FORESTER 20MY PubNo: G8270BE Version: 006

CONTINUOUSLY VARIABLE TRANSMISSION(TR580) > General Description　

SPECIFICATION

Transmission	Type			Forward continuously variable speed change, 1-reverse
	Gear ratio (including transfer reduction ratio)		Forward	3.601 — 0.513
			Rev	3.689
	Number of forward clutch plates	pcs.	Drive plate	3
			Driven plate	3
	Number of reverse brake plates	pcs.	Drive plate	4
			Driven plate	4
	CVTF capacity		L (US qt, Imp qt)	11.74 — 12.24 (12.409 — 12.938, 10.332 — 10.772)
Torque converter	Type			Symmetric, 3-element, single stage, 2-phase
	Nominal		mm (in)	236 (9.29)
	Clutch			Sprag type one-way
	Stall torque ratio			2.18
	Stall speed (at sea level)	r/min	D range	1,950 — 2,550
			R range	1,850 — 2,450
Oil pump	Type			Internal gear
	Driving method			Chain drive
	Number of teeth	pcs.	Inner rotor	8
			Outer rotor	9
Transfer	Type			Multi-plate
	Control method			Electronic hydraulic type
	Number of transfer clutch plates	pcs.	Drive plate	5
			Driven plate	5
	Gear ratio			1.000
Front differential	Type of gear			Hypoid gear
	LSD type			—
	Gear ratio			3.700
	Backlash between the differential bevel gear and differential bevel pinion		mm (in)	0.13 — 0.18 (0.005 — 0.007)
	Hypoid gear set backlash		mm (in)
	Differential gear oil capacity		L (US qt, Imp qt)	1.21 — 1.31 (1.279 — 1.385, 1.065 — 1.153)

CVTF:

Refer to “RECOMMENDED MATERIALS” for CVTF. RECOMMENDED MATERIALS>GREASE>CVTF

Always use specified CVTF. Using fluid other than specified CVTF will cause malfunction.

Differential gear oil:

For the differential gear oil, refer to “RECOMMENDED MATERIALS”. RECOMMENDED MATERIALS>GREASE>DIFFERENTIAL GEAR OIL

CONTINUOUSLY VARIABLE TRANSMISSION(TR580) > General Description　

COMPONENT

1. TORQUE CONVERTER & CONVERTER CASE

(1)	Drive plate	(13)	Air breather cap	Tightening torque: N·m (kgf-m, ft-lb)
(2)	Reinforcement drive plate	(14)	Pitching stopper bracket	T1:	22 (2.2, 16.2)
(3)	Torque converter	(15)	O-ring	T2:	22.5 (2.3, 16.6)
(4)	Seal ring	(16)	Stud bolt	T3:	25 (2.5, 18.4)
(5)	O-ring	(17)	O-ring	T4:	41 (4.2, 30.2)
(6)	Plug	(18)	O-ring	T5:	50 (5.1, 36.9)
(7)	Gasket	(19)	Plug	T6:	70 (7.1, 51.6)
(8)	Filler plug	(20)	Gasket	T7:	CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Converter Case>ASSEMBLY
(9)	O-ring	(21)	Overflow plug	T8:	CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Drive Plate>INSTALLATION
(10)	Oil cooler pipe	(22)	Drain plug
(11)	Air breather hose	(23)	Gasket
(12)	Air breather hose bracket	(24)	Converter case

2. OIL PUMP

(1)	Oil seal	(7)	Oil pump chain	Tightening torque: N·m (kgf-m, ft-lb)
(2)	Oil pump chain cover	(8)	Driven sprocket	T1:	8.5 (0.9, 6.3)
(3)	Snap ring	(9)	Oil pump	T2:	21 (2.1, 15.5)
(4)	Ball bearing	(10)	Plate
(5)	Drive sprocket	(11)	O-ring
(6)	Snap ring	(12)	O-ring

3. TRANSMISSION CASE

(1)	CVTF filter cover	(14)	Oil stopper plate	(27)	Ball bearing
(2)	Gasket	(15)	Micro-encapsulated bolt	(28)	Spring pin
(3)	CVTF filter	(16)	Roller bearing	(29)	Seal ring
(4)	Oil seal	(17)	Thrust bearing
(5)	Gasket	(18)	O-ring	Tightening torque: N·m (kgf-m, ft-lb)
(6)	Filler plug (for overhaul)	(19)	Plug	T1:	9 (0.9, 6.6)
(7)	Filler plug	(20)	Test plug (secondary pressure (line pressure))	T2:	13 (1.3, 9.6)
(8)	Air breather cap	(21)	Plug	T3:	17 (1.7, 12.5)
(9)	Air breather hose	(22)	Oil control valve holder	T4:	22 (2.2, 16.2)
(10)	Plug	(23)	O-ring	T5:	50 (5.1, 36.9)
(11)	O-ring	(24)	Plug
(12)	Plug	(25)	Transmission case
(13)	O-ring	(26)	Oil guide

4. CONTROL VALVE BODY

(1)	Air breather hose stay	(7)	O-ring	Tightening torque: N·m (kgf-m, ft-lb)
(2)	Air breather hose bracket	(8)	Oil strainer	T1:	5 (0.5, 3.7)
(3)	Valve cover	(9)	Magnet	T2:	7 (0.7, 5.2)
(4)	Gasket	(10)	Oil pan	T3:	8 (0.8, 5.9)
(5)	Control valve body	(11)	Gasket	T4:	9 (0.9, 6.6)
(6)	O-ring	(12)	Drain plug	T5:	31 (3.2, 22.9)
				T6:	CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Control Valve Body>INSTALLATION

5. REVERSE BRAKE

(1)	O-ring	(8)	Snap ring	(15)	O-ring
(2)	Snap ring	(9)	Spring retainer	(16)	Lubrication pipe
(3)	Retaining plate	(10)	Return spring	(17)	Oil guide
(4)	Reverse brake	(11)	Reverse brake piston
(5)	Drive plate	(12)	O-ring	Tightening torque: N·m (kgf-m, ft-lb)
(6)	Driven plate	(13)	Reverse brake housing	T1:	16 (1.6, 11.8)
(7)	Dish plate	(14)	O-ring	T2:	37 (3.8, 27.3)

6. FORWARD CLUTCH

(1)	O-ring	(10)	Snap ring	(19)	Balance oil guide
(2)	Seal ring	(11)	Dish plate	(20)	Thrust bearing
(3)	Thrust bearing	(12)	Forward clutch	(21)	Planetary carrier
(4)	Seal ring	(13)	Driven plate	(22)	Thrust bearing
(5)	Forward clutch drum	(14)	Drive plate	(23)	Internal gear
(6)	Seal ring	(15)	Retaining plate	(24)	Thrust gear plate
(7)	Forward clutch piston	(16)	Snap ring	(25)	Snap ring
(8)	Return spring	(17)	Sun gear	(26)	Thrust bearing
(9)	Chamber	(18)	Snap ring	(27)	Washer

7. TRANSMISSION CONTROL DEVICE

(1)	Parking rod	(9)	Inhibitor switch	Tightening torque: N·m (kgf-m, ft-lb)
(2)	Manual plate	(10)	Shifter arm shaft	T1:	5 (0.5, 3.7)
(3)	Spring pin	(11)	Cable plate	T2:	7 (0.7, 5.2)
(4)	Detent spring	(12)	Return spring	T3:	9 (0.9, 6.6)
(5)	Separator plate	(13)	Parking pawl	T4:	25 (2.5, 18.4)
(6)	Manual valve	(14)	Shaft
(7)	Spring pin	(15)	Parking support
(8)	Shifter arm

8. PRIMARY PULLEY & SECONDARY PULLEY, VARIATOR CHAIN AND REDUCTION DRIVE GEAR

(1)	Support rod	(8)	Chain guide	Tightening torque: N·m (kgf-m, ft-lb)
(2)	Primary pulley shim	(9)	Variator chain	T1:	16 (1.6, 11.8)
(3)	Primary pulley	(10)	Seal ring	T2:	21 (2.1, 15.5)
(4)	Seal ring	(11)	Secondary pulley	T3:	67.5 (6.9, 49.8)
(5)	Lubrication pipe	(12)	Reduction drive gear
(6)	O-ring	(13)	Reduction drive gear shim
(7)	Oil pressure pipe	(14)	Oil baffle

^∗: The primary pulley and secondary pulley are set parts.

9. FRONT DIFFERENTIAL GEAR

(1)	Hypoid gear set	(16)	Oil seal	(31)	O-ring
(2)	Differential case	(17)	Oil baffle	(32)	Lock plate
(3)	Drive pinion	(18)	Plug
(4)	Pinion shaft	(19)	O-ring	Tightening torque: N·m (kgf-m, ft-lb)
(5)	Spring pin	(20)	Drive pinion retainer	T1:	22 (2.2, 16.2)
(6)	Side bearing	(21)	O-ring	T2:	25 (2.5, 18.4)
(7)	Side bearing outer race	(22)	Drive pinion spacer	T3:	43 (4.4, 31.7)
(8)	Side bearing inner race	(23)	Drive pinion washer	T4:	CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Drive Pinion>ASSEMBLY
(9)	Thrust washer	(24)	Taper roller bearing (rear)
(10)	Differential bevel gear	(25)	Taper roller bearing (rear) outer race
(11)	Differential bevel pinion	(26)	Taper roller bearing (rear) inner race
(12)	Drive pinion shim	(27)	Lock nut
(13)	Taper roller bearing (front)	(28)	Plug
(14)	Taper roller bearing (front) inner race	(29)	Differential side retainer oil seal
(15)	Taper roller bearing (front) outer race	(30)	Differential side retainer

^∗: If the side bearing inner race is removed from the differential case, replace the side bearing with a new part.

10. TRANSFER AND EXTENSION CASE

(1)	O-ring	(15)	Transfer clutch plate set	(29)	Extension case
(2)	Snap ring	(16)	Pressure plate	(30)	Transmission hanger
(3)	Reduction driven gear	(17)	Driven plate	(31)	Extension case oil seal
(4)	Parking gear	(18)	Drive plate	(32)	Dust cover
(5)	Transfer drive gear	(19)	Pressure plate	(33)	O-ring
(6)	Ball bearing	(20)	Snap ring	(34)	Test plug (transfer clutch pressure)
(7)	Lock nut	(21)	Transfer clutch piston seal
(8)	Transfer drive gear shim	(22)	Return spring	Tightening torque: N·m (kgf-m, ft-lb)
(9)	Oil spacer	(23)	Transfer clutch piston	T1:	17 (1.7, 12.5)
(10)	Ball bearing	(24)	Rear drive shaft	T2:	22 (2.2, 16.2)
(11)	Transfer driven gear	(25)	Ball bearing	T3:	25 (2.5, 18.4)
(12)	Seal ring	(26)	Seal ring	T4:	35 (3.6, 25.8)
(13)	Thrust bearing	(27)	Transfer driven gear shim	T5:	95 (9.7, 70.1)
(14)	Snap ring	(28)	Gasket

11. ELECTRIC OIL PUMP

(1)	Electric oil pump	(4)	O-ring	Tightening torque: N·m (kgf-m, ft-lb)
(2)	O-ring	(5)	Electric oil pump adapter	T1:	16 (1.6, 11.8)
(3)	Plug	(6)	O-ring	T2:	22 (2.2, 16.2)

12. TRANSMISSION HARNESS AND SENSOR

(1)	Transmission case cover (rear)	(7)	O-ring	Tightening torque: N·m (kgf-m, ft-lb)
(2)	Transmission case cover (front)	(8)	Secondary pressure sensor	T1:	7 (0.7, 3.7)
(3)	Transmission harness	(9)	O-ring	T2:	8 (0.8, 5.9)
(4)	O-ring	(10)	Secondary speed sensor	T3:	13 (1.3, 9.6)
(5)	O-ring	(11)	O-ring	T4:	14 (1.4, 10.3)
(6)	Primary speed sensor	(12)	Turbine speed sensor	T5:	39 (4.0, 28.8)

13. CVTF COOLER (WITH WARMER FEATURE)

(1)	Water hose (outlet)	(5)	CVTF cooler outlet hose	Tightening torque: N·m (kgf-m, ft-lb)
(2)	Hose clamp	(6)	Water hose (inlet)	T:	23 (2.3, 17.0)
(3)	CVTF cooler inlet hose	(7)	CVTF cooler (with warmer feature)
(4)	Hose clamp	(8)	CVTF cooler bracket

14. TRANSMISSION CONTROL MODULE

(1)	Transmission control module (TCM)			Tightening torque: N·m (kgf-m, ft-lb)
				T:	7 (0.7, 5.3)

15. TRANSMISSION MOUNTING

(1)	Pitching stopper	(3)	Transmission rear crossmember	Tightening torque: N·m (kgf-m, ft-lb)
(2)	Rear cushion rubber	(4)	Stopper	T1:	35 (3.6, 25.8)
				T2:	40 (4.1, 29.5)
				T3:	50 (5.1, 36.9)
				T4:	58 (5.9, 42.8)
				T5:	70 (7.1, 51.6)

CONTINUOUSLY VARIABLE TRANSMISSION(TR580) > General Description　

CAUTION

When performing service operation, refer to “Repair Contents” in “General Description”. REPAIR CONTENTS>Repair Contents
Prior to starting work, pay special attention to the following:
1. Always wear work clothes, a work cap, and protective shoes. Additionally, wear a helmet, protective goggles, etc. if necessary.
2. Protect the vehicle using a seat cover, fender cover, etc.
3. Prepare the service tools, clean cloth, containers to catch grease and oil, etc.
Prevent scattering of grease and oil. If it scatters, wipe it off immediately to prevent it from penetrating the floor or flowing out, to protect the environmental.
If the grease and oil is spilt over the engine, exhaust pipe or the under cover, completely wipe it off to avoid emission of smoke or causing a fire.
Vehicle components are extremely hot immediately after driving. Be wary of receiving burns from heated parts.
When performing a repair, identify the cause of trouble and avoid unnecessary work.
Before disconnecting connectors of sensors or units, be sure to disconnect the ground terminal from the battery sensor.
Always use the jack-up point when the lifting device, shop jacks or rigid racks are used to support the vehicle.
Before starting works, remove dirt and corrosion around the target area.
Keep the removed parts in order and protect them from dust and dirt.
All removed parts, if to be reused, should be reinstalled in the original positions with attention to the correct directions, etc.
For the parts except for the non-reusable parts, replace then with new parts if necessary.
Be sure to tighten bolts and nuts to the specified torque.
Always use new application oil during work.
Always remove or install the transmission body in an area where lifting devices, transmission jacks, etc. are available for ready use.

