Automatic Transmission Assembly: Installation

Attach the ST to converter case.
ST 498277200 STOPPER SET

Fig 1: Attaching Stopper Set (ST 498277200) To Converter Case
Courtesy of SUBARU OF AMERICA, INC.
When completely overhauling the transmission, refill CVTF through the transmission right side plug. Ref. to CONTINUOUSLY VARIABLE TRANSMISSION (TR580) > PREPARATION FOR OVERHAUL .
Replace the front differential side retainer oil seal. Ref. to CONTINUOUSLY VARIABLE TRANSMISSION (TR580) > Differential Side Retainer Oil Seal > REPLACEMENT .
NOTE:
- Be sure to replace the differential side retainer oil seal with a new part whenever the front drive shaft is removed from the transmission.
- When a new differential side retainer oil seal has been installed, replacement is not required.
Install the rear cushion rubber on the transmission.
Tightening torque:

40 N.m (4.1 kgf-m, 29.5 ft-lb)

Fig 2: Identifying Transmission Rear Cushion Rubber
Courtesy of SUBARU OF AMERICA, INC.
Mount the transmission onto the transmission jack.
Strike and bend the transmission hanger of transmission rear with a rubber hammer etc. so that it gets in contact with the transmission case.
CAUTION: Do not apply extra overload or impact to the transmission case.

Fig 3: Removing Pitching Stopper Bracket
Courtesy of SUBARU OF AMERICA, INC.
Remove the pitching stopper bracket, if mounted.
Install the transmission onto the engine.
NOTE:
- While raising the transmission jack gradually, turn the screw of engine support, then tilt the engine forward.
- Temporarily attach the two engine connecting bolts and two nuts (lower side).
Install the transmission rear crossmember.
Tightening torque:

T1: 35 N.m (3.6 kgf-m, 25.8 ft-lb)

T2: 70 N.m (7.1 kgf-m, 51.6 ft-lb)

Fig 4: Identifying Transmission Rear Crossmember Bolts And Nuts With Torque Specification
Courtesy of SUBARU OF AMERICA, INC.
Tighten the two engine connecting bolts and two nuts (lower side).
Tightening torque:

50 N.m (5.1 kgf-m, 36.9 ft-lb)

Fig 5: Locating Engine Connecting Bolts And Nuts (Lower Side)
Courtesy of SUBARU OF AMERICA, INC.
Remove the transmission jack.
Tighten the hanger bracket.
Tightening torque:

23 N.m (2.3 kgf-m, 17.0 ft-lb)
Lower the vehicle.
Install the three engine mounting bolts (upper side).
Tightening torque:

50 N.m (5.1 kgf-m, 36.9 ft-lb)

Fig 6: Locating Transmission Engine Mounting Bolts (Upper Side)
Courtesy of SUBARU OF AMERICA, INC.
Remove the ST (STOPPER SET) from converter case.
Remove the ST (ENGINE SUPPORT BRACKET and ENGINE SUPPORT).
ST1 41099AA012 ENGINE SUPPORT BRACKET

ST2 41099AA020 ENGINE SUPPORT

Fig 7: Removing ST (Stopper Set) From Converter Case
Courtesy of SUBARU OF AMERICA, INC.
Match the torque converter screw hole with drive plate hole to install the bolt.
CAUTION:
- Do not drop the mounting bolt in the converter housing.
- Do not damage the mounting bolt.
Tightening torque:

25 N.m (2.5 kgf-m, 18.4 ft-lb)
Install the remaining three bolts by rotating the crank pulley a little at a time in the same direction as engine revolution.
Tightening torque:

25 N.m (2.5 kgf-m, 18.4 ft-lb)
Install the service hole plug.

Fig 8: Installing Service Hole Plug
Courtesy of SUBARU OF AMERICA, INC.
Install the engine ground terminals.
Tightening torque:

19 N.m (1.9 kgf-m, 14.0 ft-lb)

Fig 9: Locating Engine Ground Terminals
Courtesy of SUBARU OF AMERICA, INC.
Replace the CVTF inlet hose and CVTF outlet hose. Ref. to CONTINUOUSLY VARIABLE TRANSMISSION (TR580) > CVTF COOLER (WITH WARMER FUNCTION) .
Install the CVTF inlet hose and CVTF outlet hose to transmission.

Fig 10: Identifying CVTF Inlet And Outlet Hose
Courtesy of SUBARU OF AMERICA, INC.
Install the CVTF cooler (with warmer feature) to the transmission.
Tightening torque:

23 N.m (2.3 kgf-m, 17.0 ft-lb)

Fig 11: Locating CVTF Cooler Bolts
Courtesy of SUBARU OF AMERICA, INC.
Install the starter. Ref. to STARTING/CHARGING SYSTEMS (H4DO) > Starter > INSTALLATION .
Install the engine rear hanger.
Tightening torque:

21 N.m (2.1 kgf-m, 15.5 ft-lb)

Fig 12: Locating Engine Rear Hanger Bolts
Courtesy of SUBARU OF AMERICA, INC.
Install the pitching stopper bracket and transmission radio ground cord.
CAUTION: Be careful not to deform or damage the terminal of transmission radio ground cord.

