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Automatic Transaxle (5AT): Removal & Installation Subaru Outback BR рестайлинг

Automatic Trans 43 illustrations ~2405 words

INSTALLATION

  1. Install the rear vehicle speed sensor. NOTE: Use new O-rings. Tightening torque: 7 N.m (0.7 kgf-m, 5.2 ft-lb)
  2. Connect the rear vehicle speed sensor connector.
  3. Install the heat shield cover. Refer to «INSTALLATION»(ref-565181-S01461358122013071000000) .
  4. Tighten the bolts which connect the front exhaust pipe and rear exhaust pipe. Tightening torque: 18 N.m (1.8 kgf-m, 13.3 ft-lb)
  5. Lower the vehicle.

Scheme 125

Scheme 125: REMOVAL
Scheme 125: REMOVAL
  1. Disconnect the ground cable from battery.
  2. Lift up the vehicle.
  3. Remove the front exhaust pipe. Refer to «REMOVAL»(ref-565201-S03342601172013071000000) .
  4. Disconnect the turbine speed sensor 1 connector.
  5. Remove the turbine speed sensor 1.
  1. Install the turbine speed sensor 1. NOTE: Use new O-rings. Tightening torque: 7 N.m (0.7 kgf-m, 5.2 ft-lb)
  2. Connect the turbine speed sensor 1 connector.
  3. Install the front exhaust pipe. Refer to «INSTALLATION»(ref-565201-S28862029152013071000000) .
  4. Lower the vehicle.
  5. Connect the battery ground terminal.

Scheme 126

Scheme 126: REMOVAL
Scheme 126: REMOVAL

Scheme 127

Scheme 127
Scheme 127

Scheme 128

Scheme 128
Scheme 128
  1. Disconnect the ground cable from battery.
  2. Lift up the vehicle.
  3. Clean the transmission exterior.
  4. Remove the ATF drain plug to drain ATF. CAUTION: Directly after the vehicle has been running or the engine has been long idle running, the ATF is hot. Be careful not to burn yourself.
  5. Tighten the ATF drain plug. NOTE: Use a new gasket. Tightening torque: 20 N.m (2.0 kgf-m, 14.8 ft-lb)
  6. Remove the oil pan. CAUTION: Be sure to prevent the entering of dust and other foreign matters into oil pan.
  7. Remove the magnet.
  8. Clean the magnet.
  9. Completely remove the remaining liquid gasket on the transmission case and oil pan.
  10. Disconnect the control valve connector and front vehicle speed sensor connector.
  11. Remove the control valve body. NOTE: The control valve body is replaced as an assembly only, because it is a non-disassembly part.

Scheme 129

Scheme 129: INSTALLATION
Scheme 129: INSTALLATION

Scheme 130

Scheme 130
Scheme 130
  1. Check the control valve body for dust and other foreign matter.
  2. Install the control valve body to transmission by equally tightening the bolts. Tightening torque: 8 N.m (0.8 kgf-m, 5.9 ft-lb)
  3. Connect the control valve connector and front vehicle speed sensor connector.
  4. Attach the magnet at the specified position of the oil pan.
  5. Apply liquid gasket to the oil pan. Liquid gasket: THREE BOND 1217B (Part No. K0877YA020) or equivalent
  6. Install the oil pan by equally tightening the bolts. Tightening torque: 5 N.m (0.5 kgf-m, 3.7 ft-lb)
  7. Lower the vehicle.
  8. Connect the ground cable to battery.
  9. Pour ATF through the oil charge pipe. Refer to «AUTOMATIC TRANSMISSION FLUID»(ref-565170-S05681770412013071000000) .
  10. Check the ATF level. Refer to «INSPECTION»(ref-565170-S12832332002013071000000) .
  11. Perform Clear Memory 2 operation. Refer to «CLEAR MEMORY MODE»(ref-565205-S14828419072013071000000) .
  12. Perform learning operation. Refer to «LEARNING CONTROL»(ref-565205-S06384924472013071000000) .
  13. Perform the inspection at the end of repair work, and make sure there is no faulty as below; Excessive shift shock Oil leakage from the transmission body, etc. Occurrence of noise caused by interference etc.
  1. Install the air breather hose.
  2. Install the air intake boot. Refer to «INSTALLATION»(ref-565165-S19209019292013071000000) .
  3. Install the collector cover.

