Continuously Variable Transaxle (Cvt): Diagnosis Subaru Outback BR рестайлинг

INSPECTION

Check for leakage of CVTF from transmission.

Check that there is no leakage of differential gear oil from the converter case.

Note. Stall test is extremely important in diagnosing the condition of CVT and engine. The test is necessary to measure the engine stall speeds in "R" and "D" range.

Purposes of the stall test

1. Operational check of forward clutch and reverse brake
2. Operational check of the torque converter assembly
3. Engine performance check

1. Place wheel chocks at the front and rear of all wheels and engage the parking brake.
2. Turn the A/C OFF.
3. Using the Subaru Select Monitor, check if the throttle valve operates when you depress the accelerator pedal. Refer to «DISPLAY OF ENGINE FREEZE FRAME DATA»(ref-565182-S42652795882013071000000) .
4. Check the engine oil level. Refer to «ENGINE OIL»(ref-565156-S07435495832013071000000) .
5. Check the coolant level. Refer to «ENGINE COOLANT»(ref-565166-S16474887242013071000000) .
6. Adjust the CVTF level. Refer to «ADJUSTMENT»(ref-565171-S15048869762013071000000) .
7. Increase the CVTF temperature to 60 - 80°C (140 - 176°F) with the engine running and the select lever shifted to "N" or "P" range.
8. Shift the select lever to "D" range.
9. Depress the accelerator pedal to the full while fully depressing the foot brake pedal with your left foot.
10. When the engine speed stabilizes, quickly record the engine speed and release accelerator pedal. Shift the select lever to "N" range. Let the engine idle for one minute or more to cool it down.
11. Shift to "R" range and perform the same stall test. NOTE: Do not perform a stall test for over 5 seconds at a time. (from closed throttle, fully open throttle to stall speed reading.) Failure to follow this instruction will cause the engine oil and CVTF to deteriorate and the clutch and brake to be adversely affected. Be sure to cool down the engine for at least one minute after each stall test with the select lever set in the "P" or "N" range and with the idle speed of 1, 200 rpm or less. If the stall speed is higher than the specified range, attempt to finish the stall test in as short a time as possible, in order to prevent the CVT from sustaining damage. Stall speed standard: D range: 2, 000 - 2, 700 rpm R range: 1, 900 - 2, 600 rpm STALL TEST JUDGMENT Range Range Probable cause Lower than standard value D, R Insufficient engine output Torque converter malfunction Higher than standard value D Forward clutch slippage Secondary pressure (line pressure) is low. Variator chain malfunction R Reverse brake slippage Secondary pressure (line pressure) is low. Variator chain malfunction D, R Torque converter malfunction Control valve body malfunction TCM malfunction Damaged harness and harness connector

Note. When the select lever is shifted while the engine is idling, there will be a certain time elapse or lag before shock is felt. This symptom helps to check the condition of forward clutch and reverse brake.

1. Perform the test at normal operation CVTF temperature of 60 - 80°C (140 - 176°F).
2. Be sure to allow one minute or more interval between tests.
3. Make three measurements and take the average value.

1. Apply the parking brake.
2. Start the engine. Check the idle speed. (A/C OFF)
3. Shift the select lever from "N" to "D" range. Using a stop watch, measure the time elapsed from shifting the lever until the shock is felt. Time lag standard: 1.2 seconds or less If "N" --> "D" time lag is longer than specified: Secondary pressure (line pressure) is too low. Forward clutch worn Forward clutch piston malfunction Control valve body malfunction Learning incomplete
4. In the same manner, measure the time lag when shifting from "N" to "R" range. Time lag standard: 1.5 seconds or less If "N" --> "R" time lag is longer than specified: Secondary pressure (line pressure) is too low. Reverse brake worn Reverse brake piston malfunction Control valve body malfunction Learning incomplete

Note. If the pulley and variator chain, clutch or brake show signs of slipping or shift feel is not correct, check the secondary pressure (line pressure). Connect Subaru Select Monitor to vehicle so as to measure the engine speed and actual secondary pressure (secondary pressure (line pressure)). In many cases, slippage or inability to operate the vehicle may be due to insufficient oil pressure for the operation of clutch, brake or control valve.

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1. Lift up the vehicle.
2. Remove the secondary pressure (line pressure) test plug, and install ST1 and ST2. CAUTION: Removal of the test plug and installation of the ST shall be both performed quickly. NOTE: Use ST2 PRESSURE GAUGE ADAPTER with genuine O-ring (part No. 806916050) attached. ST1 18801AA000 OIL PRESSURE GAUGE ASSY ST2 18681AA010 PRESSURE GAUGE ADAPTER
3. Lower the vehicle.
4. Set the gauge so that it can be seen from the driver's seat.
5. Using the Subaru Select Monitor, check if the throttle valve operates when you depress the accelerator pedal. Refer to «DISPLAY OF ENGINE FREEZE FRAME DATA»(ref-565182-S42652795882013071000000) .
6. Check the engine oil level. Refer to «ENGINE OIL»(ref-565156-S07435495832013071000000) .
7. Check the coolant level. Refer to «ENGINE COOLANT»(ref-565166-S16474887242013071000000) .
8. Adjust the CVTF level. Refer to «ADJUSTMENT»(ref-565171-S15048869762013071000000) .
9. Increase the CVTF temperature to 60 - 80°C (140 - 176°F) with the engine running and the select lever shifted to "N" or "P" range.
10. Shift the select lever to "D" range.
11. Depress the accelerator pedal to the full while fully depressing the foot brake pedal with your left foot.
12. Immediately after the engine speed becomes steady, record the reading of the secondary pressure (line pressure), engine speed and actual secondary pressure on Subaru Select Monitor. And then release the accelerator pedal. Shift the select lever to "N" range. Let the engine idle for one minute or more to cool it down. NOTE: Do not continue the stall test for 5 seconds or more at a time (from fully closed throttle, fully open throttle to secondary pressure (line pressure) reading). Failure to follow this instruction will cause the engine oil and CVTF to deteriorate and the clutch and brake to be adversely affected. After performing the secondary pressure (line pressure) test, be sure to cool down the engine for at least one minute with the select lever set in "P" or "N" range and with the idle speed at 1, 200 rpm or less. Under each condition, check that the measured pressure matches almost totally with actual secondary pressure. When both measured pressure and actual secondary pressure are out of specification, judge as control valve malfunction. The value at stall is for reference because the pressure changes under different conditions or circumstances. The value at idling is steady because it is not affected by any condition or circumstance. Secondary pressure (line pressure) standard Range Throttle Brake Secondary pressure (line pressure) (MPa (kgf/cm 2 , psi)) Stall D, R Full open ON 4.5 - 6.0 (45.9 - 61.2, 652 - 870) Idling P, N Full closed OFF 0.5 - 1.5 (5.1 - 15.3, 72 - 218)
13. Remove the ST and install the plug after measurement. CAUTION: Removal of the ST and installation of the test plug shall be both performed quickly. NOTE: Use new O-rings. Apply CVTF to the O-ring. Tightening torque: 50 N.m (5.1 kgf-m, 36.9 ft-lb)
14. Adjust the CVTF level. Refer to «ADJUSTMENT»(ref-565171-S15048869762013071000000) .

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1. Lift up the vehicle.
2. Remove the rear exhaust pipe from center exhaust pipe.
3. Remove the center exhaust cover.
4. Set the transmission jack under the transmission.
5. Remove the mounting bolt of rear crossmember.
6. Lower the rear side of transmission until the transfer clutch pressure test plug can be removed.
7. Remove the transfer clutch pressure test plug.
8. Set the ST1, ST2, ST3 and ST4 to the transmission. NOTE: Use ST1 ADAPTER HOSE B with genuine union screw (part No. 801914010) and gasket (part No. 803914060) attached. Use ST3 PRESSURE GAUGE ADAPTER with genuine O-ring (part No. 806911080) attached. ST1 34099AC020 ADAPTER HOSE B ST2 34099AC010 ADAPTER HOSE A ST3 18681AA000 PRESSURE GAUGE ADAPTER ST4 498575400 OIL PRESSURE GAUGE ASSY
9. Raise the transmission, and install the rear crossmember. Tightening torque: 75 N.m (7.6 kgf-m, 55.3 ft-lb)
10. Install the rear exhaust pipe to center exhaust pipe. Tightening torque: 18 N.m (1.8 kgf-m, 13.3 ft-lb)
11. Lower the vehicle.
12. Connect the Subaru Select Monitor to the data link connector and read the current data.
13. Check the transfer clutch pressure as in secondary pressure (line pressure) test. Refer to «SECONDARY PRESSURE (LINE PRESSURE) TEST»(ref-565171-S23275331042013071000000) . NOTE: Use Subaru Select Monitor for switching to FWD mode. Refer to «AWD ON/OFF SWITCHING MODE»(ref-565171-S10388939952013071000000) . If no oil pressure is produced, if it does not change in AWD mode or if oil pressure is produced in FWD mode, there may be a problem in the control valve body. Range position ON Duty ratio (%) Accelerator pedal opening angle (%) Standard transfer clutch pressure kPa (kgf/cm 2 , psi) AWD mode FWD mode D 95 - 100 Fully opened (100) 1, 000 - 1, 200 (10.2 - 12.2, 145 - 174) - 60 Adjust ON Duty ratio to 60%. 400 - 700 (4.1 - 7.1, 58 - 102) - 0 Fully closed (0) - 0 (0, 0) N or P 0 Fully closed (0) 0
14. Lift up the vehicle.
15. Remove the rear exhaust pipe from center exhaust pipe.
16. Set the transmission jack under the transmission.
17. Remove the mounting bolt of rear crossmember.
18. Lower the rear side of transmission until the ST can be removed.
19. Remove the ST and install the plug. NOTE: Use new O-rings. Apply CVTF to the O-ring. Tightening torque: 25 N.m (2.5 kgf-m, 18.4 ft-lb)
20. Raise the transmission, and install the rear crossmember. Tightening torque: 70 N.m (7.1 kgf-m, 51.6 ft-lb)
21. Install the center exhaust cover. Tightening torque: 18 N.m (1.8 kgf-m, 13.3 ft-lb)
22. Install the rear exhaust pipe to center exhaust pipe. NOTE: Use a new gasket. Tightening torque: 18 N.m (1.8 kgf-m, 13.3 ft-lb)
23. Lower the vehicle.