CONTINUOUSLY VARIABLE TRANSMISSION(TR580) > General Description　

PREPARATION TOOL

1. SPECIAL TOOL

ILLUSTRATION	TOOL NUMBER	DESCRIPTION	REMARKS
	398177700	INSTALLER	Used for installing the ball bearing of the transfer clutch. Used together with INSTALLER (499277200). Used for installing the ball bearing of the transmission case. Used together with BUSHING 1-2 INSTALLER (499277100) and PRESS SNAP RING (28499TC010). Used for installing the taper roller bearing (front) outer race of drive pinion. Used together with PRESS SNAP RING (28499TC010). Used for installing the drive pinion plug. Used together with PRESS SNAP RING (499755602).
	398497701	SEAT	Used for removing the side bearing inner race of the front differential. Used together with REMOVER (498077000) and REMOVER (899864100). Used for installing the side bearing inner race of the front differential. Used together with BUSHING 1-2 INSTALLER (499277100).
	398527700	PULLER ASSY	Used for removing the ball bearing of transmission case. Used together with CLAW (18760AA000). Used for removing the taper roller bearing (front) outer race of drive pinion, and taper roller bearing (rear) outer race.
	398673600	COMPRESSOR	Used for removing and installing snap ring of forward clutch. Used together with COMPRESSOR SPECIAL TOOL (18762AA010).
	399513600	INSTALLER	Used for removing the ball bearing of drive sprocket. Used together with REMOVER (498077600).
	498057300	OIL SEAL INSTALLER	Used for installing the extension case oil seal.
	498077000	REMOVER	Used for removing the side bearing inner race of the front differential. Used together with REMOVER (899864100) and SEAT (398497701).
	498077300	REMOVER	Used for removing ball bearing of reduction driven gear. Used together with INSTALLER (499757002).
	498077400	REMOVER	Used for removing the ball bearing of transfer driven gear. Used together with REMOVER (899864100).
	498077600	REMOVER	Used for removing the ball bearing of drive sprocket. Used together with INSTALLER (399513600).
	498255400	PLATE	Used for adjusting hypoid gear set backlash.
	498277200	STOPPER SET	Used for removing and installing transmission body.
	498497300	CRANKSHAFT STOPPER	Used for removing and installing the drive plate.
	498515500	REMOVER	Used for removing the taper roller bearing (front) inner race of the drive pinion and drive pinion shim.
	498575400	OIL PRESSURE GAUGE ASSY	Used for measuring the transfer clutch pressure. Used together with ADAPTER HOSE B (34099AC020). Use the genuine O-ring (part No. 806908150) for installation.
	498897700	OIL PRESSURE ADAPTER SET	Used for measuring the secondary pressure (line pressure). Used together with OIL PRESSURE GAUGE ADAPTER (18681AA060) and OIL PRESSURE GAUGE ASSY (18801AA000).
	498937110	HOLDER	Used for removing and installing the drive pinion lock nut. Used together with ADAPTER (499787500) and WRENCH (499787700). Used for adjusting drive pinion preload. Used together with WRENCH (499787700). Used for adjusting hypoid gear set backlash. Used together with WRENCH (499787700).
	499267300	STOPPER PIN	Used for adjusting the inhibitor switch.
	499277100	BUSHING 1-2 INSTALLER	Used for installing the ball bearing of reduction driven gear. Used for installing the ball bearing of the transmission case. Used together with INSTALLER (398177700) and PRESS SNAP RING (28499TC010). Used for installing the side bearing inner race of the front differential. Used together with SEAT (398497701).
	499277200	INSTALLER	Used for installing the ball bearing of the transfer clutch. Used together with INSTALLER (398177700).
	499575400	GAUGE	Used for measuring the end play.
	499575500	GAUGE	Used for measuring the end play.
	499575600	GAUGE	Used for measuring the end play.
	499755502	PRESS SNAP RING	Used for installing the drive sprocket ball bearing.
	499755602	PRESS SNAP RING	Used for installing the drive pinion retainer plug. Used together with INSTALLER (398177700).
	499757002	INSTALLER	Used for removing ball bearing of reduction driven gear. Used together with REMOVER (498077300). Used for installing the parking gear. Used for installing the transfer drive gear.
	499787500	ADAPTER	Used for removing and installing the drive pinion lock nut. Used together with WRENCH (499787700) and HOLDER (498937110). Used for adjusting drive pinion preload. Used together with WRENCH (499787700) and HOLDER (498937110).
	499787700	WRENCH	Used for removing and installing the drive pinion lock nut. Used together with ADAPTER (499787500) and HOLDER (498937110). Used for adjusting drive pinion preload. Used together with HOLDER (498937110). Used for adjusting hypoid gear set backlash. Used together with HOLDER (498937110).
	499987003	SOCKET WRENCH (35)	Used for removing and installing the lock nut of reduction driven gear. Used together with PULLEY WRENCH (18355AA000) and PULLEY WRENCH PIN SET (18334AA000).
	899580100	INSTALLER	Used for installing the ball bearing of the transfer driven gear. Used for installing the taper roller bearing (front) inner race of drive pinion. Used together with EXTENSION DRIVE SHAFT (927130000).
	899864100	REMOVER	Used for removing and installing the ball bearing of the transfer driven gear. Used together with REMOVER (498077400). Used for removing the parking gear and transfer drive gear. Used for removing the side bearing inner race of the front differential. Used together with REMOVER (498077000) and SEAT (398497701).
	899904100	STRAIGHT PIN REMOVER	Used for removing the spring pin of the differential case.
	927130000	EXTENSION DRIVE SHAFT	Used for installing the taper roller bearing (front) inner race of drive pinion. Used together with INSTALLER (899580100).
	927720000	HOUSING BUSHING INSTALLER AND REMOVER	Used for installing the drive pinion retainer oil seal. Used together with REMOVER (498077600). Use BUSHING SHAFT (927880000). Used for installing the oil seal of the oil pump chain cover. Use BUSHING SHAFT (927880000) and BASE TUBE LATERAL LINK (927890000).
	18270AA040	SOCKET	Used for removing the test plug (transfer clutch pressure). Used for installing the test plug (transfer clutch pressure). Used together with SPECIAL TOOL CONDENSER (73099SG000).
	18270KA020	SOCKET (E20)	Used for removing and installing the drive pinion retainer.
	18334AA000	PULLEY WRENCH PIN SET	Used for removing and installing the lock nut of reduction driven gear. Used together with PULLEY WRENCH (18355AA000) and SOCKET WRENCH (35) (499987003).
	18355AA000	PULLEY WRENCH	Used for removing and installing the lock nut of reduction driven gear. Used together with PULLEY WRENCH PIN SET (18334AA000) and SOCKET WRENCH (35) (499987003).
	18460AA040	CHECK BOARD	Used for measuring voltage and resistance of TCM terminals.
	18632AA000	STAND ASSY	Used for disassembling and assembling the transmission body.
	18657AA000	INSTALLER	Used for installing the transmission case oil seal.
	18658AA021	WRENCH COMPL RETAINER	Used for removing and installing the differential side retainer.
	18675AA000	DIFFERENTIAL SIDE OIL SEAL INSTALLER	Used for installing the differential side retainer oil seal.
	18681AA050	ADAPTER PRESSURE GAUGE	Used for measuring the transfer clutch pressure. Used together with OIL PRESSURE GAUGE ASSY (498575400). Use the genuine union screw (part No. 801914010) and gasket (part No. 803914060) for installation.
	18681AA060	OIL PRESSURE GAUGE ADAPTER	Used for measuring the secondary pressure (line pressure). Used together with OIL PRESSURE ADAPTER SET (498897700) and OIL PRESSURE GAUGE ASSY (18801AA000). Used together with the genuine O-ring (part No. 806908150) for installation.
	18723AA000	REMOVER	Used for removing the ball bearing of transfer clutch. Used together with BEARING REMOVER (18767AA010).
	18760AA000	CLAW	Used for removing the ball bearing of transmission case. Used together with PULLER ASSY (398527700).
	18761AA010	SHEET SPECIAL TOOL	Used for removing and installing valve cover.
	18762AA001	COMPRESSOR SPECIAL TOOL	Used for disassembling and assembling transfer clutch and reverse brake. COMPRESSOR SPECIAL TOOL (18762AA000) can also be used.
	18762AA010	COMPRESSOR SPECIAL TOOL	Used for removing and installing snap ring of forward clutch. Used together with COMPRESSOR (398673600).
	18763AA000	COMPRESSOR SHAFT	Used for adjusting hypoid gear set backlash.
	18767AA010	BEARING REMOVER	Used for removing the ball bearing of transfer clutch. Used together with REMOVER (18723AA000).
	18769AA010	EXPANDER PULLEY	Used for removing and installing the secondary pulley.
	18801AA000	OIL PRESSURE GAUGE ASSY	Used for measuring the secondary pressure (line pressure). Used together with OIL PRESSURE GAUGE ADAPTER (18681AA060) and OIL PRESSURE ADAPTER SET (498897700). Use the genuine O-ring (part No. 806908150) for installation.
	20099AE020	INSTALLER	Used for installing the taper roller bearing (rear) outer race of drive pinion.
	28499TC010	PRESS SNAP RING	Used for installing the ball bearing of the transmission case. Used together with BUSHING 1-2 INSTALLER (499277100) and INSTALLER (398177700). Used for installing the taper roller bearing (front) outer race of drive pinion. Used together with INSTALLER (398177700).
	38415AA070	Axle shaft	Used for measuring the backlash of the hypoid gear set. This is the SUBARU genuine part.
	41099AA012	ENGINE SUPPORT BRACKET	Used for removing and installing transmission body. Used together with ENGINE SUPPORT (41099AA020).
	41099AA020	ENGINE SUPPORT	Used for removing and installing transmission body. Used together with ENGINE SUPPORT BRACKET (41099AA012).
	73099SG000	SPECIAL TOOL CONDENSER	Used for installing the test plug (transfer clutch pressure). Used together with SOCKET (18270AA040).
	—	SUBARU SELECT MONITOR 4	Used for setting of each function and troubleshooting for electrical system. For detailed operation procedures, refer to “Help” of application.

2. GENERAL TOOL

TOOL NAME	REMARKS
Oil pan seal cutter	Used for removing oil pan.
Circuit tester	Used for measuring resistance, voltage and current.
Thickness gauge	Used for various inspections.
Caliper	Used for measuring the dimension.
Spring scale	Used for measuring the initial load of the drive pinion.
TORX^® bit T70	Used for removing and installing the drain plug.
Push/pull gauge	Used for measuring clutch clearance.
Angle gauge	Used for installing the drive plate.
Dial gauge	Used for measuring backlash. (Lever type) Used together with magnet stand. Used for assembling the reverse brake and forward clutch. (Spindle type) Used together with magnet stand.
Magnet stand	Used for measuring backlash. Used together with the dial gauge (lever type). Used for assembling the reverse brake and forward clutch. Used together with the dial gauge (spindle type).
DST-i	Used together with Subaru Select Monitor 4.

CONTINUOUSLY VARIABLE TRANSMISSION(TR580) > CVTF　

INSPECTION

When inspecting CVTF level, observe the specified CVTF temperature.
Do not add CVTF at a cold condition since the oil may blow out.

When there is no severe conditions or intrusion of water, etc., replacement of CVTF is unnecessary.

1.

Prepare the CVTF for refiling.

2.

Connect the Subaru Select Monitor.

3.

Turn the ignition switch to ON. (Engine OFF)

4.

Display [ATF Temp.].

5.

Start the engine and raise [ATF Temp.] to 35 — 45°C (95 — 113°F).

Make sure to perform the CVTF level inspection within [ATF Temp.] of 35 — 45°C (95 — 113°F).

6.

Operate the select lever in P→R→N→D and D→N→R→P to circulate CVTF with the engine idling.

7.

With the engine idling, lift up the vehicle and remove the filler plug.

CVTF is at the specified level when it is up to the filler plug hole lower section.
Prepare the container for draining of engine oil.

8.

If the CVTF level is below the bottom of the filler plug hole, check for oil leakage, and add specified CVTF.

Always use specified CVTF. Using fluid other than specified CVTF will cause malfunction.

CVTF:

RECOMMENDED MATERIALS>GREASE>CVTF

9.

Using a new gasket, install the filler plug.

Tightening torque:

50 N·m (5.1kgf-m, 36.9ft-lb)

CONTINUOUSLY VARIABLE TRANSMISSION(TR580) > CVTF　

REPLACEMENT

Vehicle components are extremely hot immediately after driving. Be wary of receiving burns from heated parts.

When there is no severe conditions or intrusion of water, etc., replacement of CVTF is unnecessary.

1.

Remove the filler plug.

2.

Remove the drain plug to drain CVTF.

3.

Check the CVTF condition.

Determine the condition inside the transmission by inspecting the drained CVTF.

CVTF condition	Trouble and possible cause	Corrective action
Metal particles.	Excessive wear of the internal of the transmission body.	Replace CVTF and check if the transmission body operates correctly.
Thick and varnish-form fluid.	Burnt clutches.	Replace CVTF and check if the transmission body operates correctly.
Clouded CVTF or bubbles.	Water is mixed in the fluid.	Replace CVTF and check if the transmission body operates correctly. Check the water entering point.

4.

Install the drain plug using a new gasket.

Tightening torque:

31 N·m (3.2kgf-m, 22.9ft-lb)

5.

Pour the specified CVTF to the bottom end of filler plug hole.

Always use specified CVTF. Using fluid other than specified CVTF will cause malfunction.

CVTF:

RECOMMENDED MATERIALS>GREASE>CVTF

6.

Temporarily install the filler plug.

7.

Check the CVTF level. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>CVTF>INSPECTION

CONTINUOUSLY VARIABLE TRANSMISSION(TR580) > Differential Gear Oil　

INSPECTION

Vehicle components are extremely hot immediately after driving. Be wary of receiving burns from heated parts.

1.

Remove the filler plug.

2.

Remove the overflow plug.

Though immediately after removing the overflow plug, differential gear oil (approx. 8 cc) remaining in the overflow pipe may come out, this does not indicate that the specified amount is reached.

When checking the amount of the differential gear oil, be sure to fill with the differential gear oil and check that the differential gear oil flows out of the overflow plug hole.

3.

Fill the differential gear oil through the filler plug hole, and let the oil flow out of the overflow plug.

Differential gear oil:

4.

When the flow of the differential gear oil turns into a narrow stream, install the overflow plug using a new gasket.

Tightening torque:

50 N·m (5.1kgf-m, 36.9ft-lb)

5.

Using a new gasket, install the filler plug.

Tightening torque:

50 N·m (5.1kgf-m, 36.9ft-lb)

CONTINUOUSLY VARIABLE TRANSMISSION(TR580) > Differential Gear Oil　

REPLACEMENT

Vehicle components are extremely hot immediately after driving. Be wary of receiving burns from heated parts.

1.

Remove the filler plug.

2.

Drain the differential gear oil by removing drain plug using TORX^® bit T70.

3.

Remove the iron powder, etc. from the drain plug.

4.

Attach the drain plug using a new gasket, using TORX^® bit T70.

Tightening torque:

70 N·m (7.1kgf-m, 51.6ft-lb)

5.

Fill the differential gear oil from the filler plug hole.

Differential gear oil:

Differential gear oil capacity:

CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>General Description>SPECIFICATION

6.

Check the differential gear oil level. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Differential Gear Oil>INSPECTION

CONTINUOUSLY VARIABLE TRANSMISSION(TR580) > AWD ON/OFF Switching Mode　

PROCEDURE

Do not turn the power of the Subaru Select Monitor OFF during work, and do not disconnect the data link connector.
On completing the work in FWD, switch back in AWD.

1.

Shift the select lever to “P range”.

2.

Connect the Subaru Select Monitor.

3.

Turn the ignition switch to ON. (Engine OFF)

4.

Select [Diagnosis] on [Start] display of Subaru Select Monitor.

5.

On [Vehicle selection] screen, enter vehicle information and select [OK].

6.

On [Main Menu] screen, select [Each System].

7.

On [Select System] screen, select [Transmission].

8.

On [Select Function] screen, select [Work Support].

9.

On [Work Support] screen, select [AWD ON/OFF switching mode].

10.

Follow the messages displayed on the Subaru Select Monitor screen when working.

Switching completes successfully if any of the following messages is displayed.

When switching from AWD to FWD: [Switched to FF. To return to AWD, perform basic mode again.]
When switching from FWD to AWD: [Switched to AWD. To return to FF, perform basic mode again.]

When switched to FWD, AWD light illuminates.
If communication error occurs during switching mode, start in the [AWD ON/OFF switching mode] again.
If operation is interrupted before the successful end message is displayed, perform the [AWD ON/OFF switching mode] from the beginning until confirming the operation is successfully ended.

If this mode fails to complete successfully, the cause is as follows.
- Select lever is not in “P range”.
- Engine is running.

CONTINUOUSLY VARIABLE TRANSMISSION(TR580) > Road Test　

INSPECTION

Always observe the local traffic laws when performing the test.

Turn OFF the X mode switch and perform inspection. (Model with X mode switch)

1. D RANGE SHIFT FUNCTION

1.

Connect the Subaru Select Monitor.

Make sure to route the Subaru Select Monitor wires so that they do not disturb the driving.

2.

Turn the ignition switch to ON. (Engine OFF)

3.

Display [Vehicle Speed] and [Actual Gear Ratio].

4.

Make sure that the engine speed is 950 — 1,400 r/min while driving on the level road at 50 km/h (31 MPH) after accelerating from halting up to 1/4 of accelerator opening angle.

5.

Gradually decelerate from the same condition as in step 1, and check that [Actual Gear Ratio] changes smoothly according to [Vehicle Speed] until the vehicle finally stops.

Make sure to get an assistant on the vehicle and have the person read the data.

2. KICK-DOWN FUNCTION

Check if the engine speed will rise rapidly by operating the accelerator opening angle to the full from a constant speed of 50 km/h (31 MPH) or more.

3. ENGINE BRAKE OPERATION

•

MODEL WITH MANUAL MODE

Drive in “7th speed of manual mode” [100 — 110 km/h (62 — 68 MPH)], and shift down from 7th to 6th.

Check if the indicator of combination meter switches “7” → “6”, and the engine braking applies.
Drive in “6th speed of manual mode” [70 — 80 km/h (43 — 50 MPH)], and shift down from 6th to 5th.

Check if the indicator of combination meter switches “6” → “5”, and the engine braking applies.
Drive in “5th speed of manual mode” [60 — 70 km/h (37 — 43 MPH)], and shift down from 5th to 4th.

Check if the indicator of combination meter switches “5” → “4”, and the engine braking applies.
Drive in “4th speed of manual mode” [50 — 60 km/h (31 — 37 MPH)], and shift down from 4th to 3rd.

Check if the indicator of combination meter switches “4” → “3”, and the engine braking applies.
Drive in “3rd speed of manual mode” [40 — 50 km/h (25 — 31 MPH)], and shift down from 3rd to 2nd.

Check if the indicator of combination meter switches “3” → “2”, and the engine braking applies.
Drive in “2nd speed of manual mode” [20 — 30 km/h (12 — 19 MPH)], and shift down from 2nd to 1st.

Check if the indicator of combination meter switches “2” → “1”, and the engine braking applies.

•

MODEL WITHOUT MANUAL MODE

Drive in “D range” at [50 — 60 km/h (31 — 37 MPH)], and shift to “L range”.

