Continuously Variable Transmission: Removal & Installation Subaru Outback BR

REPLACEMENT

Scheme 433

Scheme 434

Scheme 435

1. Set the vehicle on a lift.
2. Lift up the vehicle, and remove the CVTF drain plug.
3. Check the CVTF condition. Ref. to «CONDITION CHECK»(ref-371903-S16973098952010091900000) , CVTF.
4. Install the CVTF drain plug and gasket. NOTE: Use a new gasket. Tightening torque: 20 N.m (2.0 kgf-m, 14.8 ft-lb)
5. Remove the filler plug.
6. Fill in the specified fluid or equivalent through the filler plug. CVT fluid: Ref. to «HYDRAULIC CONTROL AND LUBRICATION»(ref-371903-S28732902222010091900000) , SPECIFICATION, General Description. Capacity: Fill with the same amount of CVTF as drained.
7. Temporarily tighten the filler plug.
8. Idle the engine to raise CVTF temperature to 35 - 45°C (95 - 113°F) on Subaru Select Monitor.
9. Operate the select lever in P => R => N=> D and D => N => R => P to circulate CVTF with the engine idling. CAUTION: Pay special attention to the following operations as the engine is at idle.
10. Place the select lever in "P" range. Then lift up the vehicle with the engine at idle to adjust the CVTF level and check for leakage. Ref. to «ADJUSTMENT»(ref-371903-S21010063132010091900000) , CVTF.
11. Replace with a new gasket, and attach the filler plug. Tightening torque: 50 N.m (5.1 kgf-m, 36.9 ft-lb)

Scheme 436

Scheme 437

1. Lift up the vehicle.
2. Remove the differential gear oil drain plug using TORX® bit T70. Drain differential gear oil.
3. Install the differential gear oil drain plug using TORX® bit T70. NOTE: Use a new gasket. Tightening torque: 70 N.m (7.1 kgf-m, 51.6 ft-lb)
4. Pour gear oil from the charge pipe. Recommended gear oil: Ref. to «RECOMMENDED GEAR OIL»(ref-371903-S24189570652010091900000) , SPECIFICATION, General Description. Gear oil capacity: Ref. to «RECOMMENDED GEAR OIL»(ref-371903-S24189570652010091900000) , SPECIFICATION, General Description.
5. Adjust the level of differential gear oil. Ref. to «ADJUSTMENT»(ref-371903-S32148774412010091900000) , Differential Gear Oil.

REMOVAL

1. Disconnect the ground cable from battery.
2. Lift up the vehicle.
3. Remove the center exhaust pipe. Ref. to «REMOVAL»(ref-371916-S36161192712010091900000) , Center Exhaust Pipe.
4. Remove the heat shield cover.
5. Set the transmission jack under the transmission. Make sure that the support plate of transmission jack does not touch the oil pan.
6. Remove the transmission rear crossmember.
7. Remove the rear cushion rubber.

INSTALLATION

1. Attach the rear cushion rubber to the transmission. Tightening torque: 40 N.m (4.1 kgf-m, 29.5 ft-lb)
2. Install the crossmember. 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)
3. Remove the transmission jack.
4. Install the heat shield cover. Tightening torque: 18 N.m (1.8 kgf-m, 13.3 ft-lb)
5. Install the center exhaust pipe. Ref. to «INSTALLATION»(ref-371916-S02981401052010091900000) , Center Exhaust Pipe.
6. Connect the ground cable to battery.

1. Lift up the vehicle.
2. Clean the transmission exterior.
3. Remove the center exhaust pipe. Ref. to «REMOVAL»(ref-371916-S36161192712010091900000) , Center Exhaust Pipe.
4. Remove the heat shield cover.
5. Remove the propeller shaft. Ref. to «REMOVAL»(ref-371909-S33653701722010091900000) , Propeller Shaft.
6. Using a screwdriver or ST, remove the oil seal trying not to damage the extension case. ST 398527700 PULLER ASSY
7. Using the ST, install the oil seal. NOTE: Use a new oil seal. ST 498057300 OIL SEAL DRIFT
8. Install the propeller shaft. Ref. to «INSTALLATION»(ref-371909-S25688249532010091900000) , Propeller Shaft.
9. Install the heat shield cover. Tightening torque: 18 N.m (1.8 kgf-m, 13.3 ft-lb)
10. Install the center exhaust pipe. Ref. to «INSTALLATION»(ref-371916-S02981401052010091900000) , Center Exhaust Pipe.
11. Adjust the CVTF level and check there is no leakage. Ref. to «ADJUSTMENT»(ref-371903-S21010063132010091900000) , CVTF.

Scheme 438

Scheme 439

Scheme 440

Scheme 441

1. Lift up the vehicle, and remove the front wheels.
2. After pulling off the cotter pin and removing the castle nut, use a puller to remove the tie-rod end from the knuckle arm.
3. Lift up the vehicle.
4. Remove the center exhaust pipe. Ref. to «REMOVAL»(ref-371916-S36161192712010091900000) , Center Exhaust Pipe.
5. Remove the differential gear oil drain plug using TORX® bit T70, and then drain differential gear oil.
6. Tighten the differential gear oil drain plug. NOTE: Use a new gasket. Tightening torque: 70 N.m (7.1 kgf-m, 51.6 ft-lb)
7. Remove the stabilizer link. Ref. to «REMOVAL»(ref-371907-S03605187482010091900000) , Front Stabilizer.
8. Disconnect the ball joint and housing.
9. Holding the joint of front drive shaft from transmission side, pull out the drive shaft from transmission with care not to stretch the boot.
10. Remove the differential side retainer oil seal using driver wrapped with vinyl tape etc.
11. Using the ST, install the differential side retainer oil seal by lightly tapping with a hammer. ST 18675AA000 DIFFERENTIAL SIDE OIL SEAL INSTALLER NOTE: Apply differential gear oil to the oil seal lips. Oil seal has an identification mark (R, L). When installing oil seals, do not confuse the left and right.
12. Set the ST to side retainer. ST 28399SA010 OIL SEAL PROTECTOR
13. Replace the circlip of the drive shaft with a new part.
14. Insert the front drive shaft spline section into transmission and remove the ST (DIFFERENTIAL SIDE OIL SEAL INSTALLER).
15. Insert the drive shaft into the transmission securely by pressing the housing from outside of the vehicle.
16. 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 contact.
17. Install the stabilizer link. Tightening torque: 60 N.m (6.1 kgf-m, 44.3 ft-lb)
18. Install the center exhaust pipe. Ref. to «INSTALLATION»(ref-371916-S02981401052010091900000) , Center Exhaust Pipe.
19. Lower the vehicle.
20. 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.
21. 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.
22. Refill differential gear oil from the charge pipe. Ref. to «DIFFERENTIAL GEAR OIL»(ref-371903-S12079467962010091900000) .
23. Adjust the level of differential gear oil. Ref. to «ADJUSTMENT»(ref-371903-S32148774412010091900000) , Differential Gear Oil.
24. Install the front wheels.

