Continuously Variable Transaxle (Cvt): Other Subaru Outback BS

OIL PUMP

TRANSMISSION CONTROL ELEMENT

TRANSMISSION GEAR RATIO

PLATE

SELECTOR POSITION

TRANSFER

REDUCTION GEAR RATIO

RECOMMENDED GEAR OIL

Scheme 623

Tightening torque: N.m (kgf-m, ft-lb)

T1: 18 (1.8, 13.3)

T2: 22 (2.2, 16.2)

T3: 22.5 (2.3, 16.6)

T4: 25 (2.5, 18.4)

T5: 35 (3.6, 25.8)

T6: 40 (4.1, 29.5)

T7: 41 (4.2, 30.2)

T8: 50 (5.1, 36.9)

T9: 70 (7.1, 51.6)

T10: Refer to INSTALLATION .

Scheme 624

Tightening torque: N.m (kgf-m, ft-lb)

T1: 8.5 (0.9, 6.3)

T2: 21 (2.1, 15.5)

Scheme 625

Tightening torque: N.m (kgf-m, ft-lb)

T1: 5 (0.5, 3.7)

T2: 9 (0.9, 6.6)

T3: 13 (1.3, 9.6)

T4: 17 (1.7, 12.5)

T5: 25 (2.5, 18.4)

T6: 50 (5.1, 25.8)

Scheme 626

Tightening torque: N.m (kgf-m, ft-lb)

T1: 5 (0.5, 3.7)

T2: 7 (0.7, 5.2)

T3: 8 (0.8, 5.9)

T4: 9 (0.9, 6.6)

T5: 31 (3.2, 22.9)

Scheme 627

Tightening torque: N.m (kgf-m, ft-lb)

T1: 16 (1.6, 11.8)

T2: 37 (3.8, 27.3)

Scheme 628

Scheme 629

Tightening torque: N.m (kgf-m, ft-lb)

T1: 5 (0.5, 3.7)

T2: 7 (0.7, 5.2)

T3: 9 (0.9, 6.6)

T4: 18 (1.8, 13.3)

T5: 25 (2.5, 18.4)

Scheme 630

Tightening torque: N.m (kgf-m, ft-lb)

T1: 16 (1.6, 11.8)

T2: 21 (2.1, 15.5)

T3: 67.5 (6.9, 49.8)

Scheme 631

Tightening torque: N.m (kgf-m, ft-lb)

T1: 25 (2.5, 18.4)

T2: 43 (4.4, 31.7)

T3: 64 (6.5, 47.2)

T4: Refer to ASSEMBLY .

Scheme 632

Tightening torque: N.m (kgf-m, ft-lb)

T1: 25 (2.5, 18.4)

T2: 35 (3.6, 25.8)

T3: 95 (9.7, 70.1)

Scheme 633

Tightening torque: N.m (kgf-m, ft-lb)

T1: 7 (0.7, 3.7)

T2: 8 (0.8, 5.9)

T3: 14 (1.4, 10.3)

T4: 39 (4.0, 28.8)

Scheme 634

Tightening torque: N.m (kgf-m, ft-lb)

T: 7.5 (0.8, 5.5)

Scheme 635

Tightening torque: N.m (kgf-m, ft-lb)

T: 7.5 (0.8, 5.5)

Scheme 636

Tightening torque: N.m (kgf-m, ft-lb)

T1: 35 (3.6, 25.8)

T2: 40 (4.1, 29.5)

T3: 45 (4.6, 33.2)

T4: 75 (7.6, 55.3)

