Subaru Outback manuals

Subaru Outback: Automatic Transmission Assembly

A: REMOVAL

1) Remove the front wheels.

2) Disconnect the ground cable from battery.

3) Remove the air intake duct. <Ref. to IN(H4SO)-9, REMOVAL, Air Intake Duct.>

4) Remove the air intake boot assembly. <Ref. to IN(H4SO)-8, REMOVAL, Air Intake Boot.>

5) Remove the ten clips and remove the grille bracket.

Subaru Outback. Continuously Variable Transmission

6) Disconnect the following connectors.

Subaru Outback. Continuously Variable Transmission

  1. Transmission harness connectors
  2. Transmission radio ground terminal
  3. Inhibitor harness connector

7) Separate the battery cable clip to remove the bracket.

Subaru Outback. Continuously Variable Transmission

8) Remove the starter. <Ref. to SC(H4SO)-9, REMOVAL, Starter.>

9) Remove the throttle body. <Ref. to FU(H4SO)-15, REMOVAL, Throttle Body.>

10) Remove the manifold absolute pressure sensor. <Ref. to FU(H4SO)-33, REMOVAL, Manifold Absolute Pressure Sensor.>

11) Remove the bolt and disconnect the engine harness connector.

Subaru Outback. Continuously Variable Transmission

12) Remove the engine harness connector from the engine hanger rear.

Subaru Outback. Continuously Variable Transmission

13) Remove the engine hanger rear.

Subaru Outback. Continuously Variable Transmission

14) Remove the service hole plug.

Subaru Outback. Continuously Variable Transmission

15) Install the engine hanger rear for turbo model.

Part No. 10004AA180 Engine hanger rear

Tightening torque: 16 N*m (1.6 kgf-m, 11.8 ft-lb)

Subaru Outback. Continuously Variable Transmission

16) Remove the four bolts combining the torque converter and drive plate while rotating the crank pulley a little at a time in the same direction as engine revolution.

CAUTION:

Subaru Outback. Continuously Variable Transmission

17) Make sure the torque converter moves freely by rotating with finger through the starter installation hole.

18) Attach the ST to the converter case.

ST 498277200 STOPPER SET

Subaru Outback. Continuously Variable Transmission

19) After pulling off the cotter pin and removing the castle nut, use a puller to remove the tie-rod end from the knuckle arm.

Subaru Outback. Continuously Variable Transmission

  1. Cotter pin
  2. Tie-rod end
  3. Castle nut

20) Lift up the vehicle.

21) Remove the under cover.

22) Remove the center exhaust pipe. <Ref. to EX(H4SO)-8, REMOVAL, Center Exhaust Pipe.>

23) Remove the CVTF drain plug to drain CVTF. <Ref. to CVT-38, REPLACEMENT, CVTF.>

24) Remove the heat shield cover.

Subaru Outback. Continuously Variable Transmission

25) Remove the snap pin and washer from shifter arm and remove the select cable from shifter arm.

Subaru Outback. Continuously Variable Transmission

  1. Shifter arm
  2. Snap pin
  3. Select cable
  4. Washer

26) Remove the plate assembly from the transmission case.

Subaru Outback. Continuously Variable Transmission

  1. Select cable
  2. Plate ASSY

27) Drain differential gear oil. <Ref. to CVT-42, REPLACEMENT, Differential Gear Oil.>

28) Remove the CVTF CVT inlet hose and CVTF CVT outlet hose.

Subaru Outback. Continuously Variable Transmission

29) Remove the universal joint. <Ref. to PS-21, REMOVAL, Universal Joint.>

30) Remove the propeller shaft. <Ref. to DS-10, REMOVAL, Propeller Shaft.>

31) Remove the stabilizer link.

32) Disconnect the lower arm ball joint and housing.

33) Pull out the front drive shaft from transmission using a crowbar.

34) Holding the joint of front drive shaft from transmission side, pull out the drive shaft from transmission with care not to stretch the boot.

35) Lower the vehicle.

36) Remove the nuts from left and right transmission mounting brackets.

Subaru Outback. Continuously Variable Transmission

37) Set the ST1 and ST2 to vehicle.

ST1 99099AJ000 ENGINE HANGER
ST2 99099AJ010 CHAIN BALANCER

CAUTION:

Subaru Outback. Continuously Variable Transmission

38) Remove the stopper rod.

