Subaru Outback manuals

Subaru Outback: 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, REMOVAL, Control Valve Body.>

3) Remove the inhibitor switch. <Ref. to CVT-98, REMOVAL, Inhibitor Switch.>

4) Remove the spring pin.

NOTE: Prevent the spring pin from dropping in the transmission using paper towel etc.

Subaru Outback. Continuously Variable Transmission

5) Remove the bolt and remove the range select lever, manual plate and parking rod.

NOTE: Do not damage the lip of oil seal press-fitted in the case.

Subaru Outback. Continuously Variable Transmission

  1. Bolt
  2. Range select lever
  3. Manual plate
  4. Parking rod

6) Remove the detent spring.

Subaru Outback. Continuously Variable Transmission

B: INSTALLATION

1) Install the detent spring to the transmission case.

Tightening torque: 7 N*m (0.7 kgf-m, 5.2 ft-lb)

Subaru Outback. Continuously Variable Transmission

2) Install the manual plate, parking rod, range select lever and bolt.

Tightening torque: 7 N*m (0.7 kgf-m, 5.2 ft-lb)

Subaru Outback. Continuously Variable Transmission

  1. Bolt
  2. Range select lever
  3. Manual plate
  4. Parking rod

3) Install the spring pin.

NOTE: Use new spring pin.

Subaru Outback. Continuously Variable Transmission

4) Install the inhibitor switch. <Ref. to CVT-95, Inhibitor Switch.>

5) Adjust the inhibitor switch. <Ref. to CVT-95, Inhibitor Switch.>

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

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

C: INSPECTION

Make sure that the manual lever and detent spring are not worn or otherwise damaged.

Transmission 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 transmission harness. <Ref. to CVT-121, REMOVAL, Transmission Harness.>

4) Remove the secondary speed sensor. <Ref. to CVT-102, REMOVAL, Secondary Speed Sensor.>

5) Remove the inhibitor switch. <Ref. to CVT-98, REMOVAL, Inhibitor Switch.>

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

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

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

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

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

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

12) Remove the reduction driven gear. <Ref. to CVT-200, REMOVAL, Reduction Driven Gear.>

13) Remove the oil pan and control valve body. <Ref. to CVT-111, REMOVAL, Control Valve Body.>

NOTE: When removing the control valve body, also remove the pressure pipe if it is attached on the case.

Subaru Outback. Continuously Variable Transmission

14) Remove the CVTF pipe using a tire lever etc.

NOTE: Remove by hooking the stepped portion of CVTF pipe with a tire lever etc.

Subaru Outback. Continuously Variable Transmission

  1. CVTF pipe
  2. Tire lever

15) Remove the transmission case.

NOTE: The total number of transmission case mounting bolts is 15.

16) Remove the O-ring of lubrication pipe.

Subaru Outback. Continuously Variable Transmission

17) Remove the control device system. <Ref. to CVT-207, REMOVAL, Transmission Control Device.>

B: INSTALLATION

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

2) Install the control device system. <Ref. to CVT-209, INSTALLATION, Transmission Control Device.>

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

NOTE:

Subaru Outback. Continuously Variable Transmission

4) Make sure the lubrication pipe and support rod are in vertical position.

Subaru Outback. Continuously Variable Transmission

5) Apply liquid gasket seamlessly to the mating surface of transmission case.

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

Subaru Outback. Continuously Variable Transmission

6) Install the transmission case.

CAUTION: If the transmission case gets in contact with the lubrication pipe and support rod, do not install the transmission case forcibly.

NOTE:

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

7) Install the O-ring to CVTF pipe.

NOTE:

8) The smaller opening of CVTF pipe should be inserted to transmission.

NOTE: After installing, make sure the CVTF pipe does not stick out of transmission case.

Subaru Outback. Continuously Variable Transmission

9) Install the reduction driven gear. <Ref. to CVT-201, INSTALLATION, Reduction Driven Gear.>

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-147, INSTALLATION, Transfer Clutch.>

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

16) Install the inhibitor switch. <Ref. to CVT-100, INSTALLATION, Inhibitor Switch.>

17) Install the secondary speed sensor. <Ref. to CVT-103, INSTALLATION, Secondary Speed Sensor.>

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

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

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

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

C: DISASSEMBLY

1) Remove the CVTF inlet pipe and CVTF outlet pipe.