CAUTION

1. Wear appropriate work clothing, including a cap, protective goggles and protective shoes when performing any work.
2. Remove contamination including dirt and corrosion before removal, installation or disassembly.
3. Keep the disassembled parts in order and protect them from dust and dirt.
4. Do not place the valve cover with its inner side facing up until it is installed, to prevent intrusion of foreign matter into the control valve body.
5. Before removal, installation or disassembly, be sure to clarify the failure. Avoid unnecessary removal, installation, disassembly and replacement.
6. When disassembling the case and other light alloy parts, use a plastic hammer to force it apart. Do not pry apart with screwdrivers or other tools.
7. Vehicle components are extremely hot after driving. Be wary of receiving burns from heated parts.
8. Use SUBARU genuine CVTF and recommended grease. Do not mix CVTF, grease etc. of different grades or manufacturers.
9. Be sure to tighten bolts and nuts to the specified torque.
10. Place lifts, shop jacks or rigid racks at specified locations.
11. Apply CVTF onto sliding or revolving surfaces before installation.
12. Replace deformed or damaged snap rings with new parts.
13. Before installing O-rings or oil seals, apply sufficient amount of CVTF or gear oil to appropriate locations in order to avoid damage and deformation.
14. Be careful not to incorrectly install or fail to install O-rings, snap rings and other such parts.
15. Before securing a part on a vise, place cushioning material such as wood blocks, aluminum plate, or cloth between the part and the vise.
16. Avoid damaging the mating surface of the case.
17. Before applying liquid gasket, completely remove the old liquid gasket.
18. After removing the sensors, breather hose and plugs, plug the holes to avoid foreign materials intruding as necessary.
19. During disassembly or assembly, be sure to use nylon gloves or paper towels. Do not use cloth gloves or waste cloth.

GENERAL TOOL

CONDITION CHECK

Note. When replacing CVTF, determine the condition inside the transmission body by inspecting the drained CVTF.

PROCEDURE

1. Shift the select lever to "P" range.
2. Connect the Subaru Select Monitor to data link connector.
3. Turn the ignition to ON. (For model with push button ignition switch, press the push button ignition switch twice without depressing brake pedal.)
4. Turn off all switches causing an electrical load, such as headlights, A/C, seat heater and rear defogger.
5. Select {Work Support} in the « Transmission Diagnosis » screen of Subaru Select Monitor.
6. Select {Maintenance mode} in the « Work Support » screen of Subaru Select Monitor.
7. Select {AWD ON/OFF switching mode} in the « Maintenance mode » screen of the Subaru Select Monitor.
8. Follow the messages displayed on the Subaru Select Monitor screen when working. Switching completes successfully if any of the following messages is displayed. When switching from AWD to FWD: {Switched to FF. To return to AWD, perform basic mode again.} When switching from FWD to AWD: {Switched to AWD. To return to FF, perform basic mode again.} NOTE: If communication error occurs during switching mode, start in the "AWD ON/OFF switching mode" again. If operation is interrupted before the successful end message is displayed, perform the {AWD ON/OFF switching mode} from the beginning until confirming the operation is successfully ended. If this mode fails to complete successfully, the cause is as follows. Select lever is not in "P" range. Engine is running. For detailed operation procedures, refer to "Subaru Select Monitor" operating information.

GENERAL PRECAUTION

Road tests should be conducted to properly diagnose the condition of CVT.

D RANGE SHIFT FUNCTION

Make sure the engine speed is 1, 100 - 1, 400 RPM while driving on the level road at 50 km/h (31 MPH) after accelerating from halting to 1/4 of accelerator opening angle. Then stop the vehicle. Check normal gear change has occurred while the vehicle speed changes from a constant speed to zero.

KICK-DOWN FUNCTION

Check if engine speed will rise by operating the accelerator opening angle to the full from a constant speed of 50 km/h (31 MPH) or more.

LOCK-UP FUNCTION

When the accelerator is lightly depressed while driving on a flat road in "D" range, check that RPM does not change abruptly.

OIL LEAKAGE

After the driving test, inspect for leakage of CVTF and differential gear oil from the transmission body.

FRONT DIFFERENTIAL SIDE

Install in the reverse order of removal.

Insertion depth A

16 - 36 mm (0.63 - 1.42 in)

Scheme 637

TRANSMISSION CASE SIDE

Install in the reverse order of removal.

Tightening torque

Transmission case cover

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

PLANETARY CARRIER ASSY

Note. Disassemble the balance oil guide only.