Check if the indicator of combination meter switches “D” → “L”, and the engine braking applies.

4. LOCK-UP FUNCTION

When the accelerator pedal is lightly depressed from the condition where the vehicle is driven on a flat road in “D range” at a constant speed of 50 km/h (31 MPH) or more, check that rpm does not change abruptly.

5. P RANGE OPERATION

1.

Stop the vehicle on an uphill grade of 5% or more and shift to the “P range” and apply the parking brake.

2.

Check that the vehicle does not move when the parking brake is released.

Release the parking brake while being prepared to depress the brake pedal anytime.

6. NOISE AND VIBRATION

Check that noise and vibration do not occur during driving at a constant speed, accelerating, decelerating and manual shift operation.

7. Auto Start Stop

1.

Connect the Subaru Select Monitor.

2.

Turn the ignition switch to ON. (Engine OFF)

3.

Display [ATF Temp.] and [Emphasized idle stop request].

4.

Warm up the engine until [ATF Temp.] reaches 60°C (140°F) or more.

Perform the Auto Start Stop inspection while [ATF Temp.] is within the range of 60 — 90°C (140 — 194°F).

5.

Check that [Emphasized idle stop request] is [Permit].

When [Emphasized idle stop request] is [Prohibit], switch to “Permit” according to the following procedure.

(1)

Check that no DTCs are recorded in TCM, ECM and VDCCM.

(2)

Check that ATF OIL TEMP or AWD light is not blinking or illuminating.

(3)

Check the following items and conditions using Subaru Select Monitor.

Electric oil pump relay: ON
Electric oil pump status: Normal
Electric oil pump DUTY: 5 — 15%

(4)

Drive in D range at 20 — 30 km/h (12 — 19 MPH), and slowly decelerate the vehicle.

(5)

Check that [Emphasized idle stop request] is [Permit].

When [Emphasized idle stop request] is [Prohibit], retry the procedure from step (1).

6.

Turn off all systems causing an electrical load, such as headlights, A/C, seat heater and rear defogger.

7.

Shift the select lever to “D range”.

8.

Check if there is an excessive shock when the engine is restarted from the Auto Start Stop condition.

(1)

Set the vehicle to Auto Start Stop condition, and keep the condition for 5 seconds or more.

(2)

Release the brake pedal, and let the vehicle move forward for 2 seconds or more with the creep phenomenon.

Check that no excessive shock occurs at this time.

(3)

Stop the vehicle.

(4)

Repeat the steps (1) — (3) four times.

(5)

When a shock was felt, repeat the steps (1) — (4) 5 times, and then check that no shock occurs during engine restarting.

CONTINUOUSLY VARIABLE TRANSMISSION(TR580) > Stall Test　

INSPECTION

During the stall test, confirm safety in the vicinity and make sure no person is around the vehicle.

Purposes of the stall test:

Operational check of forward clutch and reverse brake
Operational check of the torque converter
Engine performance check

1.

Check the engine oil level. LUBRICATION(H4DO)>Engine Oil>INSPECTION

2.

Check the engine coolant level. COOLING(H4DO)>Engine Coolant>INSPECTION

3.

Connect the Subaru Select Monitor.

4.

Turn the ignition switch to ON. (Engine OFF)

5.

Display [ATF Temp.] and [Engine Speed].

6.

Turn off all systems causing an electrical load, such as headlights, A/C, seat heater and rear defogger.

7.

Apply the parking brake.

8.

Start the engine.

9.

Turn OFF the pre-collision brake function. (Models with EyeSight)

10.

Check the CVTF level. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>CVTF>INSPECTION

11.

Warm up until [ATF Temp.] reaches to 60 — 80°C (140 — 176°F).

12.

Place wheel chocks at the front and rear of all wheels.

13.

Shift the select lever to “D range”.

14.

Depress the accelerator pedal to the full while fully depressing the foot brake pedal with your left foot.

Do not perform the stall test for five seconds or more at a time.

Failure to follow this instruction may accelerate the engine oil and CVTF deterioration and affect the engine and transmission adversely.
If the stall speed is higher than the specified range, attempt to finish the stall test in as short a time as possible, in order to prevent the transmission from sustaining damage.

15.

When the engine speed stabilizes, quickly record [Engine Speed] and release accelerator pedal.

Standard:

1,950 — 2,550 r/min

Stall test judgment

Stall speed (at sea level)	Range	Probable cause
Lower than standard value	D	Insufficient engine output Torque converter malfunction
Higher than standard value		Forward clutch slippage Secondary pressure (line pressure) is low. Variator chain malfunction Torque converter malfunction Control valve body malfunction TCM malfunction Damaged harness and harness connector

16.

Shift the select lever to “N range”, and idle the engine for one minute or more.

17.

Shift the select lever to “R range” and perform the stall test in the same manner.

Standard:

1,850 — 2,450 r/min

Stall test judgment

Stall speed (at sea level)	Range	Probable cause
Lower than standard value	R	Insufficient engine output Torque converter malfunction
Higher than standard value		Reverse brake slippage Secondary pressure (line pressure) is low. Variator chain malfunction Torque converter malfunction Control valve body malfunction TCM malfunction Damaged harness and harness connector

CONTINUOUSLY VARIABLE TRANSMISSION(TR580) > Time Lag Test　

INSPECTION

When the select lever is shifted while idling, there will be a certain time elapse or lag before shock is felt.

1.

Connect the Subaru Select Monitor.

2.

Turn the ignition switch to ON. (Engine OFF)

3.

Display [ATF Temp.].

4.

Warm up until [ATF Temp.] reaches to 60 — 80°C (140 — 176°F).

5.

Apply the parking brake.

6.

Turn off all systems causing an electrical load, such as headlights, A/C, seat heater and rear defogger.

7.

Shift the select lever from “N range” to “D range”, and measure the time elapsed from shifting the lever until the shock is felt.

Make three measurements and take the average value.
Be sure to allow one minute or more interval between tests.

Specification:

1.5 seconds or less

If time lag is longer than specified:

Secondary pressure (line pressure) is too low.
Forward clutch worn
Forward clutch piston malfunction
Control valve body malfunction
Learning is incomplete

8.

Shift the select lever from “N range” to “R range”, and measure the time elapsed from shifting the lever until the shock is felt.

Specification:

1.5 seconds or less

If time lag is longer than specified:

Secondary pressure (line pressure) is too low.
Reverse brake worn
Reverse brake piston malfunction
Control valve body malfunction
Learning is incomplete

CONTINUOUSLY VARIABLE TRANSMISSION(TR580) > Secondary Pressure (Line Pressure) Test　

LOCATION

(A)	Test plug (secondary pressure (line pressure))

CONTINUOUSLY VARIABLE TRANSMISSION(TR580) > Secondary Pressure (Line Pressure) Test　

INSPECTION

During the secondary pressure (line pressure) test, confirm safety in the vicinity and make sure no person is around the vehicle.

Vehicle components are extremely hot immediately after driving. Be wary of receiving burns from heated parts.

1.

Check the engine oil level. LUBRICATION(H4DO)>Engine Oil>INSPECTION

2.

Check the engine coolant level. COOLING(H4DO)>Engine Coolant>INSPECTION

3.

Remove the test plug (secondary pressure (line pressure)), and install ST1, ST2 and ST3.

Due to flowing out of CVTF, quickly install the ST1, ST2 and ST3.
Be careful when setting the tool so that the ST3 does not touch the exhaust pipe.

Use the ST1 and ST3 with genuine O-ring (part No. 806908150) attached.
Prepare the container for draining of engine oil.

Preparation tool:

ST1: OIL PRESSURE GAUGE ADAPTER (18681AA060)

ST2: OIL PRESSURE ADAPTER SET (498897700)

ST3: OIL PRESSURE GAUGE ASSY (18801AA000)

4.

Set the gauge so that it can be seen from the driver’s seat.

5.

Connect the Subaru Select Monitor.

6.

Turn the ignition switch to ON. (Engine OFF)

7.

Display [ATF Temp.].

8.

Turn off all systems causing an electrical load, such as headlights, A/C, seat heater and rear defogger.

9.

Apply the parking brake.

10.

Start the engine.

11.

Turn OFF the pre-collision brake function. (Models with EyeSight)

12.

Check the CVTF level. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>CVTF>INSPECTION

13.

Warm up until [ATF Temperature] reaches to 60 — 80°C (140 — 176°F).

14.

Place wheel chocks at the front and rear of all wheels.

15.

Record the secondary pressure (line pressure) with the engine idling.

When the engine is started with the select lever in the “P range” and the secondary pressure (line pressure) at idling is measured without shifting the select lever, the value may be higher than the standard. Therefore, be sure to shift the select lever in “D range” or “R range” before measurement.

Specification:

0.5 — 1.5 MPa (5.1 — 15.3 kgf/cm², 72 — 218 psi)

16.

Shift the select lever to “D range”.

17.

Depress the accelerator pedal to the full while fully depressing the foot brake pedal with your left foot.

Do not perform this procedure for over 5 seconds at a time.

18.

When the engine speed stabilizes, quickly record the secondary pressure (line pressure) and release the accelerator pedal.

Specification:

4.5 — 6.0 MPa (45.9 — 61.2 kgf/cm², 652 — 870 psi)

19.

Shift the select lever to “N range”, and idle the engine for one minute or more.

20.

Shift the select lever to “R range” and perform the secondary pressure (line pressure) test in the same manner.

Specification:

4.5 — 6.0 MPa (45.9 — 61.2 kgf/cm², 652 — 870 psi)

21.

Remove the ST (OIL PRESSURE GAUGE ADAPTER, OIL PRESSURE ADAPTER SET and OIL PRESSURE GAUGE ASSY), and then install the test plug (secondary pressure (line pressure)) using a new O-ring.

Due to flowing out of CVTF, quickly install the test plug (secondary pressure (line pressure)).

Apply CVTF to the O-rings.

Tightening torque:

13 N·m (1.3kgf-m, 9.6ft-lb)

22.

Check the CVTF level. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>CVTF>INSPECTION

CONTINUOUSLY VARIABLE TRANSMISSION(TR580) > Transfer Clutch Pressure Test　

LOCATION

(A)	Test plug (transfer clutch pressure)

CONTINUOUSLY VARIABLE TRANSMISSION(TR580) > Transfer Clutch Pressure Test　

INSPECTION

During the transfer clutch pressure test, confirm safety in the vicinity and make sure no person is around the vehicle.

Vehicle components are extremely hot immediately after driving. Be wary of receiving burns from heated parts.

1.

Check the engine oil level. LUBRICATION(H4DO)>Engine Oil>INSPECTION

2.

Check the engine coolant level. COOLING(H4DO)>Engine Coolant>INSPECTION

3.

Remove the rear exhaust pipe. EXHAUST(H4DO)>Rear Exhaust Pipe>REMOVAL

4.

Remove the crossmember support rear LH. FRONT SUSPENSION>Crossmember Support>REMOVAL

5.

Set the transmission jack under the transmission.

6.

Remove the bolt securing the transmission rear crossmember.

7.

Tilt the transmission body to the position where the test plug (transfer clutch pressure) can be removed.

Be careful not to damage the propeller shaft.

8.

Using the ST, remove the test plug (transfer clutch pressure).

Use cloth to catch CVTF in order to prevent it from splashing.

Preparation tool:

ST: SOCKET (18270AA040)

9.

Attach the ST1 and ST2.

Be careful when setting the tool so that the ST1 does not touch the exhaust pipe.

Use ST1 with genuine gasket (Part No. 803914060) and union screw (Part No. 801914010) attached.
Use the ST2 with genuine O-ring (part No. 806908150) attached.

Preparation tool:

ST1: ADAPTER PRESSURE GAUGE (18681AA050)

ST2: OIL PRESSURE GAUGE ASSY (498575400)

10.

Install the transmission rear crossmember.

Tightening torque:

70 N·m (7.1kgf-m, 51.6ft-lb)

11.

Remove the transmission jack.

12.

Install the rear exhaust pipe. EXHAUST(H4DO)>Rear Exhaust Pipe>INSTALLATION

Reuse the new gasket at this point.

13.

Set the gauge so that it can be seen from the driver’s seat.

14.

Connect the Subaru Select Monitor.

15.

Turn the ignition switch to ON. (Engine OFF)

16.

Display [ATF Temp.] and [Transfer Duty Ratio].

17.

Turn off all systems causing an electrical load, such as headlights, A/C, seat heater and rear defogger.

18.

Apply the parking brake.

19.

Start the engine.

20.

Turn OFF the pre-collision brake function. (Models with EyeSight)

21.

Turn OFF the X mode switch. (Model with X mode switch)

22.

Check the CVTF level. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>CVTF>INSPECTION

23.

Warm up until [ATF Temp.] reaches to 60 — 80°C (140 — 176°F).

24.

Place wheel chocks at the front and rear of all wheels.

25.

Record the transfer clutch pressure with the engine idling.

Specification:

0 kPa (0 kgf/cm², 0 psi)

26.

Switch to FWD mode. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>AWD ON/OFF Switching Mode>PROCEDURE

27.

Shift the select lever to “D range”, and depress and hold the brake pedal.

28.

When the engine speed stabilizes, record the transfer clutch pressure.

Specification:

0 kPa (0 kgf/cm², 0 psi)

29.

Switch to AWD mode. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>AWD ON/OFF Switching Mode>PROCEDURE

30.

While fully depressing the brake pedal with your left foot, depress the accelerator pedal until [Transfer Duty Ratio] becomes 60%.

Do not perform this procedure for over 5 seconds at a time.

31.

When the engine speed stabilizes, quickly record the transfer clutch pressure, and release the accelerator pedal.

Specification:

400 — 700 kPa (4.1 — 7.1 kgf/cm², 58 — 102 psi)

32.

Shift the select lever to “N range”, and idle the engine for one minute or more.

33.

Shift the select lever to “D range”.

34.

Depress the accelerator pedal to the full while fully depressing the brake pedal with your left foot.

Do not perform this procedure for over 5 seconds at a time.

35.

When the engine speed stabilizes, quickly record the transfer clutch pressure, and release the accelerator pedal.

Specification:

1,000 — 1,200 kPa (10.2 — 12.2 kgf/cm², 145 — 174 psi)

36.

Shift the select lever to “N range”, and idle the engine for one minute or more.

37.

Remove the rear exhaust pipe. EXHAUST(H4DO)>Rear Exhaust Pipe>REMOVAL

38.

Set the transmission jack under the transmission.

39.

Remove the bolt securing the transmission rear crossmember.

40.

Tilt the transmission body to the position where the test plug (transfer clutch pressure) can be installed.

Be careful not to damage the propeller shaft.

41.

Remove the ST (ADAPTER HOSE B and OIL PRESSURE GAUGE ASSY), and temporarily install the test plug (transfer clutch pressure) using a new O-ring.

Apply CVTF to the O-rings.

42.

Tighten the test plug (transfer clutch pressure) using ST1 and ST2.

Preparation tool:

ST1: SOCKET (18270AA040)

ST2: SPECIAL TOOL CONDENSER (73099SG000)

Tightening torque:

Calculation formula

T = 22 N·m (2.2kgf-m, 16.2ft-lb) × L/ (100 mm (3.94in) + L)

T: Tightening torque

L: Effective length of torque wrench

If the effective length of the torque wrench used is unknown, consult the manufacturer of the torque wrench.

(a) Effective length of the ST2

(b) Effective length of the torque wrench

(c) Center of drive square of the ST2

(d) Center of drive square of the torque wrench

(e) Center of the position where a force is applied by hand

43.

Install the transmission rear crossmember.

Tightening torque:

70 N·m (7.1kgf-m, 51.6ft-lb)

44.

Remove the transmission jack.

45.

Install the crossmember support rear LH. FRONT SUSPENSION>Crossmember Support>INSTALLATION

46.

Install the rear exhaust pipe. EXHAUST(H4DO)>Rear Exhaust Pipe>INSTALLATION

47.

Check the CVTF level. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>CVTF>INSPECTION

CONTINUOUSLY VARIABLE TRANSMISSION(TR580) > Transmission Assembly　

REMOVAL

1.

Release the parking brake.

2.

Disconnect the ground terminal from battery sensor. REPAIR CONTENTS>NOTE > BATTERY

3.

Release the shift lock using a screwdriver, etc. and shift the select lever to the “N” range.

4.

Drain the CVTF. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>CVTF>REPLACEMENT

5.

Drain differential gear oil. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Differential Gear Oil>REPLACEMENT

6.

Remove the clip from the air intake boot, and loosen the clamp.

7.

Remove the air intake boot, and place it aside so that it does not interfere with the work.

Be careful not to pull out the PCV hose.

8.

Remove the CVTF cooler (with warmer feature).

Prepare the container for draining of engine oil.

(1)

Disconnect the CVTF cooler inlet hose and CVTF cooler outlet hose.

(2)

Remove the CVTF cooler (with warmer feature), and move it aside so that it does not interfere with the operation.

Suspend from the vehicle body with rope, etc.

(3)

Remove the CVTF cooler inlet hose (A) and CVTF cooler outlet hose (B).