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1. Remove the front wheels.
2. Disconnect the ground cable from battery.
3. Remove the air intake duct. Refer to «REMOVAL»(ref-565164-S20404975892013071000000) .
4. Remove the air intake boot assembly. Refer to «REMOVAL»(ref-565164-S05274062402013071000000) .
5. Remove the ten clips and remove the grille bracket.
6. Disconnect the following connectors. Transmission harness connectors Transmission radio ground terminal Inhibitor harness connector
7. Separate the battery cable clip to remove the bracket.
8. Remove the starter. Refer to «REMOVAL»(ref-565187-S23832579102013071000000) .
9. Disconnect the throttle position sensor harness connector and manifold pressure sensor harness connector.
10. Remove the bolt and disconnect the engine harness connector bracket.
11. Disconnect the engine harness connector.
12. Remove the service hole plug.
13. Remove the four bolts combining the torque converter and drive plate while rotating the crank pulley a little at a time in the same direction as engine revolution. CAUTION: Be careful not to drop bolts into converter housing. Be careful not to damage the mounting bolts.
14. Make sure the torque converter moves freely by rotating with finger through the starter installation hole.
15. Attach the ST to the converter case. ST 498277200 STOPPER SET
16. After pulling off the cotter pin and removing the castle nut, use a puller to remove the tie-rod end from the knuckle arm.
17. Lift up the vehicle.
18. Remove the under cover.
19. Remove the center exhaust pipe. Refer to «REMOVAL»(ref-565184-S03793321452013071000000) .
20. Remove the CVTF drain plug to drain CVTF. Refer to «REPLACEMENT»(ref-565171-S26759675992013071000000) .
21. Remove the center exhaust cover.
22. Remove the snap pin and washer from shifter arm and remove the select cable from shifter arm.
23. Remove the plate assembly from the transmission case.
24. Drain differential gear oil. Refer to «REPLACEMENT»(ref-565171-S02213794792013071000000) .
25. Remove the CVTF CVT inlet hose and CVTF CVT outlet hose.
26. Remove the universal joint. Refer to «REMOVAL»(ref-565179-S22667709372013071000000) .
27. Remove the propeller shaft. Refer to «REMOVAL»(ref-565177-S36474058612013071000000) .
28. Remove the stabilizer link.
29. Disconnect the lower arm ball joint and housing.
30. Pull out the front drive shaft from transmission using a crowbar.
31. Holding the joint of front drive shaft from transmission side, pull out the drive shaft from transmission with care not to stretch the boot.
32. Lower the vehicle.
33. Remove the nuts from left and right transmission mounting brackets.
34. Remove the radiator main fan and radiator sub fan. Refer to «REMOVAL»(ref-565166-S40491921312013071000000) , and «REMOVAL»(ref-565166-S17253119262013071000000) .
35. Set the ST1 and ST2 to vehicle. ST1 99099AJ000 ENGINE HANGER ST2 99099AJ010 CHAIN BALANCER CAUTION: Set so that the chain sling does not contact the engine parts. Set the arms of ST (ENGINE HANGER) at the locations shown in the figure.
36. Lift the engine slightly and remove the engine mounting bolts.
37. Remove the engine mounting nut and bolt to remove the front cushion rubber.
38. Temporarily attach ST by using two bolts. ST 41099AJ130 SPECIAL TOOL FB
39. Lift up the engine unit high enough to install the bolt and nut to vehicle. CAUTION: Do not lift up higher than enough level to install the ST to avoid damage to the hoses and pipes inside the engine room. NOTE: If it is difficult to pull out the stud bolt from transmission mounting bracket, shake the engine unit slightly while lifting up.
40. Tighten the mounting bolts on the engine side. Tightening torque: 25 N.m (2.5 kgf-m, 18.4 ft-lb)
41. Remove the ST (ENGINE HANGER).
42. Remove the left and right transmission mounting brackets. NOTE: First, remove the transmission mounting bracket on the right side of vehicle, and then tilt the engine unit to remove the left transmission mounting bracket.
43. Remove the three transmission connecting bolts.
44. Set the ST (ENGINE HANGER) again to loosen the chain sling.
45. Lift up the vehicle.
46. Set the transmission jack under the transmission.
47. Remove the hanger bracket.
48. Remove the rear crossmember.
49. Lower the transmission rear end (dust cover rear end). CAUTION: When lowering the transmission rear end, be careful not to let the converter case and steering mechanical parts contact each other. NOTE: Lower the transmission rear end by approx. 80 mm (3.1 in) (reference).
50. Rotate the handle of ST (ENGINE HANGER) to apply tension to the chain sling.
51. Remove the two transmission connecting bolts and two nuts (lower side).
52. Remove the transmission assembly. NOTE: Remove it while moving the transmission jack up and down so that the engine and transmission remain directly aligned.
53. Remove the cushion rubber.

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1. Attach the ST to converter case. ST 498277200 STOPPER SET
2. Replace the front differential side retainer oil seal. Refer to «REPLACEMENT»(ref-565171-S28943403342013071000000) . NOTE: Be sure to replace the differential side retainer oil seal with a new part whenever the front drive shaft is removed from the transmission. When a new differential side retainer oil seal has been installed, replacement is not required.
3. Install the cushion rubber on the transmission. Tightening torque: 40 N.m (4.1 kgf-m, 29.5 ft-lb)
4. Mount the transmission onto the transmission jack.
5. Strike and bend the transmission hanger of transmission rear with a soft rubber hammer etc. so that it gets in contact with the transmission case. CAUTION: Do not apply extra overload or impact to the transmission case.
6. While lifting up the transmission gradually, install the transmission to the engine. CAUTION: This operation requires at least two persons. NOTE: Keep the engine level.
7. Install the two engine connecting bolts and two nuts (lower side). Tightening torque: 50 N.m (5.1 kgf-m, 36.9 ft-lb)
8. Secure the transmission rear crossmember to the vehicle body. 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)
9. Install the hanger bracket. Tightening torque: 23 N.m (2.3 kgf-m, 17.0 ft-lb)
10. Remove the transmission jack.
11. Lower the vehicle.
12. Remove the ST (ENGINE HANGER).
13. Install the three engine mounting bolts (upper side). Tightening torque: 50 N.m (5.1 kgf-m, 36.9 ft-lb)
14. Install the left and right transmission mounting brackets. NOTE: Install to the left side of vehicle first because the engine inclines to the left. Temporarily tighten the bolt arrowed in the figure. Tightening torque: 75 N.m (7.6 kgf-m, 55.3 ft-lb)
15. Set the ST to vehicle body and lift up the engine unit slightly. ST1 99099AJ000 ENGINE HANGER ST2 99099AJ010 CHAIN BALANCER CAUTION: Set so that the chain sling does not contact the engine parts. Set the arms of ST (ENGINE HANGER) at the locations shown in the figure.
16. Remove the bolts from ST (SPECIAL TOOL FB).
17. Remove the bolt and nut to remove ST (SPECIAL TOOL FB).
18. Temporarily attach the front cushion rubber with bolts.
19. Install the bolt and nut to the front cushion rubber.
20. Tighten the bolts and nuts of front cushion rubber. NOTE: Always start tightening from the bolts on the engine side. Tightening torque: T1: 25 N.m (2.5 kgf-m, 18.4 ft-lb) T2: 45 N.m (4.6 kgf-m, 33.2 ft-lb)
21. Remove the ST (ENGINE HANGER and CHAIN SLING).
22. Install the nut to the transmission mounting bracket. Tightening torque: 45 N.m (4.6 kgf-m, 33.2 ft-lb)
23. Install the main fan and sub fan.
24. Remove the ST (STOPPER SET) from converter case.
25. Match the torque converter screw hole with drive plate hole to install the bolt. CAUTION: Do not drop the mounting bolt in the converter housing. Do not damage the mounting bolt. Tightening torque: 25 N.m (2.5 kgf-m, 18.4 ft-lb)
26. Install the remaining three bolts by rotating the crank pulley a little at a time in the same direction as engine revolution. Tightening torque: 25 N.m (2.5 kgf-m, 18.4 ft-lb)
27. Install the service hole plug.
28. Install the starter. Refer to «INSTALLATION»(ref-565187-S27231661562013071000000) .
29. Lift up the vehicle.
30. Tighten the single mounting bolt of transmission mounting bracket. Tightening torque: 75 N.m (7.6 kgf-m, 55.3 ft-lb)
31. Set the ST to side retainer. ST 28399SA010 OIL SEAL PROTECTOR
32. Replace the circlip of the drive shaft with a new part.
33. Insert the front drive shaft spline section into transmission and remove the ST (OIL SEAL PROTECTOR).
34. Insert the drive shaft into the transmission securely by pressing the housing from outside of the vehicle.
35. Install the CVTF CVT inlet hose and CVTF CVT outlet hose. NOTE: Use new CVTF CVT inlet hose and CVTF CVT outlet hose.
36. 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.
37. Install the stabilizer link. Tightening torque: 60 N.m (6.1 kgf-m, 44.3 ft-lb)
38. 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.
39. 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.
40. Install the propeller shaft. Refer to «INSTALLATION»(ref-565177-S15615832782013071000000) .
41. Install the universal joint. Refer to «INSTALLATION»(ref-565179-S14842137192013071000000) .
42. Install the plate assembly to transmission. Tightening torque: 25 N.m (2.5 kgf-m, 18.4 ft-lb)
43. Install the washer and snap pin to the shifter arm.
44. Install the center exhaust cover. Tightening torque: 18 N.m (1.8 kgf-m, 13.3 ft-lb)
45. Install the center exhaust pipe. Refer to «INSTALLATION»(ref-565184-S27754215802013071000000) .
46. Install the under cover.
47. Lower the vehicle.
48. Connect the engine harness.
49. Attach the harness connector bracket. Tightening torque: 7.5 N.m (0.76 kgf-m, 5.5 ft-lb)
50. Connect the following harness connectors. Transmission harness connectors Transmission radio ground terminal Inhibitor harness connector Tightening torque: 13 N.m (1.3 kgf-m, 9.6 ft-lb)
51. 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)
52. Attach the grille bracket.
53. Install the air intake boot assembly. Refer to «INSTALLATION»(ref-565164-S07668311112013071000000) .
54. Install the air intake duct. Refer to «INSTALLATION»(ref-565164-S36764007252013071000000) .
55. Install the front wheels. Refer to «INSTALLATION»(ref-565178-S10716996292013071000000) .
56. Connect the battery ground terminal.
57. Refill differential gear oil to adjust the differential gear oil amount. Refer to «DIFFERENTIAL GEAR OIL»(ref-565171-S39726849772013071000000) .
58. Refill CVTF to adjust the CVTF amount. Refer to «CVTF»(ref-565171-S03700449892013071000000) .
59. Perform the operation for clearing AT learning value. Refer to «CLEAR MEMORY MODE»(ref-565196-S42481880922013071000000) .
60. Perform the operation of AT learning mode. Refer to «LEARNING CONTROL»(ref-565196-S17278486372013071000000) .
61. Execute the rear differential inspection mode. Refer to «REAR DIFFERENTIAL INSPECTION MODE»(ref-565172-S13660654842013071000000) . CAUTION: Always execute the rear differential inspection mode at the replacement of the following. Replacement of transmission assembly Replacement of front differential hypoid gear set
62. Perform the road test to make sure there is no fault. Refer to «INSPECTION»(ref-565171-S21341097952013071000000) .

