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Home/Subaru/Outback/Subaru Outback BR (2009-2012)/Repair manual/Continuously Variable Transmission: Removal & Installation/INSTALLATION — Part 2
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INSTALLATION — Part 2 Subaru Outback BR

Continuously Variable Transmission: Removal & Installation 53 illustrations ~3561 words

Scheme 492

Scheme 492
Scheme 492

Scheme 493

Scheme 493
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

Scheme 494
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

Scheme 495: DISASSEMBLY
Scheme 495: DISASSEMBLY
  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

Scheme 496: ASSEMBLY
Scheme 496: ASSEMBLY
  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 497: DISASSEMBLY
Scheme 497: DISASSEMBLY

Scheme 498

Scheme 498
Scheme 498

Scheme 499

Scheme 499
Scheme 499

Scheme 500

Scheme 500
Scheme 500

Scheme 501

Scheme 501
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 502
Scheme 502

Scheme 503

Scheme 503: ASSEMBLY
Scheme 503: ASSEMBLY

Scheme 504

Scheme 504
Scheme 504

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Scheme 505

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Scheme 506
Scheme 506

Scheme 507

Scheme 507
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
Part numberThickness mm (in)
31567AB6805.6 (0.220)
31567AB6905.8 (0.228)
31567AB7006.0 (0.236)
31579AB7106.2 (0.244)

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 508: DISASSEMBLY
Scheme 508: DISASSEMBLY

Scheme 509

Scheme 509
Scheme 509

Scheme 510

Scheme 510
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 511: ASSEMBLY
Scheme 511: ASSEMBLY

Scheme 512

Scheme 512
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 513: REMOVAL
Scheme 513: REMOVAL

Scheme 514

Scheme 514
Scheme 514

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Scheme 515

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Scheme 516

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Scheme 517
Scheme 517

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Scheme 518

Scheme 519

Scheme 519
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 520
Scheme 520

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Scheme 522
Scheme 522

Scheme 523

Scheme 523
Scheme 523

Scheme 524

Scheme 524
Scheme 524

Scheme 525

Scheme 525
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 526: DISASSEMBLY
Scheme 526: DISASSEMBLY

Scheme 527

Scheme 527
Scheme 527

Scheme 528

Scheme 528
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 529: ASSEMBLY
Scheme 529: ASSEMBLY

Scheme 530

Scheme 530
Scheme 530

Scheme 531

Scheme 531
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 532: DISASSEMBLY
Scheme 532: DISASSEMBLY

Scheme 533

Scheme 533
Scheme 533

Scheme 534

Scheme 534
Scheme 534

Scheme 535

Scheme 535
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 536
Scheme 536

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Scheme 538

Scheme 538
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Scheme 542

Scheme 542
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

Scheme 543: DISASSEMBLY
Scheme 543: DISASSEMBLY
  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

Scheme 544
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)