9.

Remove the engine rear hanger.

10.

Disconnect the transmission harness connector.

11.

Remove the engine wiring harness stay.

(1)

Remove the bolts securing the engine ground and harness case.

(2)

Remove the clip (A), and remove the engine wiring harness stay.

12.

Remove the TCM. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Transmission Control Module (TCM)>REMOVAL

13.

Remove the starter. STARTING/CHARGING SYSTEMS(H4DO)>Starter>REMOVAL

14.

Separate the torque converter from drive plate.

(1)

Remove the PCV hose. EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES)(H4DO)>PCV Hose>REMOVAL > PCV HOSE NO. 1

(2)

Disconnect the connector (A), and remove the plug (B) from the service hole.

(3)

Insert the wrench into the crank pulley bolt, and rotate the crank pulley to remove the bolts (4 places) securing the torque converter to the drive plate.

(4)

Attach the ST to the converter case.

Preparation tool:

ST: STOPPER SET (498277200)

15.

Remove the bolts which hold the upper side of the transmission.

16.

Set the ST1 and ST2.

Preparation tool:

ST1: ENGINE SUPPORT BRACKET (41099AA012)

ST2: ENGINE SUPPORT (41099AA020)

17.

Remove the front drive shaft. PROPELLER SHAFT / DRIVE SHAFT / AXLE>Front Drive Shaft>REMOVAL

18.

Remove the propeller shaft. PROPELLER SHAFT / DRIVE SHAFT / AXLE>Propeller Shaft>REMOVAL

19.

Disconnect the select cable from the transmission main body.

Do not apply excessive load while holding the part (a).

20.

Remove the exhaust hanger bracket.

21.

Remove the bolts and nuts which hold the lower side of transmission.

22.

Set the transmission jack under the transmission.

Make sure that the support plates of transmission jack do not touch the oil pan.

23.

Remove the transmission rear crossmember.

24.

While lowering the transmission jack gradually, fully retract the ST (ENGINE SUPPORT), and then tilt the engine rearward.

25.

Remove the transmission body.

Adjust the position and angle of the transmission jack so that the engine and the transmission are aligned straight.

26.

Remove the rear cushion rubber.

27.

Remove the transmission cover (rear).

28.

When overhauling the transmission body, refer to “Preparation for overhaul”. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Preparation for Overhaul>PROCEDURE > BEFORE OVERHAUL

CONTINUOUSLY VARIABLE TRANSMISSION(TR580) > Transmission Assembly　

INSTALLATION

1.

When having overhauled the transmission body, refer to “Preparation for overhaul”. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Preparation for Overhaul>PROCEDURE > AFTER OVERHAUL

2.

Replace the differential side retainer oil seal with a new part. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Differential Side Retainer Oil Seal>REPLACEMENT

3.

Install the transmission case cover (rear).

Tightening torque:

8 N·m (0.8kgf-m, 5.9ft-lb)

4.

Install the rear cushion rubber.

Tightening torque:

40 N·m (4.1kgf-m, 29.5ft-lb)

5.

Place the transmission body on the transmission jack.

6.

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

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

7.

Install the transmission body.

Adjust the position and angle of the transmission jack and engine body if necessary.
Temporarily install the bolts and nuts which hold lower side of the transmission.

8.

Install the transmission rear crossmember.

Tightening torque:

T1: 35 N·m (3.6kgf-m, 25.8ft-lb)

T2: 70 N·m (7.1kgf-m, 51.6ft-lb)

9.

Remove the transmission jack.

10.

Tighten the bolts and nuts which hold lower side of the transmission.

Tightening torque:

50 N·m (5.1kgf-m, 36.9ft-lb)

11.

Install the exhaust hanger bracket.

Tightening torque:

23 N·m (2.3kgf-m, 17.0ft-lb)

12.

Connect the select cable to the transmission main body.

Do not apply excessive load while holding the part (a).

Tightening torque:

25 N·m (2.5kgf-m, 18.4ft-lb)

13.

Install the bolts which hold upper side of transmission.

Tightening torque:

50 N·m (5.1kgf-m, 36.9ft-lb)

14.

Install the propeller shaft. PROPELLER SHAFT / DRIVE SHAFT / AXLE>Propeller Shaft>INSTALLATION

15.

Install the front drive shaft. PROPELLER SHAFT / DRIVE SHAFT / AXLE>Front Drive Shaft>INSTALLATION

16.

Remove ST (ENGINE SUPPORT BRACKET and ENGINE SUPPORT).

17.

Install the torque converter to drive plate.

(1)

Remove the ST from converter case.

Be careful not to drop the ST into the converter case when removing the ST.

(2)

Insert the wrench into the crank pulley bolt, and rotate the crank pulley to attach the four bolts securing the torque converter to the drive plate.

Be careful not to drop bolts into the converter housing.

Tightening torque:

25 N·m (2.5kgf-m, 18.4ft-lb)

(3)

Install the plug (B) to the service hole, and connect the connector (A).

(4)

Install the PCV hose. EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES)(H4DO)>PCV Hose>INSTALLATION > PCV HOSE NO. 1

18.

Install the engine wiring harness stay.

(1)

Install the engine wiring harness stay, and install the clip (A).

Tightening torque:

19 N·m (1.9kgf-m, 14.0ft-lb)

(2)

Install the engine ground and the harness case.

Tightening torque:

19 N·m (1.9kgf-m, 14.0ft-lb)

19.

Install the starter. STARTING/CHARGING SYSTEMS(H4DO)>Starter>INSTALLATION

20.

Install the TCM. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Transmission Control Module (TCM)>INSTALLATION

21.

Install the CVTF cooler (with warmer feature).

(1)

Install a new CVTF cooler inlet hose (A) and a new CVTF cooler outlet hose (B).

Install the hose with the mark facing upward.

(2)

Install the CVTF cooler (with warmer feature).

Tightening torque:

23 N·m (2.3kgf-m, 17.0ft-lb)

(3)

Connect the CVTF cooler inlet hose and CVTF cooler outlet hose.

22.

Install the engine rear hanger.

Tightening torque:

21 N·m (2.1kgf-m, 15.5ft-lb)

23.

Connect the transmission harness connector to the engine wiring harness.

24.

Install the air intake boot. INTAKE (INDUCTION)(H4DO)>Air Intake Boot>INSTALLATION

25.

Shift the select lever to “P range”.

26.

Connect the ground terminal to battery sensor. REPAIR CONTENTS>NOTE > BATTERY

27.

Apply the parking brake.

28.

Fill differential gear oil. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Differential Gear Oil>REPLACEMENT

29.

Fill with CVTF. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>CVTF>REPLACEMENT

30.

Perform Clear AT learning value and AT learning mode using the Subaru Select Monitor. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>AT learning

31.

When the transmission body or hypoid gear set was replaced, perform the rear differential inspection mode using the Subaru Select Monitor. DIFFERENTIALS>Rear Differential Inspection Mode

32.

Perform the road test to make sure there is no fault. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Road Test>INSPECTION

CONTINUOUSLY VARIABLE TRANSMISSION(TR580) > Transmission Assembly　

INSPECTION

1.

Check for oil leaks.

2.

Check that there is no deformation, cracks or other damages.

CONTINUOUSLY VARIABLE TRANSMISSION(TR580) > Transmission Mounting System　

REMOVAL

1. PITCHING STOPPER

1.

Remove the clip from the air intake boot, and loosen the clamp.

2.

Remove the air intake boot, and place it aside so that it does not interfere with the work.

Be careful not to pull out the PCV hose.

3.

Remove the air breather hose bracket.

4.

Remove the pitching stopper.

5.

Remove the pitching stopper bracket.

Perform this procedure only when required.

2. TRANSMISSION REAR CROSSMEMBER AND REAR CUSHION RUBBER

1.

Disconnect the ground terminal from battery sensor. REPAIR CONTENTS>NOTE > BATTERY

2.

Remove the rear exhaust pipe. EXHAUST(H4DO)>Rear Exhaust Pipe>REMOVAL

3.

Set the transmission jack under the transmission.

Make sure that the support plates of transmission jack do not touch the oil pan.

4.

Remove the transmission rear crossmember.

5.

Remove the rear cushion rubber.

CONTINUOUSLY VARIABLE TRANSMISSION(TR580) > Transmission Mounting System　

INSTALLATION

1. PITCHING STOPPER

1.

Install the pitching stopper bracket.

Tighten the bolt side while holding the nut side.

Tightening torque:

41 N·m (4.2kgf-m, 30.2ft-lb)

2.

Install the pitching stopper.

Install with the front mark (a) facing towards the front of the vehicle.

Tightening torque:

T1: 50 N·m (5.1kgf-m, 36.9ft-lb)

T2: 58 N·m (5.9kgf-m, 42.8ft-lb)

3.

Install the air breather hose bracket.

4.

Install the air intake boot. INTAKE (INDUCTION)(H4DO)>Air Intake Boot>INSTALLATION

2. TRANSMISSION REAR CROSSMEMBER AND REAR CUSHION RUBBER

1.

Install the rear cushion rubber.

Tightening torque:

40 N·m (4.1kgf-m, 29.5ft-lb)

2.

Install the transmission rear crossmember.

Tightening torque:

T1: 35 N·m (3.6kgf-m, 25.8ft-lb)

T2: 70 N·m (7.1kgf-m, 51.6ft-lb)

3.

Remove the transmission jack.

4.

Install the rear exhaust pipe. EXHAUST(H4DO)>Rear Exhaust Pipe>INSTALLATION

5.

Connect the ground terminal to battery sensor. REPAIR CONTENTS>NOTE > BATTERY

CONTINUOUSLY VARIABLE TRANSMISSION(TR580) > Transmission Mounting System　

INSPECTION

Check that there is no deformation, cracks or other damages.

CONTINUOUSLY VARIABLE TRANSMISSION(TR580) > Extension Case Oil Seal　

REPLACEMENT

1.

Release the parking brake.

2.

Disconnect the ground terminal from battery sensor. REPAIR CONTENTS>NOTE > BATTERY

3.

Release the shift lock using a screwdriver, etc. and shift the select lever to the “N” range.

4.

Remove the propeller shaft. PROPELLER SHAFT / DRIVE SHAFT / AXLE>Propeller Shaft>REMOVAL

5.

Remove the front exhaust pipe. EXHAUST(H4DO)>Front Exhaust Pipe>REMOVAL

6.

Remove the extension case oil seal using a flat tip screwdriver wrapped with protection tape, etc.

7.

Using the ST, install a new extension case oil seal.

Apply CVTF to the oil seal lip and peripheral surface.

Preparation tool:

ST: OIL SEAL INSTALLER (498057300)

8.

Install the front exhaust pipe. EXHAUST(H4DO)>Front Exhaust Pipe>INSTALLATION

9.

Install the propeller shaft. PROPELLER SHAFT / DRIVE SHAFT / AXLE>Propeller Shaft>INSTALLATION

10.

Shift the select lever to “P range”.

11.

Connect the ground terminal to battery sensor. REPAIR CONTENTS>NOTE > BATTERY

12.

Apply the parking brake.

13.

Check the CVTF level. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>CVTF>INSPECTION

CONTINUOUSLY VARIABLE TRANSMISSION(TR580) > Extension Case Oil Seal　

INSPECTION

1.

Check for oil leaks.

2.

Check that there is no deformation, cracks or other damages.

CONTINUOUSLY VARIABLE TRANSMISSION(TR580) > Differential Side Retainer Oil Seal　

REPLACEMENT

1.

Disconnect the ground terminal from battery sensor. REPAIR CONTENTS>NOTE > BATTERY

Perform this procedure only when removing the LH side.

2.

Drain differential gear oil. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Differential Gear Oil>REPLACEMENT

3.

Remove the front drive shaft. PROPELLER SHAFT / DRIVE SHAFT / AXLE>Front Drive Shaft>REMOVAL

4.

Remove the differential side retainer oil seal using a flat tip screwdriver wrapped with protection tape, etc.

5.

Install the new differential side retainer oil seal using the ST.

Apply differential gear oil to the differential side retainer oil seal lip.
Since the differential side retainer oil seal has an identification mark (R or L), be careful not to mix up the RH and LH when installing.

Preparation tool:

ST: DIFFERENTIAL SIDE OIL SEAL INSTALLER (18675AA000)

6.

Install the front drive shaft. PROPELLER SHAFT / DRIVE SHAFT / AXLE>Front Drive Shaft>INSTALLATION

7.

Fill differential gear oil. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Differential Gear Oil>REPLACEMENT

8.

Connect the ground terminal to battery sensor. REPAIR CONTENTS>NOTE > BATTERY

CONTINUOUSLY VARIABLE TRANSMISSION(TR580) > Differential Side Retainer Oil Seal　

INSPECTION

1.

Check for oil leaks.

2.

Check that there is no deformation, cracks or other damages.

CONTINUOUSLY VARIABLE TRANSMISSION(TR580) > Inhibitor Switch　

REMOVAL

1.

Disconnect the ground terminal from battery sensor. REPAIR CONTENTS>NOTE > BATTERY

2.

Release the shift lock using a screwdriver, etc. and shift the select lever to the “N” range.

3.

Disconnect the select cable from the transmission main body.

Do not apply excessive load while holding the part (a).

4.

Remove the spring pin (A) and remove the shifter arm (B).

5.

Disconnect the connector and remove the inhibitor switch.

CONTINUOUSLY VARIABLE TRANSMISSION(TR580) > Inhibitor Switch　

INSTALLATION

1.

Temporarily connect the inhibitor switch, and connect the connector.

2.

Install the shifter arm and fix with a new spring pin.

3.

Connect the select cable to the transmission main body.

Do not apply excessive load while holding the part (a).

Tightening torque:

25 N·m (2.5kgf-m, 18.4ft-lb)

4.

Adjust the inhibitor switch. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Inhibitor Switch>ADJUSTMENT

5.

Shift the select lever to “P range”.

6.

Connect the ground terminal to battery sensor. REPAIR CONTENTS>NOTE > BATTERY

7.

Apply the parking brake.

CONTINUOUSLY VARIABLE TRANSMISSION(TR580) > Inhibitor Switch　

INSPECTION

1.

Disconnect the ground terminal from battery sensor. REPAIR CONTENTS>NOTE > BATTERY

2.

Remove the clip from the air intake boot, and loosen the clamp.

3.

Remove the air intake boot, and place it aside so that it does not interfere with the work.

Be careful not to pull out the PCV hose.

4.

Disconnect the transmission harness connector.

5.

Disconnect the ground cord.

6.

Remove the pitching stopper. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Transmission Mounting System>REMOVAL > PITCHING STOPPER

7.

Remove the transmission case cover (front).

8.

Move the lock lever in the arrow direction while pressing the lock button (A), and disconnect the connector.

9.

Set the ST between the TCM and transmission harness. TRANSMISSION (DIAGNOSTICS)>General Description>CAUTION

Special tool:

CHECK BOARD (18460AA040)

10.

Check the inhibitor switch signal circuit.

(1)

Check the circuit of each range.

If faulty, check the transmission harness for open circuit or short circuit, or poor contact.

Terminal No.	Inspection conditions	Standard
38 — 42	P range	Less than 1 Ω
37 — 42	R range
36 — 42	N range
35 — 42	D range

(2)

Check continuity when the lever is moved 1.5° in the front-rear direction from each range.

If there is continuity in only one direction or in other points, adjust the inhibitor switch. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Inhibitor Switch>ADJUSTMENT

(A)

1.5°

(B)

Initial position

(C)

Continuity range

Terminal No.	Inspection conditions	Standard
38 — 42	P range	Less than 1 Ω
37 — 42	R range
36 — 42	N range
35 — 42	D range

11.

Check the neutral switch signal circuit and back-up light circuit.

Terminal No.	Range	Standard
1 — 5	P range and N range	Less than 1 Ω
22 — 26	Except for R range	∞Ω
22 — 26	R range	Less than 1 Ω

CONTINUOUSLY VARIABLE TRANSMISSION(TR580) > Inhibitor Switch　

ADJUSTMENT

1.

Release the shift lock using a screwdriver, etc. and shift the select lever to the “N” range.

2.

Loosen the bolts holding the inhibitor switch.

3.

Insert the ST into the holes of the shifter arm and inhibitor switch.

Set the parts so that the center points of the holes are aligned.

Preparation tool:

ST: STOPPER PIN (499267300)

4.

Tighten the bolts holding the inhibitor switch.

Tightening torque:

5 N·m (0.5kgf-m, 3.7ft-lb)

CONTINUOUSLY VARIABLE TRANSMISSION(TR580) > Turbine Speed Sensor　

LOCATION

(A)	Turbine speed sensor

CONTINUOUSLY VARIABLE TRANSMISSION(TR580) > Turbine Speed Sensor　

REMOVAL

If water or oil contacts the connector terminal of turbine speed sensor, replace it with a new part.

1.

Disconnect the ground terminal from battery sensor. REPAIR CONTENTS>NOTE > BATTERY

2.

Remove the front exhaust pipe. EXHAUST(H4DO)>Front Exhaust Pipe>REMOVAL

3.