Scheme 442

1. Remove the transmission from the vehicle. Ref. to «REMOVAL»(ref-371903-S11094350542010091900000) , Automatic Transmission Assembly.
2. Remove the transmission cover on the transmission upper side.
3. Remove the harness connector from secondary speed sensor.
4. Remove the secondary speed sensor.

Scheme 443

Install in the reverse order of removal.

Note. Use new O-rings. Apply CVTF to the O-ring.

Tightening torque

Secondary speed sensor

5 N.m (0.5 kgf-m, 3.7 ft-lb)

Transmission cover

8 N.m (0.8 kgf-m, 5.9 ft-lb)

Scheme 444

Scheme 445

1. Remove the instrument panel lower cover. Ref. to «REMOVAL»(ref-371913-S16002500292010091900000) , Instrument Panel Lower Cover.
2. Set the probe of oscilloscope to TCM harness connector.
3. Start and warm up the engine.
4. Check the waveform of secondary speed sensor with engine idling.

1. Remove the air intake boot assembly. Ref. to «REMOVAL»(ref-371894-S06764648272010091900000) , Air Intake Boot.
2. Remove the harness connector from primary speed sensor.
3. Remove the primary speed sensor.

Scheme 446

Install in the reverse order of removal.

Note. Use new O-rings. Apply CVTF to the O-ring.

Tightening torque

5 N.m (0.5 kgf-m, 3.7 ft-lb)

Scheme 447

Scheme 448

1. Remove the instrument panel lower cover. Ref. to «REMOVAL»(ref-371913-S16002500292010091900000) , Instrument Panel Lower Cover.
2. Set the probe of oscilloscope to TCM harness connector.
3. Start and warm up the engine.
4. Check the waveform of primary speed sensor with engine idling.

1. Lift up the vehicle.
2. Clean the transmission exterior.
3. Remove the harness connector from front wheel speed sensor.
4. Remove the front wheel speed sensor.

Scheme 449

Install in the reverse order of removal.

Note. Use new O-rings. Apply CVTF to the O-ring.

Tightening torque

5 N.m (0.5 kgf-m, 5.2 ft-lb)

Scheme 450

Scheme 451

1. Remove the instrument panel lower cover. Ref. to «REMOVAL»(ref-371913-S16002500292010091900000) , Instrument Panel Lower Cover.
2. Set the probe of oscilloscope to TCM harness connector.
3. Lift up the vehicle and raise the vehicle speed up to 20 km/h (12 MPH).
4. Check the waveform of front wheel speed sensor when vehicle speed is at 20 km/h (12 MPH).

1. Remove the air intake boot assembly. Ref. to «REMOVAL»(ref-371894-S06764648272010091900000) , Air Intake Boot.
2. Remove the secondary pressure sensor connector.
3. Remove the secondary pressure sensor.

Note. Use Ko-ken 3/8 12-point 27 mm (manufacturer product No. 3305M-27) deep socket.

Scheme 452

Install in the reverse order of removal.

Note. Use new O-rings.

Tightening torque

39 N.m (4.0 kgf-m, 28.8 ft-lb)

Scheme 453

1. Remove the instrument panel lower cover. Ref. to «REMOVAL»(ref-371913-S16002500292010091900000) , Instrument Panel Lower Cover.
2. Start and warm up the engine.
3. Check the voltage of secondary pressure sensor with engine idling. Specification 0.7 - 0.9 V

Note. The control valve body is replaced as an assembly only, because it is a non-disassembly part.

Scheme 454

Scheme 455

Scheme 456

Scheme 457

Scheme 458

Scheme 459

Scheme 460

1. Lift up the vehicle.
2. Clean the transmission exterior.
3. Remove the CVTF drain plug to drain CVTF.
4. Install the CVTF drain plug. NOTE: Use a new gasket. Tightening torque: 20 N.m (2.1 kgf-m, 14.8 ft-lb)
5. Remove the oil pan. CAUTION: Be careful not to allow foreign matter such as dust or dirt to enter the oil pan.
6. Remove the magnet.
7. Completely remove the remaining liquid gasket on the transmission case and oil pan.
8. Disconnect the control valve harness connector.
9. Remove the oil strainer.
10. Remove the control valve body. CAUTION: Do not let the manual valve drop off.
11. Remove the pressure pipe. NOTE: It may be located in transmission case side.
12. Remove the O-ring from oil strainer.
13. Remove the O-ring from pressure pipe.