REMOVAL

  1. Remove the transmission assembly. Refer to «REMOVAL»(ref-565170-S32560761592013071000000) .
  2. Disconnect the rear vehicle speed sensor connector.
  3. Remove the rear vehicle speed sensor.
  4. Remove the extension case.
  1. Attach the selected reduction driven gear shim to end surface of reduction driven gear with vaseline. Refer to «ADJUSTMENT»(ref-565170-S18557624582013071000000) .
  2. Install the extension case. NOTE: Use a new gasket. Tightening torque: 25 N.m (2.5 kgf-m, 18.4 ft-lb)
  3. Install the rear vehicle speed sensor. NOTE: Use new O-rings. Tightening torque: 7 N.m (0.7 kgf-m, 5.2 ft-lb)
  4. Connect the rear vehicle speed sensor connector.
  5. Install the transmission assembly. Refer to «INSTALLATION»(ref-565170-S32118193262013071000000) .

Scheme 131

Scheme 131: DISASSEMBLY
Scheme 131: DISASSEMBLY

Scheme 132

Scheme 132
Scheme 132
  1. Take out the transfer clutch and rear drive shaft by lightly tapping the end of rear drive shaft. NOTE: Be careful not to damage the oil seal of the extension.
  2. Remove the snap ring using the ST and press. ST 18762AA000 COMPRESSOR SPECIAL TOOL
  3. Supply compressed air to remove the clutch piston.
  4. Remove the dust cover from extension case.
  5. Remove the oil seal from the extension case.

Scheme 133

Scheme 133: ASSEMBLY
Scheme 133: ASSEMBLY
  1. Press-fit the oil seal using the ST and press. NOTE: Use a new oil seal. ST 498057300 INSTALLER
  2. Press-fit the dust cover.
  3. Insert the transfer clutch assembly, spring retainer, return spring and clutch spring retainer.
  4. Using the ST and compressor, install the snap ring. ST 18762AA000 COMPRESSOR SPECIAL TOOL
  5. Install the transfer clutch. Refer to «INSTALLATION»(ref-565170-S35932940072013071000000) .
  6. Install the rear drive shaft.
  1. Remove the transmission assembly from vehicle body. Refer to «REMOVAL»(ref-565170-S32560761592013071000000) .
  2. Remove the extension case, and then remove the transfer clutch. Refer to «REMOVAL»(ref-565170-S34011140362013071000000) . Refer to «DISASSEMBLY»(ref-565170-S29421599772013071000000) .
  1. Select the rear drive shaft shim. Refer to «ADJUSTMENT»(ref-565170-S39743373592013071000000) .
  2. Select driven plate No. 3 Refer to «ADJUSTMENT»(ref-565170-S39743373592013071000000) .
  3. Install the extension case. Refer to «INSTALLATION»(ref-565170-S15744371412013071000000) .
  4. Install the transmission assembly to the vehicle. Refer to «INSTALLATION»(ref-565170-S32118193262013071000000) .
  1. Remove the transmission assembly from the vehicle. Refer to «REMOVAL»(ref-565170-S32560761592013071000000) .
  2. Remove the rear vehicle speed sensor, and then remove the extension case. Refer to «REMOVAL»(ref-565170-S34011140362013071000000) .
  3. Pull out the rear drive shaft from center differential assembly.
  4. Remove the drive plate and driven plate.
  1. Select shims. Refer to «ADJUSTMENT»(ref-565170-S39743373592013071000000) .
  2. Install the drive plate and driven plate.
  3. Insert the rear drive shaft into the center differential assembly.
  4. Combine the extension case, and then install the rear vehicle speed sensor. Refer to «INSTALLATION»(ref-565170-S15744371412013071000000) .
  5. Install the transmission assembly to the vehicle. Refer to «INSTALLATION»(ref-565170-S32118193262013071000000) .

Scheme 134

Scheme 134: DISASSEMBLY
Scheme 134: DISASSEMBLY

Scheme 135

Scheme 135
Scheme 135
  1. Using a press, remove the revolution gear.
  2. Using a press, remove the front and rear side ball bearings and clutch hub.
  1. Set the range select lever to the "P" range.
  2. Use a plastic hammer to install reduction driven gear assembly.
  3. Select the reduction gear shims. Refer to «ADJUSTMENT»(ref-565170-S18557624582013071000000) .
  4. Join the transmission case and the extension case, and then install the rear vehicle speed sensor. Refer to «INSTALLATION»(ref-565170-S15744371412013071000000) .
  5. Install the transmission assembly to the vehicle. Refer to «INSTALLATION»(ref-565170-S32118193262013071000000) .

