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Home >> Subaru >> 2005 >> Impreza Outback Sport, Automatic >> Repair and Diagnosis >> Transmission >> Automatic Trans >> Automatic Transmission >> AT Main Case >> Installation

AT Main Case: Installation

  1. Install the low & reverse piston without tilting.
    NOTE: Be careful not to damage the lip seal.
    Fig 1: Installing Low & Reverse Piston
    G03814030Courtesy of SUBARU OF AMERICA, INC.
  2. Install return spring.
    Fig 2: Installing Return Spring
    G03814031Courtesy of SUBARU OF AMERICA, INC.
  3. Install spring retainer.
    Fig 3: Installing Spring Retainer
    G03814032Courtesy of SUBARU OF AMERICA, INC.
  4. Install the one-way clutch inner race, spring retainer and return spring.
  5. Tighten socket head bolts evenly from the rear side of the transmission case.

    Tightening torque: 

    25 N.m (2.5 kgf-m, 18 ft-lb) 

    Fig 4: Tightening Socket Head Bolts
    G03814033Courtesy of SUBARU OF AMERICA, INC.
  6. Place the front side of transmission body up.
  7. Install thrust needle bearing.
  8. Place the dish plate, driven plate, drive plate and retaining plate neatly in this order on surface table.
  9. Set the micro gauge to retaining plate, and read its scale. Make more than three measurements at even distance and take the average value.
    NOTE: The value, which is read in the gauge at this time, is zero point.
  10. Scale and record the weight Z of a flat board which will be put on plates.
    NOTE:
    • Use a stiff flat board which does not bend against load.
    • Use a flat board of its weight less than 83 N (8.5 kgf, 18.7 lb).
  11. Put the flat board on retaining plate.
    Fig 5: Setting Micro Gauge To Retaining Plate
    G03814034Courtesy of SUBARU OF AMERICA, INC.
  12. Using the following formula, calculate N indicated on the push/pull gauge.

    N = 83 N (8.5 kgf, 18.7 lb) - Z

    N: Value indicated on push/pull gauge

    83 N (8.5 kgf, 18.7 lb): Load applied to clutch plate

    Z: Flat board weight

  13. Press the center of retaining plate applying force of N with push/pull gauge, and then measure and record the height "A". Make more than three measurements at even distance and take the average value.
    NOTE: If three points, measure the height every 120°. If four points, measure the height every 90°.
    Fig 6: Pressing Center Of Retaining Plate
    G03814035Courtesy of SUBARU OF AMERICA, INC.
  14. Installation of the low & reverse brake:

    Install the dish plate, driven plate and retaining plate, and then secure them with snap ring.

    NOTE: Pay attention to the orientation of dish plate.
    Fig 7: Installing Dish Plate, Driven Plate And Retaining Plate
    G03814036Courtesy of SUBARU OF AMERICA, INC.
  15. Apply compressed air intermittently to check for operation.
    Fig 8: Applying Compressed Air
    G03814037Courtesy of SUBARU OF AMERICA, INC.
  16. Place the same thickness of shim on both sides to prevent the plate from tilting, and then measure and record the clearance "B".
    NOTE: Do not press the shim downward with excessive force, or else the waveform of drive plates will be broken down.
    Fig 9: Installing Thickness Of Shim On Both Sides
    G03814038Courtesy of SUBARU OF AMERICA, INC.
  17. Piston stroke calculation

    Select the retaining plate within the specification by calculating with "A" and "B" dimensions which have been recorded before. If the calculated value exceeds the service limit, replace the drive plate with a new one and adjust it within the specification.

    T = A + B

    T: Piston stroke

    A: Collapse amount of drive plate

    B: Clearance between retaining plate and snap ring

    Non-turbo model 

    Initial standard: 

    2.15 - 2.65 mm (0.073 - 0.093 in) 

    Limit thickness: 

    2.95 mm (0.104 in) 

    Turbo model 

    Initial standard: 

    2.70 - 3.20 mm (0.106 - 0.126 in) 

    Limit thickness: 

    3.90 mm (0.154 in) 