Scheme 461

Scheme 462

Scheme 463

Scheme 464

Scheme 465

1. Clean the mating surface of oil pan and transmission case.
2. Check the control valve body for dust and other foreign matter.
3. Install the O-ring to the pressure pipe. NOTE: Use new O-rings. Apply CVTF to the O-ring.
4. Install the pressure pipe.
5. Install the control valve body to the transmission. CAUTION: Beware of the transmission harness getting caught in between. Do not impact or bend the transmission harness because it has the oil temperature sensor inside. NOTE: Engage the manual valve to the manual plate. Lead the transmission harness through from the point indicated by dashed line in the figure. Tightening torque: 9 N.m (0.9 kgf-m, 6.6 ft-lb)
6. Install the O-ring to oil strainer and install the oil strainer. NOTE: Use new O-rings. Apply CVTF to the O-ring. Let the transmission harness run between control valve body and oil strainer. Tightening torque: 9 N.m (0.9 kgf-m, 6.6 ft-lb)
7. Connect the control valve harness connector.
8. Clean the magnet.
9. Attach the magnet at the specified position of the oil pan.
10. Apply liquid gasket all around the oil pan mating surface seamlessly. Liquid gasket: THREE BOND 1217B (Part No. K0877YA020) or equivalent
11. Install the oil pan by equally tightening the bolts. CAUTION: Beware of the transmission harness getting caught in between. Tightening torque: 5 N.m (0.5 kgf-m, 3.7 ft-lb)
12. Fill with CVTF. Ref. to «REPLACEMENT»(ref-371903-S22220435812010091900000) , CVTF.
13. Adjust the CVTF level. Ref. to «ADJUSTMENT»(ref-371903-S21010063132010091900000) , CVTF.

Install in the reverse order of removal.

Note. Use new O-rings. Do not impact or bend the transmission harness because it has the oil temperature sensor inside. Install the transmission ground terminal at an angle of 45° approximately.

Tightening torque

T1: 5 N.m (0.5 kgf-m, 3.7 ft-lb)

T2: 16 N.m (1.6 kgf-m, 11.8 ft-lb)

Scheme 466

1. Install the TCM to the bracket. CAUTION: To avoid the damage to bracket and TCM, do not remove after installing TCM to bracket. If installed by mistake, the part must be replaced with a new part.
2. Install the TCM. Tightening torque: 7.5 N.m (0.76 kgf-m, 5.5 ft-lb)
3. Install the harness connector to TCM.
4. Install the instrument panel lower cover. Ref. to «INSTALLATION»(ref-371913-S19395593592010091900000) , Instrument Panel Lower Cover.
5. Execute the learning control promotion. Ref. to «LEARNING CONTROL»(ref-371930-S40293120542010091900000) .

Scheme 467

Scheme 468

Scheme 469

Scheme 470

Scheme 471

Scheme 472

Scheme 473

1. Lift up the vehicle.
2. Remove the under cover.
3. Remove the CVTF inlet hose and CVTF outlet hose.
4. Lift up the vehicle.
5. Remove the inlet hose and outlet hose on radiator side. CAUTION: Do not use a screwdriver or other pointed tools.
6. Remove the CVTF inlet pipe and CVTF outlet pipe.
7. Lower the vehicle.
8. Remove the battery.
9. Remove the battery cable clip from the bracket, and remove the battery cable bracket.
10. Remove the front bumper. (OUTBACK model) Ref. to «REMOVAL»(ref-371913-S11677829322010091900000) , Front Bumper.
11. Remove the headlight assembly (LH). (OUTBACK model) Ref. to «REMOVAL»(ref-371943-S10133651902010091900000) , Headlight Assembly.
12. Remove the inlet hose and outlet hose. (OUTBACK model)
13. Remove the CVTF cooler pipe assembly mounting bolt.
14. Remove the sensor cover plate. (OUTBACK model)
15. Remove the front sub sensor harness connector and front harness clip from the vehicle, and route them under the CVTF cooler pipe assembly. (OUTBACK model) CAUTION: Refer to "CAUTION" of "General Description" before replacing the front sub sensor harness connector. Ref. to «CAUTION»(ref-371944-S30297997482010091900000) , General Description.
16. Detach the A/C pipe from clip.
17. Remove the CVTF cooler pipe assembly from the vehicle.

Scheme 474

1. Temporarily attach the CVTF cooler pipe assembly to vehicle.
2. Route the front harness above the CVTF cooler pipe assembly, and install the harness clip to the vehicle, and connect the front sub sensor harness connector. (OUTBACK model)
3. Attach the sensor cover plate. (OUTBACK model) Ref. to «INSTALLATION»(ref-371944-S23118268492010091900000) , Front Sub Sensor.
4. Fix the CVTF cooler pipe assembly to vehicle. Tightening torque: 7.5 N.m (0.76 kgf-m, 5.5 ft-lb)
5. Install the A/C pipe to clip.
6. Install the inlet hose and outlet hose. (OUTBACK model) NOTE: Use the new inlet hose and outlet hose.
7. Install the headlight assembly (LH). (OUTBACK model) Ref. to «INSTALLATION»(ref-371943-S19148901792010091900000) , Headlight Assembly.
8. Install the front bumper. (OUTBACK model) Ref. to «INSTALLATION»(ref-371913-S03014473602010091900000) , Front Bumper.
9. 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)
10. Lift up the vehicle.
11. Install the CVTF inlet pipe and CVTF outlet pipe. NOTE: Use a new gasket. Tightening torque: T1: 16 N.m (1.6 kgf-m, 11.8 ft-lb) T2: 40 N.m (4.1 kgf-m, 29.5 ft-lb)
12. Install the CVTF inlet hose and CVTF outlet hose. NOTE: Use the new CVTF inlet hose and CVTF outlet hose.
13. Install the inlet hose and outlet hose on radiator side. NOTE: Use the new inlet hose and outlet hose.
14. Install the under cover.
15. Lower the vehicle.
16. Install the battery.
17. Adjust the CVTF level and check there is no leakage. Ref. to «ADJUSTMENT»(ref-371903-S21010063132010091900000) , CVTF.

1. Remove the front bumper. Ref. to «REMOVAL»(ref-371913-S11677829322010091900000) , Front Bumper.
2. Remove the headlight assembly (LH). Ref. to «REMOVAL»(ref-371943-S10133651902010091900000) , Headlight Assembly.
3. Remove the inlet hose and outlet hose.
4. Remove the CVTF oil cooler.

Scheme 475

Install in the reverse order of removal.

Tightening torque

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

Note. Use the new inlet hose and outlet hose.

Install in the reverse order of removal.

Note. Use new O-rings.

