolt hole of secondary pulley and secure the bolt and vise pliers using a band or wire. Make sure the drive pinion shaft does not move.
9. Check the backlash is within specification using ST1, ST2 and ST3. ST1 498255400 PLATE ST2 498247100 DIAL GAUGE ST3 498247001 MAGNET BASE Backlash: 0.13 - 0.18 mm (0.005 - 0.007 in)
10. Adjust the teeth contact of the front differential and drive shaft. Ref. to «ADJUSTMENT»(ref-371903-S01674983312010091900000) , Drive Pinion Shaft Assembly.

Check the following items.

1. Check the oil pump for damage and wear.
2. Rotate the oil pump by hand, and check that it rotates smoothly.

1. Measure the secondary pressure. Ref. to «INSPECTION»(ref-371903-S01718329792010091900000) , Secondary Pressure (Line Pressure) Test.
2. Remove the oil pan and oil strainer. Ref. to «REMOVAL»(ref-371903-S31374286982010091900000) , Control Valve Body.
3. Check oil strainer for clogging.

When oil strainer has no clogging, replace the oil pump.

Scheme 409

Scheme 410

Scheme 411

Scheme 412

Scheme 413

1. Remove the transmission assembly from the vehicle. Ref. to «REMOVAL»(ref-371903-S11094350542010091900000) , Automatic Transmission Assembly.
2. Remove the torque converter assembly. Ref. to «REMOVAL»(ref-371903-S13532201982010091900000) , Torque Converter Assembly.
3. Remove the oil pump chain cover.
4. Remove the seal ring from center support COM PL.
5. Remove the driven sprocket from oil pump chain cover to remove the oil pump chain. NOTE: The driven sprocket is replaced as an assembly only, because it is a non-disassembly part.
6. Remove the snap ring.
7. Remove the drive sprocket.
8. Remove the oil seal from the oil pump chain cover.

Scheme 414

Scheme 415

Scheme 416

Scheme 417

1. Clean the mating surface of oil pump chain cover and converter case cover.
2. Using the ST, install the oil seal. ST 499755602 PRESS SNAP RING
3. Install the drive sprocket and install the snap ring.
4. Place the oil pump chain on drive sprocket.
5. Place the oil pump chain on driven sprocket and install the driven sprocket to oil pump chain cover.
6. Install the seal ring to center support COMPL. NOTE: Use a new seal ring. Apply CVTF to the seal rings.
7. Apply liquid gasket seamlessly to the mating surface of oil pump chain cover. CAUTION: Do not apply liquid gasket at the arrowed hole. Liquid gasket: THREE BOND 1215 (Part No. 004403007) or equivalent
8. Install the oil pump chain cover. NOTE: There are two types of bolt. Tightening torque: 24 N.m (2.4 kgf-m, 17.7 ft-lb)
9. Install the torque converter assembly. Ref. to «INSTALLATION»(ref-371903-S22022457892010091900000) , Torque Converter Assembly.
10. Install the transmission assembly to the vehicle. Ref. to «INSTALLATION»(ref-371903-S31862939282010091900000) , Automatic Transmission Assembly.

Scheme 418

1. Remove the ball bearing using ST. ST1 498077600 REMOVER ST2 399513600 INSTALLER

Scheme 419

1. Using the ST, install the ball bearing. NOTE: Use a new ball bearing. ST 499755602 PRESS SNAP RING

1. Check the oil pump chain for damage.
2. Replace if gear teeth are broken, damaged, sharpen or excessively worn.
3. Check the bearing for seizure or wear.
4. Apply CVTF to bearing and rotate the bearing to check for noise or dragging etc.
5. Check the oil pump chain cover for damage.
6. Check for leakage of CVTF from the mating surface of oil pump chain cover.
7. Check the oil seal for damage.

