Automatic Transmission Assembly: Installation

Attach the ST to converter case.
Preparation tool:

ST: STOPPER SET (498277200)

Fig 1: Attaching ST 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: Locating Rear Cushion Rubber Bolts
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: Identifying Bending Transmission Hanger
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: 75 N.m (7.6 kgf-m, 55.3 ft-lb)

Fig 4: Identifying Transmission Rear Crossmember Bolts
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
Courtesy of SUBARU OF AMERICA, INC.
Install the exhaust hanger bracket.
Tightening torque:

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

Fig 6: Locating Exhaust Hanger Bracket Bolts
Courtesy of SUBARU OF AMERICA, INC.
Remove the transmission jack.
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 7: Locating Engine Mounting Bolts
Courtesy of SUBARU OF AMERICA, INC.
Remove the ST1 and ST2.
Preparation tool:

ST1: ENGINE SUPPORT BRACKET (41099AA012)

ST2: ENGINE SUPPORT (41099AA020)

Fig 8: Setting Engine Support Bracket And Engine Support
Courtesy of SUBARU OF AMERICA, INC.
Install the TCM. Ref. to CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Transmission Control Module (TCM)>INSTALLATION .
Insert the transmission case cover (small) between transmission case cover (large) and transmission to install.
CAUTION: When inserting, be careful that the insulator inside transmission case cover is not turned over.

Tightening torque:

7 N.m (0.7kgf-m, 5.3 ft-lb)

Fig 9: Inserting Transmission Case Cover
Courtesy of SUBARU OF AMERICA, INC.

Fig 10: Locating Transmission Case Cover Bolts
Courtesy of SUBARU OF AMERICA, INC.
Install the torque converter assembly to the drive plate.
1. Remove the ST from converter case.
  NOTE: Be careful not to drop the ST into the converter case when removing the ST.
  
  Fig 11: Removing ST From Converter Case
  Courtesy of SUBARU OF AMERICA, INC.
2. Insert the wrench into the crank pulley bolt, and rotate the crank pulley to install the bolts which hold the torque converter assembly to the drive plate using the ST.
NOTE:
- Be careful not to drop bolts into the converter housing.
- When not using the ST, use a crowfoot wrench for tightening.
- Use the following formula to calculate the reading of a torque wrench when tightening with a crowfoot wrench.
Calculation formula

T = 25 N.m (2.5kgf-m, 18.4ft-lb) x L1/ (L1+L2)

T: Reading of the torque wrench

L1: Effective length of the torque wrench

L2: Effective length of the crowfoot wrench

NOTE: If the effective length of the tool used is unknown, consult the manufacturer of the tool.

Fig 12: Measuring Length Of Torque Wrench
Courtesy of SUBARU OF AMERICA, INC.
1. Effective length of the crowfoot wrench
2. Effective length of the torque wrench
3. Center of the open end of crowfoot wrench
4. Center of drive angle of the torque wrench
5. Center of the position where a force is applied by hand
Preparation tool:

ST: SOCKET (18270AA050)

Tightening torque:

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

Fig 13: Holding Torque Converter Assembly To Drive Plate Using ST
Courtesy of SUBARU OF AMERICA, INC.
Install the remaining five 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 14: Identifying 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 15: Locating Engine Ground Terminal Bolt
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)>REMOVAL . Ref. to CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>CVTF Cooler (With Warmer Function)>INSTALLATION .
Install the CVTF inlet hose and CVTF outlet hose to transmission.

Fig 16: Locating CVTF Inlet Hose And CVTF Outlet Hose Clamps
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 17: Locating CVTF Cooler Bolts
Courtesy of SUBARU OF AMERICA, INC.
Install the starter. Ref. to STARTING/CHARGING SYSTEMS (H4DO)>Starter>INSTALLATION .
Install the engine hanger rear.
Tightening torque:

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

Fig 18: Locating Engine Hanger Rear Bolts
Courtesy of SUBARU OF AMERICA, INC.
Install the pitching stopper bracket.
Tightening torque:

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

Fig 19: Locating Pitching Stopper Bracket Bolts
Courtesy of SUBARU OF AMERICA, INC.
Connect the throttle position sensor harness connector (1), purge control solenoid valve harness connector (2), harness clip (3), vacuum hose (4) and PCV hose (5).