1. Temporarily tighten the drive plate.
2. Set the ST. ST 498497100 CRANKSHAFT STOPPER
3. Tighten the drive plate mounting bolt in three stages. NOTE: Fix the engine unit. Tighten the drive plate mounting bolt. Tightening torque: 10 N.m (1.0 kgf-m, 7.4 ft-lb) Additionally tighten the drive plate mounting bolts. Tightening torque: 40 N.m (4.1 kgf-m, 29.5 ft-lb) While checking the tightening angle with the ST, tighten the drive plate mounting bolts to the specified angle. Tightening angle: 30°±5° ST 18854AA000 ANGLE GAUGE
4. Install the transmission assembly to the vehicle. Ref. to «INSTALLATION»(ref-371903-S31862939282010091900000) , Automatic Transmission Assembly.

1. Remove the transmission assembly from vehicle body. Ref. to «REMOVAL»(ref-371903-S11094350542010091900000) , Automatic Transmission Assembly.
2. Remove the front wheel speed sensor. Ref. to «REMOVAL»(ref-371903-S34256359392010091900000) , Front Wheel Speed Sensor.
3. Remove the harness clip, and remove the extension case.

Note. The total number of extension case mounting bolts is ten.

Scheme 476

Scheme 477

Scheme 478

1. Clean the mating surface of the extension case and intermediate case.
2. Select the thrust needle bearing. Ref. to «ADJUSTMENT»(ref-371903-S27246100182010091900000) , Rear Drive Shaft.
3. Select the shim for transfer reduction driven gear. Ref. to «ADJUSTMENT»(ref-371903-S29129080972010091900000) , Transfer Reduction Driven Gear.
4. Install the selected thrust needle bearing to transfer clutch assembly. NOTE: Install the thrust needle bearing in the correct direction.
5. Attach the selected shim to transfer reduction driven gear assembly.
6. Apply liquid gasket to extension case seamlessly. Liquid gasket: THREE BOND 1215 (Part No. 004403007) or equivalent
7. Install the extension case. Tightening torque: 25 N.m (2.5 kgf-m, 18.4 ft-lb)
8. Install the front wheel speed sensor. Ref. to «INSTALLATION»(ref-371903-S08262652052010091900000) , Front Wheel Speed Sensor.
9. Install the transmission assembly. Ref. to «INSTALLATION»(ref-371903-S31862939282010091900000) , Automatic Transmission Assembly.

1. Select the thrust needle bearing. Ref. to «ADJUSTMENT»(ref-371903-S27246100182010091900000) , Rear Drive Shaft.
2. Install the selected thrust needle bearing to transfer clutch assembly. NOTE: Install the thrust needle bearing in the correct direction.
3. Install the rear drive shaft.
4. Install the extension case. Ref. to «INSTALLATION»(ref-371903-S05160737982010091900000) , Extension Case.
5. Install the transmission assembly to the vehicle. Ref. to «INSTALLATION»(ref-371903-S31862939282010091900000) , Automatic Transmission Assembly.

Scheme 479

1. Remove the ball bearing using ST. ST 498077600 REMOVER

Scheme 480

1. Using the ST, install the ball bearing. NOTE: Use a new ball bearing. Apply CVTF to press-fitting surface of ball bearing. ST 399513600 INSTALLER

1. Apply vaseline to the seal ring and attach it to the seal ring groove of transfer clutch assembly. NOTE: Use a new seal ring. When installing the seal ring, do not expand the seal ring too much.
2. Install the transfer clutch assembly.
3. Select the thrust needle bearing. Ref. to «ADJUSTMENT»(ref-371903-S27246100182010091900000) , Rear Drive Shaft.
4. Install the selected thrust needle bearing and needle bearing to transfer clutch assembly. NOTE: Install the thrust needle bearing in the correct direction.
5. Install the rear drive shaft. Ref. to «INSTALLATION»(ref-371903-S32738999372010091900000) , Rear Drive Shaft.
6. Install the extension case. Ref. to «INSTALLATION»(ref-371903-S05160737982010091900000) , Extension Case.
7. Install the transmission assembly to the vehicle. Ref. to «INSTALLATION»(ref-371903-S31862939282010091900000) , Automatic Transmission Assembly.

Scheme 481

Scheme 482

Scheme 483

Scheme 484

Scheme 485

Scheme 486

Scheme 487

1. Remove the snap ring, and then remove the retaining plate, drive plate and driven plate.
2. Using the ST, remove the snap ring. ST 18762AA000 COMPRESSOR SPECIAL TOOL
3. Remove the transfer clutch piston seal.
4. Remove the return spring.
5. Remove the transfer clutch piston by blowing compressed air through transfer clutch assembly hole. NOTE: Block the hole opposite to the one to be blown with compressed air by your finger.
6. Using ST, remove transfer drive gear, parking gear and ball bearing. ST 18767AA000 BEARING REMOVER NOTE: Let the ST sit on the parking gear.
7. Remove the snap ring from transfer reduction drive gear.
8. Using the ST, remove the parking gear from transfer reduction drive gear. ST1 499277100 BUSHING 1-2 INSTALLER ST2 18767AA000 BEARING REMOVER

Scheme 488

Scheme 489

Scheme 490

Scheme 491

Scheme 492

Scheme 493

1. Using the ST, install the parking gear to transfer reduction drive gear. ST 398177700 INSTALLER
2. Install the snap ring to transfer reduction drive gear.
3. Using the ST, install the transfer reduction drive gear to transfer reduction drive gear shaft. ST 499277100 BUSHING 1-2 INSTALLER
4. Using the ST, install the ball bearing. NOTE: Use a new ball bearing. ST 499277100 BUSHING 1-2 INSTALLER
5. Attach the transfer clutch piston to the reduction drive gear shaft. NOTE: Apply CVTF to the transfer clutch piston lip.
6. Install the return spring.
7. Install the transfer clutch piston seal.
8. Using the ST, install the snap ring. ST 18762AA000 COMPRESSOR SPECIAL TOOL
9. Install the pressure plate, driven plate, drive plate and snap ring.
10. Before measuring clearance "A", place same thickness shims on both sides to prevent the retaining plate from tilting.
11. When clearance "A" exceeds the limit for use, replace the drive plate and driven plate as a set, and select and adjust 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) PRESSURE PLATE SPECIFICATIONS Pressure plate Part number Thickness mm (in) 31593AA151 3.3 (0.130) 31593AA161 3.7 (0.146)
12. Check the clearance between the snap ring and retaining plate. Ref. to «INSPECTION»(ref-371903-S00986700372010091900000) , Transfer Clutch.