Disconnect the connector and remove the turbine speed sensor.

CONTINUOUSLY VARIABLE TRANSMISSION(TR580) > Turbine Speed Sensor　

INSTALLATION

If water or oil contacts the connector terminal of turbine speed sensor, replace it with a new part.

1.

Install the turbine speed sensor using a new O-ring, and connect the connector.

Apply CVTF to the O-rings.

Tightening torque:

7 N·m (0.7kgf-m, 5.2ft-lb)

2.

Install the front exhaust pipe. EXHAUST(H4DO)>Front Exhaust Pipe>INSTALLATION

3.

Connect the ground terminal to battery sensor. REPAIR CONTENTS>NOTE > BATTERY

CONTINUOUSLY VARIABLE TRANSMISSION(TR580) > Turbine Speed Sensor　

INSPECTION

1.

Check for oil leaks.

2.

Check the output waveform and output voltage of the turbine speed sensor.

(1)

Disconnect the ground terminal from battery sensor. REPAIR CONTENTS>NOTE > BATTERY

(2)

Remove the clip from the air intake boot, and loosen the clamp.

(3)

Remove the air intake boot, and place it aside so that it does not interfere with the work.

Be careful not to pull out the PCV hose.

(4)

Disconnect the ground cord.

(5)

Remove the pitching stopper. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Transmission Mounting System>REMOVAL > PITCHING STOPPER

(6)

Remove the transmission case cover (front).

(7)

Move the lock lever in the arrow direction while pressing the lock button (A), and disconnect the connector.

(8)

Set the ST between the TCM and transmission harness. TRANSMISSION (DIAGNOSTICS)>General Description>CAUTION

Special tool:

CHECK BOARD (18460AA040)

(9)

Install the air intake boot. INTAKE (INDUCTION)(H4DO)>Air Intake Boot>INSTALLATION

(10)

Connect the ground terminal to battery sensor. REPAIR CONTENTS>NOTE > BATTERY

(11)

Connect the probe of oscilloscope to ST.

Terminal No.	Probe
12	+
26	−

(12)

Start the engine and warm up completely.

(13)

Check the output waveform and output voltage with engine idling.

For the output waveform and output voltage, refer to the “TRANSMISSION (DIAGNOSTICS)” section. TRANSMISSION (DIAGNOSTICS)>Transmission Control Module (TCM) I/O Signal>WAVEFORM > SENSOR

(14)

After inspection, install the related parts in the reverse order of removal.

Tightening torque:

7 N·m (0.7kgf-m, 5.2ft-lb)

Tightening torque:

32.3N·m (3.3kgf-m, 23.8ft-lb)

CONTINUOUSLY VARIABLE TRANSMISSION(TR580) > Secondary Speed Sensor　

LOCATION

(A)	Secondary speed sensor

CONTINUOUSLY VARIABLE TRANSMISSION(TR580) > Secondary Speed Sensor　

REMOVAL

If water or oil contacts the connector terminal of secondary speed sensor, replace it with a new part.

1.

Disconnect the ground terminal from battery sensor. REPAIR CONTENTS>NOTE > BATTERY

2.

Remove the front exhaust pipe. EXHAUST(H4DO)>Front Exhaust Pipe>REMOVAL

3.

Disconnect the connector and remove the secondary speed sensor.

Prepare the container for draining of engine oil.

CONTINUOUSLY VARIABLE TRANSMISSION(TR580) > Secondary Speed Sensor　

INSTALLATION

If water or oil contacts the connector terminal of secondary speed sensor, replace it with a new part.

1.

Install the secondary speed sensor using a new O-ring, and connect the connector.

Apply CVTF to the O-rings.

Tightening torque:

7 N·m (0.7kgf-m, 5.2ft-lb)

2.

Install the front exhaust pipe. EXHAUST(H4DO)>Front Exhaust Pipe>INSTALLATION

3.

Connect the ground terminal to battery sensor. REPAIR CONTENTS>NOTE > BATTERY

4.

Check the CVTF level. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>CVTF>INSPECTION

CONTINUOUSLY VARIABLE TRANSMISSION(TR580) > Secondary Speed Sensor　

INSPECTION

1.

Check for oil leaks.

2.

Check the output waveform and output voltage of the secondary speed sensor.

(1)

Disconnect the ground terminal from battery sensor. REPAIR CONTENTS>NOTE > BATTERY

(2)

Remove the clip from the air intake boot, and loosen the clamp.

(3)

Remove the air intake boot, and place it aside so that it does not interfere with the work.

Be careful not to pull out the PCV hose.

(4)

Disconnect the ground cord.

(5)

Remove the pitching stopper. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Transmission Mounting System>REMOVAL > PITCHING STOPPER

(6)

Remove the transmission case cover (front).

(7)

Move the lock lever in the arrow direction while pressing the lock button (A), and disconnect the connector.

(8)

Set the ST between the TCM and transmission harness. TRANSMISSION (DIAGNOSTICS)>General Description>CAUTION

Special tool:

CHECK BOARD (18460AA040)

(9)

Install the air intake boot. INTAKE (INDUCTION)(H4DO)>Air Intake Boot>INSTALLATION

(10)

Connect the ground terminal to battery sensor. REPAIR CONTENTS>NOTE > BATTERY

(11)

Connect the probe of oscilloscope to ST.

Terminal No.	Probe
13	+
26	−

(12)

Start the engine and warm up completely.

(13)

Lift up the vehicle.

Lift up the vehicle until the tire bottom is 0.3 m (0.98ft) or more above the ground.
Make sure that safety is secured where the tiers rotate.

(14)

Turn OFF the pre-collision brake function. (Models with EyeSight)

(15)

Turn the VDC function OFF.

(16)

Release the parking brake.

(17)

Shift the select lever to “D range”.

(18)

Release the brake pedal, and rotate the tires.

(19)

Check the output waveforms and output voltage.

For the output waveform and output voltage, refer to the “TRANSMISSION (DIAGNOSTICS)” section. TRANSMISSION (DIAGNOSTICS)>Transmission Control Module (TCM) I/O Signal>WAVEFORM > SENSOR

(20)

After inspection, install the related parts in the reverse order of removal.

Tightening torque:

7 N·m (0.7kgf-m, 5.2ft-lb)

Tightening torque:

32.3N·m (3.3kgf-m, 23.8ft-lb)

CONTINUOUSLY VARIABLE TRANSMISSION(TR580) > Primary Speed Sensor　

LOCATION

(A)	Primary speed sensor

CONTINUOUSLY VARIABLE TRANSMISSION(TR580) > Primary Speed Sensor　

REMOVAL

If water or oil contacts the connector terminal of primary speed sensor, replace it with a new part.

1.

Remove the transmission body. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Transmission Assembly>REMOVAL

2.

Disconnect the connector, and remove the primary speed sensor.

CONTINUOUSLY VARIABLE TRANSMISSION(TR580) > Primary Speed Sensor　

INSTALLATION

If water or oil contacts the connector terminal of primary speed sensor, replace it with a new part.

1.

Install the primary speed sensor using a new O-ring, and connect the connector.

Apply CVTF to the O-rings.

Tightening torque:

7 N·m (0.7kgf-m, 5.2ft-lb)

2.

Install the transmission body. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Transmission Assembly>INSTALLATION

CONTINUOUSLY VARIABLE TRANSMISSION(TR580) > Primary Speed Sensor　

INSPECTION

1.

Check for oil leaks.

2.

Check the output waveform and output voltage of the primary speed sensor.

(1)

Disconnect the ground terminal from battery sensor. REPAIR CONTENTS>NOTE > BATTERY

(2)

Remove the clip from the air intake boot, and loosen the clamp.

(3)

Remove the air intake boot, and place it aside so that it does not interfere with the work.

Be careful not to pull out the PCV hose.

(4)

Disconnect the ground cord.

(5)

Remove the pitching stopper. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Transmission Mounting System>REMOVAL > PITCHING STOPPER

(6)

Remove the transmission case cover (front).

(7)

Move the lock lever in the arrow direction while pressing the lock button (A), and disconnect the connector.

(8)

Set the ST between the TCM and transmission harness. TRANSMISSION (DIAGNOSTICS)>General Description>CAUTION

Special tool:

CHECK BOARD (18460AA040)

(9)

Install the air intake boot. INTAKE (INDUCTION)(H4DO)>Air Intake Boot>INSTALLATION

(10)

Connect the ground terminal to battery sensor. REPAIR CONTENTS>NOTE > BATTERY

(11)

Connect the probe of oscilloscope to ST.

Terminal No.	Probe
14	+
42	−

(12)

Start the engine and warm up completely.

(13)

Lift up the vehicle.

Lift up the vehicle until the tire bottom is 0.3 m (0.98ft) or more above the ground.
Make sure that safety is secured where the tiers rotate.

(14)

Turn OFF the pre-collision brake function. (Models with EyeSight)

(15)

Turn the VDC function OFF.

(16)

Release the parking brake.

(17)

Shift the select lever to “D range”.

(18)

Release the brake pedal, and rotate the tires.

(19)

Check the output waveforms and output voltage.

For the output waveform and output voltage, refer to the “TRANSMISSION (DIAGNOSTICS)” section. TRANSMISSION (DIAGNOSTICS)>Transmission Control Module (TCM) I/O Signal>WAVEFORM > SENSOR

(20)

After inspection, install the related parts in the reverse order of removal.

Tightening torque:

7 N·m (0.7kgf-m, 5.2ft-lb)

Tightening torque:

32.3N·m (3.3kgf-m, 23.8ft-lb)

CONTINUOUSLY VARIABLE TRANSMISSION(TR580) > Secondary Pressure Sensor　

LOCATION

(A)	Secondary pressure sensor

CONTINUOUSLY VARIABLE TRANSMISSION(TR580) > Secondary Pressure Sensor　

REMOVAL

If water or oil contacts the connector terminal of secondary pressure sensor, replace it with a new part.

1.

Disconnect the ground terminal from battery sensor. REPAIR CONTENTS>NOTE > BATTERY

2.

Remove the front exhaust pipe. EXHAUST(H4DO)>Front Exhaust Pipe>REMOVAL

3.

Disconnect the connector and remove the secondary pressure sensor.

Prepare the container for draining of engine oil.

CONTINUOUSLY VARIABLE TRANSMISSION(TR580) > Secondary Pressure Sensor　

INSTALLATION

If water or oil contacts the connector terminal of secondary pressure sensor, replace it with a new part.

1.

Install the secondary pressure sensor using a new O-ring, and connect the connector.

Apply CVTF to the O-rings.

Tightening torque:

39 N·m (4.0kgf-m, 28.8ft-lb)

2.

Install the front exhaust pipe. EXHAUST(H4DO)>Front Exhaust Pipe>INSTALLATION

3.

Connect the ground terminal to battery sensor. REPAIR CONTENTS>NOTE > BATTERY

4.

Check the CVTF level. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>CVTF>INSPECTION

CONTINUOUSLY VARIABLE TRANSMISSION(TR580) > Secondary Pressure Sensor　

INSPECTION

1.

Check for oil leaks.

2.

Check [secondary pressure sensor voltage.] of the secondary pressure sensor.

(1)

Connect the Subaru Select Monitor.

(2)

Turn the ignition switch to ON. (Engine OFF)

(3)

Display [secondary pressure sensor voltage.].

(4)

Start the engine and warm up completely.

(5)

Shift the select lever to “D range”.

(6)

Shift the select lever to “P range”.

(7)

Check [secondary pressure sensor voltage.] with the vehicle idling.

Specification:

Approx. 1.0 V

(8)

Stop the engine.

(9)

Turn the ignition switch to ON. (Engine OFF)

(10)

Check [secondary pressure sensor voltage.].

Specification:

Approx. 0.5 V

CONTINUOUSLY VARIABLE TRANSMISSION(TR580) > Oil Pan　

REMOVAL

Vehicle components are extremely hot immediately after driving. Be wary of receiving burns from heated parts.
If any CVTF adheres to the exhaust pipe, completely wipe it off to avoid emitting smoke and causing a fire.

1.

Drain the CVTF. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>CVTF>REPLACEMENT

2.

Remove the bolts which hold the oil pan.

3.

Insert an oil pan seal cutter into the gap between oil pan and transmission case, and remove the oil pan.

Do not use the tools other than the oil pan seal cutter, in order to prevent damaging the oil pan and the transmission case.
Do not twist with excessive force. The oil pan may be deformed.

4.

Remove the magnet from the oil pan.

Remove the iron powder, etc. from the magnet.

5.

Remove the liquid gasket from the oil pan and the transmission case.

6.

Remove the oil strainer.

7.

Remove the O-ring from oil strainer.

CONTINUOUSLY VARIABLE TRANSMISSION(TR580) > Oil Pan　

INSTALLATION

1.

Install a new O-ring to the oil strainer.

Apply CVTF to the O-rings.

2.

Install the oil strainer.

Tightening torque:

9 N·m (0.9kgf-m, 6.6ft-lb)

3.

Attach the magnet on the oil pan.

4.

Apply liquid gasket to the mating surface of the oil pan as shown in the figure, and temporarily install the oil pan.

Before applying liquid gasket, degrease the old liquid gasket seal surfaces of the oil pan and transmission body.
Install within 5 min. after applying liquid gasket.

Liquid gasket:

THREE BOND 1217B (Part No. K0877YA020) or equivalent

5.

Tighten the bolts evenly.

Tightening torque:

5 N·m (0.5kgf-m, 3.7ft-lb)

6.

Fill with CVTF. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>CVTF>REPLACEMENT

CONTINUOUSLY VARIABLE TRANSMISSION(TR580) > Oil Pan　

INSPECTION

1.

Check for oil leaks.

2.

Check that there is no deformation, cracks or other damages.

3.

Check the oil passages for clogging.

CONTINUOUSLY VARIABLE TRANSMISSION(TR580) > Control Valve Body　

REMOVAL

The control valve body is a non-disassembly part.

1.

Disconnect the ground terminal from battery sensor. REPAIR CONTENTS>NOTE > BATTERY

2.

Remove the clip from the air intake boot, and loosen the clamp.

3.

Remove the air intake boot, and place it aside so that it does not interfere with the work.

Be careful not to pull out the PCV hose.

4.

Remove the TCM. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Transmission Control Module (TCM)>REMOVAL

5.

Disconnect the transmission harness connector.

6.

Remove the ground cord and the air breather hose stay.

7.

Remove the clip and remove the ground terminal.

8.

Clean the valve cover vicinity.

Make sure that foreign matter does not get into the throttle body and connector terminals.

This is necessary to prevent foreign matter from getting into the transmission.

9.

Remove the throttle body, and place it aside so that it does not interfere with the work. FUEL INJECTION (FUEL SYSTEMS)(H4DO)>Throttle Body>REMOVAL

Do not disconnect the preheater hose.

10.

Attach the ST.

The ST is included in the control valve body for repairs.

Preparation tool:

ST: SHEET SPECIAL TOOL (18761AA010)

11.

Remove the bolt securing the transmission harness.

12.

Remove the valve cover.

13.

Disconnect the connector from the control valve body, and remove the transmission harness from the valve cover.

14.

Remove the O-rings.

15.

Remove the gasket.

16.

Remove the control valve body.

Do not remove any bolts other than specified in the figure.

17.

Remove the O-rings.

18.

Remove the liquid gasket from the mating surface of valve cover and transmission body.

CONTINUOUSLY VARIABLE TRANSMISSION(TR580) > Control Valve Body　

INSTALLATION

1.

Check the control valve body for foreign matter adhesion.

2.

Set new O-rings.

Apply CVTF to the O-rings.

3.

Install the control valve body.

(1)

Set the control valve body to the transmission body.

Perform installation so that the O-ring is not displaced.

(2)

Temporarily tighten the bolt (silver).

(3)

Attach the bolt (black).

Tightening torque:

9 N·m (0.9kgf-m, 6.6ft-lb)

(4)

Tighten the bolt (silver).

Tightening torque:

9 N·m (0.9kgf-m, 6.6ft-lb)

4.

Install a new O-ring to the transmission harness.

Apply CVTF to the O-rings.

5.

Temporarily attach the transmission harness to the valve cover.

6.

Set the gasket to the transmission body, and apply the liquid gasket to the oblong hole.

Before applying liquid gasket, degrease the old liquid gasket seal surface of the transmission body and valve cover.
Install within 5 min. after applying liquid gasket.

Liquid gasket:

THREE BOND 1215B or equivalent

7.

Connect the connector to the control valve body.

8.

Install the valve cover.

Be careful not to catch the ST (SHEET SPECIAL TOOL).

Tightening torque:

8 N·m (0.8kgf-m, 5.9ft-lb)

9.

Tighten the bolt which holds the transmission harness.

Tightening torque:

7 N·m (0.7kgf-m, 5.2ft-lb)

10.

Remove the ST (SHEET SPECIAL TOOL).

11.

Install the throttle body. FUEL INJECTION (FUEL SYSTEMS)(H4DO)>Throttle Body>INSTALLATION

12.