Scheme 136

Scheme 136: DISASSEMBLY
Scheme 136: DISASSEMBLY

Scheme 137

Scheme 137
Scheme 137

Scheme 138

Scheme 138
Scheme 138

Scheme 139

Scheme 139
Scheme 139
  1. Remove the ball bearing from reduction driven gear using ST. ST 498077300 REMOVER
  2. Remove the ball bearing on the reverse side with the same procedure as step 1 ). ST 498077300 REMOVER
  3. Remove the snap ring of the parking gear.
  4. Using the ST, remove the parking gear. ST 18767AA000 REMOVER

Scheme 140

Scheme 140: ASSEMBLY
Scheme 140: ASSEMBLY

Scheme 141

Scheme 141
Scheme 141

Scheme 142

Scheme 142
Scheme 142
  1. Using the ST, install the parking gear. ST 499755602 PRESS
  2. Install the snap ring.
  3. Install the ball bearing to the reduction driven gear using a press. NOTE: Use a new ball bearing. ST 18654AA000 INSTALLER
  4. Install the ball bearing on the reverse side with the same procedure as step 3 ). ST 18654AA000 INSTALLER
  1. Install the center differential assembly with the shim(s). NOTE: Press-fit it to the bottom of bearing shoulder completely.
  2. Insert the rear drive shaft. Refer to «INSTALLATION»(ref-565170-S20482293902013071000000) .
  3. Join the transmission case and the extension case, and then install the rear vehicle speed sensor. Refer to «INSTALLATION»(ref-565170-S15744371412013071000000) .
  4. Install the transmission assembly to the vehicle. Refer to «INSTALLATION»(ref-565170-S32118193262013071000000) .

Scheme 143

Scheme 143: DISASSEMBLY
Scheme 143: DISASSEMBLY

Scheme 144

Scheme 144
Scheme 144

Scheme 145

Scheme 145
Scheme 145

Scheme 146

Scheme 146
Scheme 146
  1. Remove the seal ring.
  2. Remove the ball bearing using the ST and the press. ST 498077600 REMOVER
  3. Remove the snap ring, and pull out the pinion shaft from center differential assembly.
  4. Remove the pinion gear and washers from center differential assembly.
  5. Pull out the intermediate shaft and thrust bearing.

Scheme 147

Scheme 147: ASSEMBLY
Scheme 147: ASSEMBLY

Scheme 148

Scheme 148
Scheme 148
  1. Install the thrust bearing onto intermediate shaft.
  2. Insert the intermediate shaft into the center differential assembly.
  3. Install the pinion gears and washers.
  4. Insert the pinion shaft into the center differential assembly. NOTE: Insert the pinion shaft with the side with the plug side facing the front side (gear side). After inserting the pinion shaft, adjust its position so that the cutout portion on the front side is on the inner side.
  5. Install the snap ring.
  6. Using a press, press-fit the ball bearing into the center differential assembly. NOTE: Use a new ball bearing. ST 498077000 REMOVER
  7. Apply vaseline onto the seal ring outer surface and shaft grooves.
  8. Install a new seal ring.
  1. Secure the oil pump cover. NOTE: Use a new gasket. Tightening torque: 41 N.m (4.2 kgf-m, 30.2 ft-lb)
  2. Install the converter case assembly to the transmission case assembly. Refer to «INSTALLATION»(ref-565170-S34293644402013071000000) .
  3. Install the transmission harness connector to the stay.
  4. Install the ATF cooler pipe. Refer to «INSTALLATION»(ref-565170-S10324685202013071000000) .
  5. Install the torque converter assembly. Refer to «INSTALLATION»(ref-565170-S33922980042013071000000) .
  6. Install the transmission assembly to the vehicle. Refer to «INSTALLATION»(ref-565170-S32118193262013071000000) .

Scheme 149

Scheme 149: FRONT BRAKE
Scheme 149: FRONT BRAKE

Scheme 150

Scheme 150
Scheme 150

Scheme 151

Scheme 151
Scheme 151
  1. Remove the snap ring.
  2. Remove the retaining plate, drive plate and driven plate.
  3. Using the ST1, ST2 and ST3, remove the snap ring. ST1 18762AA000 COMPRESSOR SPECIAL TOOL ST2 18765AA000 COMPRESSOR SUPPORT ST3 18763AA000 COMPRESSOR SHAFT
  4. Remove the retainer and return spring.
  5. Remove the front brake piston using compressed air.
  6. Remove the D-ring from front brake piston.