Scheme 322

1. Disconnect the ground cable from battery.
2. Lift up the vehicle.
3. Remove the center exhaust pipe. Refer to «REMOVAL»(ref-565184-S03793321452013071000000) .
4. Remove the center exhaust 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.

Scheme 323

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 center exhaust cover. Tightening torque: 18 N.m (1.8 kgf-m, 13.3 ft-lb)
5. Install the center exhaust pipe. Refer to «INSTALLATION»(ref-565184-S27754215802013071000000) .
6. Connect the battery ground terminal.

1. Check the crossmember for bends or damage.
2. Check that the cushion rubber is not stiff, cracked or otherwise damaged.

Check for leakage of CVTF from the joint section of transmission and propeller shaft. If a leak is found, inspect the propeller shaft and replace the oil seal.

Check for leakage of gear oil from differential side retainer oil seal part. If there is an oil leak, inspect the front drive shaft and replace the oil seal.

When the driving condition or starter motor operation is improper, first check the shift linkage for improper operation. If the shift linkage is functioning properly, check the inhibitor switch.

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1. Remove the air intake boot assembly. Refer to «REMOVAL»(ref-565164-S05274062402013071000000) .
2. Disconnect the inhibitor harness connector.
3. Check for continuity in inhibitor switch circuit by shifting the select lever in "P", "R", "N" and "D" respectively. NOTE: Check that there is no continuity in the starter circuit when the select lever is in the "R" and "D" ranges. When inhibitor switch is normal, check there is no poor contact in vehicle side connector and no open circuit in harness. Signal sent to TCM Range Terminal No. P 1 - 7 R 2 - 7 N 3 - 7 D 4 - 7 Starter circuit P/N 15 - 16 Back-up light circuit R 13 - 14
4. Check that there is continuity at equal points when the select lever is moved 1.5° in both directions from the "N" range. If there is continuity in only one direction or in other points, adjust the inhibitor switch. Refer to «ADJUSTMENT»(ref-565171-S19149361002013071000000) .
5. Repeat the above inspection in other gear ranges. If there is fault, adjust the inhibitor switch and select cable. Refer to «ADJUSTMENT»(ref-565171-S19149361002013071000000) and «ADJUSTMENT»(ref-565197-S31315338362013071000000) .

Scheme 327

1. Shift the select lever to "N" range.
2. Loosen the two bolts holding the inhibitor switch.
3. Insert the ST vertically into the holes of the shifter arm and switch body. ST 499267300 STOPPER PIN
4. Tighten the two bolts holding the inhibitor switch. Tightening torque: 5 N.m (0.5 kgf-m, 3.7 ft-lb)
5. Repeat the inspection of the inhibitor switch. If the inhibitor switch is determined to be "faulty", replace it.

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1. Shift the select lever to "N" range.
2. Disconnect the ground cable from battery.
3. Lift up the vehicle.
4. Remove the center exhaust pipe. Refer to «REMOVAL»(ref-565184-S03793321452013071000000) .
5. Remove the snap pin and washer from the shifter arm.
6. Remove the spring pin and shifter arm.
7. Remove the inhibitor harness connector from inhibitor switch.
8. Remove the two inhibitor switch securing bolts.
9. Remove the inhibitor switch from the transmission case.

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1. Install the inhibitor switch to the transmission case temporarily.
2. Connect the inhibitor harness connector to the inhibitor switch.
3. Install the shifter arm and fix with the spring pin. NOTE: Use new spring pin.
4. Shift the shifter arm to "N" range.
5. Install the ST vertically in the cutout of shifter arm and the hole of switch body. ST 499267300 STOPPER PIN
6. Tighten the two bolts holding the inhibitor switch. Tightening torque: 5 N.m (0.5 kgf-m, 3.7 ft-lb)
7. Install the select cable to the shifter arm.
8. Install the washer and snap pin to the shifter arm.
9. Install the center exhaust pipe. Refer to «INSTALLATION»(ref-565184-S27754215802013071000000) .
10. Lower the vehicle.
11. Connect the battery ground terminal.
12. Check the inhibitor switch. Refer to «INSPECTION»(ref-565171-S42861680552013071000000) .

1. Remove the instrument panel lower cover. Refer to «REMOVAL»(ref-565181-S34862331172013071000000) .
2. Start and warm up the engine.
3. Shift the select lever to "P" or "N" range.
4. Depress the brake pedal and hold it.
5. Check "secondary pressure sensor voltage" by using Subaru Select Monitor while the engine is idling. Refer to «OPERATION»(ref-565196-S07402396132013071000000) . Standard Approx. 0.8 V
6. Check "secondary pressure sensor voltage" with engine stopped and ignition switch turned on by using Subaru Select Monitor. Refer to «OPERATION»(ref-565196-S07402396132013071000000) . Specification: Approx. 0.5 V

1. Check each part for damage or dust.
2. Check oil strainer for clogging.

1. Check each part for damage or dust.
2. Measure the resistance of each solenoid, sensor and ground wire.

Note. Measurement should be performed at a temperature of 20°C (68°F).

Scheme 333

1. Solenoid

1. Oil temperature sensor

1. Transmission ground

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1. Remove the transmission from the vehicle. Refer to «REMOVAL»(ref-565171-S25233894212013071000000) .
2. Remove the transmission case cover.
3. Remove the harness connector from the ground terminal, turbine speed sensor, primary speed sensor, secondary speed sensor and secondary pressure sensor.
4. Remove the harness connector from inhibitor switch.
5. Remove the inhibitor harness connector from the transmission harness stay.
6. Remove the harness clip from the transmission, and remove the inhibitor harness.

Scheme 338

1. Disconnect the ground cable from battery.
2. Remove the air intake boot assembly. Refer to «REMOVAL»(ref-565164-S05274062402013071000000) .
3. Disconnect the following connectors. Transmission harness connectors Inhibitor harness connector Transmission radio ground terminal
4. Remove the air breather hose from the transmission hanger, and remove the transmission hanger and the transmission radio ground cord.
5. Remove the transmission case cover.
6. Remove the transmission harness stay and ground terminal.
7. Remove the transmission harness connector from the harness stay.
8. Clean the transmission exterior.
9. Set the ST on the vehicle. ST 18761AA010 SHEET SPECIAL TOOL
10. Remove the valve cover and gasket.
11. Remove the transmission harness connector from the control valve body.
12. Remove the transmission harness from the valve cover.
13. Remove the O-ring from the transmission harness.

1. Visually check the harness and connector for damage or crack.
2. Check the harness terminal for rust, disconnection or poor contact.
3. Check the continuity between harness terminals.

Note. For details of transmission harness circuit, refer to appropriate SYSTEM WIRING DIAGRAM article.

Harness continuity standard

Less than 1 ohms

Scheme 339

Scheme 340

1. Disconnect the ground cable from battery.
2. Remove the instrument panel lower cover. Refer to «REMOVAL»(ref-565181-S34862331172013071000000) .
3. Remove the bulkhead harness connector from TCM.
4. Remove the TCM. NOTE: Replace the TCM and bracket as a set.

Scheme 341

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 (0.8 kgf-m, 5.5 ft-lb)
3. Install the harness connector to TCM.
4. Install the instrument panel lower cover. Refer to «INSTALLATION»(ref-565181-S00927673132013071000000) .
5. Perform the diagnosis again. Refer to «LEARNING CONTROL»(ref-565196-S17278486372013071000000) .

Repair or replace any faulty hoses, pipes, clamps, and washers found in the inspection below.

1. Check for CVTF leaks in joints between the transmission, radiator, pipes, and hoses.
2. Check the clamp for deformation.
3. Lightly bend the hose and check for cracks in the surface or other damages.
4. Pinch the hose with your fingers and check for poor elasticity. Also check for poor elasticity in the parts where the clamp was installed by pressing with your fingernail.
5. Check for peeling, cracks, and deformation at the tip of the hose.

Scheme 342

1. Remove the air intake boot assembly. Refer to «REMOVAL»(ref-565164-S05274062402013071000000) .
2. Remove the air breather hose.

Scheme 343

1. Remove the transmission assembly. Refer to «REMOVAL»(ref-565171-S25233894212013071000000) .
2. Remove the transmission case cover.
3. Remove the air breather hose.

Check the hose for peeling, crack or clogging.

Scheme 344

1. Remove the transmission assembly from the vehicle. Refer to «REMOVAL»(ref-565171-S25233894212013071000000) .
2. Set the ST. ST 498497300 CRANKSHAFT STOPPER
3. Remove the drive plate and reinforcement drive plate.

