Continuously Variable Transmission: Other Subaru Outback BR

OIL PUMP

OIL PUMP SPECIFICATION

TRANSMISSION CONTROL ELEMENT

TRANSMISSION CONTROL ELEMENT SPECIFICATIONS

TRANSMISSION GEAR RATIO

TRANSMISSION GEAR RATIO SPECIFICATIONS

PLATE

PLATE SPECIFICATIONS

SELECTOR POSITION

SELECTOR POSITION SPECIFICATIONS

TRANSFER

TRANSFER SPECIFICATIONS

REDUCTION GEAR RATIO

REDUCTION GEAR RATIO SPECIFICATIONS

RECOMMENDED GEAR OIL

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

Scheme 555

Scheme 556

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

T1: 9 (0.9, 6.6)

T2: 16 (1.6, 11.8)

T3: 18 (1.8, 13.3)

T4: 25 (2.5, 18.4)

T5: 35 (3.6, 25.8)

T6: 41 (4.2, 30.2)

T7: 50 (5.1, 36.9)

T8: 70 (7.1, 51.6)

T9: Ref. to INSTALLATION , Drive Plate.

Scheme 557

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

T1: 8.5 (0.9, 6.3)

T2: 24 (2.4, 17.7)

Scheme 558

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

T1: 13 (1.3, 9.6)

T2: 16 (1.6, 11.8)

T3: 25 (2.5, 18.4)

T4: 35 (3.6, 25.8)

Scheme 559

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

T1: 5 (0.5, 3.7)

T2: 9 (0.9, 6.6)

T3: 20 (2.0, 14.8)

T4: 50 (5.1, 36.9)

Scheme 560

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

T: 25 (2.5, 18.4)

Scheme 561

Scheme 562

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

T1: 21.5 (2.2, 15.9)

T2: 24 (2.4, 17.7)

T3: 25 (2.5,18.4)

Scheme 563

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

T1: 5 (0.5, 3.7)

T2: 7 (0.7, 5.2)

T3: 25 (2.5, 18.4)

Scheme 564

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

T1: 21 (2.1, 15.5)

T2: 25 (2.5, 18.4)

T3: 33 (3.4, 24.3)

Scheme 565

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

T1: 25 (2.5, 18.4)

T2: 43 (4.4, 31.7)

T3: 69 (7.0, 50.9)

T4: 70 (7.1, 51.6)

T5: 130 (13.3, 95.9)

Scheme 566

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

T: 25 (2.5, 18.4)

Scheme 567

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

T1: 5 (0.5, 3.7)

T2: 8 (0.8, 5.9)

T3: 16 (1.6, 11.8)

T4: 39 (4.0, 28.8)

Scheme 568

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

T1: 7.5 (0.76, 5.5)

T2: 16 (1.6, 11.8)

T3: 40 (4.1, 29.5)

Scheme 569

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

T: 7.5 (0.75, 5.5)

Scheme 570

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

T1: 35 (3.6,25.8)

T2: 40 (4.1,33.2)

T3: 45 (4.6,51.6)

T4: 75 (7.6,55.3)

CAUTION

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

GENERAL TOOL

GENERAL TOOL CHART

CONDITION CHECK

Note. When replacing CVTF, determine the condition inside the transmission body by inspecting the drained CVTF.

FLUID CONDITION CHART

PROCEDURE

Note. During variator chain break-in, VDC warning light and EPB warning light illuminate because of the difference between the vehicle speed value and G sensor value. This is not the malfunction. If the warning light illuminates, clear the VDC and EPB memory after the variator chain break-in is finished. Ref. to CLEAR MEMORY MODE . Ref. to CLEAR MEMORY MODE . During variator chain break-in, if the above malfunction code is detected, fail mode is entered. If this happens, symptom such as engine speed rapid increase occurs, even when the accelerator pedal is depressed gradually.

1. Lift up the vehicle. CAUTION: Lift up the vehicle until the tire bottom is 0.3 m (0.98 ft) or more above the ground.
2. Shift the select lever from "P" to "N" range.
3. Apply the electronic parking brake.
4. Connect the Subaru Select Monitor to data link connector.
5. Idle the engine to raise CVTF temperature to 40 - 50°C (104 - 122°F) on Subaru Select Monitor. NOTE: When CVTF temperature does not rise easily or if you want to rise CVTF temperature faster, maintain the engine speed within 2,000 - 2,500 RPM at "P" or "N" range to raise the CVTF temperature.
6. With the select lever in "P" or "N" range, increase the engine speed to 3,000 - 3,500 RPM from the idling condition, and maintain approximately five seconds, then release the accelerator pedal.
7. Depress the accelerator pedal gradually again from idling condition to increase the engine speed to 3,000 - 3,500 RPM, and maintain approximately five seconds, then release the accelerator pedal.
8. Release the electronic parking brake.
9. Shift the select lever into manual mode to set the 1st.
10. Depress the accelerator pedal gradually, and increase the engine speed to 5,300 RPM from engine idling condition. NOTE: Increase the engine speed while observing it, so as not to overspeed the engine.
11. Return the accelerator pedal to fully closed position to lower the engine speed to 4,000 RPM.
12. Depress the accelerator pedal gradually again, and increase the engine speed to 5,300 RPM.
13. Repeat the step 11) and 12) for 40 times.
14. Return the accelerator pedal to return the engine idling speed.
15. Shift the select lever to "P" range, and then turn the engine to OFF.