Scheme 152

Scheme 152: OIL PUMP
Scheme 152: OIL PUMP
  1. Take out the oil pump housing.
  2. Take out the oil pump body.

Scheme 153

Scheme 153: FRONT BRAKE
Scheme 153: FRONT BRAKE

Scheme 154

Scheme 154
Scheme 154
  1. Apply ATF to D-ring, and then install it to the front brake piston. NOTE: Use a new D-ring.
  2. Install the front brake piston to oil pump cover. NOTE: Install by aligning the "delta" mark on front brake piston surface with the oil pump cover rib.
  3. Install the retainer and return spring.
  4. Install the front brake piston assembly using ST1, ST2 and ST3. ST1 18762AA000 COMPRESSOR SPECIAL TOOL ST2 18765AA000 COMPRESSOR SUPPORT ST3 18763AA000 COMPRESSOR SHAFT
  5. Install the genuine driven plate instead of retaining plate, and temporarily assemble the drive plate and driven plate. Part No. 31536AA290 Driven plate
  6. Install the snap ring.
  7. Measure the clearance between the retaining plate and snap ring. If the value exceeds the specification, replace the drive plate and driven plate as a set and select the retaining plate so that the value is within the specification. NOTE: The thickness of the genuine drive plate is 2.8±0.05 mm (0.11±0.002 in). Front brake clearance specification: 0.7 - 1.1 mm (0.028 - 0.043 in) Front brake retaining plate Part No. Thickness mm (in) 31567AB130 3.4 (0.134) 31567AB140 3.6 (0.142) 31567AB150 3.8 (0.150) 31567AB160 4.0 (0.157)
  8. Remove the snap ring, replace the driven plate used in measurement of clearance with the retaining plate, and then reassemble.
  1. Assemble the drive pinion assembly to oil pump cover. NOTE: Be careful not to bend the shim. Tightening torque: 70 N.m (7.1 kgf-m, 51.6 ft-lb)
  2. Adjust the tooth contact between drive pinion shaft assembly and the front differential side gear. Refer to «ADJUSTMENT»(ref-565170-S26914544682013071000000) .
  3. Join the converter case with the transmission case. Refer to «INSTALLATION»(ref-565170-S34293644402013071000000) .
  4. Install the transmission harness connector to the stay.
  5. Install the ATF cooler pipe. Refer to «INSTALLATION»(ref-565170-S10324685202013071000000) .
  6. Install the torque converter assembly. Refer to «INSTALLATION»(ref-565170-S33922980042013071000000) .
  7. Install the transmission assembly to the vehicle. Refer to «INSTALLATION»(ref-565170-S32118193262013071000000) .

Scheme 155

Scheme 155: DISASSEMBLY
Scheme 155: DISASSEMBLY

Scheme 156

Scheme 156
Scheme 156

Scheme 157

Scheme 157
Scheme 157
  1. Flatten the lock nut tab, and then remove the lock nut while holding the rear spline part of the shaft using ST1 and ST2. Pull out the drive pinion collar. ST1 18667AA010 HOLDER ST2 499787700 WRENCH ST3 499787500 ADAPTER
  2. Remove the O-ring.
  3. Separate the roller bearing and outer race from shaft using a press.
  4. Separate the front roller bearing from the shaft using a press and the ST. ST 498517000 REPLACER

