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Home >> Subaru >> 1997 >> Legacy Outback Limited, Automatic >> Repair and Diagnosis >> Transmission >> Automatic Trans >> Overhaul - 4-Speed >> Transaxle Reassembly

Transaxle Reassembly

  1. Install washer and snap ring to speedometer shaft and install oil seal. Using driver, install shaft into converter case. Install NEW vehicle speed sensor No. 2. Tighten to 39-65 INCH lbs. (4.4-7.4 N.m). Install speedometer driven gear to speedometer shaft, secure with snap ring.
  2. Install oil seal to converter case. Install differential case. DO NOT damage speedometer drive and driven gears and differential side retainer contact surfaces. Insert shafts into differential case and tap into place. Install snap rings to axle shafts. Measure shaft end play. End play should be approximately .012-.020" (.30-.50 mm). If no play is felt, ensure shaft is fully inserted. If shaft is installed correctly and no play is felt or play exceeds specification, replace axle shaft.
  3. Wrap axle shafts splined portions with tape. Install oil seals and taper roller bearing outer races to differential side retainers. Install retainers into converter case after coating threads with oil. Using Handle (499787000), screw in retainers until light contact is felt. Screw in right side slightly deeper than left side.
  4. Install drive pinion shaft with selected shim(s) to oil pump housing. Tighten 4 bearing retainer bolts to 28-33 ft. lbs. (38-44 N.m). Clean oil pump housing and converter case mating surfaces. Install oil pump housing to converter case. Tighten bolts to 28-33 ft. lbs. (38-44 N.m).
  5. Using Socket (498937100) and Wrench (499787100), rotate drive pinion several times. See Fig 1 . Tighten left side retainer until contact is felt when rotating shaft. Loosen right side retainer. Tighten left side retainer and loosen right side retainer until pinion shaft can no longer be turned. This is the "zero" state.
  6. After "zero" state is established, loosen left side retainer 3 notches and secure with locking tab. Loosen right side retainer and retighten by hand until it stops. Repeat several times. Tighten right side retainer 1 3/4 notches further and secure with locking tab. This sets preload.
    7. NOTE: Turning retainer by one notch changes backlash about .002" (.05 mm).
  7. Using Socket (499787100), Magnet Base (498247001) and dial indicator, measure backlash. See Fig 2 . Backlash should be .005-.007" (.13-.18 mm). After confirming backlash as being correct, inspect tooth contact.
  8. Remove pump housing and apply Red Lead to 3 or 4 tooth surfaces of ring gear. Install pump housing. Rotate drive pinion shaft forward and reverse several times. Remove oil pump housing and check tooth contact pattern. See GEAR TOOTH CONTACT PATTERNS article in APPLICATIONS & IDENTIFICATION.
  9. When tooth contact is correct, mark retainer positions and loosen. Install "O" rings and retighten to marked positions. Tighten lock tab bolts to 17-19 ft. lbs. (23-27 N.m). Install NEW seal pipe to converter case.
  10. Install 2 oil seals to drive pinion shaft oil seal retainer with Installer (499247300). Install "O" ring to oil seal retainer with lubricant. Install seal to oil pump housing bore. Install oil seal retainer and tighten bolts to 53-71 INCH lbs. (6-8 N.m).
  11. Apply lubricant to grooves on oil pump cover and install seal rings. Install rubber seal to converter case. Press bearing into transmission case. Install oil seal using plastic hammer. Install manual plate and shaft. Drive in roll pin and ensure smooth operation. Install manual lever, parking rod and nut. Tighten nut to 33-36 ft. lbs. (45-49 N.m). Install inhibitor switch. Install detent manual spring and position so spring's center is aligned with center of manual plate. Tighten bolt to 44-62 INCH lbs. (5-7 N.m).
  12. Install lathe-cut seal rings and lip seal to low and reverse piston. Using Compressor (398673600) and Seat (498627000), install piston into case. See Fig 3 . DO NOT damage seal lip or tilt piston when installing. Using Installer (398497701), install needle bearing to one-way clutch inner race. Install 4 seal rings, and apply lubricant to groove of inner race and to seal ring so seal ring won't expand. Install spring retainer and spring on inner race and install to recessed portion of piston. Tighten bolts from rear side of transmission case to 17-20 ft. lbs. (23-27 N.m).
  13. Install band servo piston assembly. Install snap ring. Set transmission case vertically on wooden blocks with rear of case down. Install dish plates, driven plates, drive plates, pressure plate and snap ring. Ensure orientation of dish plate. See Figure .
  14. Apply compressed air intermittently to check operation. See Figure . Measure clearance between snap ring and pressure plate. Standard clearance is .028-.039" (.70-1.00 mm) with an allowable limit of .087" (2.20 mm). If clearance is not within specifications, install correct pressure plate. See LOW & REVERSE BRAKE PRESSURE PLATE  table.
    LOW & REVERSE BRAKE PRESSURE PLATE