Install the clip, and connect the ground terminal.

Tightening torque:

14 N·m (1.4kgf-m, 10.3ft-lb)

13.

Install the ground cord and the air breather hose stay.

Tightening torque:

7 N·m (0.7kgf-m, 5.2ft-lb)

14.

Connect the transmission harness connector to the engine wiring harness.

15.

Install the TCM. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Transmission Control Module (TCM)>INSTALLATION

16.

Install the air intake boot. INTAKE (INDUCTION)(H4DO)>Air Intake Boot>INSTALLATION

17.

Connect the ground terminal to battery sensor. REPAIR CONTENTS>NOTE > BATTERY

18.

Check the CVTF level. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>CVTF>INSPECTION

19.

Perform AT learning mode using the Subaru Select Monitor. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>AT learning

CONTINUOUSLY VARIABLE TRANSMISSION(TR580) > Control Valve Body　

INSPECTION

1.

Check for oil leaks.

2.

Check that there is no deformation, cracks or other damages.

3.

Measure the resistance of each solenoid, sensor and ground wire.

Measurement should be performed at a temperature of 20°C (68°F).

	Terminal No.	Standard
Primary UP solenoid	2 — Control valve body	10 — 14.2 Ω
Secondary solenoid	3 — Control valve body	4.8 — 8.4 Ω
F&R clutch solenoid	4 — Control valve body	3.5 — 7.1 Ω
Primary DOWN solenoid	7 — Control valve body	10 — 14.2 Ω
Lock-up duty solenoid	9 — Control valve body	10 — 14.2 Ω
AWD solenoid	10 — Control valve body	1.5 — 4.9 Ω
Oil temperature sensor	1 — 6	Approx. 2.5 kΩ [20°C (68°F)]
Ground	8 — Control valve body	Less than 1 Ω

CONTINUOUSLY VARIABLE TRANSMISSION(TR580) > Electric Fluid Pump　

REMOVAL

1.

Disconnect the ground terminal from battery sensor. REPAIR CONTENTS>NOTE > BATTERY

2.

Drain the CVTF. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>CVTF>REPLACEMENT

3.

Remove the front exhaust pipe. EXHAUST(H4DO)>Front Exhaust Pipe>REMOVAL

4.

Disconnect the connector and remove the electric oil pump.

Prepare the container for draining of engine oil.

5.

Remove the O-rings.

CONTINUOUSLY VARIABLE TRANSMISSION(TR580) > Electric Fluid Pump　

INSTALLATION

1.

Install a new O-ring.

Apply CVTF to the O-rings.

2.

Install the electric oil pump, and connect the connector.

Tightening torque:

22 N·m (2.2kgf-m, 16.2ft-lb)

3.

Install the front exhaust pipe. EXHAUST(H4DO)>Front Exhaust Pipe>INSTALLATION

4.

Connect the ground terminal to battery sensor. REPAIR CONTENTS>NOTE > BATTERY

5.

Fill with CVTF. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>CVTF>REPLACEMENT

CONTINUOUSLY VARIABLE TRANSMISSION(TR580) > Electric Fluid Pump　

DISASSEMBLY

1.

Remove the electric oil pump.

2.

Remove the O-rings.

3.

Remove the plug.

CONTINUOUSLY VARIABLE TRANSMISSION(TR580) > Electric Fluid Pump　

ASSEMBLY

1.

Install the plugs with new O-rings.

Apply CVTF to the O-rings.

Tightening torque:

16 N·m (1.6kgf-m, 11.8ft-lb)

2.

Install a new O-ring.

Apply CVTF to the O-rings.

3.

Install the electric oil pump.

Tightening torque:

22 N·m (2.2kgf-m, 16.2ft-lb)

CONTINUOUSLY VARIABLE TRANSMISSION(TR580) > Electric Fluid Pump　

INSPECTION

1.

Check for oil leaks.

2.

Check that there is no deformation, cracks or other damages.

3.

Perform the road test (Auto Start Stop) and check that no shift shock occurs immediately after engine starting. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Road Test>INSPECTION > Auto Start Stop

4.

Perform the following oil pressure test for the electric oil pump, and check [secondary pressure sensor voltage.].

(1)

Connect the Subaru Select Monitor.

(2)

Turn the ignition switch to ON. (Engine OFF)

(3)

Display [ATF Temp.] and [secondary pressure sensor voltage.].

(4)

Start the engine and raise [ATF Temp.] to 60 — 80°C (140 — 176°F).

(5)

Stop the engine and leave it for three minutes or more.

(6)

Turn the ignition switch to ON. (Engine OFF)

(7)

Record [secondary pressure sensor voltage.].

This voltage is “E1”.

(8)

Start the engine.

(9)

Turn off all systems causing an electrical load, such as headlights, A/C, seat heater and rear defogger.

(10)

Shift the select lever to “D range” and set the vehicle to the Auto Start Stop status.

Listen to the operating sound to check that the electric oil pump is operating.

(11)

Leave it for five seconds or more with the vehicle set to the Auto Start Stop status, and record [secondary pressure sensor voltage.] during the Auto Start Stop.

This voltage is “E2”.

(12)

Calculate the difference between the recorded voltage “E1” and “E2”.

Specification:

0.045 V

CONTINUOUSLY VARIABLE TRANSMISSION(TR580) > Transmission Harness　

REMOVAL

1.

Remove the transmission body. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Transmission Assembly>REMOVAL

2.

Remove the air breather hose. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Air Breather Hose>REMOVAL

3.

Disconnect the ground terminal (electric oil pump side), and then disconnect the connector from the electric oil pump, turbine speed sensor, primary speed sensor, secondary speed sensor and secondary pressure sensor.

4.

Disconnect the connector from inhibitor switch.

5.

Disconnect the ground terminal (valve cover side).

6.

Disconnect the transmission harness from the control valve body. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Control Valve Body>REMOVAL

7.

Remove all clips and remove the transmission harness.

CONTINUOUSLY VARIABLE TRANSMISSION(TR580) > Transmission Harness　

INSTALLATION

1.

Set the transmission harness, and install the clip.

2.

Connect the transmission harness to the control valve body. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Control Valve Body>INSTALLATION

3.

Connect the ground terminal (valve cover side).

Tightening torque:

14 N·m (1.4kgf-m, 10.3ft-lb)

4.

Connect the connector to the inhibitor switch.

5.

Connect the ground terminal (electric oil pump side), and then connect the connector to the electric oil pump, turbine speed sensor, primary speed sensor, secondary speed sensor and secondary pressure sensor.

Tightening torque:

13 N·m (1.3kgf-m, 9.6ft-lb)

6.

Install the air breather hose. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Air Breather Hose>INSTALLATION

7.

Install the transmission body. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Transmission Assembly>INSTALLATION

CONTINUOUSLY VARIABLE TRANSMISSION(TR580) > Transmission Harness　

INSPECTION

1.

Check that there is no deformation, cracks or other damages.

2.

Check the terminal for rusting.

CONTINUOUSLY VARIABLE TRANSMISSION(TR580) > X MODE Switch　

REMOVAL

1.

Disconnect the ground terminal from battery sensor. REPAIR CONTENTS>NOTE > BATTERY

2.

Release the shift lock using a screwdriver, etc. and shift the select lever to the “N” range.

3.

Remove the cover assembly front. EXTERIOR/INTERIOR TRIM>Console Box>REMOVAL

4.

Remove the X mode switch.

CONTINUOUSLY VARIABLE TRANSMISSION(TR580) > X MODE Switch　

INSTALLATION

1.

Install the X mode switch.

2.

Install the cover assembly front. EXTERIOR/INTERIOR TRIM>Console Box>INSTALLATION

3.

Shift the select lever to “P range”.

4.

Connect the ground terminal to battery sensor. REPAIR CONTENTS>NOTE > BATTERY

5.

Apply the parking brake.

CONTINUOUSLY VARIABLE TRANSMISSION(TR580) > X MODE Switch　

INSPECTION

1.

Check the resistance between connector terminals.

Terminal No.	Inspection conditions	Standard
1 — 4	Counterclockwise (hold)	0 Ω
	PUSH (hold)	Approx. 1 kΩ
	Clockwise (hold)	Approx. 3.67 kΩ

2.

Apply battery voltage between the connector terminals to check lighting status of illumination.

When applying battery voltage, do not mix up the positive (+) side and the negative (−) side.

Incorrect polarity connection may cause LED damage inside the switch.

Terminal No.	Inspection conditions	Specifications
2 (+) — 3 (−)	Apply battery voltage.	Light ON

CONTINUOUSLY VARIABLE TRANSMISSION(TR580) > Transmission Control Module (TCM)　

REMOVAL

When replacing the TCM, be sure to perform [Start count reading ECU to SSM] before operation and perform [Start count writing SSM to ECU] after operation. AUTO START STOP (DIAGNOSTICS)>Work Support>NOTE
When [Start count reading ECU to SSM] cannot be performed due to TCM malfunction, be sure to replace the starter and fuel pump relay at the same time. STARTING/CHARGING SYSTEMS(H4DO)>Starter FUEL INJECTION (FUEL SYSTEMS)(H4DO)>Fuel Pump Relay

1.

Disconnect the ground terminal from battery sensor. REPAIR CONTENTS>NOTE > BATTERY

2.

Remove the clip from the air intake boot, and loosen the clamp.

3.

Remove the air intake boot, and place it aside so that it does not interfere with the work.

Be careful not to pull out the PCV hose.

4.

Disconnect the ground cord.

5.

Remove the pitching stopper. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Transmission Mounting System>REMOVAL > PITCHING STOPPER

6.

Remove the transmission case cover (front).

7.

Move the lock lever in the arrow direction while pressing the lock button (A), and disconnect the connector.

8.

Remove the TCM.

CONTINUOUSLY VARIABLE TRANSMISSION(TR580) > Transmission Control Module (TCM)　

INSTALLATION

When replacing the TCM, be sure to perform [Start count reading ECU to SSM] before operation and perform [Start count writing SSM to ECU] after operation. AUTO START STOP (DIAGNOSTICS)>Work Support>NOTE
When [Start count reading ECU to SSM] cannot be performed due to TCM malfunction, be sure to replace the starter and fuel pump relay at the same time. STARTING/CHARGING SYSTEMS(H4DO)>Starter FUEL INJECTION (FUEL SYSTEMS)(H4DO)>Fuel Pump Relay

1.

Install the TCM.

Tightening torque:

7 N·m (0.7 kgf-m, 5.2 ft-lb)

2.

Connect the connector.

Move the lock lever and confirm that a clicking sound is heard.

3.

Install the transmission case cover (front).

Insert the transmission case cover (front) between transmission case cover (rear) and transmission body.
When inserting, be careful that the insulator inside transmission case cover is not turned over.

Tightening torque:

7 N·m (0.7 kgf-m, 5.2 ft-lb)

4.

Install the pitching stopper. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Transmission Mounting System>INSTALLATION > PITCHING STOPPER

5.

Connect the ground cord.

Tightening torque:

32.3N·m (3.3 kgf-m, 23.8 ft-lb)

6.

Install the air intake boot. INTAKE (INDUCTION)(H4DO)>Air Intake Boot>INSTALLATION

7.

Connect the ground terminal to battery sensor. REPAIR CONTENTS>NOTE > BATTERY

8.

Perform AT learning mode using the Subaru Select Monitor. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>AT learning

CONTINUOUSLY VARIABLE TRANSMISSION(TR580) > Relay and Fuse　

LOCATION

(A)	TCM fuse (20 A)	(C)	IG fuse (10 A)	(D)	Electric oil pump relay
(B)	IG fuse (15 A)

CONTINUOUSLY VARIABLE TRANSMISSION(TR580) > Relay and Fuse　

INSPECTION

1. CHECK FUSE

Check fuse for blown out.

2. CHECK RELAY

1.

Check that there is no deformation, cracks or other damages.

2.

Check the resistance between terminals.

Terminal No.	Inspection conditions	Standard
3 — 4	Apply battery voltage between terminals 1 and 2.	Less than 1 Ω
3 — 4	Always	1 MΩ or more

CONTINUOUSLY VARIABLE TRANSMISSION(TR580) > CVTF Cooler (With Warmer Function)　

REMOVAL

If CVTF and engine coolant spills over the engine, completely wipe it off to avoid emission of smoke and causing a fire.

1.

Disconnect the ground terminal from battery sensor. REPAIR CONTENTS>NOTE > BATTERY

2.

Drain engine coolant. COOLING(H4DO)>Engine Coolant>REPLACEMENT

3.

Remove the clip from the air intake boot, and loosen the clamp.

4.

Remove the air intake boot, and place it aside so that it does not interfere with the work.

Be careful not to pull out the PCV hose.

5.

Remove the CVTF cooler (with warmer feature).

Prepare the container for draining of engine oil.

(1)

Disconnect the CVTF cooler inlet hose and CVTF cooler outlet hose.

(2)

Disconnect the water hose (inlet) (A) and water hose (outlet) (B).

(3)

Remove the CVTF cooler (with warmer feature).

(4)

Remove the CVTF cooler inlet hose (A) and CVTF cooler outlet hose (B).

6.

Remove the water hose (outlet).

Perform this procedure only when required.

(1)

Remove the EGR cooler. EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES)(H4DO)>EGR Cooler>REMOVAL

(2)

Remove the water hose (outlet).

CONTINUOUSLY VARIABLE TRANSMISSION(TR580) > CVTF Cooler (With Warmer Function)　

INSTALLATION

1.

Install the water hose (outlet).

(1)

Install the water hose (outlet) to the thermostat cover.

(2)

Install the EGR cooler. EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES)(H4DO)>EGR Cooler>INSTALLATION

2.

Install the CVTF cooler (with warmer feature).

(1)

Install a new CVTF cooler inlet hose (A) and a new CVTF cooler outlet hose (B).

Install the hose with the mark facing upward.

(2)

Install the CVTF cooler (with warmer feature).

Tightening torque:

23 N·m (2.3kgf-m, 17.0ft-lb)

(3)

Connect the water hose (inlet) (A) and water hose (outlet) (B).

(4)

Connect the CVTF cooler inlet hose and CVTF cooler outlet hose.

3.

Install the air intake boot. INTAKE (INDUCTION)(H4DO)>Air Intake Boot>INSTALLATION

4.

Connect the ground terminal to battery sensor. REPAIR CONTENTS>NOTE > BATTERY

5.

Fill engine coolant. COOLING(H4DO)>Engine Coolant>REPLACEMENT

6.

Check the CVTF level. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>CVTF>INSPECTION

CONTINUOUSLY VARIABLE TRANSMISSION(TR580) > CVTF Cooler (With Warmer Function)　

DISASSEMBLY

1.

Remove the bracket.

CONTINUOUSLY VARIABLE TRANSMISSION(TR580) > CVTF Cooler (With Warmer Function)　

ASSEMBLY

1.

Attach the bracket.

Tightening torque:

23 N·m (2.3kgf-m, 17.0ft-lb)

CONTINUOUSLY VARIABLE TRANSMISSION(TR580) > CVTF Cooler (With Warmer Function)　

INSPECTION

1.

Check for oil leaks.

2.

Check for leaks.

3.

Check that there is no deformation, cracks or other damages.

CONTINUOUSLY VARIABLE TRANSMISSION(TR580) > Air Breather Hose　

REMOVAL

1. FRONT DIFFERENTIAL SIDE

1.

Remove the clip from the air intake boot, and loosen the clamp.

2.

Remove the air intake boot, and place it aside so that it does not interfere with the work.

Be careful not to pull out the PCV hose.

3.

Remove the air breather hose.

4.

Remove the air breather cap.

2. TRANSMISSION CASE SIDE

1.

Remove the transmission body. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Transmission Assembly>REMOVAL

2.

Remove the air breather hose.

3.

Remove the air breather cap.

CONTINUOUSLY VARIABLE TRANSMISSION(TR580) > Air Breather Hose　

INSTALLATION

1. FRONT DIFFERENTIAL SIDE

1.

Install the air breather cap.

2.

Install the air breather hose.

3.

Install the air intake boot. INTAKE (INDUCTION)(H4DO)>Air Intake Boot>INSTALLATION

2. TRANSMISSION CASE SIDE

1.

Install the air breather cap.

2.

Install the air breather hose.

3.

Install the transmission body. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Transmission Assembly>INSTALLATION

4.

Install the air breather hose to the air breather hose bracket.

Assemble with the mark position facing in the direction shown in the figure.

CONTINUOUSLY VARIABLE TRANSMISSION(TR580) > Air Breather Hose　

INSPECTION

1.

Check that there is no deformation, cracks or other damages.

2.

Check the hose for clogging.

CONTINUOUSLY VARIABLE TRANSMISSION(TR580) > Drive Plate　

REMOVAL

1.

Remove the transmission body. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Transmission Assembly>REMOVAL

2.

Set the ST, and then remove the reinforcement drive plate, drive plate and crankshaft position sensor plate.

Preparation tool:

ST: CRANKSHAFT STOPPER (498497300)

CONTINUOUSLY VARIABLE TRANSMISSION(TR580) > Drive Plate　

INSTALLATION

1.