Scheme 345

Scheme 346

1. Temporarily install the drive plate and reinforcement drive plate. NOTE: Align the knock pin hole of the crankshaft position sensor plate to the knock pin of the crankshaft to secure the knock pin.
2. Set the ST. ST 498497300 CRANKSHAFT STOPPER
3. Tighten the drive plate mounting bolt in two stages. Tighten the drive plate mounting bolt. Tightening torque: 30 N.m (3.1 kgf-m, 22.1 ft-lb) While checking the tightening angle with the ST, tighten the drive plate mounting bolts to the specified angle. Tightening angle: 30° - 35° ST 18854AA000 ANGLE GAUGE
4. Install the transmission assembly to the vehicle. Refer to «INSTALLATION»(ref-565171-S34027850992013071000000) .

Check the drive cable for damage.

Scheme 347

1. Remove the transmission assembly from the vehicle. Refer to «REMOVAL»(ref-565171-S25233894212013071000000) .
2. Pull out the torque converter assembly horizontally. CAUTION: Do not scratch the inside of engaging parts.
3. Remove the O-ring from the input shaft.

Scheme 348

1. Install the O-ring to the input shaft. NOTE: Use new O-rings. Apply CVTF to the O-ring.
2. While holding the torque converter assembly by hand, carefully install it into the torque converter case. NOTE: Apply CVTF to the oil seal lip. Do not damage the oil seal and O-ring.
3. Engage the splines while gently rotating the torque converter assembly by hand, and securely insert the assembly.
4. Measure depth "A", from converter case end surface to drive plate contacting surface. Standard (reference): 6.8 mm (0.268 in)
5. Install the transmission assembly to the vehicle. Refer to «INSTALLATION»(ref-565171-S34027850992013071000000) .

1. Check the protrusion of torque converter center (front boss) is not deformed or damaged.
2. Check the ring gear and exterior for break or damage.

1. Check there is no leak of CVTF from the joint between extension case and transmission case.
2. Check there is no damage or cracks on the extension case and other parts.

1. Inspect the drive plate facing for wear and damage.
2. Driven plate for discoloration (burned color)
3. Make sure the snap ring is not worn and the return spring has no permanent distortion, damage, or deformation.
4. Check the lip seal for damage.
5. Inspect the extension end play, and adjust it to within the standard value. Refer to «ADJUSTMENT»(ref-565171-S16379846502013071000000) .

1. Before measuring clearance "A" between snap ring and driven plate, place same thickness shims on both sides to prevent the plate from tilting.
2. When clearance "A" exceeds the limit for use, replace the drive plate and driven plate as a set, and select the pressure plate within the initial specified value. Initial standard: 0.7 - 1.1 mm (0.028 - 0.043 in) Limit thickness: 1.45 mm (0.057 in)
3. Check for tight corner braking phenomenon when the vehicle is moved forward with the steering fully turned. If tight corner braking occurs, perform the following procedures. With the steering wheel held at fully turned position, drive the vehicle in "D" range and with vehicle speed at approx. 5 km/h (3 MPH) in both clockwise and counterclockwise directions for approx. ten times each, while repeating acceleration and braking intermittently. If the tight corner braking phenomenon still persists, drive the vehicle again in a circle for several laps.

Scheme 349

Scheme 350

Scheme 351

1. Install the transfer clutch assembly to the extension case with the transfer driven gear shims and thrust bearings removed.
2. Install the thrust bearing to the transfer driven gear. NOTE: Make sure to install in the right direction.
3. Using the ST, measure the height "A" from the ST end face to the thrust bearing catch surface of the transfer clutch assembly. ST 499575500 GAUGE
4. Using the ST, measure the height "B" from the transmission case mating surface to the end of ST. ST 499575500 GAUGE
5. Obtain the thickness of transfer driven gear shim using the following formula to select one to three transfer driven gear shims. T (mm) = A - B - (0.05 - 0.25) [T (in) = A - B - (0.002 - 0.01)] T: Transfer driven gear shim thickness A: Height from the ST end face to the transfer clutch assembly thrust bearing catch surface B: Height from the mating surface of the transmission case to the end of the ST 0.05 - 0.25 mm (0.002 - 0.01 in): Clearance Transfer driven gear shim Part No. Thickness mm (in) 33280AA030 0.3 (0.012) 33280AA040 0.4 (0.016) 33280AA050 0.5 (0.020)

Scheme 352

1. Remove the transmission assembly from the vehicle. Refer to «REMOVAL»(ref-565171-S25233894212013071000000) .
2. Remove the extension case. Refer to «REMOVAL»(ref-565171-S42191516522013071000000) .
3. Remove the transfer clutch assembly. Refer to «REMOVAL»(ref-565171-S18851069972013071000000) .
4. Remove the transfer driven gear assembly.
5. Remove the seal ring from the transfer driven gear assembly.

1. Check the ball bearing for smooth rotation.
2. Check the ball bearing for excessive looseness.
3. Check the transfer driven gear for breakage or damage.

1. Check the parking pawl for breakage or damage.
2. Check for worn, broken and/or damaged return spring.

Scheme 353

1. Remove the transmission assembly from the vehicle. Refer to «REMOVAL»(ref-565171-S25233894212013071000000) .
2. Remove the extension case. Refer to «REMOVAL»(ref-565171-S42191516522013071000000) .
3. Remove the transfer clutch assembly. Refer to «REMOVAL»(ref-565171-S18851069972013071000000) .
4. Remove the transfer driven gear assembly. Refer to «REMOVAL»(ref-565171-S21203357002013071000000) .
5. Remove the parking pawl. Refer to «REMOVAL»(ref-565171-S24495240752013071000000) .
6. Remove the reduction driven gear assembly.

1. Check the ball bearing for smooth rotation.
2. Check the ball bearing for excessive looseness.
3. Make sure each gear is not broken or damaged.

Scheme 354

Scheme 355

1. Measure the height "A" from the ST upper face to the ball bearing catch surface. ST 499575600 GAUGE
2. Measure the height "B" from the ST to the mating surface of the transmission case. ST 499575600 GAUGE
3. Obtain the thickness of transfer drive gear shim using the following formula to select one to three transfer drive gear shims. T (mm) = A - B - (0.05 - 0.25) [T (in) = A - B - (0.002 - 0.01)] T: Shim thickness A: Height from the ST upper face to the ball bearing catch surface B: Height from ST to transmission case mating surface 0.05 - 0.25 mm (0.002 - 0.01 in): Clearance Transfer drive gear shim Part No. Thickness mm (in) 33279AA090 0.3 (0.012) 33279AA100 0.4 (0.016) 33279AA110 0.5 (0.020)

Scheme 356

Scheme 357

Scheme 358

Scheme 359

Scheme 360

Scheme 361

1. Remove the transmission assembly from the vehicle. Refer to «REMOVAL»(ref-565171-S25233894212013071000000) .
2. Remove the inhibitor switch. Refer to «REMOVAL»(ref-565171-S40947888972013071000000) .
3. Remove the oil pan and oil strainer. Refer to «REMOVAL»(ref-565171-S25928384982013071000000) .
4. Shift the manual plate to "N" range, and remove the spring pin. NOTE: Prevent the spring pin from dropping in the transmission using paper towel etc.
5. Remove the detent spring.
6. Remove the manual plate from the shifter arm shaft, and remove the shift connecting rod of the manual valve.
7. Remove the manual plate and parking rod.
8. Remove the bolt, and remove the shifter arm shaft. NOTE: Do not damage the lip of oil seal press-fitted in the case.
9. Remove the manual valve.
10. Remove the extension case. Refer to «REMOVAL»(ref-565171-S42191516522013071000000) .
11. Remove the parking support.

Scheme 362

1. Install the parking support. Tightening torque: 25 N.m (2.5 kgf-m, 18.4 ft-lb)
2. Install the extension case. Refer to «INSTALLATION»(ref-565171-S29449905692013071000000) .
3. Install the manual valve.
4. Install the shifter arm shaft and bolt. NOTE: Do not damage the lip of oil seal press-fitted in the case. Tightening torque: 7 N.m (0.7 kgf-m, 5.2 ft-lb)
5. Install the parking rod to the manual plate.
6. Insert the parking rod into the transmission case, and install the shift connecting rod of the manual valve to the manual plate.
7. Install the manual plate to the shifter arm shaft.
8. Install the detent spring to the transmission case. Tightening torque: 7 N.m (0.7 kgf-m, 5.2 ft-lb)
9. Install the spring pin. NOTE: Use new spring pin.
10. Install the inhibitor switch. Refer to «INSTALLATION»(ref-565171-S42170851092013071000000) .
11. Adjust the inhibitor switch. Refer to «ADJUSTMENT»(ref-565171-S19149361002013071000000) .
12. Install the oil strainer and oil pan. Refer to «INSTALLATION»(ref-565171-S13637756932013071000000) .
13. Install the transmission assembly to the vehicle. Refer to «INSTALLATION»(ref-565171-S34027850992013071000000) .

Make sure that the manual plate and detent spring are not worn or otherwise damaged.

Scheme 363

Scheme 364

Scheme 365

Scheme 366

1. Remove the transmission assembly from the vehicle. Refer to «REMOVAL»(ref-565171-S25233894212013071000000) .
2. Remove the air breather hose. Refer to «REMOVAL»(ref-565171-S18514547522013071000000) .
3. Remove the control valve body. Refer to «REMOVAL»(ref-565171-S09238030962013071000000) .
4. Remove the transmission harness. Refer to «REMOVAL»(ref-565171-S07882957322013071000000) .
5. Remove the turbine speed sensor. Refer to «REMOVAL»(ref-565171-S14698043872013071000000) .
6. Remove the secondary speed sensor. Refer to «REMOVAL»(ref-565171-S19806174662013071000000) .
7. Remove the primary speed sensor. Refer to «REMOVAL»(ref-565171-S23215947932013071000000) .
8. Remove the inhibitor switch. Refer to «REMOVAL»(ref-565171-S40947888972013071000000) .
9. Remove the extension case. Refer to «REMOVAL»(ref-565171-S42191516522013071000000) .
10. Remove the transfer clutch assembly. Refer to «REMOVAL»(ref-565171-S18851069972013071000000) .
11. Remove the transfer driven gear assembly. Refer to «REMOVAL»(ref-565171-S21203357002013071000000) .
12. Remove the parking pawl. Refer to «REMOVAL»(ref-565171-S24495240752013071000000) .
13. Remove the reduction driven gear assembly. Refer to «REMOVAL»(ref-565171-S12720202822013071000000) .
14. Remove the oil pan and oil strainer. Refer to «REMOVAL»(ref-565171-S25928384982013071000000) .
15. Remove the transmission control device. Refer to «REMOVAL»(ref-565171-S31594552872013071000000) .
16. Remove the oil baffle securing bolt.
17. Remove the CVTF cooler pipe COMPL. Refer to «REMOVAL»(ref-565171-S08152006782013071000000) .
18. Remove the transmission case. NOTE: The total number of transmission case mounting bolts is 15.
19. Remove the oil baffle.
20. Remove the O-ring.
21. Remove the seal ring from the transmission case.