Scheme 420

Scheme 421

Scheme 422

1. Remove the transmission assembly from the vehicle. Ref. to «REMOVAL»(ref-371903-S11094350542010091900000) , Automatic Transmission Assembly.
2. Remove the air breather hose. Ref. to «REMOVAL»(ref-371903-S42539743082010091900000) , Air Breather Hose.
3. Remove the oil pan and control valve body. Ref. to «REMOVAL»(ref-371903-S31374286982010091900000) , Control Valve Body.
4. Remove the transmission harness. Ref. to «REMOVAL»(ref-371903-S40361978382010091900000) , Transmission Harness.
5. Remove the extension case. Ref. to «REMOVAL»(ref-371903-S18410168992010091900000) , Extension Case.
6. Remove the rear drive shaft. Ref. to «REMOVAL»(ref-371903-S20465131602010091900000) , Rear Drive Shaft.
7. Remove the transfer clutch assembly. Ref. to «REMOVAL»(ref-371903-S12564414742010091900000) , Transfer Clutch.
8. Remove the transfer reduction driven gear assembly. to CVT-160, REMOVAL, Transfer Reduction Driven Gear.
9. Remove the intermediate case. Ref. to «REMOVAL»(ref-371903-S09838808512010091900000) , Intermediate Case.
10. Remove the forward clutch assembly. Ref. to «REMOVAL»(ref-371903-S15268192012010091900000) , Forward Clutch Assembly.
11. Remove the reduction driven gear. Ref. to «REMOVAL»(ref-371903-S17527593052010091900000) , Reduction Driven Gear.
12. Remove the transmission case. Ref. to «REMOVAL»(ref-371903-S16674758132010091900000) , Transmission Case.
13. Remove the primary pulley, secondary pulley and variator chain. Ref. to «REMOVAL»(ref-371903-S30531158412010091900000) , Primary Pulley and Secondary Pulley.
14. Remove the drive pinion shaft assembly. Ref. to «REMOVAL»(ref-371903-S24707370692010091900000) , Drive Pinion Shaft Assembly.
15. Remove the oil stopper plate and lubrication pipe.
16. Flip over the converter case.
17. Remove the converter case cover.
18. Remove the O-ring.
19. Remove the seal ring from converter case cover.

Scheme 423

Scheme 424

1. Clean the mating surface of converter case cover and converter case.
2. Adjust the shims of front reduction drive gear and front reduction driven gear. Ref. to «ADJUSTMENT»(ref-371903-S22947208182010091900000) , Front Reduction Drive Gear. Ref. to «ADJUSTMENT»(ref-371903-S12680531152010091900000) , Front Reduction Driven Gear.
3. Install the O-ring. NOTE: Use new O-rings. Apply CVTF to the O-ring.
4. Apply CVTF to the selected shims and install each to the catch surface of bearing.
5. Install the seal ring to converter case cover. NOTE: Use a new seal ring. When installing the seal ring, do not expand the seal ring too much.
6. Apply liquid gasket seamlessly to the mating surface of converter case cover. Liquid gasket: THREE BOND 1215 (Part No. 004403007) or equivalent
7. Install the converter case cover. Tightening torque: 24 N.m (2.4 kgf-m, 17.7 ft-lb)
8. Flip over the converter case cover.
9. Install the oil stopper plate and lubrication pipe. Tightening torque: 9 N.m (0.9 kgf-m, 6.6 ft-lb)
10. Install the drive pinion shaft assembly. Ref. to «INSTALLATION»(ref-371903-S26963116062010091900000) , Drive Pinion Shaft Assembly.
11. Install the primary pulley, secondary pulley and variator chain. Ref. to «INSTALLATION»(ref-371903-S36883906552010091900000) , Primary Pulley and Secondary Pulley.
12. Install the transmission case. Ref. to «INSTALLATION»(ref-371903-S27250346402010091900000) , Transmission Case.
13. Install the forward clutch assembly. Ref. to «INSTALLATION»(ref-371903-S36652881282010091900000) , Forward Clutch Assembly.
14. Install the intermediate case. Ref. to «INSTALLATION»(ref-371903-S03316523282010091900000) , Intermediate Case.
15. Install the transfer reduction driven gear assembly. Ref. to «INSTALLATION»(ref-371903-S30695490442010091900000) , Transfer Reduction Driven Gear.
16. Install the transfer clutch assembly. Ref. to «INSTALLATION»(ref-371903-S21370970802010091900000) , Transfer Clutch.
17. Install the rear drive shaft. Ref. to «INSTALLATION»(ref-371903-S32738999372010091900000) , Rear Drive Shaft.
18. Install the extension case. Ref. to «INSTALLATION»(ref-371903-S05160737982010091900000) , Extension Case.
19. Install the transmission harness. Ref. to «INSTALLATION»(ref-371903-S11130017622010091900000) , Transmission Harness.
20. Install the control valve body and oil pan. Ref. to «INSTALLATION»(ref-371903-S03125368572010091900000) , Control Valve Body.
21. Install the air breather hose. Ref. to «INSTALLATION»(ref-371903-S20333854442010091900000) , Air Breather Hose.
22. Install the transmission assembly to the vehicle. Ref. to «INSTALLATION»(ref-371903-S31862939282010091900000) , Automatic Transmission Assembly.