Temporarily attach the reinforcement drive plate, drive plate and crankshaft position sensor plate, and set the ST.

Install with the stamped mark of the crankshaft position sensor plate facing the transmission side.
Align the knock pin hole of the crankshaft position sensor plate to the knock pin of the crankshaft to secure the knock pin.

(A)

Crankshaft position sensor plate

(B)

Drive plate

(C)

Reinforcement drive plate

Preparation tool:

ST: CRANKSHAFT STOPPER (498497300)

2.

Tighten the bolts securing the drive plate.

(1)

Tighten the bolts securing the drive plate.

Tightening torque:

30 N·m (3.1kgf-m, 22.1ft-lb)

(2)

Using an angle gauge, further tighten the bolts securing the drive plate.

Tightening angle:

30° — 35°

3.

Install the transmission body. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Transmission Assembly>INSTALLATION

CONTINUOUSLY VARIABLE TRANSMISSION(TR580) > Drive Plate　

INSPECTION

Check that there is no deformation, cracks or other damages.

CONTINUOUSLY VARIABLE TRANSMISSION(TR580) > Torque Converter　

REMOVAL

1.

Remove the transmission body. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Transmission Assembly>REMOVAL

2.

Remove the ST from converter case.

3.

Pull out the torque converter horizontally.

Do not scratch the inside of engaging parts.

4.

Remove the O-ring from the input shaft.

CONTINUOUSLY VARIABLE TRANSMISSION(TR580) > Torque Converter　

INSTALLATION

1.

Install a new O-ring to the input shaft.

Apply CVTF to the O-rings.

2.

Install the torque converter.

Do not damage the oil seal and O-ring.

Apply CVTF to the oil seal lip.
Engage the splines while gently rotating the torque converter by hand.

3.

Measure the dimension “A” from converter case end surface to drive plate mounting surface.

Specification:

6.8 mm (0.268in) or less

4.

Attach the ST to converter case.

Preparation tool:

ST: STOPPER SET (498277200)

5.

Install the transmission body. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Transmission Assembly>INSTALLATION

CONTINUOUSLY VARIABLE TRANSMISSION(TR580) > Torque Converter　

INSPECTION

Check that there is no deformation, cracks or other damages.

CONTINUOUSLY VARIABLE TRANSMISSION(TR580) > Preparation for Overhaul　

PROCEDURE

1. BEFORE OVERHAUL

1.

Remove the torque converter. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Torque Converter>REMOVAL

2.

Attach the ST.

When attaching the ST to the (a) positions, spacers or similar of 2.0 mm (0.08in) or more in thickness are necessary.

Preparation tool:

ST: STAND ASSY (18632AA000)

3.

Place the transmission body.

Prepare a container for draining of oil, because CVTF remaining inside the transmission body may flow out from the input shaft portion.

2. AFTER OVERHAUL

1.

Install the torque converter. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Torque Converter>INSTALLATION

2.

Remove the filler plug (for overhaul), and refill approx. 10 L (10.6 US qt, 8.8 Imp qt) of CVTF.

Always use specified CVTF. Using fluid other than specified CVTF will cause malfunction. RECOMMENDED MATERIALS>GREASE>CVTF

3.

Using a new gasket, install the filler plug (for overhaul).

Tightening torque:

50 N·m (5.1kgf-m, 36.9ft-lb)

CONTINUOUSLY VARIABLE TRANSMISSION(TR580) > Extension Case　

REMOVAL

1.

Remove the transmission body. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Transmission Assembly>REMOVAL

2.

Remove the electric oil pump. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Electric Fluid Pump>REMOVAL

3.

Remove the extension case and transmission hanger (A).

4.

Remove the O-ring from the transmission case.

5.

Remove the liquid gasket from the extension case and the transmission case.

CONTINUOUSLY VARIABLE TRANSMISSION(TR580) > Extension Case　

INSTALLATION

1.

Select the transfer drive gear shim. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Reduction Driven Gear>ADJUSTMENT

2.

Select the transfer driven gear shim. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Transfer Clutch>ADJUSTMENT

3.

Attach the selected transfer drive gear shim to extension case with vaseline.

4.

Attach the selected transfer driven gear shim to extension case with vaseline.

5.

Install a new O-ring to the transmission case.

Apply CVTF to the O-rings.

6.

Apply liquid gasket to the mating surface of the extension case as shown in the figure, and temporarily install the extension case.

Before applying liquid gasket, degrease the old liquid gasket seal surfaces of the extension case and transmission case.
Install within 5 min. after applying liquid gasket.

Liquid gasket:

THREE BOND 1215B or equivalent

7.

Install the extension case to transmission hanger.

Tightening torque:

25 N·m (2.5kgf-m, 18.4ft-lb)

8.

Install the electric oil pump. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Electric Fluid Pump>INSTALLATION

9.

Install the transmission body. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Transmission Assembly>INSTALLATION

CONTINUOUSLY VARIABLE TRANSMISSION(TR580) > Extension Case　

DISASSEMBLY

1.

Remove the extension case oil seal from the extension case. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Extension Case Oil Seal>REPLACEMENT

2.

Remove the dust cover from extension case.

3.

Remove all plugs.

CONTINUOUSLY VARIABLE TRANSMISSION(TR580) > Extension Case　

ASSEMBLY

1.

Install all plugs using new O-rings or gaskets.

Apply CVTF to the O-rings.

Tightening torque:

T1: 22 N·m (2.2kgf-m, 16.2ft-lb)

T2: 35 N·m (3.6kgf-m, 25.8ft-lb)

2.

Install the dust cover into extension case.

3.

Install a new extension case oil seal to extension case. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Extension Case Oil Seal>REPLACEMENT

CONTINUOUSLY VARIABLE TRANSMISSION(TR580) > Extension Case　

INSPECTION

1.

Check for oil leaks.

2.

Check that there is no deformation, cracks or other damages.

CONTINUOUSLY VARIABLE TRANSMISSION(TR580) > Extension Case　

ADJUSTMENT

When replacing the extension case, select the transfer drive gear shim and transfer driven gear shim.

Refer to “Reduction Driven Gear” for selection of the transfer drive gear shim. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Reduction Driven Gear>ADJUSTMENT
Refer to “Transfer Clutch” for selection of the transfer driven gear shim. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Transfer Clutch>ADJUSTMENT

CONTINUOUSLY VARIABLE TRANSMISSION(TR580) > Transfer Clutch　

REMOVAL

1.

Remove the transmission body. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Transmission Assembly>REMOVAL

2.

Remove the electric oil pump. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Electric Fluid Pump>REMOVAL

3.

Remove the extension case. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Extension Case>REMOVAL

4.

Remove the transfer clutch.

5.

Remove the thrust bearing.

6.

Remove the seal rings.

7.

Remove the seal rings.

CONTINUOUSLY VARIABLE TRANSMISSION(TR580) > Transfer Clutch　

INSTALLATION

1.

Install the thrust bearing.

Make sure to install in the right direction.

2.

Install the transfer clutch.

3.

Select the transfer driven gear shim.

4.

Remove the transfer clutch from the extension case.

5.

Attach the selected transfer driven gear shim to extension case with vaseline.

6.

Install a new seal ring to the transfer clutch.

Apply CVTF to the seal rings.

7.

Install a new seal ring to the transfer driven gear.

Apply CVTF to the seal rings.

8.

Install the transfer clutch.

9.

Install the extension case. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Extension Case>INSTALLATION

10.

Install the electric oil pump. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Electric Fluid Pump>INSTALLATION

11.

Install the transmission body. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Transmission Assembly>INSTALLATION

CONTINUOUSLY VARIABLE TRANSMISSION(TR580) > Transfer Clutch　

DISASSEMBLY

1.

Remove the snap ring (A), and then remove the pressure plate, drive plate and driven plate.

2.

Compress the return spring using the ST and a press to remove the snap ring (A) and the transfer clutch piston seal (B).

Preparation tool:

ST: COMPRESSOR SPECIAL TOOL (18762AA001)

3.

Remove the return spring.

4.

Remove the transfer clutch piston by blowing compressed air through transfer clutch hole.

Plug the holes through which the compressed air is not blown.

5.

Remove the ball bearing using ST1, ST2 and a press.

Preparation tool:

ST1: BEARING REMOVER (18767AA010)

ST2: REMOVER (18723AA000)

CONTINUOUSLY VARIABLE TRANSMISSION(TR580) > Transfer Clutch　

ASSEMBLY

1.

Install the transfer clutch piston.

Apply CVTF to the transfer clutch piston lip.

2.

Install the return spring.

3.

Install the transfer clutch piston seal (B).

Apply CVTF to the lip section of transfer clutch piston seal.

4.

Compress the return spring using the ST and a press to install the snap ring (A).

Preparation tool:

ST: COMPRESSOR SPECIAL TOOL (18762AA001)

5.

Install the pressure plate and transfer clutch plate set, and then install the snap ring (A).

6.

Blow compressed air through transfer clutch hole, and check the transfer clutch piston operation.

Plug the holes through which the compressed air is not blown.

7.

Before measuring clearance “A”, place same thickness shims on both sides to prevent the plate from tilting.

8.

When the clearance “A” exceeds the limit, select the transfer clutch plate set and pressure plate, and adjust the clearance “A” within the specified value.

Specification:

0.7 — 1.1 mm (0.028 — 0.043in)

Service limit:

1.3 mm (0.051in)

(1)

Measure the thickness of the pressure plate for the transfer clutch plate set that has been used before replacement.

(2)

Select the transfer clutch plate set that uses the pressure plate of which the value is close to the measured value in (1), and check the clearance “A”.

(3)

When the clearance “A” exceeds the limit for use in step (2), replace the pressure plate installed on the lower side of the transfer clutch plate set, and check the clearance “A” again.

(4)

When the clearance “A” exceeds the limit for use in step (3), select the transfer clutch plate set that was not used in step (2), and adjust the clearance “A” again.

9.

Check the clearance between snap ring and pressure plate. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Transfer Clutch>INSPECTION

10.

Install a new ball bearing using ST1, ST2 and a press.

Apply CVTF to the ball bearing.

Preparation tool:

ST1: INSTALLER (398177700)

ST2: INSTALLER (499277200)

CONTINUOUSLY VARIABLE TRANSMISSION(TR580) > Transfer Clutch　

INSPECTION

1.

Check that there is no deformation, cracks or other damages.

2.

Check the driven plate for discoloration (burnt color).

3.

Before measuring clearance “A” between snap ring and driven plate, place same thickness shims on both sides to prevent the plate from tilting.

4.

When clearance “A” exceeds the limit, replace the drive plate and driven plate as a set, and select the pressure plate within the specified value.

Specification:

0.7 — 1.1 mm (0.028 — 0.043in)

Service limit:

1.3 mm (0.051in)

5.

Check for tight corner braking phenomenon when the vehicle is moved forward with the steering fully turned. If tight corner braking occurs, perform the following procedures.

(1)

Turn OFF the X mode switch. (Model with X mode switch)

(2)

With the steering wheel held at fully turned position, drive the vehicle in “D range” and with vehicle speed at approx. 5 km/h (3 MPH) in both clockwise and counterclockwise directions for approx. ten times each, while repeating acceleration and braking intermittently.

(3)

If the tight corner braking phenomenon still persists, drive the vehicle again in a circle for several laps.

CONTINUOUSLY VARIABLE TRANSMISSION(TR580) > Transfer Clutch　

ADJUSTMENT

1.

Install the transfer clutch to the extension case with the transfer driven gear shims and thrust bearings removed.

2.

Install the thrust bearing.

Make sure to install in the right direction.

3.

Using the ST, measure the height “A” from the ST end face to the thrust bearing catch surface of the transfer clutch.

Preparation tool:

ST: GAUGE (499575500)

4.

Using the ST, measure the height “B” from the transmission case mating surface to the end of ST.

Preparation tool:

ST: GAUGE (499575500)

5.

Obtain the thickness of transfer driven gear shim using the following formula to select one to three transfer driven gear shims.

T mm = A − B − (0.05 — 0.25)

[T in = A − B − (0.002 — 0.01)]

T: Transfer driven gear shim thickness

A: Height from the ST end face to the transfer clutch thrust bearing catch surface

B: Height from the mating surface of the transmission case to the end of the ST

0.05 — 0.25 mm (0.002 — 0.01in): Clearance

CONTINUOUSLY VARIABLE TRANSMISSION(TR580) > Transfer Driven Gear　

REMOVAL

1.

Remove the transmission body. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Transmission Assembly>REMOVAL

2.

Remove the electric oil pump. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Electric Fluid Pump>REMOVAL

3.

Remove the extension case. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Extension Case>REMOVAL

4.

Remove the transfer clutch. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Transfer Clutch>REMOVAL

5.

Remove the transfer driven gear.

6.

Remove the seal rings.

CONTINUOUSLY VARIABLE TRANSMISSION(TR580) > Transfer Driven Gear　

INSTALLATION

1.

Install the transfer driven gear.

2.

Install the transfer clutch. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Transfer Clutch>INSTALLATION

3.

Select the transfer driven gear shim. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Transfer Clutch>ADJUSTMENT

4.

Install the extension case. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Extension Case>INSTALLATION

5.

Install the electric oil pump. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Electric Fluid Pump>INSTALLATION

6.

Install the transmission body. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Transmission Assembly>INSTALLATION

CONTINUOUSLY VARIABLE TRANSMISSION(TR580) > Transfer Driven Gear　

DISASSEMBLY

1.

Remove the ball bearing using ST1, ST2 and a press.

Preparation tool:

ST1: REMOVER (498077400)

ST2: REMOVER (899864100)

CONTINUOUSLY VARIABLE TRANSMISSION(TR580) > Transfer Driven Gear　

ASSEMBLY

1.

Using the ST and a press, install the ball bearing.

Apply CVTF to the ball bearing.

Preparation tool:

ST: INSTALLER (899580100)

CONTINUOUSLY VARIABLE TRANSMISSION(TR580) > Transfer Driven Gear　

INSPECTION

1.

Check that there is no deformation, cracks or other damages.

2.

Check the ball bearing for smooth rotation.

3.

Check the ball bearing for excessive looseness.

CONTINUOUSLY VARIABLE TRANSMISSION(TR580) > Transfer Driven Gear　

ADJUSTMENT

When the transfer driven gear or ball bearing is replaced, select the transfer driven gear shim. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Transfer Clutch>ADJUSTMENT

CONTINUOUSLY VARIABLE TRANSMISSION(TR580) > Transfer Drive Gear　

SPECIFICATION

Refer to “Reduction Driven Gear” for removal and installation procedures.

CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Reduction Driven Gear>DISASSEMBLY
CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Reduction Driven Gear>ASSEMBLY

CONTINUOUSLY VARIABLE TRANSMISSION(TR580) > Parking Pawl　

REMOVAL

1.

Remove the transmission body. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Transmission Assembly>REMOVAL

2.

Shift the inhibitor switch to “N range”.

Align the holes of the shifter arm and inhibitor switch.

3.

Remove the electric oil pump. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Electric Fluid Pump>REMOVAL

4.

Remove the extension case. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Extension Case>REMOVAL

5.

Remove the parking pawl shaft (A), return spring (B) and parking pawl (C).

CONTINUOUSLY VARIABLE TRANSMISSION(TR580) > Parking Pawl　

INSTALLATION

1.

Confirm that the inhibitor switch is in the “N range”.

2.

Install the parking pawl shaft (A), return spring (B) and parking pawl (C).

Make sure that the end of return spring sticks out of parking pawl as shown in (a). Make sure that the other end contacts the rib of transmission case as shown in (b).

3.

Install the extension case. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Extension Case>INSTALLATION

4.

Install the electric oil pump. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Electric Fluid Pump>INSTALLATION

5.

Install the transmission body. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Transmission Assembly>INSTALLATION

CONTINUOUSLY VARIABLE TRANSMISSION(TR580) > Parking Pawl　

INSPECTION

Check that there is no deformation, cracks or other damages.

CONTINUOUSLY VARIABLE TRANSMISSION(TR580) > Reduction Driven Gear　

REMOVAL

1.

Remove the transmission body. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Transmission Assembly>REMOVAL

2.

Remove the electric oil pump. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Electric Fluid Pump>REMOVAL

3.

Remove the extension case. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Extension Case>REMOVAL

4.

Remove the transfer clutch. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Transfer Clutch>REMOVAL

5.

Remove the transfer driven gear. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Transfer Driven Gear>REMOVAL

6.

Remove the parking pawl. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Parking Pawl>REMOVAL

7.

Remove the reduction driven gear and oil spacer.

CONTINUOUSLY VARIABLE TRANSMISSION(TR580) > Reduction Driven Gear　

INSTALLATION

1.

Install the reduction driven gear and oil spacer.

Tightening torque:

17 N·m (1.7kgf-m, 12.5ft-lb)

2.

Select the transfer drive gear shim. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Reduction Driven Gear>ADJUSTMENT

3.

Install the parking pawl. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Parking Pawl>INSTALLATION

4.

