Subaru Crosstrek manuals

Subaru Crosstrek Service Manual: Installation

CONTINUOUSLY VARIABLE TRANSMISSION(TR580) > Automatic Transmission Assembly

INSTALLATION

1. Attach the ST to converter case.

ST 498277200STOPPER SET

2. When completely overhauling the transmission, refill CVTF through the transmission right side plug. Preparation for Overhaul">

3. Replace the front differential side retainer oil seal. Differential Side Retainer Oil Seal > REPLACEMENT">

NOTE:

Be sure to replace the differential side retainer oil seal with a new part whenever the front drive shaft is removed from the transmission.

When a new differential side retainer oil seal has been installed, replacement is not required.

4. Install the rear cushion rubber on the transmission.

Tightening torque:

40 N·m (4.1 kgf-m, 29.5 ft-lb)

5. Mount the transmission onto the transmission jack.

6. Strike and bend the transmission hanger of transmission rear with a rubber hammer etc. so that it gets in contact with the transmission case.

CAUTION:

Do not apply extra overload or impact to the transmission case.

7. Remove the pitching stopper bracket, if mounted.

8. Install the transmission onto the engine.

NOTE:

While raising the transmission jack gradually, turn the screw of engine support, then tilt the engine forward.

Temporarily attach the two engine connecting bolts and two nuts (lower side).

9. Install the transmission rear crossmember.

Tightening torque:

T1: 35 N·m (3.6 kgf-m, 25.8 ft-lb)

T2: 70 N·m (7.1 kgf-m, 51.6 ft-lb)

10. Tighten the two engine connecting bolts and two nuts (lower side).

Tightening torque:

50 N·m (5.1 kgf-m, 36.9 ft-lb)

11. Tighten the hanger bracket.

Tightening torque:

23 N·m (2.3 kgf-m, 17.0 ft-lb)

12. Remove the transmission jack.

13. Lower the vehicle.

14. Install the three engine mounting bolts (upper side).

Tightening torque:

50 N·m (5.1 kgf-m, 36.9 ft-lb)

15. Remove the ST (STOPPER SET) from converter case.

16. Remove the ST (ENGINE SUPPORT BRACKET and ENGINE SUPPORT).

ST1 41099AA012ENGINE SUPPORT BRACKET
ST2 41099AA020ENGINE SUPPORT

17. Match the torque converter screw hole with drive plate hole to install the bolt.

CAUTION:

Do not drop the mounting bolt in the converter housing.

Do not damage the mounting bolt.

Tightening torque:

25 N·m (2.5 kgf-m, 18.4 ft-lb)

18. Install the remaining three bolts by rotating the crank pulley a little at a time in the same direction as engine revolution.

Tightening torque:

25 N·m (2.5 kgf-m, 18.4 ft-lb)

19. Install the service hole plug.

20. Install the throttle valve body. Throttle Body > INSTALLATION">

21. Install the engine ground terminals.

Tightening torque:

19 N·m (1.9 kgf-m, 14.0 ft-lb)

22. Replace the CVTF inlet hose and CVTF outlet hose. CVTF Cooler (With Warmer Function) > REMOVAL"> CVTF Cooler (With Warmer Function) > INSTALLATION">

23. Install the CVTF inlet hose and CVTF outlet hose to transmission.

24. Install the CVTF cooler (with warmer feature) to the transmission.

Tightening torque:

23 N·m (2.3 kgf-m, 17.0 ft-lb)

25. Install the starter. Starter > INSTALLATION">

26. Install the engine hanger rear.

Tightening torque:

21 N·m (2.1 kgf-m, 15.5 ft-lb)

27. Install the pitching stopper bracket and transmission radio ground cord.

CAUTION:

Be careful not to deform or damage the terminal of transmission radio ground cord.

Tightening torque:

41 N·m (4.2 kgf-m, 30.2 ft-lb)

28. Install the air breather hose to the pitching stopper bracket.

29. Install the pitching stopper.

Tightening torque:

T1: 50 N·m (5.1 kgf-m, 36.9 ft-lb)

T2: 58 N·m (5.9 kgf-m, 42.8 ft-lb)

30. Connect the EGR control valve harness connector, throttle position sensor harness connector and manifold absolute pressure sensor harness connector.

31. Connect the engine harness connectors, then install the harness connector bracket.

Tightening torque:

7.5 N·m (0.8 kgf-m, 5.5 ft-lb)

32. Lift up the vehicle.

33. Set the ST to side retainer.

ST 28399SA010OIL SEAL PROTECTOR

34. Replace the circlip of the drive shaft with a new part.

35. Insert the front drive shaft spline section into transmission and remove the ST (OIL SEAL PROTECTOR).

NOTE:

Before inserting the RH front drive shaft into transmission, turn the steering wheel to the right hand at full lock.

Before inserting the LH front drive shaft into transmission, turn the steering wheel to the left hand at full lock.

36. Insert the drive shaft into the transmission securely by pressing the housing from outside of the vehicle.

37. Insert the ball joint into housing and secure with bolt.

Tightening torque:

50 N·m (5.1 kgf-m, 36.9 ft-lb)

CAUTION:

Do not apply grease to the tapered portion of ball stud.

Before tightening, make sure the lower side of housing and stepped section of ball joint are in contact.

38. Install the stabilizer bracket.

Tightening torque:

25 N·m (2.5 kgf-m, 18.4 ft-lb)

39. Install the jack-up plate.

Tightening torque:

60 N·m (6.1 kgf-m, 44.3 ft-lb)

40. Install the plate assembly to transmission.

Tightening torque:

25 N·m (2.5 kgf-m, 18.4 ft-lb)

(A)

Select cable

(B)

Plate ASSY

41. Install the washer and snap pin to the shifter arm.

CAUTION:

Do not apply extra overload while holding the part (A).

(A)

Shifter arm

(B)

Snap pin

(C)

Select cable

(D)

Washer

42. Install the propeller shaft. Propeller Shaft > INSTALLATION">

43. Install the center exhaust cover.

Tightening torque:

18 N·m (1.8 kgf-m, 13.3 ft-lb)

44. Install the center exhaust pipe. Center Exhaust Pipe > INSTALLATION">

45. Install the under cover.

46. Lower the vehicle.

47. Connect the following harness connectors.

Transmission harness connectors

Inhibitor harness connector

Transmission radio ground terminal

Tightening torque:

13 N·m (1.3 kgf-m, 9.6 ft-lb)

(A)

Transmission harness connectors

(B)

Inhibitor harness connector

(C)

Transmission radio ground terminal

48. Install the air intake boot assembly. Air Intake Boot > INSTALLATION">

49. Install the front tires. Tire and Wheel > INSTALLATION">

50. Connect the battery ground terminal.

51. Refill differential gear oil to adjust the differential gear oil amount. Differential Gear Oil">

52. Refill CVTF to adjust the CVTF level. CVTF">

53. Perform the operation for clearing AT learning value. Clear Memory Mode">

54. Perform the operation of AT learning mode. Learning Control">

55. Execute the rear differential inspection mode. Rear Differential Inspection Mode">

CAUTION:

Always execute the rear differential inspection mode at the replacement of the following.

Replacement of transmission assembly

Replacement of front differential hypoid gear set

56. Perform the road test to make sure there is no fault. Road Test > INSPECTION">

Automatic transmission assembly
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