INSTALLATION — Part 1 Subaru Outback BR

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