LEMON Manuals: Even more car manuals for everyone
Home >> Subaru >> 2005 >> Impreza Outback Sport, Automatic >> Repair and Diagnosis >> Transmission >> Automatic Trans >> Automatic Transmission >> Automatic Transmission Assembly >> Installation

Automatic Transmission Assembly: Installation

  1. Replace the differential side oil seal with new one. < Ref. to REPLACEMENT , Differential Side Retainer Oil Seal. >
    NOTE: Replacement is not necessary when new oil seal has been installed.
  2. Install the rear cushion rubber to transmission assembly.

    Tightening torque: 

    39 N.m (4.0 kgf-m, 29 ft-lb) 

  3. Install the ST to converter case.

    ST 498277200 STOPPER SET

    Fig 1: Installing Special Tool To Converter Case
    G03813717Courtesy of SUBARU OF AMERICA, INC.
  4. Install the transmission onto engine.
    1. Gradually raise the transmission with transmission jack.
      Fig 2: Installing Transmission Onto Engine
      G03813718Courtesy of SUBARU OF AMERICA, INC.
    2. Engage them at splines.
    3. While gradually lifting the transmission jack, turn the screw of engine support, and then tilt the engine forward.
  5. Install the transmission rear crossmember.

    Tightening torque: 

    T1: 35 N.m (3.6 kgf-m, 26 ft-lb) 

    T2: 70 N.m (7.1 kgf-m, 51 ft-lb) 

    Fig 3: Installing Transmission Rear Crossmember
    G03813719Courtesy of SUBARU OF AMERICA, INC.
  6. Take off the transmission jack.
  7. Tighten the nuts and bolts which hold the lower side of transmission to engine.

    Tightening torque: 

    50 N.m (5.1 kgf-m, 37 ft-lb) 

    Fig 4: Tightening Nuts And Bolts
    G03813720Courtesy of SUBARU OF AMERICA, INC.
  8. Tighten the bolt of clutch housing cover.
  9. Lower the vehicle.
  10. Connect the engine and transmission.
    1. Remove the ST from converter case.
      NOTE: Be careful not to drop the ST into the converter case when removing ST.

      ST 498277200 STOPPER SET

    2. Install the starter.

      < Ref. to INSTALLATION , Starter. >

    3. Tighten the bolt which holds the upper side of transmission to engine.

      Tightening torque: 

      50 N.m(5.1 kgf-m, 37 ft-lb) 

      Fig 5: Tightening Bolt
      G03813721Courtesy of SUBARU OF AMERICA, INC.
  11. Install the torque converter clutch to drive plate.
    1. Tighten the bolts which hold the torque converter clutch to drive plate.
    2. Tighten the other bolts while rotating the engine by using ST.
      • Non-turbo model

        ST 499977100 CRANK PULLEY WRENCH

      • Turbo model

        ST 499977400 CRANK PULLEY WRENCH

      Tightening torque: 

      25 N.m (2.5 kgf-m, 18 ft-lb) 

      Fig 6: Tightening Bolt
      G03813722Courtesy of SUBARU OF AMERICA, INC.
    3. Clog the plug onto service hole.
    4. Install the V-belt cover.
  12. Remove the STs.

    ST 41099AC000 ENGINE SUPPORT BRACKET

    Fig 7: Removing Special Tool
    G03813723Courtesy of SUBARU OF AMERICA, INC.
  13. Install the pitching stopper bracket.

    Tightening torque: 

    41 N.m (4.2 kgf-m, 30 ft-lb) 

  14. Install the pitching stopper.

    Tightening torque: 

    T1: 50 N.m (5.1 kgf-m, 37 ft-lb) 

    T2: 50 N.m (5.9 kgf-m, 43 ft-lb) 

    Fig 8: Installing Pitching Stopper
    G03813724Courtesy of SUBARU OF AMERICA, INC.
  15. Lift-up the vehicle.
  16. Replace the snap ring of front drive shaft with a new one.
  17. Apply grease to the oil seal lips.
  18. Install the ST to side retainer.