1. Remove the transmission assembly from the vehicle. Ref. to «REMOVAL»(ref-371903-S11094350542010091900000) , Automatic Transmission Assembly.
2. Remove the front wheel speed sensor, and remove the extension case. Ref. to «REMOVAL»(ref-371903-S18410168992010091900000) , Extension Case.
3. Remove the transfer clutch assembly. Ref. to «REMOVAL»(ref-371903-S12564414742010091900000) , Transfer Clutch.
4. Remove the transfer reduction driven gear assembly.

Scheme 494

1. Install the reduction driven gear assembly.
2. Select shims. Ref. to «ADJUSTMENT»(ref-371903-S29129080972010091900000) , Transfer Reduction Driven Gear.
3. Mount the selected shim onto ball bearing.
4. Install the transfer clutch assembly. Ref. to «INSTALLATION»(ref-371903-S21370970802010091900000) , Transfer Clutch.
5. Install the extension case. Ref. to «INSTALLATION»(ref-371903-S05160737982010091900000) , Extension Case.
6. Install the transmission assembly to the vehicle. Ref. to «INSTALLATION»(ref-371903-S31862939282010091900000) , Automatic Transmission Assembly.

Scheme 495

1. Using the ST, remove the ball bearing (large) from transfer reduction driven gear. ST1 899864100 REMOVER ST2 398497701 SEAT ST3 498077600 REMOVER
2. Using the ST, remove the ball bearing (small) from transfer reduction driven gear. ST1 899864100 REMOVER ST2 398497701 SEAT ST3 18720AA000 REMOVER

Scheme 496

1. Install the new ball bearing (large) to reduction driven gear using the ST. ST 499277100 REMOVER NOTE: Use a new ball bearing. Install to the splines inside transfer reduction driven gear shaft.
2. Install the new ball bearing (small) to reduction driven gear. NOTE: Use a new ball bearing. ST 499277100 REMOVER

Note. Although CVTF filter is a maintenance-free part, replace it if a large quantity of wear debris and metal particles are found in CVTF and CVTF filter. For removal of CVTF filter, refer to "Intermediate Case". Ref. to REMOVAL , Intermediate Case.

Note. For removal of CVTF filter, refer to "Intermediate Case". Ref. to INSTALLATION , Intermediate Case.

Note. For removal of reverse brake assembly, refer to "Intermediate Case". Ref. to REMOVAL , Intermediate Case.

Note. For removal of reverse brake assembly, refer to "Intermediate Case". Ref. to INSTALLATION , Intermediate Case.

Scheme 497

Scheme 498

Scheme 499

Scheme 500

Scheme 501

1. Remove the snap ring.
2. Remove the retaining plate, drive plate, driven plate and dish plate.
3. Set the ST1, ST2 and ST3 to intermediate case. ST1 18762AA000 COMPRESSOR SPECIAL TOOL ST2 18763AA000 COMPRESSOR SHAFT ST3 18765AA000 COMPRESSOR SUPPORT
4. Compress the return spring using the set ST to remove the snap ring.
5. Using the ST, remove the snap ring and spring retainer.
6. Remove the return spring.
7. Remove the reverse brake piston by blowing compressed air intermittently from intermediate case hole.

Scheme 502

Scheme 503

Scheme 504

Scheme 505

Scheme 506

Scheme 507

1. Apply CVTF to the seal of reverse brake piston and install it to intermediate case.
2. Install the return spring.
3. Install the spring retainer.
4. Set the ST1, ST2 and ST3 to intermediate case. ST1 18762AA000 COMPRESSOR SPECIAL TOOL ST2 18763AA000 COMPRESSOR SHAFT ST3 18765AA000 COMPRESSOR SUPPORT
5. Compress the return spring using the set ST to install the snap ring.
6. Check the operation of reverse brake piston by blowing compressed air intermittently from intermediate case hole.
7. Place the dish plate, driven plate, drive plate and retaining plate neatly in this order on surface table.
8. Set the dial gauge to retaining plate, and read its scale. NOTE: The value, which is read in the gauge at this time, is zero point.
9. Scale and record the weight "Z" of a flat board which will be put on retaining plate. NOTE: Use a stiff board which does not bend against load as a flat board to be put on retaining plate. Use a flat board weighing less than 84 N (8.6 kgf, 18.9 lb).
10. Put the flat board on retaining plate.
11. Using the following formula, read the push/pull gauge, and calculate "N". N = 84 N (8.6 kgf, 18.9 lb) - Z 84 N (8.6 kgf, 18.9 lb): Load applied to clutch plate Z: Flat board weight
12. Press the center of retaining plate by applying a force of "N" or more using push/pull gauge, and then measure and record the compression amount "A". NOTE: Measure at four points with a 90° interval and calculate the average.
13. Install the dish plate, drive plate, driven plate and retaining plate to intermediate case. NOTE: Install the dish plate in the correct direction.
14. Measure and record the clearance "B" between the retaining plate and snap ring.
15. Piston stroke calculation Calculate with A and B dimensions recorded before. If it exceeds the limit for use, replace with a new drive plate and adjust within the initial standard value. S mm (in) = A + B S: Piston stroke A: Compression amount of drive plate and dish plate B: Clearance between retaining plate and snap ring Initial standard: 2.88 - 3.18 mm (0.113 - 0.125 in) Limit thickness: 3.38 mm (0.133 in)