    RETAINING PLATE THICKNESS CHART

    Retaining plate
    Part number Thickness mm (in)
    31667AA420 3.8 (0.150)
    31667AA320 4.1 (0.161)
    31667AA330 4.4 (0.173)
    31667AA340 4.7 (0.185)
    31667AA350 5.0 (0.197)
    31667AA360 5.3 (0.209)
    31667AA370 5.6 (0.220)
    31667AA380 5.9 (0.232)
  18. Install the low & reverse brake leaf spring.
    Fig 10: Installing Low & Reverse Brake Leaf Spring
    G03814039Courtesy of SUBARU OF AMERICA, INC.
  19. Install the 2-4 brake piston and 2-4 brake retainer by aligning hole of 2-4 brake retainer and hole of transmission case.
    Fig 11: Installing 2-4 Brake Piston And 2-4 Brake Retainer
    G03814040Courtesy of SUBARU OF AMERICA, INC.
  20. Install 2-4 brake piston return spring to transmission case.
    Fig 12: Installing 2-4 Brake Piston Return Spring To Transmission Case
    G03814041Courtesy of SUBARU OF AMERICA, INC.
  21. Position snap ring in transmission. Using ST, press the snap ring into place.

    ST 498677100 COMPRESSOR

    Fig 13: Positioning Snap Ring In Transmission Using Special Tool
    G03814042Courtesy of SUBARU OF AMERICA, INC.
  22. Install planetary gear and low clutch assembly to transmission case.

    Install carefully while rotating the low clutch and planetary gear assembly slowly paying special attention not to damage the seal ring.

    Fig 14: Installing Planetary Gear And Low Clutch Assembly To Transmission Case
    G03814043Courtesy of SUBARU OF AMERICA, INC.
  23. Selection of 2-4 brake retaining plate (Turbo model)
    1. Install pressure plate, drive plate, driven plate, retaining plate and snap ring.
      Fig 15: Installing Pressure Plate, Drive Plate, Driven Plate, Retaining Plate And Snap Ring
      G03814044Courtesy of SUBARU OF AMERICA, INC.
    2. Install a new 2-4 brake oil seal to transmission case.
      Fig 16: Installing 2-4 Brake Oil Seal To Transmission Case
      G03814045Courtesy of SUBARU OF AMERICA, INC.
    3. After all 2-4 brake component parts have been installed, blow in air intermittently and confirm the operation of the brake.
      Fig 17: Applying Air Pressure
      G03814046Courtesy of SUBARU OF AMERICA, INC.
    4. Check the clearance between the retaining plate and the snap ring.
    NOTE: Select a retaining plate with a suitable value from the following table, so that the clearance becomes the standard value.
    If it exceeds the service limit, replace the drive plate with a new one and adjust it within the specification.

    Initial standard: 

    0.8 - 1.2 mm (0.031 - 0.047 in) 

    Limit thickness: 

    1.5 mm (0.059 in) 

    Fig 18: Identifying Drive Plate
    G03814047Courtesy of SUBARU OF AMERICA, INC.
    RETAINING PLATE THICKNESS CHART

    Retaining plate
    Part No. Thickness mm (in)
    31567AA991 5.6 (0.220)
    31567AB001 5.8 (0.228)
    31567AB011 6.0 (0.236)
    31567AB021 6.2 (0.244)
    31567AB031 6.4 (0.252)
    31567AB041 6.6 (0.260)
  24. Selection of 2-4 brake retaining plate (Non-turbo model)
    1. Place the dish plate, driven plate, drive plate and retaining plate neatly in this order on surface table.
    2. Set the micro gauge to clutch, and read its scale.
      NOTE: The value, which is read in the gauge at this time, is zero point.
    3. Scale and record the weight Z of a flat board which will be put on plates.
      NOTE:
      • Use a stiff flat board which does not bend against load.
      • Use a flat board of its weight less than 100 N (10.2 kgf, 22.5 lb).
    4. Put the flat board on retaining plate.
      Fig 19: Setting Micro Gauge To Clutch
      G03814048Courtesy of SUBARU OF AMERICA, INC.
    5. Using the following formula, calculate N indicated on the push/pull gauge.

