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Home >> Subaru >> 1992 >> Justy GL, 4D Hatchback, Automatic CVT >> Repair and Diagnosis >> Transmission >> Automatic Trans >> Overhaul - ECVT >> Transaxle Disassembly

Transaxle Disassembly

  1. Remove brush holder. Remove electromagnetic powder clutch from flywheel. DO NOT  remove drive plate. DO NOT  hold slip ring using bare hands or a cloth stained with oil or grease. If slip ring is stained, clean using volatile oil. DO NOT  invert removed electromagnetic powder clutch. Avoid damage when handling. Handle or store with slip ring facing up.
  2. Install transaxle on Transmission Stand (499935600). Remove drain plug, and drain ECVT fluid. Tighten plug temporarily. Remove cap, and drain oil from propeller shaft joint. Remove oil pump shaft. Remove clutch housing from transaxle.
  3. On 4WD model, disconnect solenoid connector and remove solenoid and transfer valve rod. Remove plug and aluminum gasket. Remove spring and ball from plug hole. Remove transfer cover and 4WD indicator light switch connector. Drive out spring pin and remove fork and sleeve. Using pliers, remove snap ring, synchro transfer hub and coupling. Remove transfer driven gear and washer.
  4. On all models, remove clutch housing from transmission case by lightly tapping protruded portions near mating surfaces using a plastic hammer. On 4WD model, remove transfer apply pipe and transfer actuator body assembly. See Fig 1.
  5. On all models, remove differential assembly and shift connecting rod from transmission case. Face shift cam straight-pin downward. Using Straight-Pin Remover 2 (398791700), gradually tap straight-pin out until shift arm rotates smoothly. DO NOT  allow straight-pin to drop into case or hit secondary pulley.
  6. Using Snap Ring Expander (899471410), remove outer snap ring, engine brake cam and inner snap ring. Remove shift arm straight-pin and shift arm from transmission case. Set sleeve to "D" range and remove shift cam.
  7. Remove needle bearing and snap ring. DO NOT  scratch needle bearing rolling surface. Slightly lift sleeve and hub assembly and pull out countergear with countergear shaft. Remove sleeve and hub assembly with reverse driven gear as a unit. Remove needle bearing.
  8. Remove reverse idler gear and shaft. Remove lubricating pipe and engine brake pipe. Remove engine brake body and lubricating nozzle. Remove oil pan, gasket and control valve body. See ON-VEHICLE SERVICE. Remove oil pump bolts. Using Oil Pump Remover (499715600) or slide hammer, remove oil pump assembly.
  9. Remove side case, and separate transmission case from side case by tapping lightly. DO NOT  invert transmission case as this may cause engine brake valve (if equipped) to fall off.
  10. Remove ratio sensor, second engine brake pipe and parking pawl. Remove 3 retainer bolts. Install 2 clip bands on steel belt to prevent separation of steel blocks and steel bands. See Fig 2.
  11. Install Secondary Pulley Puller (499195400) and Seat (899524105) to secondary pulley and push pulley until groove width is 2.05-2.09" (52.0-53.0 mm). See Fig 3. To prevent damage to pulley interior, DO NOT  expand groove more than specified.
  12. Remove secondary pulley from side case and engage "V" grooves of primary and secondary pulleys with each other. Remove belt from primary pulley with secondary pulley. Avoid scratching cone surfaces. DO NOT  force secondary pulley out; force may damage belt.
    NOTE: Always protect belt and pulley mating surfaces.
  13. Remove belt from secondary pulley and wrap in chamois or nylon cloth. Install secondary pulley into Holder (498935400). Position straight-pin of pilot pipe toward center of primary pulley. Remove primary pulley and place on chamois or nylon cloth.
Fig 1: Removing Transfer Apply Pipe
G93A24042Courtesy of SUBARU OF AMERICA, INC.
Fig 2: Securing Steel Belt For Removal
G93B24043Courtesy of SUBARU OF AMERICA, INC.
Fig 3: Installing Secondary Pulley Puller
G93C24044Courtesy of SUBARU OF AMERICA, INC.
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