RETAINING PLATE SPECIFICATIONS

1. Install the straight pin to reduction driven gear assembly.
2. Fit the straight pin portion to the recess portion of transmission case and install the reduction driven gear and install the snap ring.
3. Select the snap ring. Ref. to «ADJUSTMENT»(ref-371903-S26542166952010091900000) , Reduction Driven Gear.
4. Install the selected snap ring.
5. Install the forward clutch assembly. Ref. to «INSTALLATION»(ref-371903-S36652881282010091900000) , Forward Clutch Assembly.
6. Install the intermediate case. Ref. to «INSTALLATION»(ref-371903-S03316523282010091900000) , Intermediate Case.
7. Install the transfer reduction driven gear assembly. Ref. to «INSTALLATION»(ref-371903-S30695490442010091900000) , Transfer Reduction Driven Gear.
8. Install the transfer clutch assembly. Ref. to «INSTALLATION»(ref-371903-S21370970802010091900000) , Transfer Clutch.
9. Install the rear drive shaft. Ref. to «INSTALLATION»(ref-371903-S32738999372010091900000) , Rear Drive Shaft.
10. Install the extension case. Ref. to «INSTALLATION»(ref-371903-S05160737982010091900000) , Extension Case.
11. Install the transmission to vehicle. Ref. to «INSTALLATION»(ref-371903-S31862939282010091900000) , Automatic Transmission Assembly.

Scheme 508

Scheme 509

Scheme 510

1. Remove the bearing retainer using ST1, ST2 and ST3. ST1 899864100 REMOVER ST2 398497701 SEAT ST3 18767AA000 REMOVER
2. Remove the snap ring.
3. Remove the ball bearing using ST1, ST2 and ST3. ST1 899864100 REMOVER ST2 398497701 Seat ST3 498077600 REMOVER

Scheme 511

Scheme 512

1. Using the ST, install the ball bearing to bearing retainer. ST 398177700 INSTALLER NOTE: Use a new ball bearing. Make sure to install the ball bearing in the right direction. Apply CVTF to the press-fitting area.
2. Using the ST, install the reduction driven gear. ST 499277200 INSTALLER

Note. Always replace primary pulley and secondary pulley as an assembly because they are non-disassembled parts.

Scheme 513

Scheme 514

Scheme 515

Scheme 516

Scheme 517

Scheme 518

Scheme 519

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 transmission case. Ref. to «REMOVAL»(ref-371903-S16674758132010091900000) , Transmission Case.
12. Set the ST to secondary pulley and expand the V groove of pulley to an extent that variator chain gets loose. ST 18769AA000 PULLEY EXPANDER
13. Remove the chain guide from lubrication pipe and support rod.
14. Remove the lubrication pipe and support rod.
15. Detach the six claws to remove the two chain guide.
16. Remove the secondary pulley mounting bolt.
17. Remove the secondary pulley from drive pinion retainer and intersect the V groove of secondary pulley and V groove of primary pulley. Remove the variator chain from secondary pulley and remove the secondary pulley. CAUTION: Cover the V grooves of secondary pulley and primary pulley with cloth to protect the both pulleys and variator chain from scratching.
18. Remove the variator chain from primary pulley.
19. Remove the primary pulley mounting bolt.
20. Remove the primary pulley.
21. Remove the two seal rings from drive pinion retainer.
22. Remove the two seal rings from primary pulley.

Scheme 520

Scheme 521

Scheme 522

Scheme 523

Scheme 524

Scheme 525

1. Select shims for pulley alignment. Ref. to «ADJUSTMENT»(ref-371903-S30450512622010091900000) , Primary Pulley and Secondary Pulley.
2. Install the two seal rings to drive pinion retainer. NOTE: Use a new seal ring. Apply CVTF to the seal rings. When installing the seal ring, do not expand the seal ring too much.
3. Install the selected shims to the primary pulley bearing catch surface.
4. Install the two seal rings to primary pulley. NOTE: Use a new seal ring. Apply CVTF to the seal rings.
5. Install the primary pulley and adjust the position of bolt holes of primary bearing retainer and converter case to tighten the primary pulley bolt. NOTE: Use a new seal washer. Tightening torque: 21 N.m (2.1 kgf-m, 15.5 ft-lb)
6. Set the ST to secondary pulley and expand the V groove of pulley. ST1 18769AA000 PULLEY EXPANDER
7. Place the variator chain on the primary pulley groove and attach the secondary pulley and variator chain together to the drive pinion retainer. CAUTION: Cover the V grooves of primary pulley and secondary pulley with cloth to protect the both pulleys and variator chain from scratching. Place the variator chain on primary pulley. Intersect the V groove of primary pulley and the V groove of secondary pulley and install the secondary pulley while placing the variator chain on secondary pulley. While aligning the bolt hole of secondary bearing retainer and the bolt hole of driving pinion retainer, install the secondary pulley to drive pinion retainer.
8. Install the secondary pulley bolt. Tightening torque: 33 N.m (3.4 kgf-m, 24.3 ft-lb)
9. Install the chain guide. NOTE: Install it with two claws facing outward and with four claws facing inward.
10. Engage the cutout portions of support rod and drive pinion retainer and install the support rod.
11. Engage the cutout portions of lubrication pipe and drive pinion retainer and install the lubrication pipe.
12. Install the chain guide so that the lubrication pipe and support rod run through between the protrusions of each chain guide. Then remove the ST (PULLEY EXPANDER).
13. Install the O-ring to the lubrication pipe. NOTE: Use new O-rings.
14. Install the lubrication pipe.
15. Install the transmission case. Ref. to «INSTALLATION»(ref-371903-S27250346402010091900000) , Transmission Case.
16. Install the forward clutch assembly. Ref. to «INSTALLATION»(ref-371903-S36652881282010091900000) , Forward Clutch Assembly.
17. Install the intermediate case. Ref. to «INSTALLATION»(ref-371903-S03316523282010091900000) , Intermediate Case.
18. Install the transfer reduction driven gear assembly. Ref. to «INSTALLATION»(ref-371903-S30695490442010091900000) , Transfer Reduction Driven Gear.
19. Install the transfer clutch assembly. Ref. to «INSTALLATION»(ref-371903-S21370970802010091900000) , Transfer Clutch.
20. Install the rear drive shaft. Ref. to «INSTALLATION»(ref-371903-S32738999372010091900000) , Rear Drive Shaft.
21. Install the extension case. Ref. to «INSTALLATION»(ref-371903-S05160737982010091900000) , Extension Case.
22. Install the transmission harness. Ref. to «INSTALLATION»(ref-371903-S11130017622010091900000) , Transmission Harness.
23. Install the control valve body and oil pan. Ref. to «INSTALLATION»(ref-371903-S03125368572010091900000) , Control Valve Body.
24. Install the air breather hose. Ref. to «INSTALLATION»(ref-371903-S20333854442010091900000) , Air Breather Hose.
25. Install the transmission assembly to the vehicle. Ref. to «INSTALLATION»(ref-371903-S31862939282010091900000) , Automatic Transmission Assembly.

