Subaru Outback manuals

Subaru Outback: Drive Pinion Shaft Assembly

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) Using the ST, remove the drive pinion retainer and lubrication pipe.

ST 18270KA020 SOCKET (E20)

Subaru Outback. Continuously Variable Transmission

14) Remove the O-ring.

Subaru Outback. Continuously Variable Transmission

15) Remove the oil pump.

Subaru Outback. Continuously Variable Transmission

16) Remove the O-ring.

Subaru Outback. Continuously Variable Transmission

B: INSTALLATION

1) Clean the mating surface of drive pinion retainer and converter case.

2) Adjust the backlash and tooth contact between drive pinion shaft assembly and the front differential side gear. <Ref. to CVT-256, ADJUSTMENT, Drive Pinion Shaft Assembly.>

3) Install the O-ring for oil pump to drive pinion retainer.

NOTE:

Subaru Outback. Continuously Variable Transmission

4) Install the oil pump.

NOTE: Apply CVTF to the bolt.

Tightening torque: 8.5 N*m (0.9 kgf-m, 6.3 ft-lb)

Subaru Outback. Continuously Variable Transmission

5) Apply liquid gasket seamlessly to the mating surface of drive pinion retainer.

NOTE: Be careful not to block the arrowed hole when applying liquid gasket.

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

Subaru Outback. Continuously Variable Transmission

6) Install the O-ring to the lubrication pipe.

NOTE:

Subaru Outback. Continuously Variable Transmission

7) Install the drive pinion retainer and lubrication pipe to converter case and tighten the bolt using the ST.

ST 18270KA020 SOCKET (E20)

NOTE: Do not confuse the three different-length bolts when installing.

Tightening torque: 43 N*m (4.4 kgf-m, 31.7 ft-lb)

Subaru Outback. Continuously Variable Transmission

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

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

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

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

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

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

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

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

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

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

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

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

C: DISASSEMBLY

1) Remove the drive pinion assembly.

Subaru Outback. Continuously Variable Transmission

2) Flatten the tab of the lock nut.

3) Using ST1 and ST2, fix at the spline portion of drive pinion shaft to remove the lock nut.

ST1 18621AA000 WRENCH
ST2 18667AA010 HOLDER

Subaru Outback. Continuously Variable Transmission

4) Remove the taper roller bearing rear side inner race and outer race from drive pinion shaft.

Subaru Outback. Continuously Variable Transmission

5) Using ST, remove the taper roller bearing front side inner race from drive pinion shaft.

ST 498077000 REMOVER

Subaru Outback. Continuously Variable Transmission

6) Remove the two oil seals using a screwdriver wrapped with cloth etc.

CAUTION: Do not damage the fitting surface of drive pinion bearing.

Subaru Outback. Continuously Variable Transmission

7) Remove the plug from drive pinion retainer.

D: ASSEMBLY

1) Install the O-ring to plug and install the plug to drive pinion retainer.

NOTE:

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

2) Using the ST, install the oil seal to drive pinion retainer.

NOTE:

Pulley side

ST 18657AA020 OIL SEAL INSTALLER

Subaru Outback. Continuously Variable Transmission

Front differential side

ST 499277100 INSTALLER

Subaru Outback. Continuously Variable Transmission

3) Measure the dimension "A" of drive pinion shaft.

ST 398643600 GAUGE

Subaru Outback. Continuously Variable Transmission

4) Press-fit the new inner bearing inner race using the ST.

ST 499277200 INSTALLER

Subaru Outback. Continuously Variable Transmission

5) Press-fit the new outer bearing outer race and inner bearing inner race.

CAUTION: Damage may result if too much force is applied to the roller bearing.

NOTE: Press in to a position where the bearing rotates smoothly without play.

Subaru Outback. Continuously Variable Transmission

6) Tighten a new lock nut using the ST.

Using the following formula, calculate the torque for a torque wrench.

T2 = L2/(L1 + L2) × T1
T1: 130 N*m (13.3 kgf-m, 95.9 ft-lb)
[Required torque setting]
T2: Tightening torque
L1: ST1 length 0.1 m (3.94 in)
L2: Torque wrench length

Example:

Subaru Outback. Continuously Variable Transmission

ST1 18621AA000 WRENCH
ST2 18667AA010 HOLDER

NOTE: Tighten the lock nut while directly aligning ST1 and torque wrench.

Subaru Outback. Continuously Variable Transmission

7) Apply differential gear oil to roller of bearing and rotate the bearing several times.

8) Measure the starting torque of the bearing. Make sure the starting torque is within the specified range. If the torque is not within specified range, replace the roller bearing.

Starting torque: 11.6 - 34.7 N (1.2 - 3.5 kgf, 2.6 - 7.8 lb)

Subaru Outback. Continuously Variable Transmission

9) Crimp the lock nut in 2 locations.

