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Primary Pulley and Secondary Pulley: Removal

NOTE: Always replace primary pulley and secondary pulley as an assembly because they are non-disassembled parts.
  1. Remove the transmission assembly from the vehicle. Refer to , REMOVAL , Automatic Transmission Assembly.
  2. Remove the air breather hose. Refer to , REMOVAL , Air Breather Hose.
  3. Remove the oil pan and control valve body. Refer to , REMOVAL , Control Valve Body.
  4. Remove the transmission harness. Refer to , REMOVAL , Transmission Harness.
  5. Remove the extension case. Refer to , REMOVAL , Extension Case.
  6. Remove the rear drive shaft. Refer to , REMOVAL , Rear Drive Shaft.
  7. Remove the transfer clutch assembly. Refer to , REMOVAL , Transfer Clutch.
  8. Remove the transfer reduction driven gear assembly. Refer to , REMOVAL , Transfer Reduction Driven Gear.
  9. Remove the intermediate case. Refer to , REMOVAL , Intermediate Case.
  10. Remove the forward clutch assembly. Refer to , REMOVAL , Forward Clutch Assembly.
  11. Remove the transmission case. Refer to , REMOVAL , Transmission Case.
  12. Set the ST to secondary pulley and expand the V groove of pulley to an extent that variator chain gets loose.

    ST 18769AA000 EXPANDER PULLEY

    Fig 1: Identifying Secondary Pulley With Expander Pulley
    G06654646Courtesy of SUBARU OF AMERICA, INC.
  13. Remove the chain guide from lubrication pipe and support rod.
  14. Remove the lubrication pipe and support rod.
    Fig 2: Identifying Lubrication Pipe And Support Rod
    G06654647Courtesy of SUBARU OF AMERICA, INC.
  15. Detach the six claws to remove the two chain guide.
    Fig 3: Locating Claws On Chain Guide
    G06654648Courtesy of SUBARU OF AMERICA, INC.
  16. Remove the secondary pulley mounting bolt.
    Fig 4: Locating Secondary Pulley Mounting Bolt
    G06654649Courtesy of SUBARU OF AMERICA, INC.
  17. Remove the secondary pulley from drive pinion retainer and intersect the V groove of secondary pulley and V groove of primary pulley. Remove the variator chain from secondary pulley and remove the secondary pulley.
    CAUTION: Cover the V grooves of secondary pulley and primary pulley with cloth to protect the both pulleys and variator chain from scratching.
    Fig 5: Identifying V Grooves Of Secondary Pulley And Primary Pulley
    G06654650Courtesy of SUBARU OF AMERICA, INC.
  18. Remove the variator chain from primary pulley.
  19. Remove the primary pulley mounting bolt.
    Fig 6: Locating Primary Pulley Mounting Bolt
    G06654651Courtesy of SUBARU OF AMERICA, INC.
  20. Remove the primary pulley.
  21. Remove the two seal rings from drive pinion retainer.
    Fig 7: Locating Seal Rings On Drive Pinion Retainer
    G06654652Courtesy of SUBARU OF AMERICA, INC.
  22. Remove the two seal rings from primary pulley.
    Fig 8: Locating Seal Rings On Primary Pulley
    G06654653Courtesy of SUBARU OF AMERICA, INC.
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