For removal of variator chain, refer to "Primary Pulley and Secondary Pulley". Ref. to REMOVAL , Primary Pulley and Secondary Pulley.

For installation of variator chain, refer to "Primary Pulley and Secondary Pulley". Ref. to INSTALLATION , Primary Pulley and Secondary Pulley.

Note. Refer to "Drive Pinion Shaft" for removal procedures. Ref. to REMOVAL , Drive Pinion Shaft Assembly.

Note. Refer to "Drive Pinion Shaft" for removal procedures. Ref. to INSTALLATION , Drive Pinion Shaft Assembly.

1. Clean the mating surface of converter case cover and converter case.
2. Select the shim for front reduction drive gear. Ref. to «ADJUSTMENT»(ref-371903-S22947208182010091900000) , Front Reduction Drive Gear.
3. Install the front reduction drive gear and front reduction driven gear together.
4. Install the converter case cover. Ref. to «INSTALLATION»(ref-371903-S36485169952010091900000) , Converter Case Cover.
5. Install the drive pinion shaft assembly. Ref. to «INSTALLATION»(ref-371903-S26963116062010091900000) , Drive Pinion Shaft Assembly.
6. Install the primary pulley, secondary pulley and variator chain. Ref. to «INSTALLATION»(ref-371903-S36883906552010091900000) , Primary Pulley and Secondary Pulley.
7. Install the transmission case. Ref. to «INSTALLATION»(ref-371903-S27250346402010091900000) , Transmission Case.
8. Install the forward clutch assembly. Ref. to «INSTALLATION»(ref-371903-S36652881282010091900000) , Forward Clutch Assembly.
9. Install the intermediate case. Ref. to «INSTALLATION»(ref-371903-S03316523282010091900000) , Intermediate Case.
10. Install the transfer reduction driven gear assembly. Ref. to «INSTALLATION»(ref-371903-S30695490442010091900000) , Transfer Reduction Driven Gear.
11. Install the transfer clutch assembly. Ref. to «INSTALLATION»(ref-371903-S21370970802010091900000) , Transfer Clutch.
12. Install the rear drive shaft. Ref. to «INSTALLATION»(ref-371903-S32738999372010091900000) , Rear Drive Shaft.
13. Install the extension case. Ref. to «INSTALLATION»(ref-371903-S05160737982010091900000) , Extension Case.
14. Install the primary speed sensor. Ref. to «INSTALLATION»(ref-371903-S40646793472010091900000) , Primary Speed Sensor.
15. Install the transmission harness. Ref. to «INSTALLATION»(ref-371903-S11130017622010091900000) , Transmission Harness.
16. Install the control valve body and oil pan. Ref. to «INSTALLATION»(ref-371903-S03125368572010091900000) , Control Valve Body.
17. Install the air breather hose. Ref. to «INSTALLATION»(ref-371903-S20333854442010091900000) , Air Breather Hose.
18. Install the transmission assembly to the vehicle. Ref. to «INSTALLATION»(ref-371903-S31862939282010091900000) , Automatic Transmission Assembly.

Scheme 526

Scheme 527

Scheme 528

1. Remove the seal ring and O-ring.
2. Using the ST, remove the ball bearing from front reduction drive gear. ST 899864100 REMOVER
3. Using the ST, remove the ball bearing from front reduction drive gear. ST 498077000 REMOVER

Scheme 529

Scheme 530

Scheme 531

1. Using the ST, install the ball bearing to front reduction drive gear. NOTE: Use a new ball bearing. ST 18651AA000 INSTALLER
2. Using ST1 and ST2, install the ball bearing to front reduction drive gear. NOTE: Use a new ball bearing. ST1 499757002 PRESS SNAP RING ST2 398177700 INSTALLER
3. Install the seal ring. NOTE: Use a new seal ring. When installing the seal ring, do not expand the seal ring too much. Install the O-ring when installing the torque converter assembly.

Note. For removal of front reduction driven gear, refer to the "Front Reduction Drive Gear". Ref. to REMOVAL , Front Reduction Drive Gear.

Note. For installation of front reduction driven gear, refer to the "Front Reduction Drive Gear". Ref. to INSTALLATION , Front Reduction Drive Gear.

Scheme 532

Scheme 533

Scheme 534

Scheme 535

1. Using the ST, remove the ball bearing, front reduction driven gear and front reduction driven shaft. ST1 899864100 REMOVER ST2 18767AA000 BEARING REMOVER
2. Remove the snap ring.
3. Remove the retaining plate, drive plate, driven plate and dish plate.
4. Remove the seal ring from front reduction driven shaft.
5. Using the round bar with diameter of 7 mm (0.28 in), tap the entire circumference around the ball bearing outer race a little at a time through the front reduction driven shaft hole, to remove the ball bearing.

