Subaru Outback (BR): Intermediate Case

A: REMOVAL

1) Remove the transmission assembly from vehicle body. <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 assembly. <Ref. to CVT-158, REMOVAL, Transfer Reduction Driven Gear.>

6) Remove the intermediate case.

NOTE:

• The total number of intermediate case mounting bolts is 14.
• Inside the transmission is a single bolt (arrowed).

7) Remove the CVTF filter.

8) Remove the O-ring from the transmission case.

B: INSTALLATION

1) Clean the mating surface of intermediate case and transmission case.

2) Face the O-ring side of the CVTF filter to the intermediate case side, and install the CVTF filter.

NOTE: Apply CVTF to the O-ring.

3) Install the O-ring to the transmission case.

NOTE:

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

4) Apply liquid gasket to intermediate case seamlessly.

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

5) Install the intermediate case and the transmission hanger to the transmission case.

NOTE: Make sure to install the arrowed bolt.

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

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 CVTF filler plug.

2) Remove all plugs from intermediate case.

3) Remove the reverse brake assembly. <Ref. to CVT-171, DISASSEMBLY, Reverse Brake Assembly.>

D: ASSEMBLY

1) Install the reverse brake. <Ref. to CVT-174, ASSEMBLY, Reverse Brake Assembly.>

2) install all plugs to intermediate case.

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

NOTE: Use new O-rings.

3) Install the CVTF filler plug.

NOTE: Replace the gasket of CVTF filler plug with a new part after installing the transmission assembly to vehicle and adjusting CVTF fluid.

E: INSPECTION

• Check the intermediate case for fissures, cracks or damage.
• Check for leakage of CVTF from the connections between intermediate case and transmission case, and between intermediate case and extension case.

CVTF Filter

A: REMOVAL

NOTE:

• Although CVTF filter is a maintenance-free part, replace it if a large quantity of wear debris and metal particles are found in CVTF and CVTF filter.
• For removal of CVTF filter, refer to "Intermediate Case". <Ref. to CVT-165, REMOVAL, Intermediate Case.>

B: INSTALLATION

NOTE: For removal of CVTF filter, refer to "Intermediate Case". <Ref. to CVT-166, INSTALLATION, Intermediate Case.>

C: INSPECTION

• Check if a large quantity of wear debris or metal particles are in CVTF and CVTF filter.
• Check for broken part or damaged O-ring.

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