Subaru Outback manuals

Subaru Outback: Forward Clutch Assembly

A: REMOVAL

1) Remove the transmission from the vehicle. <Ref. to CVT-55, REMOVAL, Automatic Transmission Assembly.>

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

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

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

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

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

7) Remove the thrust needle bearing.

Subaru Outback. Continuously Variable Transmission

8) Remove the forward clutch assembly.

Subaru Outback. Continuously Variable Transmission

9) Remove the washer.

Subaru Outback. Continuously Variable Transmission

B: INSTALLATION

1) Select a washer. <Ref. to CVT-198, ADJUSTMENT, Forward Clutch Assembly.>

2) Install the selected washer.

Subaru Outback. Continuously Variable Transmission

3) Install the forward clutch assembly.

Subaru Outback. Continuously Variable Transmission

4) Install the thrust needle bearing.

NOTE: Install the thrust needle bearing in the correct direction.

Subaru Outback. Continuously Variable Transmission

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

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

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

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

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

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

C: DISASSEMBLY

1) Remove the planetary carrier assembly.

Subaru Outback. Continuously Variable Transmission

2) Remove the thrust needle bearing.

Subaru Outback. Continuously Variable Transmission

3) Remove the snap ring.

NOTE: Use marking or labeling to the upper snap ring for measurement of the snap ring thickness when selecting the retaining plate.

Subaru Outback. Continuously Variable Transmission

4) Remove the internal gear.

Subaru Outback. Continuously Variable Transmission

5) Remove the sun gear.

Subaru Outback. Continuously Variable Transmission

6) Remove the washer.

Subaru Outback. Continuously Variable Transmission

7) Remove the thrust needle bearing.

Subaru Outback. Continuously Variable Transmission

8) Remove the snap ring.

Subaru Outback. Continuously Variable Transmission

9) Remove the retaining plate, drive plate, driven plate and dish plate.

Subaru Outback. Continuously Variable Transmission

10) Using the ST, remove the snap ring.

ST 18762AA000 COMPRESSOR SPECIAL TOOL

Subaru Outback. Continuously Variable Transmission

11) Remove the forward clutch piston seal.

Subaru Outback. Continuously Variable Transmission

12) Remove the return spring.

Subaru Outback. Continuously Variable Transmission

13) Remove the forward clutch piston by blowing compressed air intermittently from end of forward clutch drum.

Subaru Outback. Continuously Variable Transmission

D: ASSEMBLY

1) Install the forward clutch piston to forward clutch drum.

NOTE:

Subaru Outback. Continuously Variable Transmission

2) Install the return spring.

Subaru Outback. Continuously Variable Transmission

3) Install the forward clutch piston seal.

NOTE: Apply CVTF to the sealing area of forward clutch piston seal.

Subaru Outback. Continuously Variable Transmission

4) Compress the return spring using the ST to install the snap ring.

ST 18762AA000 COMPRESSOR SPECIAL TOOL

Subaru Outback. Continuously Variable Transmission

5) Measure thickness "A" of the retaining plate installed.

Subaru Outback. Continuously Variable Transmission

6) Measure thickness "B" of internal gear on the workbench.

Subaru Outback. Continuously Variable Transmission

7) Measure thickness "C" of labelled or marked snap ring.

Subaru Outback. Continuously Variable Transmission

8) Install the dish plate, drive plate and driven plate.

9) Install the snap ring at the location (upper groove) indicated in the figure.

Subaru Outback. Continuously Variable Transmission

10) Measure depth "D" of snap ring and driven plate while lifting the snap ring.

Subaru Outback. Continuously Variable Transmission

11) Calculate clearance "T" from internal gear to retaining plate with the obtained value from step 5) through step 10).

Formula: T mm (in) = D - A - B - C

Subaru Outback. Continuously Variable Transmission

12) If the value "T" obtained from step 11) exceeds the limit for use, replace the drive plate and driven plate with new parts and select the retaining plate within the initial standard value.

Initial standard: 1.2 - 1.6 mm (0.047 - 0.063 in)

Limit thickness: 2.4 mm (0.09 in)

Subaru Outback. Continuously Variable Transmission

13) Remove the snap ring.

Subaru Outback. Continuously Variable Transmission

14) Replace with the selected retaining plate to install.

15) Install the snap ring to the lower groove.

Subaru Outback. Continuously Variable Transmission

16) Install the thrust needle bearing.

NOTE: Install the thrust needle bearing in the correct direction.

Subaru Outback. Continuously Variable Transmission

17) Install the washer.

Subaru Outback. Continuously Variable Transmission

18) Install the sun gear.

Subaru Outback. Continuously Variable Transmission

19) Install the internal gear.

Subaru Outback. Continuously Variable Transmission

20) Install the snap ring.

21) Install the thrust needle bearing.

NOTE: Make sure to install in the right direction.

Subaru Outback. Continuously Variable Transmission

22) Install the planetary carrier assembly.

Subaru Outback. Continuously Variable Transmission

E: INSPECTION

F: ADJUSTMENT

1) Measure depth "A" from the ST upper face to the washer catch surface.

ST 398643600 GAUGE

Subaru Outback. Continuously Variable Transmission

2) Install the forward clutch assembly to intermediate case.

3) Setting the ST, measure height "B" from the ST upper side to the immediate case mating surface.

ST 499575600 GAUGE

Subaru Outback. Continuously Variable Transmission

4) Obtain the thickness of washer using the following formula.

Calculation formula:

T (mm) = (A - 15) - (B - 15) - (0.35 - 0.70)
[T (in) = (A - 0.591) - (B - 0.591) - (0.014 - 0.028) ]
T: Washer thickness
A: Depth from the ST upper face to the washer catch surface
B: Height from the upper surface of the ST to the mating surface of the intermediate case
15 mm (0.591 in): Thickness of ST
0.35 - 0.70 mm (0.014 - 0.028 in): Clearance

5) Select the washer matching value "T" obtained from step 4).

Subaru Outback. Continuously Variable Transmission

READ NEXT:

 Reduction Driven Gear

A: REMOVAL 1) Remove the transmission from the vehicle. <Ref. to CVT-55, REMOVAL, Automatic Transmission Assembly.> 2) Remove the extension case. <Ref. to CVT-138, REMOVAL, Extension Case.&

 Transmission Control Device

A: REMOVAL 1) Remove the transmission assembly from vehicle body. <Ref. to CVT-55, REMOVAL, Automatic Transmission Assembly.> 2) Remove the oil pan and control valve body. <Ref. to CVT-111,

 Primary Pulley and Secondary Pulley

A: REMOVAL NOTE: Always replace primary pulley and secondary pulley as an assembly because they are non-disassembled parts. 1) Remove the transmission assembly from the vehicle. <Ref. to CVT-55,

SEE MORE:

 Evaporator

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 Vehicle placard

The vehicle placard is affixed to the driver’s side B-pillar. Example: The vehicle placard shows original tire size, recommended cold tire inflation pressure on each tire at maximum loaded vehicle weight, seating capacity and loading information.

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