1. Shift the select lever to "P" range.
2. Connect the Subaru Select Monitor to data link connector.
3. Turn the ignition switch to ON. (In the case of a push button start, press the push button ignition switch twice without stepping on the brake)
4. Turn off all switches causing an electrical load, such as headlights, A/C, seat heater and rear defogger.
5. Select {AT related learning & inspecting mode} in the & Transmission Diagnosis» screen of the Subaru Select Monitor.
6. Select {AWD ON/OFF switching mode} in the & Learning and inspection mode related to AT& display screen of the Subaru Select Monitor.
7. Follow the messages displayed on the Subaru Select Monitor screen when working. Switching completes successfully if any of the following messages is displayed.

1. When switching from AWD to FWD: {Switched to FF. To return to AWD, perform basic mode again.}
2. When switching from FWD to AWD: {Switched to AWD. To return to FF, perform basic mode again.}

Note. If communication error occurs during switching mode, start in the "AWD ON/OFF switching mode" again. If operation is interrupted before the successful end message is displayed, perform the {AWD ON/OFF switching mode} from the beginning until confirming the operation is successfully ended. If this mode fails to complete successfully, the cause is as follows. Select lever is not in "P" range. Engine is running. For details concerning the operation procedure, refer to PC application help for Subaru Select Monitor.

GENERAL PRECAUTION

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

D RANGE SHIFT FUNCTION

Make sure the engine speed is 1,100 - 1,300 RPM while driving on the level road at 50 km/h (31 MPH) after accelerating from halting to 1/4 of accelerator opening angle. Then stop the vehicle. Check normal gear change has occurred while the vehicle speed changes from a constant speed to zero.

KICK-DOWN FUNCTION

Check if engine speed will rise by operating the accelerator opening angle to the full from a constant speed of 50 km/h (31 MPH) or more.

LOCK-UP FUNCTION

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

OIL LEAKAGE

After the driving test, inspect for leakage of CVTF and differential gear oil from the transmission body.

SIDE RETAINER

Note. After adjusting the drive pinion backlash and tooth contact, replace the oil seal and O-ring with new parts.

Scheme 571

Scheme 572

Scheme 573

Scheme 574

Scheme 575

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

Scheme 576

Scheme 577

Scheme 578

Scheme 579

Scheme 580

Scheme 581

1. Install the washer and differential bevel gear into differential case (LH).
2. Install the differential bevel gear pinions into differential case (LH) and install the pinion shaft.
3. Install the straight pin.
4. Install the differential case (RH) to hypoid driven gear and secure with vise.
5. Install the washer and differential bevel gear to the differential case (RH).
6. Using the ST, install the hypoid driven gear by tightening the installation bolt. ST 18270KA020 SOCKET (E20) Tightening torque: 69 N.m (7.0 kgf-m, 50.9 ft-lb)
7. Measurement of backlash (Selection of washer) Install the SUBARU genuine axle shaft to differential case. Part No. 38415AA070 Axle shaft Measure the gear backlash using ST1 and ST2, and then insert the ST2 through the window of differential case. ST1 498247001 MAGNET BASE ST2 498247100 Dial gauge NOTE: Measure the backlash by applying a differential bevel pinion tooth between two differential bevel gear teeth. When measuring, fix the differential bevel pinion gear in place with a screwdriver covered with waste cloth, or a similar tool. Specification: 0.13 - 0.18 mm (0.0051 - 0.0071 in) If the backlash is not within specification, select a washer from the table below and replace. WASHER SPECIFICATIONS Washer Part number Thickness mm (in) 803038021 0.95 (0.037) 803038022 1.00 (0.039) 803038023 1.05 (0.041)
8. Using the ST, install the left and right taper roller bearings. ST1 499277100 BUSHING 1-2 INSTALLER ST2 398497701 SEAT

Note. After adjusting the backlash and tooth contact, replace the oil seal and O-ring of side retainer with new parts.

Scheme 582

1. Press-fit the bearing outer race to side retainer.
2. Using the ST, install the oil seal. NOTE: Use a new oil seal. Apply differential oil to the oil seal lip. Oil seal has an identification mark (R, L). When installing oil seals, do not confuse the left and right. ST 18675AA000 DIFFERENTIAL SIDE OIL SEAL INSTALLER
3. Install the O-ring. NOTE: Use new O-rings.