Subaru Outback. Continuously Variable Transmission

39) Lift the engine slightly and remove the engine mounting bolts.

Subaru Outback. Continuously Variable Transmission

40) Remove the engine mounting nut and bolt to remove the front cushion rubber.

Subaru Outback. Continuously Variable Transmission

41) Temporarily attach ST by using two bolts.

ST 41099AJ000 SPECIAL TOOL H4

Subaru Outback. Continuously Variable Transmission

42) Lift up the engine unit high enough to install the bolt and nut to vehicle.

CAUTION: Do not lift up higher than enough level to install the ST to avoid damage to the hoses and pipes inside the engine room.

NOTE:

Subaru Outback. Continuously Variable Transmission

43) Tighten the mounting bolts on the engine side.

Tightening torque: 25 N*m (2.5 kgf-m, 18.4 ft-lb)

Subaru Outback. Continuously Variable Transmission

44) Remove the ST (ENGINE HANGER).

45) Remove the left and right transmission mounting brackets.

NOTE: First, remove the transmission mounting bracket on the right side of vehicle, and then tilt the engine unit to remove the left transmission mounting bracket.

Subaru Outback. Continuously Variable Transmission

46) Remove the four transmission connecting bolts.

Subaru Outback. Continuously Variable Transmission

47) Set the ST (ENGINE HANGER) again to loosen the chain sling.

48) Lift up the vehicle.

49) Set the transmission jack under the transmission.

50) Remove the rear crossmember.

Subaru Outback. Continuously Variable Transmission

51) Lower the transmission rear end (dust cover rear end).

CAUTION: When lowering the transmission rear end, be careful not to let the converter case and steering mechanical parts contact each other.

NOTE: Lower the transmission rear end by approx. 80 mm (3.1 in) (reference).

Subaru Outback. Continuously Variable Transmission

52) Rotate the handle of ST (ENGINE HANGER) to apply tension to the chain sling.

53) Remove the two transmission connecting bolts and two nuts (lower side).

Subaru Outback. Continuously Variable Transmission

54) Remove the transmission assembly.

NOTE: Remove it while moving the transmission jack up and down so that the engine and transmission remain directly aligned.

55) Remove the cushion rubber.

Subaru Outback. Continuously Variable Transmission

B: INSTALLATION

1) Attach the ST to converter case.

ST 498277200 STOPPER SET

Subaru Outback. Continuously Variable Transmission

2) When completely overhauling the transmission, refill approx. 10 Subaru Outback. 10 (2.6 US qt, 8.8 Imp qt) of CVTF through the transmission right side plug, and install the plug.

CAUTION: Always use specified CVTF or equivalent. Using other fluid than specified or equivalent will cause malfunction. <Ref. to CVT-4, HYDRAULIC CONTROL AND LUBRICATION, SPECIFICATION, General Description.>

NOTE: Use a new gasket.

Tightening torque: 35 N*m (3.6 kgf-m, 25.8 ft-lb)

Subaru Outback. Continuously Variable Transmission

3) Replace the front differential side retainer oil seal. <Ref. to CVT-91, REPLACEMENT, Differential Side Retainer Oil Seal.>

NOTE:

4) Install the cushion rubber on the transmission.

Tightening torque: 40 N*m (4.1 kgf-m, 29.5 ft-lb)

Subaru Outback. Continuously Variable Transmission

5) Mount the transmission onto the transmission jack.

6) Strike and bend the transmission hanger of transmission rear with a soft 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.

Subaru Outback. Continuously Variable Transmission

7) While lifting up the transmission gradually, install the transmission to the engine.

CAUTION: This operation requires at least two persons.

NOTE: Keep the engine level.

8) Install the two engine connecting bolts and two nuts (lower side).

Tightening torque: 50 N*m (5.1 kgf-m, 36.9 ft-lb)

Subaru Outback. Continuously Variable Transmission

9) Secure the transmission rear crossmember to the vehicle body.

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)

Subaru Outback. Continuously Variable Transmission

10) Remove the transmission jack.

11) Lower the vehicle.

12) Remove the ST (ENGINE HANGER).

13) Install the four engine mounting bolts (upper side).

Tightening torque: 50 N*m (5.1 kgf-m, 36.9 ft-lb)

Subaru Outback. Continuously Variable Transmission

14) Install the left and right transmission mounting brackets.