    Part No. Thickness In. (mm)
    31667AA180 .256 (6.50)
    31667AA190 .268 (6.80)
    31667AA200 .280 (7.10)
    31667AA210 .291 (7.40)
    31667AA220 .303 (7.70)
    31667AA230 .315 (8.00)
    31667AA240 .323 (8.20)
    31667AA250 .331 (8.40)
    31667AA310 .339 (8.60)
  15. Install thrust needle bearing on one-way clutch inner race. Install forward clutch drum assembly. Rotate drum slowly, ensuring not to damage seal ring. Drum is installed correctly when its position is .098" (2.50 mm) below inner race surface.
  16. Install thrust needle bearing and thrust washer to overrunning clutch hub. See Figure . Install overrunning clutch hub into transmission case. Ensure splines are correctly engaged. Install one-way outer race assembly. Ensure forward clutch splines are correctly engaged.
  17. Install thrust needle bearing and thrust washer to rear internal gear. Install the rear internal gear while rotating it. See Figure . Engage thrust needle bearing with dog of overrunning clutch hub. Installation is complete when snap ring top surface of forward clutch drum is receded approximately .138" (3.50 mm) into rear internal gear.
  18. Install thrust needle bearing to inside of rear planetary carrier with lubricant. Install carrier into transmission case while rotating. Install rear sun gear with oil groove facing up.
  19. Attach thrust needle bearing to both sides of front planetary carrier with lubricant. Install front planetary carrier while aligning splines with forward clutch drum and while rotating pinion. Attach thrust needle bearing to front sun gear and install front sun gear while rotating. Attach thrust needle bearing to high clutch hub with lubricant and install by engaging with splines of front planetary carrier. Install high clutch assembly and engage with clutch splines.
  20. Install reverse clutch assembly by engaging high clutch outer splines with reverse clutch splines and front sun gear with cut out portion of reverse clutch drum. Install brake band assembly. Install strut to band servo piston stem and tighten temporarily to hold band in place.
  21. Adjust total end play and reverse clutch end play. Measure distance from transmission case mating surface to recessed portion of high clutch drum. Subtract thickness of gauge block ("t"), this will be measurement ("H"). See Fig 4 . Measure distance from transmission case mating surface to top surface of reverse clutch drum. Subtract thickness of gauge block ("t"), this will be measurement ("M").
  22. Measure distance from oil pump mating surface to top surface of oil pump support with needle bearing. Subtract thickness of gauge block ("t"), this will be measurement ("h"). Measure distance from oil pump mating surface to thrust surface of reverse clutch. Subtract thickness of gauge block ("t"), this will be measurement ("m"). See Fig 4 .
  23. Calculate clearance between high clutch drum and pump support. Use the following equation: Clearance = (H + .016") - h  . Gasket thickness is .016" (.40 mm). Select appropriate bearing race that will provide end play of .010-.022" (.25-.55 mm) clearance. See BEARING RACE SELECTION  table.
    BEARING RACE SELECTION

    Part No. In. (mm)
    803031021 .031 (.80)
    803031022 .039 (1.00)
    803031023 .047 (1.20)
    803031024 .055 (1.40)
    803031025 .063 (1.60)
    803031026 .071 (1.80)
    803031027 .079 (2.00)
  24. Calculate clearance between oil pump support and end of reverse clutch drum. Use the following equation: Clearance = (M + .016") - m  . Gasket thickness is .016" (.40 mm). Select appropriate thrust washer that will provide .022-.035" (.55-.90 mm) clearance. See THRUST WASHER SELECTION  table.
    THRUST WASHER SELECTION

    Part No. In. (mm)
    31299AA000 .028 (.70)
    31299AA010 .035 (.90)
    31299AA020 .043 (1.10)
    31299AA030 .051 (1.30)
    31299AA040 .059 (1.50)
    31299AA050 .067 (1.70)
    31299AA060 .075 (1.90)
  25. Install selected bearing race in recess of high clutch. Attach thrust washer to oil pump cover with petroleum jelly. Install gasket to case mating surface. Align dowel pins and install oil pump housing to case. Ensure there is no clearance between mating surfaces. Clearance between mating surfaces indicates a damaged seal ring. Install oil pump housing nuts and tighten to 28-33 ft. lbs. (38-44 N.m).
  26. Apply Liquid Gasket (Three-Bond 1215) to converter case mating surface. Ensure rubber seal and seal pipe are fitted in position. Install converter case to transmission case and tighten bolts to 28-33 ft. lbs. (38-44 N.m).
  27. With oil pans facing upward, install accumulators and springs to transmission case. Ensure proper spring installation positions. See ACCUMULATOR SPRING SPECIFICATIONS  table.
    ACCUMULATOR SPRING SPECIFICATIONS

