Subaru Outback (BR): Converter Case Cover

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 extension case. <Ref. to CVT-138, REMOVAL, Extension Case.>

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

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

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

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

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

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

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

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

14) Remove the oil stopper plate and lubrication pipe.

15) Flip over the converter case.

16) Remove the oil pump chain cover and the oil pump chain. <Ref. to CVT-282, REMOVAL, Oil Pump Chain.>

17) Remove the converter case cover.

18) Remove the O-ring.

19) Remove the seal ring from converter case cover.

B: INSTALLATION

1) Clean the mating surface of converter case cover and converter case.

2) Adjust the shims of front reduction drive gear and front reduction driven gear. <Ref. to CVT-302, ADJUSTMENT, Front Reduction Drive Gear.> <Ref. to CVT-311, ADJUSTMENT, Front Reduction Driven Gear.>

3) Install the O-ring.

NOTE:

• Use new O-rings.
• Apply CVTF to the O-ring.

4) Apply CVTF to the selected shims and install each to the catch surface of bearing.

5) Install the seal ring to converter case cover.

NOTE:

• Use a new seal ring.
• When installing the seal ring, do not expand the seal ring too much.

6) Apply liquid gasket seamlessly to the mating surface of converter case cover.

Liquid gasket: THREE BOND 1215 (Part No. 004403007) or equivalent

7) Install the converter case cover.

Tightening torque: 24 N*m (2.4 kgf-m, 17.7 ft-lb)

8) Install the oil pump chain cover and the oil pump chain. <Ref. to CVT-284, INSTALLATION, Oil Pump Chain.>

9) Flip over the converter case cover.

10) Install the oil stopper plate and lubrication pipe.

Tightening torque: 9 N*m (0.9 kgf-m, 6.6 ft-lb)

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

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

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

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

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

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

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

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

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

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

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

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

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

C: DISASSEMBLY

1) Using ST, remove the center support COMPL.

ST 18270KA010 SOCKET (E16)

2) Remove the plug and O-ring.

D: ASSEMBLY

1) Install the plugs.

NOTE:

• Use new O-rings.
• Apply CVTF to the O-ring.

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

2) Using ST, install the center support COMPL.

ST 18270KA010 SOCKET (E16)

Tightening torque: 21.5 N*m (2.2 kgf-m, 15.9 ft-lb)

E: INSPECTION

• Check for leakage of CVTF from the connection between converter case and converter case cover.

Check there is no damage or cracks on the converter case cover.

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.>

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