NOTE:

Tightening torque: 75 N*m (7.6 kgf-m, 55.3 ft-lb)

Subaru Outback. Continuously Variable Transmission

15) Set the ST1 to vehicle body and lift up the engine unit slightly.

ST1 99099AJ000 ENGINE HANGER
ST2 99099AJ010 CHAIN BALANCER

CAUTION:

Subaru Outback. Continuously Variable Transmission

16) Remove the bolts from ST (SPECIAL TOOL H4).

Subaru Outback. Continuously Variable Transmission

17) Remove the bolt and nut to remove ST (SPECIAL TOOL H4).

Subaru Outback. Continuously Variable Transmission

18) Temporarily attach the front cushion rubber with bolts.

Subaru Outback. Continuously Variable Transmission

19) Install the bolt and nut to the front cushion rubber.

Subaru Outback. Continuously Variable Transmission

20) Tighten the bolts and nuts of front cushion rubber.

NOTE: Always start tightening from the bolts on the engine side.

Tightening torque:
T1: 25 N*m (2.5 kgf-m, 18.4 ft-lb)
T2: 45 N*m (4.6 kgf-m, 33.2 ft-lb)

Subaru Outback. Continuously Variable Transmission

21) Remove the ST (ENGINE HANGER and CHAIN SLING).

22) Install the stopper rod.

Tightening torque: 36 N*m (3.7 kgf-m, 26.6 ft-lb)

Subaru Outback. Continuously Variable Transmission

23) Install the nut to the transmission mounting bracket.

Tightening torque: 45 N*m (4.6 kgf-m, 33.2 ft-lb)

Subaru Outback. Continuously Variable Transmission

24) Remove the ST (STOPPER SET) from converter case.

25) Match the torque converter screw hole with drive plate hole to install the bolt.

CAUTION:

Tightening torque: 25 N*m (2.5 kgf-m, 18.4 ft-lb)

26) 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)

27) Install the service hole plug.

Subaru Outback. Continuously Variable Transmission

28) Install the starter. <Ref. to SC(H4SO)-10, INSTALLATION, Starter.>

29) Lift up the vehicle.

30) Tighten the single mounting bolt of transmission mounting bracket.

Tightening torque: 75 N*m (7.6 kgf-m, 55.3 ft-lb)

Subaru Outback. Continuously Variable Transmission

31) Set the ST to side retainer.

ST 28399SA010 OIL SEAL PROTECTOR

Subaru Outback. Continuously Variable Transmission

32) Replace the circlip of the drive shaft with a new part.

33) Insert the front drive shaft spline section into transmission and remove the ST (OIL SEAL PROTECTOR).

34) Insert the drive shaft into the transmission securely by pressing the housing from outside of the vehicle.

35) Install the CVTF CVT inlet hose and CVTF CVT outlet hose.

NOTE: Use new CVTF CVT inlet hose and CVTF CVT outlet hose.

Subaru Outback. Continuously Variable Transmission

36) Insert the ball joint into housing and secure with bolt.

Tightening torque: 50 N*m (5.1 kgf-m, 36.9 ft-lb)

CAUTION:

37) Install the stabilizer link.

Tightening torque: 60 N*m (6.1 kgf-m, 44.3 ft-lb)

38) Connect the tie-rod end and knuckle arm, and attach the castle nut.

Tightening torque: 27 N*m (2.75 kgf-m, 19.9 ft-lb)

CAUTION: When connecting, do not hit the cap at the bottom of tie-rod end with hammer.

39) After tightening the castle nut to the specified tightening torque, tighten it further within 60º until the cotter pin hole is aligned with slot in the nut. Fit the cotter pin into the nut, and then bend the pin to lock.

Subaru Outback. Continuously Variable Transmission

  1. Cotter pin
  2. Tie-rod end
  3. Castle nut

40) Install the propeller shaft. <Ref. to DS-11, INSTALLATION, Propeller Shaft.>

41) Install the universal joint. <Ref. to PS-22, INSTALLATION, Universal Joint.>

42) Install the plate assembly to transmission.

Tightening torque: T: 25 N*m (2.5 kgf-m, 18.4 ft-lb)

Subaru Outback. Continuously Variable Transmission

  1. Select cable
  2. Plate ASSY

43) Install the washer and snap pin to the shifter arm.