Scheme 158

Scheme 158: ASSEMBLY
Scheme 158: ASSEMBLY

Scheme 159

Scheme 159
Scheme 159

Scheme 160

Scheme 160
Scheme 160

Scheme 161

Scheme 161
Scheme 161

Scheme 162

Scheme 162
Scheme 162
  1. Measure the dimension "A" of drive pinion shaft. ST 398643600 GAUGE
  2. Using a press, press-fit the new roller bearing into the specified position. NOTE: If excessive force is applied to roller bearing, the roller bearing will not turn easily.
  3. After fitting a new O-ring to the shaft, attach the drive pinion collar to the shaft.
  4. Tighten the new lock nuts using ST1, ST2 and ST3. Calculate the tightening torque using following formula. T2 = L2/(L1 + L2) x T1 T1: 116 N.m (11.8 kgf-m, 85.6 ft-lb) [Required torque setting] T2: Tightening torque L1: ST2 length 0.072 m (2.83 in) L2: Torque wrench length Example: Torque wrench length m (in) Tightening torque N.m (kgf-m, ft-lb) 0.4 (15.75) 98 (10.0, 72.3) 0.45 (17.72) 100 (10.2, 73.8) 0.5 (19.69) 101 (10.3, 74.5) 0.55 (21.65) 102 (10.4, 75.2) ST1 18667AA010 HOLDER ST2 499787700 WRENCH ST3 499787500 ADAPTER NOTE: Attach ST2 to torque wrench as straight as possible.
  5. Measure the starting torque of the bearing. Make sure the starting torque is within the specified range. If the torque is not within specified range, replace the roller bearing. Starting torque: 7.6 - 38.1 N (0.775 - 3.88 kgf, 1.7 - 8.6 lbf)
  6. Crimp the locknut in 2 locations.
  7. Measure the dimension "B" of the drive pinion shaft. ST 398643600 GAUGE
  8. Calculate the thickness "t" mm (in) of the drive pinion shim. t = 6.5±0.0625 (0.256±0.0025) - (B - A)
  9. Select three or less shims from following table. Drive pinion shim Part No. Thickness mm (in) 31451AA180 0.150 (0.0059) 31451AA190 0.175 (0.0069) 31451AA200 0.200 (0.0079) 31451AA210 0.225 (0.0089) 31451AA220 0.250 (0.0098) 31451AA230 0.275 (0.0108)
  1. Remove the transmission assembly from the vehicle. Refer to «REMOVAL»(ref-565170-S32560761592013071000000) .
  2. Pull out the torque converter assembly. Refer to «REMOVAL»(ref-565170-S11805246132013071000000) .
  3. Remove the transmission harness connector from stay.
  4. Remove the ATF cooler inlet pipe and outlet pipe. Refer to «REMOVAL»(ref-565170-S39517426232013071000000) .
  5. Separate the converter case from the transmission case. Refer to «REMOVAL»(ref-565170-S42421263502013071000000) .
  6. Remove the differential side retainers using ST. NOTE: Hold the differential case assembly by hand to avoid damaging the differential side retainer mounting hole of the converter case. ST 18630AA010 WRENCH COMPL RETAINER
  7. Remove the front differential assembly while being careful not to damage the attachment part of the retainer.

Scheme 163

Scheme 163: INSTALLATION
Scheme 163: INSTALLATION

Scheme 164

Scheme 164
Scheme 164
  1. When installing the front differential assembly to the case, be careful not to damage the inside of case (particularly, the differential side retainer mating surface).
  2. Install the O-ring to left and right side retainers. NOTE: Use new O-rings.
  3. Using the ST, install the side retainer. Refer to «ADJUSTMENT»(ref-565170-S16510745372013071000000) . ST 18630AA010 WRENCH COMPL RETAINER
  4. Adjust the backlash of the front differential. Refer to «ADJUSTMENT»(ref-565170-S16510745372013071000000) .
  5. Install the lock plate. Tightening torque: 25 N.m (2.5 kgf-m, 18.4 ft-lb)
  6. Install the converter case to the transmission case. Refer to «INSTALLATION»(ref-565170-S34293644402013071000000) .
  7. Install the transmission harness connector to the stay.
  8. Install the ATF cooler pipe. Refer to «INSTALLATION»(ref-565170-S10324685202013071000000) .
  9. Install the torque converter assembly. Refer to «INSTALLATION»(ref-565170-S33922980042013071000000) .
  10. Install the transmission assembly to the vehicle. Refer to «INSTALLATION»(ref-565170-S32118193262013071000000) .

Scheme 165

Scheme 165: DIFFERENTIAL CASE ASSEMBLY
Scheme 165: DIFFERENTIAL CASE ASSEMBLY

Scheme 166

Scheme 166
Scheme 166

Scheme 167

Scheme 167
Scheme 167
  1. Remove the taper roller bearing using the ST and the press. ST 498077000 REMOVER
  2. Secure the case in a vise, remove the hypoid driven gear tightening bolts, and then separate the hypoid driven gear into case (RH) and case (LH).
  3. Pull out the straight pin and shaft, and then remove the differential bevel gear, washer and differential bevel pinion.

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