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Home >> Subaru >> 2006 >> 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: Identifying Low & Reverse Piston
    G05002754
  2. Install return spring.
    Fig 2: Identifying Return Spring
    G05002752
  3. Install spring retainer.
    Fig 3: Identifying Spring Retainer
    G05002751
  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, 18.4 ft-lb) 

    Fig 4: Turning Transmission Case
    G05002750
  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 8.5 kg (18.7 lb).
  11. Put the flat board on retaining plate.
    Fig 5: Putting Flat Board On Retaining Plate
    G05002759
  12. Using the following formula, calculate N indicated on the push/pull gauge.

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

    N: Value indicated on push/pull gauge

    83 N (8.5 kgf, 18.7 lbf): 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: Measuring Height
    G05002760
  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: Identifying Snap Ring
    G05002761
  15. Apply compressed air intermittently to check for operation.
    Fig 8: Applying Compressed Air
    G05002753
  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: Measuring Record Clearance "B"
    G05002763
  17. Piston stroke calculation

    Calculate with "A" and "B" dimensions which have been recorded before, and if the 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) 

    THICKNESS SPECIFICATIONS

    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)
    NOTE: Do not make adjustment unless the drive plate is replaced.
  18. Install the low & reverse brake leaf spring.
    Fig 10: Identifying Leaf Spring
    G05002764
  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: Identifying 2-4 Brake Piston And 2-4 Brake Piston Retainer
    G05002765
  20. Install 2-4 brake piston return spring to transmission case.
    Fig 12: Identifying Brake Return Spring
    G05002745
  21. Position snap ring in transmission. Using ST, press the snap ring into place.

    ST 498677100 COMPRESSOR

    Fig 13: Identifying Compressor With ST
    G05002767
  22. Install planetary gear and low clutch assembly to transmission case.
    CAUTION: If installing it while rotating the low clutch and planetary gear assembly, rotate them slowly and pay attention not to damage the seal ring.
    Fig 14: Identifying Thrust Needle Bearing, Planetary Gear Assembly And Low Clutch Assembly
    G05002742
  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: Identifying Retaining Plate, Drive Plate And Driven Plate
      G05002741
    2. Install a new 2-4 brake oil seal to transmission case.
      Fig 16: Locating Brake Seal
      G05002743
    3. After all 2-4 brake component parts have been installed, blow in air intermittently and confirm the operation of the brake.
      Fig 17: Blowing Air In Brake Components
      G05002771
    4. Check the clearance between the retaining plate and the snap ring.
    NOTE: Do not make adjustment unless the drive plate is replaced.

    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 Thickness
    G05002772
    THICKNESS SPECIFICATIONS

    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 10.2 kg (22.5 lb).
    4. Put the flat board on retaining plate.
      Fig 19: Putting Flat Board On Retaining Plate
      G05002759
    5. Using the following formula, calculate N indicated on the push/pull gauge.

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

      N: Value indicated on push/pull gauge

      100 N (10.2 kgf, 22.5 lbf): 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°. If four points, measure the height every 90°.
      Fig 20: Measuring Flat Board Weight
      G05002774
    7. Install the pressure plate, drive plate, driven plate, retaining plate and snap ring.
      Fig 21: Identifying Retaining Plate, Drive Plate And Driven Plate
      G05002741
    8. Install a new 2-4 brake oil seal to transmission case.
      Fig 22: Locating Brake Oil Seal To Transmission Case
      G05002776
    9. After all 2-4 brake component parts have been installed, blow air intermittently and confirm the operation of brake.
      Fig 23: Blowing Air In Brake Components
      G05002771
    10. Measure and record the clearance "B" between the retaining plate and snap ring.
      Fig 24: Identifying Clearance "B" Between Retaining Plate And Snap Ring
      G05002778
    11. Piston stroke calculation

      Calculate with "A" and "B" dimensions which have been recorded before, and if the 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

      initial standard: 1.7 - 2.1 mm (0.067 - 0.083 in) 

      Limit thickness: 2.3 mm (0.091 in) 

      THICKNESS SPECIFICATIONS

      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)
      NOTE: Do not make adjustment unless the drive plate is replaced.
  25. Be careful not to mistake the location of the leaf spring to be inserted.
    Fig 25: Identifying Leaf Spring And Retaining Plate
    G05002779
  26. Install thrust needle bearing in the correct direction.
    Fig 26: Identifying Snap Ring And Thrust Needle Bearing
    G05002780
  27. Install front sun gear and thrust needle bearing.
    Fig 27: Identifying Front Sun Gear And Thrust Needle Bearing
    G05002781
  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: Identifying Thrust Needle Bearing And High Clutch Hub
    G05002782
  30. Install the high clutch assembly.
    Fig 29: Identifying High Clutch Assembly
    G05002783
  31. Adjust total end play. < Ref. to ADJUSTMENT , Oil Pump Housing. >
  32. Install the thrust needle bearing in proper direction.
    Fig 30: Identifying Thrust Needle Bearing, High Clutch And Reverse Clutch Assembly
    G05002784
  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: Identifying Inhibitor Switch Harness And Transmission Harness
    G05002785
  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 rotating it lightly by hand, and then check the protrusion amount.

    Normal protrusion amount A: 50 - 55 mm (1.97 - 2.17 in) 

    Fig 32: Identifying Input Shaft
    G05002576
  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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