Scheme 367

Scheme 368

1. Clean the mating surface of transmission case and converter case.
2. Select the reduction gear shim. Refer to «ADJUSTMENT»(ref-565171-S25021989002013071000000) .
3. Remove the transmission case, and install the selected reduction gear shim to the reduction drive gear.
4. Install the O-rings to the reverse clutch housing and drive pinion retainer. NOTE: Use new O-rings. Apply CVTF to the O-ring.
5. Install the seal ring to the transmission case. NOTE: Use a new seal ring. Apply CVTF to the seal rings.
6. Cover the secondary pulley with the oil baffle, and temporarily install it with bolts.
7. Apply liquid gasket seamlessly to the mating surface of transmission case. Liquid gasket: THREE BOND 1215 (Part No. 004403007) or equivalent
8. Install the transmission case. NOTE: The total number of transmission case mounting bolts is 15. Tightening torque: 22 N.m (2.2 kgf-m, 16.2 ft-lb)
9. Install the CVTF cooler pipe COMPL. Refer to «INSTALLATION»(ref-565171-S38561598572013071000000) .
10. Install the oil baffle securing bolt. Tightening torque: 16 N.m (1.6 kgf-m, 11.8 ft-lb)
11. Install the transmission control device. Refer to «INSTALLATION»(ref-565171-S27061479222013071000000) .
12. Install the oil pan and oil strainer. Refer to «INSTALLATION»(ref-565171-S13637756932013071000000) .
13. Install the reduction driven gear assembly. Refer to «INSTALLATION»(ref-565171-S38195132452013071000000) .
14. Install the parking pawl. Refer to «INSTALLATION»(ref-565171-S09501619832013071000000) .
15. Install the transfer driven gear assembly. Refer to «INSTALLATION»(ref-565171-S12902225502013071000000) .
16. Install the transfer clutch assembly. Refer to «INSTALLATION»(ref-565171-S41489659632013071000000) .
17. Install the extension case. Refer to «INSTALLATION»(ref-565171-S29449905692013071000000) .
18. Install the inhibitor switch. Refer to «INSTALLATION»(ref-565171-S42170851092013071000000) .
19. Install the secondary speed sensor. Refer to «INSTALLATION»(ref-565171-S37027063852013071000000) .
20. Install the primary speed sensor. Refer to «INSTALLATION»(ref-565171-S13932683402013071000000) .
21. Install the turbine speed sensor. Refer to «INSTALLATION»(ref-565171-S00757293952013071000000) .
22. Install the transmission harness. Refer to «INSTALLATION»(ref-565171-S16701987602013071000000) .
23. Install the control valve body. Refer to «INSTALLATION»(ref-565171-S04085919832013071000000) .
24. Install the air breather hose. Refer to «INSTALLATION»(ref-565171-S10481716132013071000000) .
25. Install the transmission assembly to the vehicle. Refer to «INSTALLATION»(ref-565171-S34027850992013071000000) .

Scheme 369

Scheme 370

Scheme 371

Scheme 372

Scheme 373

1. Remove the oil stopper plate.
2. Remove all plugs from the transmission case.
3. Remove the oil seal using a screwdriver wrapped with cloth etc.
4. Remove the CVTF filter cover and gasket.
5. Remove the CVTF filter.

Scheme 374

Scheme 375

1. Face the O-ring side of the CVTF filter to the transmission case side, and install the CVTF filter. NOTE: Apply CVTF to the O-ring of CVTF filter.
2. Install the CVTF filter cover and gasket. NOTE: Use a new gasket. Tightening torque: 17 N.m (1.7 kgf-m, 12.5 ft-lb)
3. Using the ST, install the oil seal. NOTE: Use a new oil seal. Apply CVTF to the oil seal lip and press-fitting surface. ST 18657AA000 INSTALLER
4. Install all plugs. NOTE: Use new O-rings. Apply CVTF to the O-ring. For the plug (A), fill the CVTF, and then tighten the plug (A) using a new O-ring. Tightening torque: T1: 13 N.m (1.3 kgf-m, 9.6 ft-lb) T2: 25 N.m (2.5 kgf-m, 18.4 ft-lb) T3: 50 N.m (5.1 kgf-m, 36.9 ft-lb)
5. Install the oil stopper plate. NOTE: Use a new bolt. Tightening torque: 9 N.m (0.9 kgf-m, 6.6 ft-lb)

1. Check the transmission case for damage.
2. Check for leakage of CVTF from the connection between converter case and transmission case.
3. Check the bearing for smooth operation.
4. Check the bearing for seizure or wear.

1. Check if a large quantity of wear debris or metal particles are in CVTF and CVTF filter.
2. Check for broken part or damaged O-ring.

Scheme 376

1. Remove the transmission assembly from the vehicle. Refer to «REMOVAL»(ref-565171-S25233894212013071000000) .
2. Remove the air breather hose. Refer to «REMOVAL»(ref-565171-S18514547522013071000000) .
3. Remove the control valve body. Refer to «REMOVAL»(ref-565171-S09238030962013071000000) .
4. Remove the transmission harness. Refer to «REMOVAL»(ref-565171-S07882957322013071000000) .
5. Remove the turbine speed sensor. Refer to «REMOVAL»(ref-565171-S14698043872013071000000) .
6. Remove the secondary speed sensor. Refer to «REMOVAL»(ref-565171-S19806174662013071000000) .
7. Remove the primary speed sensor. Refer to «REMOVAL»(ref-565171-S23215947932013071000000) .
8. Remove the inhibitor switch. Refer to «REMOVAL»(ref-565171-S40947888972013071000000) .
9. Remove the extension case. Refer to «REMOVAL»(ref-565171-S42191516522013071000000) .
10. Remove the transfer clutch assembly. Refer to «REMOVAL»(ref-565171-S18851069972013071000000) .
11. Remove the transfer driven gear assembly. Refer to «REMOVAL»(ref-565171-S21203357002013071000000) .
12. Remove the parking pawl. Refer to «REMOVAL»(ref-565171-S24495240752013071000000) .
13. Remove the reduction driven gear assembly. Refer to «REMOVAL»(ref-565171-S12720202822013071000000) .
14. Remove the oil pan and oil strainer. Refer to «REMOVAL»(ref-565171-S25928384982013071000000) .
15. Remove the transmission control device. Refer to «REMOVAL»(ref-565171-S31594552872013071000000) .
16. Remove the transmission case. Refer to «REMOVAL»(ref-565171-S10021727672013071000000) .
17. Remove the reduction drive gear.

Check the reduction drive gear for breakage or damage.

Scheme 377

Scheme 378

Scheme 379

1. Install the transmission case, and secure it with four or five bolts. Tightening torque: 22 N.m (2.2 kgf-m, 16.2 ft-lb)
2. Measure depth "A" from the ST upper face to the reduction drive gear end face. ST 499575400 GAUGE
3. Raise and hold the reduction drive gear.
4. Measure depth "B" from the ST upper face to the reduction drive gear end face. ST 499575400 GAUGE
5. Obtain the thickness of reduction drive gear shim using the following formula to select one to three reduction drive gear shims. T (mm) = A - B - (0.05 - 0.25) [T (in) = A - B - (0.002 - 0.01)] T: Reduction drive gear shim thickness A: Depth from the ST upper face to the reduction drive gear end surface B: Depth from the ST upper face to the reduction drive gear end surface 0.05 - 0.25 mm (0.002 - 0.01 in): Clearance Part No. Reduction drive gear shim thickness mm (in) 31288AA260 0.3 (0.012) 31288AA270 0.4 (0.016) 31288AA280 0.5 (0.020) 31288AA290 0.6 (0.024)

1. Check the surface of primary and secondary pulley cones for damage or wear.
2. Check the primary and secondary pulley for damage.
3. Check the bearing for seizure or wear.
4. Apply CVTF to bearing and rotate the bearing to check for noise or dragging etc.

Scheme 380

Scheme 381

1. Measure the depth "Lp" from the ST upper face to the primary pulley bearing catch surface at several points and calculate the average. ST 499575400 GAUGE
2. Measure the depth "Ls" from the ST upper face to the secondary pulley bearing catch surface at several points and calculate the average. ST 499575400 GAUGE
3. Calculate the following formula. Calculation formula: T (mm) = B - A + Lp - Ls - 28.602 [T (in) = B - A + Lp - Ls - 1.126] T: Pulley alignment A: Specified primary pulley dimension B: Specified secondary pulley dimension Lp: Depth from the ST upper face to the primary pulley bearing catch surface Ls: Depth from the ST upper face to the secondary pulley bearing catch surface 28.602 mm (1.126 in): Constant Pulley alignment T mm (in) Thickness of shim mm (in) -0.05 - 0.049(-0.002 - 0.002) No shims 0.050 - 0.149(0.002 - 0.006) 0.1 (0.004) 0.150 - 0.249(0.006 - 0.010) 0.2 (0.008) 0.250 - 0.349(0.010 - 0.014) 0.3 (0.012) 0.350 - 0.449(0.014 - 0.018) 0.4 (0.016) 0.450 - 0.549(0.018 - 0.022) 0.5 (0.020) 0.550 - 0.649(0.022 - 0.026) 0.6 (0.024) 0.650 - 0.749(0.026 - 0.029) 0.7 (0.028) 0.750 - 0.849(0.029 - 0.033) 0.8 (0.031) 0.850 - 0.949(0.033 - 0.037) 0.9 (0.035) 0.950 - 1.049(0.037 - 0.041) 1.0 (0.039) 1.050 - 1.149(0.041 - 0.045) 1.1 (0.043)
4. Select one to two shims so that the total thickness meets the value obtained from step 3 ). Part No. Shim thickness mm (in) 32451AA050 0.1 (0.004) 32451AA060 0.2 (0.008) 32451AA070 0.3 (0.012) 32451AA080 0.4 (0.016) 32451AA090 0.5 (0.020) 32451AA100 0.6 (0.024)

