Subaru Outback (BR): 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, Control Valve Body.>

4) Remove the transmission harness. <Ref. to CVT-121, REMOVAL, Transmission Harness.>

5) Remove the secondary pressure sensor. <Ref. to CVT-109, REMOVAL, Secondary Pressure Sensor.>

6) Remove the primary speed sensor. <Ref. to CVT-105, REMOVAL, Primary Speed Sensor.>

7) Remove the extension case. <Ref. to CVT-138, REMOVAL, Extension Case.>

8) Remove the rear drive shaft. <Ref. to CVT-141, REMOVAL, Rear Drive Shaft.>

9) Remove the transfer clutch assembly. <Ref. to CVT-146, REMOVAL, Transfer Clutch.>

10) Remove the transfer reduction driven gear assembly. <Ref. to CVT-158, REMOVAL, Transfer Reduction Driven Gear.>

11) Remove the intermediate case. <Ref. to CVT-165, REMOVAL, Intermediate Case.>

12) Remove the forward clutch assembly. <Ref. to CVT-180, REMOVAL, Forward Clutch Assembly.>

13) Remove the transmission case. <Ref. to CVT-211, REMOVAL, Transmission Case.>

14) Remove the primary pulley, secondary pulley and variator chain. <Ref. to CVT-226, REMOVAL, Primary Pulley and Secondary Pulley.>

15) Remove the drive pinion shaft assembly. <Ref. to CVT-242, REMOVAL, Drive Pinion Shaft Assembly.>

16) Remove the front differential assembly. <Ref. to CVT-263, REMOVAL, Front Differential Assembly.>

17) Remove the converter case cover. <Ref. to CVT-289, REMOVAL, Converter Case Cover.>

18) Remove the front reduction drive gear and front reduction driven gear. <Ref. to CVT-297, REMOVAL, Front Reduction Drive Gear.>

B: INSTALLATION

1) Install the front reduction drive gear and front reduction driven gear. <Ref. to CVT-298, INSTALLATION, Front Reduction Drive Gear.>

2) Install the converter case cover. <Ref. to CVT-291, INSTALLATION, Converter Case Cover.>

3) Install the front differential assembly. <Ref. to CVT-264, INSTALLATION, Front Differential Assembly.>

4) Install the drive pinion shaft assembly. <Ref. to CVT-244, INSTALLATION, Drive Pinion Shaft Assembly.>

5) Install the primary pulley, secondary pulley and steel chain. <Ref. to CVT-230, INSTALLATION, Primary Pulley and Secondary Pulley.>

6) Install the transmission case. <Ref. to CVT-213, INSTALLATION, Transmission Case.>

7) Install the forward clutch assembly. <Ref. to CVT-181, INSTALLATION, Forward Clutch Assembly.>

8) Install the intermediate case. <Ref. to CVT-166, INSTALLATION, Intermediate Case.>

9) Install the transfer reduction driven gear. <Ref. to CVT-158, INSTALLATION, Transfer Reduction Driven Gear.>

10) Install the transfer clutch assembly. <Ref. to CVT-147, INSTALLATION, Transfer Clutch.>

11) Install the rear drive shaft. <Ref. to CVT-141, INSTALLATION, Rear Drive Shaft.>

12) Install the extension case. <Ref. to CVT-138, INSTALLATION, Extension Case.>

13) Install the primary speed sensor. <Ref. to CVT-105, INSTALLATION, Primary Speed Sensor.>

14) Install the secondary pressure sensor. <Ref. to CVT-109, INSTALLATION, Secondary Pressure Sensor.>

15) Install the transmission harness. <Ref. to CVT-123, INSTALLATION, Transmission Harness.>

16) Install the control valve body and oil pan. <Ref. to CVT-115, INSTALLATION, Control Valve Body.>

17) Install the air breather hose. <Ref. to CVT-132, INSTALLATION, Air Breather Hose.>

18) Install the transmission assembly to the vehicle. <Ref. to CVT-70, INSTALLATION, Automatic Transmission Assembly.>

C: DISASSEMBLY

1) Remove the transmission hanger and transmission radio ground cord.

2) Remove the oil drain plug and overflow drain plug. <Ref. to CVT-42, REPLACEMENT, Differential Gear Oil.>

3) Remove all plugs.

D: ASSEMBLY

1) Install the oil drain plug and overflow drain plug.

NOTE: Overflow plug of differential gear oil is temporarily attached.

2) Install all plugs.

NOTE: Use new O-rings.

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

3) Install the transmission hanger and transmission radio ground cord.

Tightening torque: 41 N*m (4.2 kgf-m, 30.2 ft-lb)

1. Install within the range of 30º approximately.

E: INSPECTION

• Check for leakage of CVTF from the connection between converter case and transmission case.
• Check there is no damage or cracks on the converter case.

F: ADJUSTMENT

When replacing the converter case cover, select the following shims.

• Select the shim for front reduction drive gear. <Ref. to CVT-302, ADJUSTMENT, Front Reduction Drive Gear.>
• Select the shim for front reduction driven gear. <Ref. to CVT-311, ADJUSTMENT, Front Reduction Driven Gear.>
• Select shims for primary pulley. <Ref. to CVT-236, ADJUSTMENT, Primary Pulley and Secondary Pulley.>

Diagnostics with Phenomenon

A: INSPECTION

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