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Transaxle Reassembly: Notes

  1. Install side case to Stand (499935600). Install pilot pipe to side case and face straight-pin toward center of pulleys. Install seal ring on secondary guide using Seal Ring Guide (499305500).
  2. Clean and dress mating surface of side case. Install Gauge (499575700) to side case. See Fig 1. Using depth micrometer, measure depth between gauge top surface and mounting portion of primary pulley bearing ("Lp"). Measure between gauge top surface and mounting portion of secondary pulley bearing ("Ls"). See Fig 1. Measure in 4 positions and average results.
  3. Calculate thickness of shim using values measured and equation: X=A-(B+Lp-Ls)+.002"-.963". "A"= indicated primary pulley dimension and "B"= indicated secondary pulley dimension. Select appropriate shim. See SECONDARY PULLEY SHIM SPECIFICATION  table. Install shim on secondary pulley bearing mounting surface.
    SECONDARY PULLEY SHIM SPECIFICATION

    "X"-In. (mm) Part No. Thickness In. (mm) (Calculated Dimension)
    0-.001 (0-.05) Not Used 0 (0)
    .001-.006 (.05-.15) 803054021 .004 (.10)
    .006-.009 (.15-.25) 803054022 .008 (.20)
    .009-.014 (.25-.35) 803054023 .012 (.30)
    .014-.018 (.35-.45) 803054024 .016 (.40)
    .018-.022 (.45-.55) 803054025 .020 (.50)
    .022-.026 (.55-.65) 803054026 .024 (.60)
  4. Clean and dress mating surface of transmission case. Install gauge to transmission case. See Fig 4. Measure depth "C" between gauge top surface and recess for snap ring at 2.76" (70.0 mm) hole using depth gauge. Measure at 4 positions and average readings.
    Fig 1: Measuring Pulley Bearing Depth
    G93B24068Courtesy of SUBARU OF AMERICA, INC.
    Fig 2: Measuring Pulley Bearing Depth
    G93C24069Courtesy of SUBARU OF AMERICA, INC.
    Fig 3: Measuring Pulley Bearing Depth
    G93F24070Courtesy of SUBARU OF AMERICA, INC.
    Fig 4: Measuring Depth Of Snap Ring Recess
    G93G24071Courtesy of SUBARU OF AMERICA, INC.
    Fig 5: Measuring Depth Of Snap Ring Recess
    G93H24072Courtesy of SUBARU OF AMERICA, INC.
  5. Using measured values and equation: X=C+Lp-D-2t, calculate thickness of snap ring. "D"= indicated primary pulley dimension and "t" is gauge thickness. Select appropriate snap ring. Refer to the PRIMARY PULLEY SNAP RING SPECIFICATION  table. Install selected snap ring to primary pulley.
    PRIMARY PULLEY SNAP RING SPECIFICATION

    "X"-In. (mm) Part No. Thickness In. (mm) (Calculated Dimension)
    .047-.050 (1.20-1.28) 805062022 .053 (1.35)
    .050-.054 (1.28-1.36) 805062023 .056 (1.43)
    .054-.057 (1.36-1.44) 805062024 .059 (1.51)
    .057-.060 (1.44-1.52) 805062025 .062 (1.59)
    .060-.063 (1.52-1.60) 805062026 .066 (1.67)
    .063-.066 (1.60-1.68) 805062027 .069 (1.75)
    .066-.069 (1.68-1.76) 805062028 .072 (1.83)
  6. If reusing the old side case, proceed to step 8). If the case is to be replaced with a new one, perform steps 2) and 3) on the new side case. Calculate for each side case LD=LP-LS. LD1 is for the old side case and LD2 if for the new case. Proper shim selection is determined by equation LD1-LD2. Refer to SHIM SELECTION EXAMPLES  and the SHIM SELECTION  table.
  7. Proper snap ring selection is determined by the equation LP1-LP2. LP1 is the old side case and LP2 is for new side case. For examples of snap ring selection, see SNAP RING SELECTION EXAMPLES  and the SNAP RING SELECTION  table.
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