      N = 100 N (10.2 kgf, 22.5 lb) - Z

      N: Value indicated on push/pull gauge

      100 N (10.2 kgf, 22.5 lb): Load applied to clutch plate

      Z: Flat board weight

    6. Press the center of retaining plate applying force of N with push/pull gauge, and then measure and record the height A. Make more than three measurements at even distance and take the average value.
      NOTE: If three points, measure the height every 120° four points, measure the height every 90°.
      Fig 20: Pressing Center Of Retaining Plate
      G03814049Courtesy of SUBARU OF AMERICA, INC.
    7. Install the pressure plate, drive plate, driven plate, retaining plate and snap ring.
      Fig 21: Installing Pressure Plate, Drive Plate, Driven Plate, Retaining Plate And Snap Ring
      G03814050Courtesy of SUBARU OF AMERICA, INC.
    8. Install a new 2-4 brake oil seal to transmission case.
      Fig 22: Installing 2-4 Brake Oil Seal To Transmission Case
      G03814051Courtesy of SUBARU OF AMERICA, INC.
    9. After all 2-4 brake component parts have been installed, blow air intermittently and confirm the operation of brake.
      Fig 23: Applying Air Pressure
      G03814052Courtesy of SUBARU OF AMERICA, INC.
    10. Measure and record the clearance "B" between the retaining plate and snap ring.
      Fig 24: Identifying Clearance Between Retaining Plate And Snap Ring
      G03814053Courtesy of SUBARU OF AMERICA, INC.
    11. Piston stroke calculation

      Select the retaining plate within the specification by calculating with "A" and "B" dimensions which have been recorded before. If the calculated value exceeds the usage limit, replace the drive plate with a new one and adjust it within the specification.

      T = A + B

      T: Piston stroke

      A: Collapse amount of drive plate

      B: Clearance between retaining plate and snap ring

      Initial standard: 

      1.7 - 2.1 mm (0.067 - 0.083 in) 

      Limit thickness: 

      2.3 mm (0.091 in) 

      RETAINING PLATE THICKNESS CHART

      Retaining plate
      Part number Thickness mm (in)
      31567AA991 5.6 (0.220)
      31567AB001 5.8 (0.228)
      31567AB011 6.0 (0.236)
      31567AB021 6.2 (0.244)
      31567AB031 6.4 (0.252)
      31567AB041 6.6 (0.260)
  25. Be careful not to mistake the location of the leaf spring to be inserted.
    Fig 25: Identifying Leaf Spring
    G03814054Courtesy of SUBARU OF AMERICA, INC.
  26. Install thrust needle bearing in the correct direction.
    Fig 26: Installing Thrust Needle Bearing
    G03814055Courtesy of SUBARU OF AMERICA, INC.
  27. Install front sun gear and thrust needle bearing.
    Fig 27: Installing Front Sun Gear And Thrust Needle Bearing
    G03814056Courtesy of SUBARU OF AMERICA, INC.
  28. Install the high clutch hub.

    Attach the thrust needle bearing to the hub with vaseline and install the hub by correctly engaging the splines of the front planetary carrier.

  29. Install the thrust needle bearing in proper direction.
    Fig 28: Installing Thrust Needle Bearing
    G03814057Courtesy of SUBARU OF AMERICA, INC.
  30. Install the high clutch assembly.
    Fig 29: Installing High Clutch Assembly
    G03814058Courtesy of SUBARU OF AMERICA, INC.
  31. Adjust total end play. < Ref. to ADJUSTMENT , Oil Pump Housing. >
  32. Install the thrust needle bearing in proper direction.
    Fig 30: Installing Thrust Needle Bearing
    G03814059Courtesy of SUBARU OF AMERICA, INC.
  33. Install the oil pump housing assembly.
  34. Install the converter case assembly to the transmission case assembly. < Ref. to INSTALLATION , Converter Case. >
  35. Insert inhibitor switch and transmission connector into stay.
    Fig 31: Inserting Inhibitor Switch And Transmission Connector Into Stay
    G03814060Courtesy of SUBARU OF AMERICA, INC.
  36. Install air breather hose. < Ref. to INSTALLATION , Air Breather Hose. >
  37. Install oil cooler pipes. < Ref. to INSTALLATION , ATF Cooler Pipe and Hose. >
  38. Install the oil charge pipe with O-ring. < Ref. to INSTALLATION , Oil Charge Pipe. >
  39. Insert the input shaft while turning lightly by hand. At this time, not to damage the bushing.

    Normal protrusion A: 

    50 - 55 mm (1.97 - 2.17 in) 

    Fig 32: Inserting Input Shaft
    G03814061Courtesy of SUBARU OF AMERICA, INC.
  40. Install the torque converter clutch assembly. < Ref. to INSTALLATION , Torque Converter Clutch Assembly. >
  41. Install the transmission assembly to the vehicle. < Ref. to INSTALLATION , Automatic Transmission Assembly. >
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