Scheme 638

1. Remove the snap ring.
2. Remove the balance oil guide.

Scheme 639

Scheme 640

1. Remove the snap ring.
2. Remove the thrust gear plate.

Scheme 641

Scheme 642

Scheme 643

Scheme 644

1. Install the forward clutch piston to forward clutch drum. NOTE: Apply CVTF to the seal of forward clutch piston. Insert it all the way to the end.
2. Install the return spring.
3. Install the chamber COMPL. NOTE: Apply CVTF to the sealing area of chamber COMPL.
4. Compress the return spring using the ST to install the snap ring. ST1 18762AA010 COMPRESSOR SPECIAL TOOL ST2 398673600 COMPRESSOR
5. Check the operation of forward clutch piston by blowing compressed air intermittently from forward clutch carrier hole.
6. Place the driven plate, drive plate and retaining plate neatly in this order on surface table.
7. Set the dial gauge to retaining plate, and read its scale. NOTE: The value, which is read in the gauge at this time, is zero point.
8. Scale and record the weight "Z" of a flat board which will be put on retaining plate. NOTE: The value, which is read in the gauge at this time, is zero point. Use a flat board weighing less than 52 N (5.3 kgf, 11.7 lb).
9. Put the flat board on retaining plate.
10. Using the following formula, read the push/pull gauge and calculate "N". N = 52 N (5.3 kgf, 11.7 lb) - Z 52 N (5.3 kgf, 11.7 lb) : Load applied to clutch plate Z: Flat board weight
11. Press the center of retaining plate by applying a force of "N" using push/pull gauge, and then measure and record the compression amount "A". NOTE: Measure at four points with a 90° interval and calculate the average.
12. Install the dish plate, drive plate, driven plate, retaining plate and snap ring to the forward clutch carrier. NOTE: Install the dish plate in the correct direction.
13. Measure and record the clearance "B" between the retaining plate and snap ring.
14. Piston stroke calculation Calculate with A and B dimensions recorded before. If it exceeds the limit, replace with a new drive plate and adjust within the initial standard value. S mm (in) = A + B S: Piston stroke A: Compression amount of drive plate and dish plate B: Clearance between retaining plate and snap ring Initial standard: 1.0 - 1.4 mm (0.040 - 0.055 in) Limit thickness: 1.6 mm (0.063 in) Retaining plate Item number Thickness mm (in) 31567AB760 4.2 (0.165) 31567AB770 4.4 (0.173) 31567AB780 4.6 (0.181) 31567AB790 4.8 (0.189) 31567AB830 5.0 (0.197)

Note. Assemble in the reverse order of disassembly.

INTERNAL GEAR

Note. Assemble in the reverse order of disassembly.

SIDE RETAINER

Note. After adjusting the drive pinion backlash and tooth contact, replace the oil seal and O-ring with new parts.

Scheme 645

Scheme 646

1. Remove the O-ring.
2. Remove the oil seal.

Scheme 647

Scheme 648

Scheme 649

Scheme 650

Scheme 651

Scheme 652

Scheme 653

1. Install the washer and differential bevel gear into the differential case (RH).
2. Install the differential bevel pinions into differential case (RH) and install the pinion shaft.
3. Install the straight pin.
4. Install the washer and differential bevel gear to the differential case (LH).
5. Install the differential case (RH) to the hypoid driven gear.
6. Install the differential case (LH) to the differential case (RH).
7. Using the ST, install the hypoid driven gear by tightening the installation bolt. ST 18270KA020 SOCKET (E20) Tightening torque: 64 N.m (6.5 kgf-m, 47.2 ft-lb)
8. Measure the backlash, and select the washer. Install the SUBARU genuine axle shaft to differential case. Part No. 38415AA070 Axle shaft Using ST1 and ST2, insert the ST2 through the window of differential case. Measure the backlash of the gear. NOTE: Measure the backlash by applying a differential bevel pinion tooth between two differential bevel gear teeth. When measuring, fix the differential bevel pinion gear in place with a screwdriver covered with cloth, or a similar tool. ST1 498247001 MAGNET BASE ST2 498247100 DIAL GAUGE Specification: 0.13 - 0.18 mm (0.0051 - 0.0071 in) If the backlash is not within specification, select a washer from the table below and replace. Washer Part No. Thickness mm (in) 803038021 0.95 (0.037) 803038022 1.00 (0.039) 803038023 1.05 (0.041)
9. Using the ST, install the left and right taper roller bearings. ST1 499277100 BUSHING 1-2 INSTALLER ST2 398497701 SEAT

Note. After adjusting the backlash and tooth contact, replace the oil seal and O-ring of side retainer with new parts.

Scheme 654

1. Using the ST, install the oil seal. NOTE: Use a new oil seal. Apply differential gear oil to the oil seal lip and press-fitting surface. Oil seal has an identification mark (R, L). When installing oil seals, do not confuse the left and right. ST 18675AA000 DIFFERENTIAL SIDE OIL SEAL INSTALLER
2. Install the O-ring. NOTE: Use new O-rings. Apply the differential gear oil to O-ring.