    Spring Outer Diameter In. (mm) Free Length In. (mm)
    1-2 1.122 (28.50) 1.752 (44.50)
    2-3 .807 (20.50) 1.220 (31.00)
    3-4 .681 (17.30) 1.720 (43.70)
    N-D .701 (17.80) 1.437 (36.50)
  28. Install and route transmission harness. Set range select lever to No. 2 position. Install control valve body by engaging manual valve and manual lever and tighten bolts to 61-78 INCH lbs. (7-9 N.m). DO NOT pinch harness or damage gasket. Tighten control valve body bolts evenly in crisscross pattern.
  29. Install oil filter to control valve body, install oil cooler outlet pipe and tighten bolts to 61-78 INCH lbs. (7-9 N.m). Connect 4 electrical connectors. Apply Liquid Gasket (Three-Bond 1217B) and install oil pan with magnet to transmission case. Tighten bolts evenly in crisscross pattern to 38-48 INCH lbs. (4.4-5.4 N.m).
  30. Press in NEW oil seal in extension housing. Install filter in extension housing. Install transfer clutch valve assembly and install pipe, clamp and transfer clutch assembly to extension housing. Tighten bolts to 61-78 INCH lbs. (7-9 N.m). Install reduction driven gear, parking pawl and shaft. Set shift select lever to "P" and tighten drive pinion lock nut to 69-76 ft. lbs. (93-103 N.m). Stake lock nut securely.
  31. Install reduction drive gear. Determine extension housing end play. Measure distance from transmission case mating surface to reduction drive gear end surface ("I"). "I" = Measured Distance Minus Both Gauge Thicknesses  . See Fig 5 . Measure distance from extension mating surface to end of rear drive shaft ("L"). "L" = Measured Distance Minus Gauge Thickness  . See Fig 5 .
  32. Calculate clearance between end of reduction drive gear and end of rear drive shaft. Use the following equation: Clearance = ("L" + .016") - "I"  . Thickness of gasket is .016". Select appropriate thrust needle bearing to provide clearance of .002-.008" (.05-.20 mm). See THRUST BEARING SELECTION (AWD)  table.
    THRUST BEARING SELECTION (AWD)

    Part No. In. (mm)
    806535020 .150 (3.80)
    806535030 .157 (4.00)
    806535040 .165 (4.20)
    806535050 .173 (4.40)
    806535060 .181 (4.60)
    806535070 .189 (4.80)
    806535090 .197 (5.00)
  33. Install selected thrust needle bearing to end surface of reduction drive gear with petroleum jelly. Install parking return spring. Remove transfer clutch from extension housing. Install needle bearing on reduction drive shaft and install transfer clutch to transfer clutch hub. Ensure correct spline teeth engagement. Install gasket and extension housing halfway. Connect duty solenoid "C" connector. Complete gasket and extension housing installation. Tighten bolts to 17-20 ft. lbs. (23-27 N.m). Install vehicle speed sensor No. 1.
  34. Install inhibitor switch to transmission case. Fit projecting portion of switch into recessed portion of case and tighten bolts temporarily. Set selector lever to "N". With Stopper Pin (499267300) adjust inhibitor switch so hole of range selector lever is aligned with inhibitor switch hole. Tighten bolts to 25-35 INCH lbs. (2.9-3.9 N.m).
  35. Attach transmission harness and inhibitor switch cord. Install oil cooler inlet and outlet pipe. Install oil charge pipe. Tighten brake band adjusting screw to 78 INCH lbs. (9 N.m) then back off 3 turns. Tighten lock nut to 18-21 ft. lbs. (24-28 N.m). Install strut bar bracket. Install air breather hoses to transmission case and oil pump housing.
  36. Install input shaft while turning lightly. Install oil pump shaft to torque converter. Ensure clip fits securely in groove. Install torque converter assembly to converter case, ensuring not to damage bushing. Rotate shaft lightly by hand to engage splines securely.
Fig 1: Setting Drive Pinion Preload
G93F24666Courtesy of SUBARU OF AMERICA, INC.
Fig 2: Measuring Differential Backlash
G93H24668Courtesy of SUBARU OF AMERICA, INC.
Fig 3: Installing Low & Reverse Piston
G93B24670Courtesy of SUBARU OF AMERICA, INC.
Fig 4: Measuring Reverse Clutch & Total End Play
G93D24672Courtesy of SUBARU OF AMERICA, INC.
Fig 5: Measuring Transfer Clutch End Play
G93H24676Courtesy of SUBARU OF AMERICA, INC.
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