Scheme 382

Scheme 383

Scheme 384

Scheme 385

1. Clean the mating surface of current drive pinion retainer and converter case.
2. Measure and record the shim thickness that is attached on the current reverse brake housing.
3. Using the current drive pinion retainer, measure the depth "Lp1" from the ST upper face to the primary pulley bearing catch surface at several points and calculate the average. ST 499575400 GAUGE
4. Using the current drive pinion retainer or current reverse brake housing, measure the depth "Ls1" from the ST upper face to the secondary pulley bearing catch surface at several points and calculate the average. ST 499575400 GAUGE
5. Calculate the "LD1" using the following formula and record it. Calculation formula: LD1 mm (in) = Ls1 - Lp1 LD1: Height from the primary pulley bearing catch surface to the secondary pulley bearing catch surface Lp1: Depth from the ST upper face to the primary pulley bearing catch surface Ls1: Depth from the ST upper face to the secondary pulley bearing catch surface
6. Using the new drive pinion retainer or new reverse brake housing, measure the depth "Lp2" from the ST upper face to the primary pulley bearing catch surface at several points and calculate the average. ST 499575400 GAUGE
7. Using the new drive pinion retainer or new reverse brake housing, measure the depth "Ls2" from the ST upper face to the secondary pulley bearing catch surface at several points and calculate the average. ST 499575400 GAUGE
8. Calculate the "LD2" using the following formula and record it. Calculation formula: LD2 mm (in) = Ls2 - Lp2 LD2: Height from the primary pulley bearing catch surface to the secondary pulley bearing catch surface Lp2: Depth from the ST upper face to the primary pulley bearing catch surface Ls2: Depth from the ST upper face to the secondary pulley bearing catch surface
9. Calculate the recorded values of "LD1" and "LD2" to obtain the positive number to select the shims. Calculation formula: T1 mm (in) = LD1 - LD2 or T2 mm (in) = LD2 - LD1 T1, T2: Difference between new drive pinion retainer or new reverse brake housing and current drive pinion retainer or current reverse brake housing LD1: Calculated value of current drive pinion retainer or current reverse brake housing LD2: Calculated value of new drive pinion retainer or new reverse brake housing Difference of the case (T1) mm (in) Shim selection procedure 0 - 0.050 (0 - 0.00197) Select a new shim of the same thickness with the shim that is used on the primary pulley side of the current reverse brake housing. 0.051 - 0.150 (0.00201 - 0.00591) Select a shim which is 0.1 mm (0.004 in) thicker than the shim that is used on the primary pulley side of the current reverse brake housing. 0.151 - 0.250 (0.00594 - 0.00984) Select a shim which is 0.2 mm (0.008 in) thicker than the shim that is used on the primary pulley side of the current reverse brake housing. 0.251 - 0.350 (0.00988 - 0.01378) Select a shim which is 0.3 mm (0.012 in) thicker than the shim that is used on the primary pulley side of the current reverse brake housing. 0.351 - 0.450 (0.01382 - 0.01772) Select a shim which is 0.4 mm (0.016 in) thicker than the shim that is used on the primary pulley side of the current reverse brake housing. 0.451 - 0.550 (0.01776 - 0.02165) Select a shim which is 0.5 mm (0.020 in) thicker than the shim that is used on the primary pulley side of the current reverse brake housing. 0.551 - 0.600 (0.02169 - 0.02362) Select a shim which is 0.6 mm (0.024 in) thicker than the shim that is used on the primary pulley side of the current reverse brake housing. Difference of the case (T2) mm (in) Shim selection procedure 0 - 0.050 (0 - 0.00197) Select a new shim of the same thickness with the shim that is used on the primary pulley side of the current reverse brake housing. 0.051 - 0.150 (0.00201 - 0.00591) Select a shim which is 0.1 mm (0.004 in) thinner than the shim that is used on the primary pulley side of the current reverse brake housing. 0.151 - 0.250 (0.00594 - 0.00984) Select a shim which is 0.2 mm (0.008 in) thinner than the shim that is used on the primary pulley side of the current reverse brake housing. 0.251 - 0.350 (0.00988 - 0.01378) Select a shim which is 0.3 mm (0.012 in) thinner than the shim that is used on the primary pulley side of the current reverse brake housing. 0.351 - 0.450 (0.01382 - 0.01772) Select a shim which is 0.4 mm (0.016 in) thinner than the shim that is used on the primary pulley side of the current reverse brake housing. 0.451 - 0.550 (0.01776 - 0.02165) Select a shim which is 0.5 mm (0.020 in) thinner than the shim that is used on the primary pulley side of the current reverse brake housing. 0.551 - 0.600 (0.02169 - 0.02362) Select a shim which is 0.6 mm (0.024 in) thinner than the shim that is used on the primary pulley side of the current reverse brake housing. Part No. Shim thickness mm (in) 32451AA050 0.1 (0.004) 32451AA060 0.2 (0.008) 32451AA070 0.3 (0.012) 32451AA080 0.4 (0.016) 32451AA090 0.5 (0.020) 32451AA100 0.6 (0.024)

Check the variator chain for damage and wear.

1. Inspect the drive plate facing for wear and damage.
2. Check the driven plate for discoloration (burnt color).
3. Check for worn snap ring, fatigue or damaged return spring or deformed spring retainer.
4. Make sure the clearance between retaining plate and snap ring of reverse brake is within the limit. If it exceeds the limit, replace with a new drive plate and select and adjust the retaining plate within the initial standard value. Refer to «ASSEMBLY»(ref-565171-S36467206772013071000000) .

Scheme 386

Scheme 387

Scheme 388

Scheme 389

Scheme 390

Scheme 391

1. Remove the transmission assembly from the vehicle. Refer to «REMOVAL»(ref-565171-S25233894212013071000000) .
2. Remove the air breather hose. Refer to «REMOVAL»(ref-565171-S18514547522013071000000) .
3. Remove the control valve body. Refer to «REMOVAL»(ref-565171-S09238030962013071000000) .
4. Remove the transmission harness. Refer to «REMOVAL»(ref-565171-S07882957322013071000000) .
5. Remove the turbine speed sensor. Refer to «REMOVAL»(ref-565171-S14698043872013071000000) .
6. Remove the secondary speed sensor. Refer to «REMOVAL»(ref-565171-S19806174662013071000000) .
7. Remove the primary speed sensor. Refer to «REMOVAL»(ref-565171-S23215947932013071000000) .
8. Remove the inhibitor switch. Refer to «REMOVAL»(ref-565171-S40947888972013071000000) .
9. Remove the extension case. Refer to «REMOVAL»(ref-565171-S42191516522013071000000) .
10. Remove the transfer clutch assembly. Refer to «REMOVAL»(ref-565171-S18851069972013071000000) .
11. Remove the transfer driven gear assembly. Refer to «REMOVAL»(ref-565171-S21203357002013071000000) .
12. Remove the parking pawl. Refer to «REMOVAL»(ref-565171-S24495240752013071000000) .
13. Remove the reduction driven gear assembly. Refer to «REMOVAL»(ref-565171-S12720202822013071000000) .
14. Remove the oil pan and oil strainer. Refer to «REMOVAL»(ref-565171-S25928384982013071000000) .
15. Remove the transmission control device. Refer to «REMOVAL»(ref-565171-S31594552872013071000000) .
16. Remove the transmission case. Refer to «REMOVAL»(ref-565171-S10021727672013071000000) .
17. Remove the reduction drive gear. Refer to «REMOVAL»(ref-565171-S14810903062013071000000) .
18. Remove the primary pulley, secondary pulley and variator chain. Refer to «REMOVAL»(ref-565171-S17045180802013071000000) .
19. Remove the reverse brake assembly. Refer to «REMOVAL»(ref-565171-S25843916972013071000000) .
20. Remove the internal gear.
21. Remove the thrust bearing.
22. Remove the planetary carrier.
23. Remove the thrust bearing and sun gear.
24. Remove the forward clutch assembly.
25. Remove the thrust bearing and seal ring.

Scheme 392

Scheme 393

Scheme 394

Scheme 395

Scheme 396

1. Install the thrust bearing to the converter case. NOTE: Face the temper color surface to the converter case side.
2. Install the seal ring to the input shaft. NOTE: Use a new seal ring. When installing the seal ring, do not expand the seal ring too much. Apply CVTF to the seal rings.
3. Install the forward clutch assembly to the converter case.
4. Install the sun gear. NOTE: Face the end face of the sun gear to the reverse brake side as shown in the figure.
5. Install the thrust bearing to the sun gear. NOTE: Face the temper color surface to the reverse brake side.
6. Install the planetary carrier.
7. Install the thrust bearing. NOTE: Face the temper color surface to the reverse brake side.
8. Install the internal gear.
9. Install the thrust bearing to the internal gear. NOTE: Face the temper color surface to the reverse brake side.
10. Select a washer. Refer to «ADJUSTMENT»(ref-565171-S12734269592013071000000) .
11. Install the reverse brake assembly. Refer to «INSTALLATION»(ref-565171-S27892486382013071000000) .
12. Install the primary pulley, secondary pulley and variator chain. Refer to «INSTALLATION»(ref-565171-S18141182462013071000000) .
13. Install the reduction drive gear. Refer to «INSTALLATION»(ref-565171-S10677884572013071000000) .
14. Install the transmission case. Refer to «INSTALLATION»(ref-565171-S17278631832013071000000) .
15. Install the transmission control device. Refer to «INSTALLATION»(ref-565171-S27061479222013071000000) .
16. Install the oil strainer and oil pan. Refer to «INSTALLATION»(ref-565171-S13637756932013071000000) .
17. Install the reduction driven gear assembly. Refer to «INSTALLATION»(ref-565171-S38195132452013071000000) .
18. Install the transfer driven gear assembly. Refer to «INSTALLATION»(ref-565171-S12902225502013071000000) .
19. Install the transfer clutch assembly. Refer to «INSTALLATION»(ref-565171-S41489659632013071000000) .
20. Install the parking pawl. Refer to «INSTALLATION»(ref-565171-S09501619832013071000000) .
21. Install the extension case. Refer to «INSTALLATION»(ref-565171-S29449905692013071000000) .
22. Install the inhibitor switch. Refer to «INSTALLATION»(ref-565171-S42170851092013071000000) .
23. Install the secondary speed sensor. Refer to «INSTALLATION»(ref-565171-S37027063852013071000000) .
24. Install the primary speed sensor. Refer to «INSTALLATION»(ref-565171-S13932683402013071000000) .
25. Install the turbine speed sensor. Refer to «INSTALLATION»(ref-565171-S00757293952013071000000) .
26. Install the transmission harness. Refer to «INSTALLATION»(ref-565171-S16701987602013071000000) .
27. Install the control valve body. Refer to «INSTALLATION»(ref-565171-S04085919832013071000000) .
28. Install the air breather hose. Refer to «INSTALLATION»(ref-565171-S10481716132013071000000) .
29. Install the transmission assembly to the vehicle. Refer to «INSTALLATION»(ref-565171-S34027850992013071000000) .