10) Measure the dimension "B" of the drive pinion shaft.

ST 398643600 GAUGE

Subaru Outback. Continuously Variable Transmission

11) Obtain thickness "t" mm (in) of the drive pinion shim.

t = 6.55+-0.1225 - (B - A)

12) Select three or less shims from following table.

Subaru Outback. Continuously Variable Transmission

13) Install the shims selected for drive pinion retainer and drive pinion shaft assembly.

NOTE: Be careful not to bend the shim.

Tightening torque: 70 N*m (7.1 kgf-m, 51.6 ft-lb)

Subaru Outback. Continuously Variable Transmission

E: INSPECTION

CAUTION: Before measuring, apply differential gear oil to roller of bearing and rotate the bearing several times.

Starting torque: 11.6 - 34.7 N (1.2 - 3.5 kgf, 2.6 - 7.8 lb)

Subaru Outback. Continuously Variable Transmission

F: ADJUSTMENT

1) Remove the liquid gasket from the mating surface completely.

2) Using the ST, install the drive pinion retainer to converter case.

ST1 18270KA020 SOCKET (E20)

NOTE: Do not confuse the three different-length bolts when installing.

Tightening torque: 43 N*m (4.4 kgf-m, 31.7 ft-lb)

Subaru Outback. Continuously Variable Transmission

3) Rotate the drive pinion several times using ST1 and ST2.

ST1 18667AA010 HOLDER
ST2 499787700 WRENCH

Subaru Outback. Continuously Variable Transmission

4) Adjust the drive pinion and hypoid driven gear backlash. <Ref. to CVT-277, ADJUSTMENT, Front Differential Assembly.>

5) Using the ST, remove the drive pinion retainer from converter case.

ST1 18270KA020 SOCKET (E20)

6) Apply lead-free red dye evenly on the both sides of three to four teeth of the hypoid driven gear. Then install the drive pinion retainer and rotate the drive pinion in both directions several times. Remove the drive pinion retainer and check the tooth contact pattern.

If the teeth contact is inappropriate, adjust the backlash or thickness of the shim. <Ref. to CVT-277, ADJUSTMENT, Front Differential Assembly.>

NOTE:

After correction, wipe off the lead-free red dye.

Check item: Tooth contact surface is slightly shifted toward the toe side under a no-load condition.

(When driving, it moves towards the heel side.)

Subaru Outback. Continuously Variable Transmission

  1. Toe side
  2. Heel side

Check item: Backlash is too large.

Contact pattern

Subaru Outback. Continuously Variable Transmission

Corrective action: Increase thickness of pinion height adjusting washer according to the procedure for bringing drive pinion close to hypoid driven gear side.

Subaru Outback. Continuously Variable Transmission

Check item: Backlash is too small.

Contact pattern

Subaru Outback. Continuously Variable Transmission

Corrective action: Reduce the thickness of pinion height adjusting washer according to the procedure for bringing drive pinion away from hypoid driven gear.

Subaru Outback. Continuously Variable Transmission

Check item: Teeth contact area is too small.

Contact pattern

Subaru Outback. Continuously Variable Transmission

Corrective action: Reduce the thickness of pinion height adjusting washer according to the procedure for bringing drive pinion away from hypoid driven gear side.

Subaru Outback. Continuously Variable Transmission

Check item: Teeth contact area is too small.

Contact pattern

Subaru Outback. Continuously Variable Transmission

Corrective action: Increase the thickness of the pinion height adjusting washer according to the procedures for moving the drive pinion closer to the hypoid driven gear.

Subaru Outback. Continuously Variable Transmission

7) If tooth contact is correct, mark the differential side retainer position and loosen. After fitting a new O-ring and oil seal, screw in the differential side retainer to the marked position.

8) Tighten the lock plate with specified torque.

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

Subaru Outback. Continuously Variable Transmission

  1. Lock plate

READ NEXT:

 Front Differential Assembly

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

 Oil Pump

A: REMOVAL NOTE: Refer to "Drive Pinion Shaft" for removal procedures. <Ref. to CVT-242, REMOVAL, Drive Pinion Shaft Assembly.> B: INSTALLATION NOTE: Refer to "Drive Pinion Shaft" for removal p

 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

SEE MORE:

 Engine exhaust gas (carbon monoxide)

WARNING ● Never inhale engine exhaust gas. Engine exhaust gas contains carbon monoxide, a colorless and odorless gas which is dangerous, or even lethal, if inhaled. ● Always properly maintain the engine exhaust system to prevent engine exhaust gas from entering the vehicle. ●

 Steps for Determining Correct Load Limit

1. Locate the statement “The combined weight of occupants and cargo should never exceed XXX pounds” on your vehicle’s placard. 2. Determine the combined weight of the driver and passengers that will be riding in your vehicle. 3. Subtract the combined weight of the driver and passengers f

© 2010-2022 Copyright www.suoutback.com