Scheme 425

Scheme 426

1. Remove the oil pump chain cover. Ref. to «REMOVAL»(ref-371903-S28754517432010091900000) , Oil Pump Chain.
2. Using TORX® E16, remove the center support COMPL.
3. Remove the plug and O-ring.

1. Replace if its tooth surfaces are broken, damaged or excessively worn.
2. Check the bearing for seizure or wear.
3. Apply CVTF to bearing and rotate the bearing to check for noise or dragging etc.

1. Replace if its tooth surfaces are broken, damaged or excessively worn.
2. Check the bearing for seizure or wear.
3. Apply CVTF to bearing and rotate the bearing to check for noise or dragging etc.

Scheme 427

Scheme 428

Scheme 429

1. Measure height "A" from the ST upper face to the bearing end face using the ST. ST 398643600 GAUGE
2. Measure depth "B" from the converter case cover upper face to the bearing catch surface.
3. Using the ST, measure height "C" from the ST upper face to the converter case cover mating surface. ST 398643600 GAUGE
4. Calculate clearance "T" using the following formula. Calculation formula: T mm = (A - 15) - ((C - 15) - B) [T in = (A - 0.591) - ((C - 0.591) - B)] T: Clearance A: Depth from the ST upper face to the bearing end surface B: Depth from the converter case cover upper face to the bearing catch surface C: Height from the ST upper face to the converter case cover mating surface 15 mm (0.591 in): Thickness of ST THICKNESS CHART Clearance "T" mm (in) Thickness of shim mm (in) Part number 1.070 - 1.174 (0.042 - 0.045) 1.0 (0.039) 31288AA160 1.175 - 1.274 (0.046 - 0.050) 1.1 (0.043) 31288AA170 1.275 - 1.374 (00049 - 0.053) 1.2 (0.047) 31288AA180 1.375 - 1.474 (0.054 - 0.057) 1.3 (0.051) 31288AA220 1.475 - 1.580 (0.058 - 0.062) 1.4 (0.055) 31288AA230

1. Check the drive plate for wear and damage.
2. Check the driven plate for discoloration (burnt color).
3. Check for worn snap ring, fatigue or damaged return spring or deformed piston retainer.
4. Replace if its tooth surfaces are broken, damaged or excessively worn.
5. Check the bearing for seizure or wear.
6. Apply CVTF to bearing and rotate the bearing to check for noise or dragging etc.

Scheme 430

Scheme 431

Scheme 432

1. Using the ST, measure height "A" from the ST upper face to the mating surface of the case. ST 398643600 GAUGE
2. Measure depth "B" from the converter case cover upper face to the bearing catch surface.
3. Measure depth "C" from the ST upper face to the bearing end face using the ST. ST 398643600 GAUGE
4. Using the following formula, calculate clearance "T" to select a shim. Formula: T mm = (C - 15) - ((A - 15) - B) [T in = (C - 0.591) - ((A - 0.591) - B)] T: Clearance A: Height from the ST upper face to the converter case mating surface B: Depth from the converter case cover upper face to the bearing catch surface C: Depth from the ST upper face to the bearing end face 15 mm (0.591 in): Thickness of ST THICKNESS CHART Clearance "T" mm (in) Thickness of shim mm(in) 0.470 - 0.569 (0.019 - 0.021) 0.4 0.570 - 0.669 (90.022 - 0.025) 0.5 0.670 - 0.769 (0.026 - 0.029) 0.6 0.770 - 0.869 (0.030 - 0.033) 0.7 0.870 - 0.980 (0.034 - 0.039) 0.8
5. Select one to two shims so that the total thickness meets the value obtained from above.

THICKNESS CHART

1. Check for leakage of CVTF from the connection between converter case and transmission case.
2. Check there is no damage or cracks on the converter case.

SYMPTOMS CHART