Scheme 397

Scheme 398

Scheme 399

Scheme 400

Scheme 401

1. Remove the snap ring.
2. Remove the retaining plate, drive plate, driven plate and dish plate.
3. Compress the return spring using the ST to remove the snap ring. ST1 18762AA010 COMPRESSOR SPECIAL TOOL ST2 398673600 COMPRESSOR
4. Remove the chamber COMPL and snap ring.
5. Remove the return spring.
6. Remove the forward clutch piston by blowing compressed air intermittently from the forward clutch carrier hole.

1. Check the forward clutch drum, internal gear, sun gear and forward clutch piston lip for wear or damage.
2. Inspect the drive plate facing for wear and damage.
3. Check the driven plate for discoloration (burnt color).
4. Check for worn snap ring, fatigue or damaged return spring or deformed spring retainer.
5. Make sure the clearance between retaining plate and internal gear of forward clutch is within the limit. If it exceeds the standard, replace the forward clutch. Refer to «ASSEMBLY»(ref-565171-S01552496622013071000000) .

Scheme 402

Scheme 403

1. Install the thrust bearing to the internal gear. NOTE: Face the temper color surface to the reverse brake side.
2. Measure depth "A" from the ST upper face to the washer mounting surface. ST 499575600 GAUGE
3. Measure the height "B" from the ST upper face to the mating surface of the drive pinion retainer. ST 499575600 GAUGE
4. Obtain the thickness of washer using the following formula to select the washer. T (mm) = A - B - (0.35 - 0.70) [T (in) = A - B - (0.014 - 0.028)] T: Shim thickness A: Depth from the ST upper face to the washer mounting surface B: Height from ST upper face to the drive pinion retainer mating surface 0.35 - 0.70 mm (0.014 - 0.028 in): Clearance Washer Part No. Thickness mm (in) 803064020 1.3 (0.051) 803064021 1.55 (0.061) 803064022 1.8 (0.071) 803064023 2.05 (0.081) 803064024 2.3 (0.091) 803064025 2.55 (0.100)

1. Make sure that all component parts are free of scratches, holes and other faults.
2. Check the tooth contact. Refer to «ADJUSTMENT»(ref-565171-S13201949212013071000000) .
3. Apply CVTF to bearing and rotate the bearing to check for noise or dragging etc.
4. Check the starting torque of drive pinion shaft.

ST1 498937110 HOLDER

ST2 499787700 WRENCH

Starting torque

5.1 - 17.1 N (0.5 - 1.7 kgf, 1.1 - 3.8 lbf)

Scheme 404

Scheme 405

Scheme 406

Scheme 407

Scheme 408

Scheme 409

Scheme 410

Scheme 411

Scheme 412

Scheme 413

1. Remove the liquid gasket from the mating surface completely.
2. Using the ST, install the drive pinion retainer to converter case. ST 18270KA020 SOCKET (E20) NOTE: Do not confuse the three different-length bolts when installing. Tightening torque: 43 N.m (4.4 kgf-m, 31.7 ft-lb)
3. Rotate the drive pinion several times using ST1 and ST2. ST1 498937110 HOLDER ST2 499787700 WRENCH
4. Adjust the drive pinion and hypoid driven gear backlash. Refer to «ADJUSTMENT»(ref-565171-S15056782402013071000000) .
5. Using the ST, remove the drive pinion retainer from converter case. ST 18270KA020 SOCKET (E20)
6. Apply lead-free red dye evenly on the both sides of three to four teeth of the hypoid driven gear. Then install the drive pinion retainer and rotate the drive pinion in both directions several times. Remove the drive pinion retainer and check the tooth contact pattern. If the teeth contact is inappropriate, adjust the backlash or thickness of the shim. Refer to «ADJUSTMENT»(ref-565171-S15056782402013071000000) . NOTE: After correction, wipe off the lead-free red dye. Correct tooth contact Check item: Tooth contact surface is slightly shifted toward the toe side under a no-load condition. (When driving, it moves towards the heel side.) Face contact Check item: Backlash is too large. Contact pattern Corrective action: Increase thickness of drive pinion shim according to the procedures for moving the drive pinion close to hypoid driven gear. Flank contact Check item: Backlash is too small. Contact pattern Corrective action: Reduce the thickness of the drive pinion shim according to the procedures for moving the drive pinion away from the hypoid driven gear. Toe contact (inside contact) Check item: Teeth contact area is too small. Contact pattern Corrective action: Reduce the thickness of the drive pinion shim according to the procedures for moving the drive pinion away from the hypoid driven gear side. Heel contact (outside end contact) Check item: Teeth contact area is too small. Contact pattern Corrective action: Increase the thickness of the drive pinion shim according to the procedures for moving the drive pinion closer to the hypoid driven gear.
7. Using the ST, loosen the differential side retainer until the mounting groove of the O-ring appears, and then install the O-ring. NOTE: When loosening the differential side retainer, record the number of the turns made. Perform this for both left and right differential side retainers. Use new O-rings. Apply the differential gear oil to O-ring. ST 18658AA020 WRENCH COMPL RETAINER
8. Using the ST, tighten the retainer to the position before it is loosened. ST 18658AA020 WRENCH COMPL RETAINER
9. Replace the differential side retainer oil seal with a new part. Refer to «DIFFERENTIAL SIDE RETAINER OIL SEAL»(ref-565171-S18675545152013071000000) .
10. Install the lock plate. Tightening torque: 25 N.m (2.5 kgf-m, 18.4 ft-lb)

Scheme 414

Scheme 415

Scheme 416

1. Remove the transmission assembly from the vehicle. Refer to «REMOVAL»(ref-565171-S25233894212013071000000) .
2. Remove the air breather hose. Refer to «REMOVAL»(ref-565171-S18514547522013071000000) .
3. Remove the control valve body. Refer to «REMOVAL»(ref-565171-S09238030962013071000000) .
4. Remove the transmission harness. Refer to «REMOVAL»(ref-565171-S07882957322013071000000) .
5. Remove the turbine speed sensor. Refer to «REMOVAL»(ref-565171-S14698043872013071000000) .
6. Remove the secondary speed sensor. Refer to «REMOVAL»(ref-565171-S19806174662013071000000) .
7. Remove the primary speed sensor. Refer to «REMOVAL»(ref-565171-S23215947932013071000000) .
8. Remove the inhibitor switch. Refer to «REMOVAL»(ref-565171-S40947888972013071000000) .
9. Remove the extension case. Refer to «REMOVAL»(ref-565171-S42191516522013071000000) .
10. Remove the transfer clutch assembly. Refer to «REMOVAL»(ref-565171-S18851069972013071000000) .
11. Remove the transfer driven gear assembly. Refer to «REMOVAL»(ref-565171-S21203357002013071000000) .
12. Remove the parking pawl. Refer to «REMOVAL»(ref-565171-S24495240752013071000000) .
13. Remove the reduction driven gear assembly. Refer to «REMOVAL»(ref-565171-S12720202822013071000000) .
14. Remove the oil pan and oil strainer. Refer to «REMOVAL»(ref-565171-S25928384982013071000000) .
15. Remove the transmission control device. Refer to «REMOVAL»(ref-565171-S31594552872013071000000) .
16. Remove the transmission case. Refer to «REMOVAL»(ref-565171-S10021727672013071000000) .
17. Remove the reduction drive gear. Refer to «REMOVAL»(ref-565171-S14810903062013071000000) .
18. Remove the primary pulley, secondary pulley and variator chain. Refer to «REMOVAL»(ref-565171-S17045180802013071000000) .
19. Remove the reverse brake assembly. Refer to «REMOVAL»(ref-565171-S25843916972013071000000) .
20. Remove the forward clutch assembly. Refer to «REMOVAL»(ref-565171-S02798411872013071000000) .
21. Remove the drive pinion shaft assembly. Refer to «REMOVAL»(ref-565171-S16941532562013071000000) .
22. Remove the lock plates on both sides.
23. Remove the differential side retainers using ST. NOTE: When the wrench COMPL retainer interferes with the converter case, align the cutout portion with the interference part. Support the differential case assembly by hand to avoid damaging the retainer mounting hole of the converter case. Keep the left and right differential side retainers and left and right bearing outer races by attaching tags or in similar ways to make it possible to identify RH and LH sides. ST 18658AA020 WRENCH COMPL RETAINER
24. Remove the front differential assembly while being careful not to damage the attachment part of the retainer.
25. Remove the oil seals and O-rings from both differential side retainers. Refer to «SIDE RETAINER»(ref-565171-S40892298892013071000000) .