Fig 20: Identifying Throttle Position Sensor Harness Connector, Harness Clip, Vacuum Hose And PCV Hose
Courtesy of SUBARU OF AMERICA, INC.
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 21: Locating Pitching Stopper Bolts
Courtesy of SUBARU OF AMERICA, INC.
Install the air breather hose and air breather hose bracket.

Fig 22: Locating Air Breather Hose With Bracket
Courtesy of SUBARU OF AMERICA, INC.
Install the engine harness connector bracket.
Tightening torque:

19 N.m (1.9 kgf-m, 14 ft-lb)

Fig 23: Locating Engine Harness Connector Bracket Bolts
Courtesy of SUBARU OF AMERICA, INC.
Connect the transmission harness connector.

Fig 24: Connecting Transmission Harness Connector
Courtesy of SUBARU OF AMERICA, INC.
Lift up the vehicle.
Set the ST to the side retainer.
Preparation tool:

ST: OIL SEAL PROTECTOR (28399SA010)

Fig 25: Setting ST To Side Retainer
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.
CAUTION:
- To prevent the front lower arm assembly from damaging the ball joint dust cover, place the ball joint on the upper side of the front lower arm assembly before starting the operation.
- Be careful not to damage the front lower arm assembly and ball joint by covering the upper side of the front lower arm assembly with a cloth.
Insert the ball joint into the front arm assembly, and fix with nuts.
Tightening torque:

100 N.m (10.2kgf-m, 73.8 ft-lb)

Fig 26: Identifying Flange Nuts
Courtesy of SUBARU OF AMERICA, INC.
Install the stabilizer link.
Tightening torque:

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

Fig 27: Locating Stabilizer Link Nut
Courtesy of SUBARU OF AMERICA, INC.
Install the front ABS wheel speed sensor. Ref. to VEHICLE DYNAMICS CONTROL (VDC)>Front ABS Wheel Speed Sensor>INSTALLATION .
Install the brake hose bracket.
Tightening torque:

33 N.m (3.4kgf-m, 24.3 ft-lb)

Fig 28: Locating Brake Hose Bracket Bolt
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 29: Locating Plate Assembly To Transmission Case Bolts
Courtesy of SUBARU OF AMERICA, INC.
Install the washer and snap pin to the shifter arm.
CAUTION: Do not apply excessive load while holding the part (A).

Fig 30: Measuring Shifter Arm Length
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Fig 31: Identifying Shifter Arm, Snap Pin, Washer And Select Cable
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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 32: Locating Center Exhaust Cover Bolts
Courtesy of SUBARU OF AMERICA, INC.
Install the front exhaust pipe. Ref. to EXHAUST (H4DO)>Front Exhaust Pipe>INSTALLATION .
Install the crossmember support rear.
Tightening torque:

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

Fig 33: Locating Rear Crossmember Support Nuts
Courtesy of SUBARU OF AMERICA, INC.
Install the under cover.
Lower the vehicle.
Using the ST, tighten the self-locking nut of the front suspension strut mount.
CAUTION:
- Use a new self-lock nut.
- Tighten in the state where the wheels are in full contact with the ground.
Preparation tool:

ST: STRUT MOUNT SOCKET (20399AG000)

Tightening torque:

55 N.m (5.6kgf-m, 40.6ft-lb)

Fig 34: Tightening Self-Locking Nut Of Front Suspension Strut Mount
Courtesy of SUBARU OF AMERICA, INC.
Connect the transmission radio ground terminal.
Tightening torque:

32.3 N.m (3.3 kgf-m, 23.8 ft-lb)

Fig 35: Locating Transmission Radio Ground Terminal Bolt
Courtesy of SUBARU OF AMERICA, INC.
Install the air intake boot. 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. Ref. to REPAIR CONTENTS>NOTE>SAFETY .
Refill differential gear oil to adjust the differential gear oil amount. Ref. to CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Differential Gear Oil>ADJUSTMENT .
Refill CVTF to adjust the CVTF level. Ref. to CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>CVTF>ADJUSTMENT .
Using the Subaru Select Monitor, perform «Clear AT learning value» on «Work Support», and perform the operation of AT learning mode. Ref. to 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
Inspect the wheel alignment and adjust if necessary. Ref. to FRONT SUSPENSION>Wheel Alignment>ADJUSTMENT .
Perform the road test to make sure there is no fault. Ref. to CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Road Test>INSPECTION .