Subaru Outback. Continuously Variable Transmission

  1. Shifter arm
  2. Snap pin
  3. Select cable
  4. Washer

44) Install the heat shield cover.

Tightening torque: 18 N*m (1.8 kgf-m, 13.3 ft-lb)

Subaru Outback. Continuously Variable Transmission

45) Install the center exhaust pipe. <Ref. to EX(H4SO)-8, INSTALLATION, Center Exhaust Pipe.>

46) Install the under cover.

47) Lower the vehicle.

48) Remove the engine hanger rear for turbo model and install the engine hanger rear for non-turbo model.

Tightening torque: 16 N*m (1.6 kgf-m, 11.8 ft-lb)

Subaru Outback. Continuously Variable Transmission

49) Install the engine harness connector to the engine hanger rear, connect the harness connector, and install the harness connector bracket.

Tightening torque: 7.5 N*m (0.76 kgf-m, 5.5 ft-lb)

Subaru Outback. Continuously Variable Transmission

50) Install the throttle body. <Ref. to FU(H4SO)-15, INSTALLATION, Throttle Body.>

51) Install the manifold absolute pressure sensor. <Ref. to FU(H4SO)-34, INSTALLATION, Manifold Absolute Pressure Sensor.>

52) Connect the following harness connectors.

Tightening torque: 13 N*m (1.3 kgf-m, 9.6 ft-lb)

Subaru Outback. Continuously Variable Transmission

  1. Transmission harness connectors
  2. Transmission radio ground terminal
  3. Inhibitor harness connector

53) Install the battery cable bracket, and install the battery cable clip to the bracket.

Tightening torque: 7.5 N*m (0.76 kgf-m, 5.5 ft-lb)

Subaru Outback. Continuously Variable Transmission

54) Attach the grille bracket.

Subaru Outback. Continuously Variable Transmission

55) Install the air intake boot assembly. <Ref. to IN(H4SO)-8, INSTALLATION, Air Intake Boot.>

56) Install the air intake duct. <Ref. to IN(H4SO)-9, INSTALLATION, Air Intake Duct.>

57) Install the front wheels.

58) Connect the battery ground terminal.

59) Refill differential gear oil to adjust the differential gear oil amount. <Ref. to CVT-41, Differential Gear Oil.>

60) Refill CVTF to adjust the CVTF amount. <Ref. to CVT-37, CVTF.>

61) Perform the variator chain break-in. <Ref. to CVT-44, Variator Chain Break-in.>

CAUTION: Always execute the variator chain break-in after the replacement of the following.

62) Perform Clear Memory 2 operation. <Ref. to CVT(diag)-18, Clear Memory Mode.>

63) Perform learning control promotion. <Ref. to CVT(diag)-20, Learning Control.>

64) Execute the rear differential inspection mode. <Ref. to DI-84, Rear Differential Inspection Mode.>

CAUTION: Always execute the rear differential inspection mode at the replacement of the following.

65) Perform the road test to make sure there is no fault. <Ref. to CVT-46, INSPECTION, Road Test.>

READ NEXT:

 Transmission Mounting System

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 Inhibitor Switch

A: INSPECTION When the driving condition or starter motor operation is improper, first check the shift linkage for improper operation. If the shift linkage is functioning properly, check the inhibit

 Secondary Speed Sensor

A: REMOVAL CAUTION: Be sure to prevent water or oil from contacting the connector terminal of secondary speed sensor. If adhesion occurs, replace with a new part. 1) Remove the transmission from the

SEE MORE:

 Converter Case

A: REMOVAL 1) Remove the transmission assembly from the vehicle. <Ref. to CVT-55, REMOVAL, Automatic Transmission Assembly.> 2) Remove the air breather hose. <Ref. to CVT-132, REMOVAL, Air Breather Hose.> 3) Remove the oil pan and control valve body. <Ref. to CVT-111, REMOVAL, Cont

 Rear Hub Unit Bearing

A: REMOVAL 1) Lift up the vehicle, and then remove the rear wheels. 2) Remove the axle nut. CAUTION: Do not loosen the axle nut while the rear axle is loaded. Doing so may damage the hub bearing. Lift the crimped section of axle nut. Remove the axle nut using a socket wrench while depressing th

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