Scheme 417

1. Install the front differential assembly to the converter case. NOTE: Be careful not to damage the inside of the case (especially the mounting surface of the differential side retainers).
2. Install the bearing outer race.
3. Temporarily install the differential side retainers using ST. ST 18658AA020 WRENCH COMPL RETAINER
4. Adjust the backlash of the front differential. Refer to «ADJUSTMENT»(ref-565171-S15056782402013071000000) .
5. Inspect and adjust the tooth contact. Refer to «ADJUSTMENT»(ref-565171-S13201949212013071000000) .
6. Using the ST, loosen the differential side retainer until the mounting groove of the O-ring appears, and then install the O-ring. NOTE: When loosening the differential side retainer, record the number of the turns made. Perform this for both left and right differential side retainers. Use new O-rings. Apply the differential gear oil to O-ring. ST 18658AA020 WRENCH COMPL RETAINER
7. Using the ST, tighten the retainer to the position before it is loosened. ST 18658AA020 WRENCH COMPL RETAINER
8. Install the oil seal to the differential side retainer. Refer to «DIFFERENTIAL SIDE RETAINER OIL SEAL»(ref-565171-S18675545152013071000000) .
9. Install the lock plate. Tightening torque: 25 N.m (2.5 kgf-m, 18.4 ft-lb)
10. Install the drive pinion shaft assembly. Refer to «INSTALLATION»(ref-565171-S23415410342013071000000) .
11. Install the forward clutch assembly. Refer to «INSTALLATION»(ref-565171-S19401841212013071000000) .
12. Install the reverse brake assembly. Refer to «INSTALLATION»(ref-565171-S27892486382013071000000) .
13. Install the primary pulley, secondary pulley and variator chain. Refer to «INSTALLATION»(ref-565171-S18141182462013071000000) .
14. Install the reduction drive gear. Refer to «INSTALLATION»(ref-565171-S10677884572013071000000) .
15. Install the transmission case. Refer to «INSTALLATION»(ref-565171-S17278631832013071000000) .
16. Install the oil strainer and oil pan. Refer to «INSTALLATION»(ref-565171-S13637756932013071000000) .
17. Install the transmission control device. Refer to «INSTALLATION»(ref-565171-S27061479222013071000000) .
18. Install the reduction driven gear assembly. Refer to «INSTALLATION»(ref-565171-S38195132452013071000000) .
19. Install the transfer driven gear assembly. Refer to «INSTALLATION»(ref-565171-S12902225502013071000000) .
20. Install the transfer clutch assembly. Refer to «INSTALLATION»(ref-565171-S41489659632013071000000) .
21. Install the parking pawl. Refer to «INSTALLATION»(ref-565171-S09501619832013071000000) .
22. Install the extension case. Refer to «INSTALLATION»(ref-565171-S29449905692013071000000) .
23. Install the inhibitor switch. Refer to «INSTALLATION»(ref-565171-S42170851092013071000000) .
24. Install the secondary speed sensor. Refer to «INSTALLATION»(ref-565171-S37027063852013071000000) .
25. Install the primary speed sensor. Refer to «INSTALLATION»(ref-565171-S13932683402013071000000) .
26. Install the turbine speed sensor. Refer to «INSTALLATION»(ref-565171-S00757293952013071000000) .
27. Install the transmission harness. Refer to «INSTALLATION»(ref-565171-S16701987602013071000000) .
28. Install the control valve body. Refer to «INSTALLATION»(ref-565171-S04085919832013071000000) .
29. Install the air breather hose. Refer to «INSTALLATION»(ref-565171-S10481716132013071000000) .
30. Install the transmission assembly to the vehicle. Refer to «INSTALLATION»(ref-565171-S34027850992013071000000) .

Scheme 418

Scheme 419

Scheme 420

Scheme 421

Scheme 422

Scheme 423

1. Remove the taper roller bearing using the ST. ST1 498077000 REMOVER ST2 899864100 REMOVER ST3 398497701 SEAT
2. Remove the hypoid driven gear mounting bolt using the ST. ST 18270KA020 SOCKET (E20)
3. Remove the differential case (LH).
4. Remove the differential bevel gear and washer from differential case.
5. Remove the straight pin.
6. Remove the pinion shaft, then remove the differential bevel gear, washer and differential bevel pinion.

1. Check each component for scratches, damage or other faults.
2. Using the ST, check the backlash of pinion gear.

ST1 498247001 MAGNET BASE

ST2 498247100 DIAL GAUGE

Specification

0.13 - 0.18 mm (0.0051 - 0.0071 in)

1. Measure the hypoid gear backlash, and then adjust it to be within specification. Refer to «ADJUSTMENT»(ref-565171-S15056782402013071000000) .

Scheme 424

Scheme 425

Scheme 426

Scheme 427

1. Using the ST, screw-in the retainer until resistance is felt. NOTE: RH side should be screwed-in more than LH side. ST 18658AA020 WRENCH COMPL RETAINER
2. Remove the remaining liquid gasket from the mating surface completely.
3. Using the ST, install the drive pinion assembly to converter case. ST 18270KA020 SOCKET (E20) NOTE: Do not confuse the three different-length bolts when installing. Tightening torque: 43 N.m (4.4 kgf-m, 31.7 ft-lb)
4. Rotate the drive pinion shaft ten times or more using ST1 and ST2. ST1 18667AA010 HOLDER ST2 499787700 WRENCH
5. While rotating the pinion shaft, tighten the retainer LH and loosen the retainer RH until the shaft can't be turned anymore. The backlash is "zero" when the pinion shaft comes to the point where it doesn't rotate.
6. After the "zero" state is established, loosen the retainer LH by 3 notches and secure it with the lock plate. Retighten the retainer RH until it stops. Rotate the drive pinion 2 or 3 times. Tighten the retainer RH further 1-3/4 notches. This sets the preload. Finally, secure the retainer with its lock plate. NOTE: Turning the retainer by every one tooth changes the backlash approx. 0.05 mm (0.0020 in).
7. Insert the two SUBARU genuine axle shafts into differential case. Part No. 38415AA070 Axle shaft
8. Install the ST to the drive pinion retainer, and wrap the drive pinion shaft with cloth and pinch with vise pliers. Using a tie-wrap or a wire, fix the vise pliers to the ST. Make sure the drive pinion shaft does not move. ST 18763AA000 COMPRESSOR SHAFT
9. Check the backlash is within specification using ST1, ST2 and ST3. ST1 498255400 PLATE ST2 498247100 DIAL GAUGE ST3 498247001 MAGNET BASE Backlash: 0.13 - 0.18 mm (0.005 - 0.007 in)
10. Adjust the teeth contact of the front differential and drive shaft. Refer to «ADJUSTMENT»(ref-565171-S13201949212013071000000) .

Scheme 428

Scheme 429

Scheme 430

Scheme 431

Scheme 432

Scheme 433

1. Remove the transmission assembly from the vehicle. Refer to «REMOVAL»(ref-565171-S25233894212013071000000) .
2. Remove the torque converter assembly. Refer to «REMOVAL»(ref-565171-S02331579712013071000000) .
3. Remove the oil pump chain cover. NOTE: Oil pump chain cover may be hard to remove because the driven sprocket is installed to the shaft side of the oil pump. In this case, do not apply excessive force to remove it.
4. Remove the seal ring.
5. Remove the driven sprocket from oil pump chain cover to remove the oil pump chain. NOTE: The driven sprocket is replaced as an assembly only, because it is a non-disassembly part. If the ball bearing is removed from the driven sprocket, replace with a new part.
6. Remove the snap ring.
7. Remove the drive sprocket.
8. Remove the oil seal from the oil pump chain cover.

Scheme 434

Scheme 435

Scheme 436

Scheme 437

1. Clean the mating surface of oil pump chain cover and converter case.
2. Using the ST, install the oil seal. NOTE: Use a new oil seal. Apply CVTF to the oil seal lip and press-fitting surface. ST 499755602 PRESS SNAP RING
3. Install the drive sprocket.
4. Install the snap ring so that its cutout portion is securely fitted into the snap ring groove of the oil pump chain cover.
5. Place the oil pump chain on drive sprocket.
6. Place the oil pump chain on driven sprocket and install the driven sprocket to oil pump chain cover.
7. Install the seal ring. 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.
8. Apply liquid gasket seamlessly to the mating surface of oil pump chain cover. CAUTION: Do not apply liquid gasket at the arrowed hole. Liquid gasket: THREE BOND 1215 (Part No. 004403007) or equivalent
9. Install the oil pump chain cover. Tightening torque: 21 N.m (2.1 kgf-m, 15.5 ft-lb)
10. Install the torque converter assembly. Refer to «INSTALLATION»(ref-565171-S42336819462013071000000) .
11. Install the transmission assembly to the vehicle. Refer to «INSTALLATION»(ref-565171-S34027850992013071000000) .

Scheme 438

Scheme 439

1. Remove the snap ring.
2. Remove the ball bearing using ST. ST1 498077600 REMOVER ST2 399513600 INSTALLER

Scheme 440

1. Using the ST, install the ball bearing. NOTE: Use a new ball bearing. ST 499755502 PRESS SNAP RING
2. Install the snap ring.

1. Check the oil pump chain for damage.
2. Replace if gear teeth are broken, damaged, sharpen or excessively worn.
3. Check the bearing for seizure or wear.
4. Apply CVTF to bearing and rotate the bearing to check for noise or dragging etc.
5. Check the oil pump chain cover for damage.
6. Check for leakage of CVTF from the mating surface of oil pump chain cover.
7. Check the oil seal for damage.

Scheme 441

Scheme 442

1. Remove the transmission assembly from the vehicle. Refer to «REMOVAL»(ref-565171-S25233894212013071000000) .
2. Remove the torque converter assembly. Refer to «REMOVAL»(ref-565171-S02331579712013071000000) .
3. Remove the oil pump chain cover. Refer to «REMOVAL»(ref-565171-S26870228912013071000000) .
4. Remove the oil pump and the plate.
5. Remove the O-ring.

Check the following items.

1. Check the oil pump for damage and wear.
2. Rotate the oil pump by hand, and check that it rotates smoothly.

1. Measure the secondary pressure. Refer to «INSPECTION»(ref-565171-S35679031122013071000000) .
2. Remove the oil pan and oil strainer. Refer to «REMOVAL»(ref-565171-S09238030962013071000000) .
3. Check oil strainer for clogging. When oil strainer has no clogging, replace the oil pump.

1. Check for leakage of CVTF from the connection between converter case and transmission case.
2. Check there is no damage or cracks on the converter case.