    ST 28399SA010 OIL SEAL PROTECTOR

    Fig 9: Installing Special Tool To Side Retainer
    G03813725Courtesy of SUBARU OF AMERICA, INC.
  19. Align the spline of front differential shaft to that of differential bevel gear for insertion, and remove them using ST.

    ST 28399SA010 OIL SEAL PROTECTOR

  20. Insert the front drive shaft into transmission securely by pressing the front housing from outside.
    Fig 10: Inserting Front Drive Shaft Into Transmission
    G03813726Courtesy of SUBARU OF AMERICA, INC.
  21. Install the ball joint into housing.
  22. Connect the stabilizer link to transverse link, and tighten the bolts.
    NOTE: Discard the loosened self-locking nut and replace with a new one.

    Tightening torque: 

    T1: 30 N.m (3.1 kgf-m, 22 ft-lb) 

    T2: 50 N.m (5.1 kgf-m, 37 ft-lb) 

    Fig 11: Connecting Stabilizer Link To Transverse Link
    G03813727Courtesy of SUBARU OF AMERICA, INC.
  23. Install the shift select cable onto select lever.

    < Ref. to INSTALLATION , Select Cable. >

  24. Install the oil charge pipe, and connect the ATF cooler hoses to pipe.
    Fig 12: Installing Oil Charge Pipe And Connecting ATF Cooler Hoses To Pipe
    G03813728Courtesy of SUBARU OF AMERICA, INC.
  25. Install the propeller shaft.

    < Ref. to INSTALLATION , Propeller Shaft. >

  26. Install the heat shield cover. (If equipped)
    Fig 13: Installing Heat Shield Cover
    G03813729Courtesy of SUBARU OF AMERICA, INC.
  27. Install the rear exhaust pipe and muffler assembly.

    Non-turbo model

    < Ref. to INSTALLATION , Rear Exhaust Pipe. > < Ref. to INSTALLATION , Muffler. >

    Turbo model

    < Ref. to INSTALLATION , Rear Exhaust Pipe. > < Ref. to INSTALLATION , Muffler. >

  28. Install the front and center exhaust pipe. (Non-turbo model)

    < Ref. to INSTALLATION , Front Exhaust Pipe. >

  29. Install the center exhaust pipe. (Turbo model) < Ref. to INSTALLATION , Center Exhaust Pipe. >
  30. Install the under cover.
  31. Lower the vehicle.
  32. Install the ATF level gauge.
    Fig 14: Installing ATF Level Gauge
    G03813730Courtesy of SUBARU OF AMERICA, INC.
  33. Connect the following connectors.
    1. Transmission harness connectors
    2. Transmission ground terminal
  34. Install the air cleaner case stay.

    Tightening torque: 

    16 N.m (1.6 kgf-m, 12 ft-lb) 

  35. Install the air cleaner case or air intake chamber. (Non-turbo model)

    < Ref. to INSTALLATION , Air Cleaner Case. >

  36. Install the air intake chamber. (Non-turbo model) < Ref. to INSTALLATION , Air Intake Chamber. >
  37. Install the intercooler. (Turbo model) < Ref. to INSTALLATION , Intercooler. >
  38. Connect the battery ground cable.
  39. Fill ATF up to the middle of the "COLD" side on level gauge by using oil charge pipe. < Ref. to , AUTOMATIC TRANSMISSION FLUID . >
  40. Take off the vehicle from lift arms.
  41. Check select lever operation.

    < Ref. to INSPECTION , Inhibitor Switch. >

  42. Bleed air from control valve. (Non-turbo model) < Ref. to AIR BLEEDING OF CONTROL VALVE . >
  43. Check the ATF level. < Ref. to AUTOMATIC TRANSMISSION FLUID . >
  44. Perform the advance operation of learning control. (Non-turbo model) < Ref. to FACILITATION OF LEARNING CONTROL , OPERATION, Subaru Select Monitor. >
  45. Check the road test. < Ref. to , ROAD TEST . >
scientia non olet · About LEMON Manuals