Scheme 536

Scheme 537

Scheme 538

Scheme 539

Scheme 540

Scheme 541

Scheme 542

1. Place the dish plate, driven plate, drive plate and retaining plate neatly in this order on surface table. NOTE: Make sure of the direction of dish plate.
2. Set the dial gauge to retaining plate, and read its scale. NOTE: The value, which is read in the gauge at this time, is zero point.
3. Scale and record the weight "Z" of a flat board which will be put on retaining plate. NOTE: Use a stiff board which does not bend against load as a flat board to be put on retaining plate. Use a flat board weighing less than 130 N (13.3 kgf, 29.2 lb).
4. Put the flat board on retaining plate.
5. Using the following formula, calculate load "N", a force of pressing with push/pull gauge. N = 130 N (13.3 kgf, 29.2 lb) - Z 130 N (13.3 kgf, 29.2 lb): Load applied to clutch plate Z: Flat board weight
6. Press the center of retaining plate by applying a force of "N" using push/pull gauge, and then measure and record the compression amount "A". NOTE: Measure at four points with a 90° interval and calculate the average.
7. Install the dish plate, driven plate, drive plate, retaining plate and snap ring. NOTE: Make sure of the direction of dish plate.
8. Measure and record the clearance "B" between the retaining plate and snap ring. NOTE: Before measuring, press down the whole circumference of retaining plate using your finger.
9. Piston stroke calculation Calculate with A and B dimensions recorded before. If out of standard, replace with a new drive plate and adjust it within standard. S mm (in) = A + B S: Piston stroke A: Compression amount of drive plate and dish plate B: Clearance between retaining plate and snap ring Specification: 2.4 - 2.8 mm (0.094 - 0.11 in) RETAINING PLATE SPECIFICATIONS Retaining plate Part number Thickness mm (in) 31667AB430 3.1 (0.122) 31667AB440 3.3 (0.130) 31667AB450 3.5 (0.138)
10. Press-fit the ball bearing into front driven shaft. NOTE: Use a new ball bearing.
11. Install the seal ring to the front driven shaft. NOTE: Install a new seal ring. Apply CVTF to the seal rings.
12. Install the front driven shaft to front driven gear.
13. Using the ST, install the ball bearing. NOTE: Use a new ball bearing. ST 18651AA000 INSTALLER
14. Install the front reduction driven gear assembly to converter case cover.
15. Apply compressed air intermittently to check the piston operation. NOTE: Hold the arrowed area with a finger.

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 secondary pressure sensor. Ref. to «REMOVAL»(ref-371903-S08651531232010091900000) , Secondary Pressure Sensor.
6. Remove the primary speed sensor. Ref. to «REMOVAL»(ref-371903-S00426178232010091900000) , Primary Speed Sensor.
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 transmission case. Ref. to «REMOVAL»(ref-371903-S16674758132010091900000) , Transmission Case.
15. Remove the primary pulley, secondary pulley and variator chain. Ref. to «REMOVAL»(ref-371903-S30531158412010091900000) , Primary Pulley and Secondary Pulley.
16. Remove the drive pinion shaft assembly. Ref. to «REMOVAL»(ref-371903-S24707370692010091900000) , Drive Pinion Shaft Assembly.
17. Remove the front differential assembly. Ref. to «REMOVAL»(ref-371903-S12588615662010091900000) , Front Differential Assembly.
18. Remove the converter case cover. Ref. to «REMOVAL»(ref-371903-S12973246672010091900000) , Converter Case Cover.
19. Remove the front reduction drive gear and front reduction driven gear. Ref. to «REMOVAL»(ref-371903-S36672061592010091900000) , Front Reduction Drive Gear.

1. Install the front reduction drive gear and front reduction driven gear. Ref. to «INSTALLATION»(ref-371903-S34365335412010091900000) , Front Reduction Drive Gear.
2. Install the converter case cover. Ref. to «INSTALLATION»(ref-371903-S36485169952010091900000) , Converter Case Cover.
3. Install the front differential assembly. Ref. to «INSTALLATION»(ref-371903-S01275456592010091900000) , Front Differential Assembly.
4. Install the drive pinion shaft assembly. Ref. to «INSTALLATION»(ref-371903-S26963116062010091900000) , Drive Pinion Shaft Assembly.
5. Install the primary pulley, secondary pulley and steel chain. Ref. to «INSTALLATION»(ref-371903-S36883906552010091900000) , Primary Pulley and Secondary Pulley.
6. Install the transmission case. Ref. to «INSTALLATION»(ref-371903-S27250346402010091900000) , Transmission Case.
7. Install the reduction driven gear. Ref. to «INSTALLATION»(ref-371903-S20267797932010091900000) , Reduction Driven Gear.
8. Install the forward clutch assembly. Ref. to «INSTALLATION»(ref-371903-S36652881282010091900000) , Forward Clutch Assembly.
9. Install the intermediate case. Ref. to «INSTALLATION»(ref-371903-S03316523282010091900000) , Intermediate Case.
10. Install the transfer reduction driven gear. Ref. to «INSTALLATION»(ref-371903-S30695490442010091900000) , Transfer Reduction Driven Gear.
11. Install the transfer clutch assembly. Ref. to «INSTALLATION»(ref-371903-S21370970802010091900000) , Transfer Clutch.
12. Install the rear drive shaft. Ref. to «INSTALLATION»(ref-371903-S32738999372010091900000) , Rear Drive Shaft.
13. Install the extension case. Ref. to «INSTALLATION»(ref-371903-S05160737982010091900000) , Extension Case.
14. Install the primary speed sensor. Ref. to «INSTALLATION»(ref-371903-S40646793472010091900000) , Primary Speed Sensor.
15. Install the secondary pressure sensor. Ref. to «INSTALLATION»(ref-371903-S01360043322010091900000) , Secondary Pressure Sensor.
16. Install the transmission harness. Ref. to «INSTALLATION»(ref-371903-S11130017622010091900000) , Transmission Harness.
17. Install the control valve body and oil pan. 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 543

1. Remove the transmission hanger and transmission radio ground cord.
2. Remove the oil drain plug and overflow drain plug. Ref. to «REPLACEMENT»(ref-371903-S01649799972010091900000) , Differential Gear Oil.
3. Remove all plugs.

Scheme 544

1. Install the oil drain plug and overflow drain plug. NOTE: Overflow plug of differential gear oil is temporarily attached.
2. Install all plugs. NOTE: Use new O-rings. Tightening torque: 25 N.m (2.5 kgf-m, 18.4 ft-lb)
3. Install the transmission hanger and transmission radio ground cord. Tightening torque: 41 N.m (4.2 kgf-m, 30.2 ft-lb)