Subaru Outback. Continuously Variable Transmission

  1. CVTF outlet pipe
  2. CVTF inlet pipe

2) Remove all plugs from the transmission case.

Subaru Outback. Continuously Variable Transmission

3) Remove the lubrication pipe.

Subaru Outback. Continuously Variable Transmission

4) Remove the oil seal using a screwdriver wrapped with cloth etc.

Subaru Outback. Continuously Variable Transmission

5) Remove the ball bearing from reduction driven gear using ST.

ST 398527700 PULLER ASSY

Subaru Outback. Continuously Variable Transmission

6) Remove the snap ring on primary pulley side.

Subaru Outback. Continuously Variable Transmission

7) Using the ST, remove the roller bearing on primary pulley side.

NOTE: Warm up the bearing area of transmission case using a drier or heat gun.

ST 398527700 PULLER ASSY

Subaru Outback. Continuously Variable Transmission

8) Remove the snap ring on secondary pulley side.

Subaru Outback. Continuously Variable Transmission

9) Using the ST, remove the roller bearing on secondary pulley side.

NOTE: Warm up the bearing area of transmission case using a drier or heat gun.

ST 398527700 PULLER ASSY

Subaru Outback. Continuously Variable Transmission

D: ASSEMBLY

1) Using the ST, install the oil seal.

ST 18657AA000 INSTALLER

Subaru Outback. Continuously Variable Transmission

2) Using ST1 and ST2, install the ball bearing on the reduction gear side.

NOTE: Use a new ball bearing.

ST1 398177700 INSTALLER
ST2 499755602 PRESS SNAP RING

Subaru Outback. Continuously Variable Transmission

3) Using ST1 and ST2, install the roller bearing on primary pulley side.

NOTE:

ST1 398177700 INSTALLER
ST2 20299AG010 PRESS SNAP RING

Subaru Outback. Continuously Variable Transmission

4) Install the snap ring on primary pulley side.

NOTE: Use new snap rings.

Subaru Outback. Continuously Variable Transmission

5) Using ST1 and ST2, install the roller bearing on secondary pulley side.

NOTE:

ST1 398177700 INSTALLER
ST2 499755602 PRESS SNAP RING

Subaru Outback. Continuously Variable Transmission

6) Install the snap ring on secondary pulley side.

NOTE: Use new snap rings.

Subaru Outback. Continuously Variable Transmission

7) Install all plugs.

NOTE: Use new gaskets and O-rings.

Tightening torque:
T1: 13 N*m (1.3 kgf-m, 9.6 ft-lb)
T2: 25 N*m (2.5 kgf-m, 18.4 ft-lb)
T3: 35 N*m (3.5 kgf-m, 25.8 ft-lb)

Subaru Outback. Continuously Variable Transmission

8) Install the lubrication pipe and O-ring.

NOTE:

Tightening torque: 16 N*m (1.6 kgf-m, 11.8 ft-lb)

Subaru Outback. Continuously Variable Transmission

9) Install the CVTF inlet pipe and CVTF outlet pipe.

NOTE: Use a new gasket.

Tightening torque:
T1: 16 N*m (1.6 kgf-m, 11.8 ft-lb)
T2: 40 N*m (4.1 kgf-m, 29.5 ft-lb)

Subaru Outback. Continuously Variable Transmission

  1. CVTF outlet pipe
  2. CVTF inlet pipe

E: INSPECTION

F: ADJUSTMENT

NOTE: When replacing the transmission case with a new part, perform the following check and adjustment for the selection.

READ NEXT:

 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,

 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

 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

SEE MORE:

 Rear Gate

A: REMOVAL CAUTION: Rear gate panels are heavy. When removing and installing them, always work in a team of two or more persons. 1. REAR GATE PANEL 1) Disconnect the ground cable from battery. 2) Remove the following parts. <Ref. to EI-164, REMOVAL, Rear Gate Garnish.> Rear gate trim Rear

 Passenger's Airbag Module

A: REMOVAL CAUTION: Refer to "CAUTION" of "General Description" before handling the airbag module. <Ref. to AB-9, CAUTION, General Description.> 1) Turn the ignition switch to OFF. 2) Disconnect the ground cable from battery and wait for at least 60 seconds before starting work. 3) Remove

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