Tightening torque:

41 N.m (4.2 kgf-m, 30.2 ft-lb)

Fig 13: Locating Pitching Stopper Bracket Bolts
Courtesy of SUBARU OF AMERICA, INC.
Install the air breather hose to the pitching stopper bracket.
Install the pitching stopper.
Tightening torque:

T1: 50 N.m (5.1 kgf-m, 36.9 ft-lb)

T2: 58 N.m (5.9 kgf-m, 42.8 ft-lb)

Fig 14: Identifying Pitching Stopper
Courtesy of SUBARU OF AMERICA, INC.
Connect the EGR control valve harness connector, throttle position sensor harness connector and manifold absolute pressure sensor harness connector.
Connect the engine harness connectors, then install the harness connector bracket.
Tightening torque:

7.5 N.m (0.8 kgf-m, 5.5 ft-lb)
Lift up the vehicle.
Apply grease to the side retainer oil seal lip.
Set the ST to side retainer.
ST 28399SA010 OIL SEAL PROTECTOR

Fig 15: Identifying Oil Seal Protector (ST 28399SA010)
Courtesy of SUBARU OF AMERICA, INC.
Replace the circlip of the drive shaft with a new part.
Insert the front drive shaft spline section into transmission and remove the ST (OIL SEAL PROTECTOR).
NOTE:
- Before inserting the RH front drive shaft into transmission, turn the steering wheel to the right hand at full lock.
- Before inserting the LH front drive shaft into transmission, turn the steering wheel to the left hand at full lock.
Insert the drive shaft into the transmission securely by pressing the housing from outside of the vehicle.
Insert the ball joint into housing and secure with bolt.
Tightening torque:

50 N.m (5.1 kgf-m, 36.9 ft-lb)
CAUTION:
- Do not apply grease to the tapered portion of ball stud.
- Before tightening, make sure the lower side of housing and stepped section of ball joint are in contact.
Fig 16: Locating Ball Joint Bolt
Courtesy of SUBARU OF AMERICA, INC.
Attach the stabilizer link to the front arm.
Tightening torque:

60 N.m (6.1 kgf-m, 44.3 ft-lb)

Fig 17: Locating Stabilizer Link To Front Arm
Courtesy of SUBARU OF AMERICA, INC.
Install the plate assembly to transmission.
Tightening torque:

25 N.m (2.5 kgf-m, 18.4 ft-lb)

Fig 18: Locating Plate Assembly To Transmission Bolts
Courtesy of SUBARU OF AMERICA, INC.
Install the washer and snap pin to the shifter arm.

Fig 19: Installing Washer And Snap Pin To Shifter Arm
Courtesy of SUBARU OF AMERICA, INC.
Install the propeller shaft. Ref. to DRIVE SHAFT SYSTEM > Propeller Shaft > INSTALLATION .
Install the center exhaust cover.
Tightening torque:

18 N.m (1.8 kgf-m, 13.3 ft-lb)

Fig 20: Identifying Center Exhaust Cover
Courtesy of SUBARU OF AMERICA, INC.
Install the center exhaust pipe. Ref. to EXHAUST (H4DO) > Center Exhaust Pipe > INSTALLATION .
Install the under cover - front.
Install the under cover front - transmission.
Tightening torque:

18 N.m (1.8 kgf-m, 13.3 ft-lb)
Lower the vehicle.
Connect the following harness connectors.
- Transmission harness connectors
- Inhibitor harness connector
- Transmission radio ground terminal
  Tightening torque:
  
  13 N.m (1.3 kgf-m, 9.6 ft-lb)
Fig 21: Identifying Transmission Harness Connectors
Courtesy of SUBARU OF AMERICA, INC.
Install the air intake boot assembly. Ref. to INTAKE (INDUCTION) (H4DO) > Air Intake Boot > INSTALLATION .
Install the front tires. Ref. to WHEEL AND TIRE SYSTEM > Tire and Wheel > INSTALLATION .
Connect the battery ground terminal.
Refill differential gear oil to adjust the differential gear oil amount. Ref. to CONTINUOUSLY VARIABLE TRANSMISSION (TR580) > DIFFERENTIAL GEAR OIL .
Refill CVTF to adjust the CVTF level. Ref. to CONTINUOUSLY VARIABLE TRANSMISSION (TR580) > CVTF .
Perform the diagnosis again. Ref. to CONTINUOUSLY VARIABLE TRANSMISSION (DIAGNOSTICS) > LEARNING CONTROL .
Execute the rear differential inspection mode. Ref. to DIFFERENTIALS > REAR DIFFERENTIAL INSPECTION MODE .
CAUTION:
Always execute the rear differential inspection mode at the replacement of the following.
- Replacement of transmission assembly
- Replacement of front differential hypoid gear set
Perform the road test to make sure there is no fault. Ref. to CONTINUOUSLY VARIABLE TRANSMISSION (TR580) > Road Test > INSPECTION .