Attach the selected transfer drive gear shim to extension case with vaseline.

5.

Install the transfer driven gear. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Transfer Driven Gear>INSTALLATION

6.

Install the transfer clutch. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Transfer Clutch>INSTALLATION

7.

Install the extension case. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Extension Case>INSTALLATION

8.

Install the electric oil pump. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Electric Fluid Pump>INSTALLATION

9.

Install the transmission body. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Transmission Assembly>INSTALLATION

CONTINUOUSLY VARIABLE TRANSMISSION(TR580) > Reduction Driven Gear　

DISASSEMBLY

1.

Flatten the tab of the lock nut.

2.

Using the ST1, ST2 and ST3, counter the rotation of the reduction driven gear, and remove the lock nut.

Place cloth between the contacting surface of the vise and the reduction driven gear to prevent reduction driven gear damage.

Preparation tool:

ST1: PULLEY WRENCH (18355AA000)

ST2: PULLEY WRENCH PIN SET (18334AA000)

ST3: SOCKET WRENCH (35) (499987003)

3.

Remove the ball bearing using ST1, ST2 and a press.

Preparation tool:

ST1: INSTALLER (499757002)

ST2: REMOVER (498077300)

4.

Using the ST and a press, remove the parking gear and transfer drive gear.

Preparation tool:

ST: REMOVER (899864100)

5.

Remove the snap ring from reduction driven gear.

CONTINUOUSLY VARIABLE TRANSMISSION(TR580) > Reduction Driven Gear　

ASSEMBLY

1.

Using the ST and a press, install the parking gear.

Apply CVTF to the press-fitting surface of the parking gear.

Preparation tool:

ST: INSTALLER (499757002)

2.

Using the ST and a press, install the transfer drive gear.

Apply CVTF to the press-fitting surface of the transfer drive gear.

Preparation tool:

ST: INSTALLER (499757002)

3.

Using the ST and a press, install a new ball bearing.

Apply CVTF to the ball bearing.

Preparation tool:

ST: BUSHING 1-2 INSTALLER (499277100)

4.

Using the ST1, ST2 and ST3, counter the rotation of the reduction driven gear, and install a new lock nut.

Place cloth between the contacting surface of the vise and the reduction driven gear to prevent reduction driven gear damage.

Preparation tool:

ST1: PULLEY WRENCH (18355AA000)

ST2: PULLEY WRENCH PIN SET (18334AA000)

ST3: SOCKET WRENCH (35) (499987003)

Tightening torque:

95 N·m (9.7kgf-m, 70.1ft-lb)

5.

Crimp the lock nut so that the dimension of A becomes 18.9 mm (0.74in) or less.

Do not allow the lock nut to be cracked during crimping operation.

6.

Install the snap ring.

CONTINUOUSLY VARIABLE TRANSMISSION(TR580) > Reduction Driven Gear　

INSPECTION

1.

Check that there is no deformation, cracks or other damages.

2.

Check the ball bearing for smooth rotation.

3.

Check the ball bearing for excessive looseness.

CONTINUOUSLY VARIABLE TRANSMISSION(TR580) > Reduction Driven Gear　

ADJUSTMENT

1.

Measure the height “A” from the ST upper face to the ball bearing catch surface.

Preparation tool:

ST: GAUGE (499575600)

2.

Measure the height “B” from the ST to the mating surface of the transmission case.

Preparation tool:

ST: GAUGE (499575600)

3.

Obtain the thickness of transfer drive gear shim using the following formula to select one to three transfer drive gear shims.

T mm = A − B − (0.05 — 0.25)

[T in = A − B − (0.002 — 0.01) ]

T: Shim thickness

A: Height from the ST upper face to the ball bearing catch surface

B: Height from ST to transmission case mating surface

0.05 — 0.25 mm (0.002 — 0.01in): Clearance

CONTINUOUSLY VARIABLE TRANSMISSION(TR580) > Transmission Control Device　

REMOVAL

1.

Remove the transmission body. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Transmission Assembly>REMOVAL

2.

Remove the inhibitor switch. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Inhibitor Switch>REMOVAL

3.

Remove the oil pan and oil strainer. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Oil Pan>REMOVAL

4.

Shift the manual plate to “N range”, and remove the spring pin.

Prevent the spring pin from dropping using paper towel, etc.

5.

Remove the detent spring.

6.

Remove the bolt securing the shifter arm shaft, and remove the shifter arm shaft.

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

7.

Remove the shift connecting rod (C) of manual valve.

8.

Remove the parking rod (A) and manual plate (B).

9.

Remove the manual valve.

10.

Remove the extension case. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Extension Case>REMOVAL

11.

Remove the parking support.

CONTINUOUSLY VARIABLE TRANSMISSION(TR580) > Transmission Control Device　

INSTALLATION

1.

Install the parking support.

Tightening torque:

25 N·m (2.5kgf-m, 18.4ft-lb)

2.

Install the extension case. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Extension Case>INSTALLATION

3.

Install the manual valve.

4.

Install the manual plate (B) to the parking rod (A).

5.

Install the shift connecting rod (C) of manual valve.

6.

Insert the shifter arm shaft to the transmission body, install the manual plate to the shifter arm shaft, and secure the shifter arm shaft with a bolt.

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

Tightening torque:

7 N·m (0.7kgf-m, 5.2ft-lb)

7.

Install the detent spring.

Tightening torque:

7 N·m (0.7kgf-m, 5.2ft-lb)

8.

Install a new spring pin.

9.

Install the inhibitor switch. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Inhibitor Switch>INSTALLATION

10.

Install the oil strainer and oil pan. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Oil Pan>INSTALLATION

11.

Install the transmission body. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Transmission Assembly>INSTALLATION

CONTINUOUSLY VARIABLE TRANSMISSION(TR580) > Transmission Control Device　

INSPECTION

Check that there is no deformation, cracks or other damages.

CONTINUOUSLY VARIABLE TRANSMISSION(TR580) > Transmission Case　

REMOVAL

1.

Remove the transmission body. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Transmission Assembly>REMOVAL

2.

Remove the air breather hose. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Air Breather Hose>REMOVAL

3.

Remove the control valve body. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Control Valve Body>REMOVAL

4.

Remove the transmission harness. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Transmission Harness>REMOVAL

5.

Remove the turbine speed sensor. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Turbine Speed Sensor>REMOVAL

6.

Remove the secondary speed sensor. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Secondary Speed Sensor>REMOVAL

7.

Remove the primary speed sensor. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Primary Speed Sensor>REMOVAL

8.

Remove the inhibitor switch. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Inhibitor Switch>REMOVAL

9.

Remove the electric oil pump. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Electric Fluid Pump>REMOVAL

10.

Remove the extension case. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Extension Case>REMOVAL

11.

Remove the transfer clutch. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Transfer Clutch>REMOVAL

12.

Remove the transfer driven gear. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Transfer Driven Gear>REMOVAL

13.

Remove the parking pawl. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Parking Pawl>REMOVAL

14.

Remove the reduction driven gear. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Reduction Driven Gear>REMOVAL

15.

Remove the oil pan and oil strainer. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Oil Pan>REMOVAL

16.

Remove the transmission control device. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Transmission Control Device>REMOVAL

17.

Remove the bolt securing the oil baffle.

18.

Remove the oil cooler pipe.

19.

Remove the transmission case.

20.

Remove the oil pressure pipe and the oil baffle.

21.

Remove the O-rings.

22.

Remove the seal ring from the transmission case.

23.

Remove the liquid gasket from the transmission case and converter case.

CONTINUOUSLY VARIABLE TRANSMISSION(TR580) > Transmission Case　

INSTALLATION

1.

Select the reduction drive gear shim. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Reduction Drive Gear>ADJUSTMENT

2.

Remove the transmission case, and install the selected reduction drive gear shim to the reduction drive gear.

3.

Install new O-rings to the reverse clutch housing and drive pinion retainer.

Apply CVTF to the O-rings.

4.

Install a new seal ring to the transmission case.

Apply CVTF to the seal rings.

5.

Install a new O-ring to the oil pressure pipe.

Apply CVTF to the O-rings.

6.

Temporarily install the oil baffle with bolts, and then install the oil pressure pipe.

7.

Apply liquid gasket to the mating surface of the transmission case as shown in the figure, and temporarily install the transmission case.

Before applying liquid gasket, degrease the old liquid gasket seal surface of the transmission case and converter case.
Install within 5 min. after applying liquid gasket.

Liquid gasket:

THREE BOND 1215B or equivalent

8.

Tighten the bolts evenly.

Tightening torque:

22 N·m (2.2kgf-m, 16.2ft-lb)

9.

Install the oil cooler pipe using a new O-ring.

Apply CVTF to the O-rings.

Tightening torque:

25 N·m (2.5kgf-m, 18.4ft-lb)

10.

Tighten the bolt securing the oil baffle, and install the remaining bolts.

Tightening torque:

16 N·m (1.6kgf-m, 11.8ft-lb)

11.

Install the transmission control device. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Transmission Control Device>INSTALLATION

12.

Install the oil pan and oil strainer. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Oil Pan>INSTALLATION

13.

Install the reduction driven gear. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Reduction Driven Gear>INSTALLATION

14.

Install the parking pawl. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Parking Pawl>INSTALLATION

15.

Install the transfer driven gear. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Transfer Driven Gear>INSTALLATION

16.

Install the transfer clutch. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Transfer Clutch>INSTALLATION

17.

Install the extension case. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Extension Case>INSTALLATION

18.

Install the electric oil pump. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Electric Fluid Pump>INSTALLATION

19.

Install the inhibitor switch. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Inhibitor Switch>INSTALLATION

20.

Install the secondary speed sensor. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Secondary Speed Sensor>INSTALLATION

21.

Install the primary speed sensor. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Primary Speed Sensor>INSTALLATION

22.

Install the turbine speed sensor. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Turbine Speed Sensor>INSTALLATION

23.

Install the transmission harness. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Transmission Harness>INSTALLATION

24.

Install the control valve body. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Control Valve Body>INSTALLATION

25.

Install the air breather hose. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Air Breather Hose>INSTALLATION

26.

Install the transmission body. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Transmission Assembly>INSTALLATION

CONTINUOUSLY VARIABLE TRANSMISSION(TR580) > Transmission Case　

DISASSEMBLY

1.

Remove the oil stopper plate.

2.

Remove the plug, and remove the oil control valve holder.

(A)	Oil control valve holder

3.

Remove the O-ring from the oil control valve holder.

4.

Remove all plugs.

5.

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

6.

Remove the ball bearing of the secondary pulley using the ST1 and ST2.

(1)

Remove the claw (A) of ST1, and attach the claw of ST2.

Preparation tool:

ST1: PULLER ASSY (398527700)

ST2: CLAW (18760AA000)

(2)

Remove the ball bearing of the secondary pulley using the ST1 and ST2.

Preparation tool:

ST1: PULLER ASSY (398527700)

ST2: CLAW (18760AA000)

7.

Remove the oil guide.

8.

Remove the roller bearing.

9.

Remove the thrust bearing.

10.

Remove the CVTF filter cover and gasket.

11.

Remove the CVTF filter.

CONTINUOUSLY VARIABLE TRANSMISSION(TR580) > Transmission Case　

ASSEMBLY

1.

Install the CVTF filter with its O-ring side faced to the transmission case side.

Apply CVTF to the O-rings.

2.

Using a new gasket, install the CVTF filter cover.

Tightening torque:

17 N·m (1.7kgf-m, 12.5ft-lb)

3.

Install a new oil seal using ST.

Apply CVTF to the oil seal lip and press-fitting surface.

Preparation tool:

ST: INSTALLER (18657AA000)

4.

Using a new O-ring, install the oil control valve holder, and install the plug.

Apply CVTF to the O-rings.

Tightening torque:

50 N·m (5.1kgf-m, 36.9ft-lb)

5.

Install the oil guide.

6.

Press-fit the spring pin into a new ball bearing (secondary pulley side).

(1)

Hold the spring pin with a knock pin punch or the like, and press-fit with a hammer.

Insert wooden pieces between the contacting surfaces of the vise and the bearing race to prevent bearing race damage.

(2)

Measure the height “A” of the spring pin.

Specification:

4.4 mm (0.173in) or less

7.

Install the ball bearing (secondary pulley side) using ST1, ST2, ST3 and a press.

Align the spring pin (B) to the cutout of the transmission case.
Press-fit the spring pin (B) so that it is positioned on near side (the retainer (A) should be seen on your side).

Preparation tool:

ST1: BUSHING 1-2 INSTALLER (499277100)

ST2: INSTALLER (398177700)

ST3: PRESS SNAP RING (28499TC010)

8.

Install the plugs using new O-rings and new gaskets.

Apply CVTF to the O-rings.
For the plug (a), fill the CVTF, and then tighten the plug using a new gasket.

Tightening torque:

T1: 13 N·m (1.3kgf-m, 9.6ft-lb)

T2: 22 N·m (2.2kgf-m, 16.2ft-lb)

T3: 50 N·m (5.1kgf-m, 36.9ft-lb)

9.

Install the oil stopper plate.

Always use a new MEC (Micro-encapsulated) bolt.

Tightening torque:

9 N·m (0.9kgf-m, 6.6ft-lb)

10.

Install the thrust bearing.

Make sure to install in the right direction.

11.

Install the roller bearing.

CONTINUOUSLY VARIABLE TRANSMISSION(TR580) > Transmission Case　

INSPECTION

1.

Check for oil leaks.

2.

Check that there is no deformation, cracks or other damages.

3.

Check the bearings for smooth operation.

4.

Check all the bearings for seizure.

CONTINUOUSLY VARIABLE TRANSMISSION(TR580) > Transmission Case　

ADJUSTMENT

When replacing the transmission case with a new part, perform the following adjustment.

Select the transfer driven gear shim. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Transfer Clutch>ADJUSTMENT
Select the transfer drive gear shim. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Reduction Driven Gear>ADJUSTMENT
Select the reduction drive gear shim. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Reduction Drive Gear>ADJUSTMENT

CONTINUOUSLY VARIABLE TRANSMISSION(TR580) > CVTF Filter　

SPECIFICATION

Refer to “Transmission Case” for removal and installation procedures.

During installation, check if a large quantity of wear debris or metal particles are in CVTF and CVTF filter.

CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Transmission Case>DISASSEMBLY
CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Transmission Case>ASSEMBLY

CONTINUOUSLY VARIABLE TRANSMISSION(TR580) > Reduction Drive Gear　

REMOVAL

1.

Remove the transmission body. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Transmission Assembly>REMOVAL

2.

Remove the air breather hose. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Air Breather Hose>REMOVAL

3.

Remove the control valve body. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Control Valve Body>REMOVAL

4.

Remove the transmission harness. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Transmission Harness>REMOVAL

5.

Remove the turbine speed sensor. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Turbine Speed Sensor>REMOVAL

6.

Remove the secondary speed sensor. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Secondary Speed Sensor>REMOVAL

7.

Remove the primary speed sensor. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Primary Speed Sensor>REMOVAL

8.

Remove the inhibitor switch. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Inhibitor Switch>REMOVAL

9.

Remove the electric oil pump. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Electric Fluid Pump>REMOVAL

10.

Remove the extension case. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Extension Case>REMOVAL

11.

Remove the transfer clutch. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Transfer Clutch>REMOVAL

12.

Remove the transfer driven gear. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Transfer Driven Gear>REMOVAL

13.

Remove the parking pawl. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Parking Pawl>REMOVAL

14.

Remove the reduction driven gear. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Reduction Driven Gear>REMOVAL

15.

Remove the oil pan and oil strainer. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Oil Pan>REMOVAL

16.

Remove the transmission control device. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Transmission Control Device>REMOVAL

17.

Remove the transmission case. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Transmission Case>REMOVAL

18.

Remove the reduction drive gear shim.

19.

Remove the reduction drive gear.

CONTINUOUSLY VARIABLE TRANSMISSION(TR580) > Reduction Drive Gear　

INSTALLATION

1.

Install the reduction drive gear.

2.

Select the reduction drive gear shim. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Reduction Drive Gear>ADJUSTMENT

3.

Install the selected reduction drive gear shim.

4.

Install the transmission case. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Transmission Case>INSTALLATION

5.

Install the transmission control device. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Transmission Control Device>INSTALLATION

6.

Install the oil strainer and oil pan. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Oil Pan>INSTALLATION

7.

Install the reduction driven gear. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Reduction Driven Gear>INSTALLATION

8.

Install the parking pawl. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Parking Pawl>INSTALLATION

9.

Install the transfer driven gear. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Transfer Driven Gear>INSTALLATION

10.

Install the transfer clutch. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Transfer Clutch>INSTALLATION

11.

Install the extension case. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Extension Case>INSTALLATION

12.

Install the electric oil pump. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Electric Fluid Pump>INSTALLATION

13.

Install the inhibitor switch. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Inhibitor Switch>INSTALLATION

14.

Install the secondary speed sensor. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Secondary Speed Sensor>INSTALLATION

15.

Install the primary speed sensor. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Primary Speed Sensor>INSTALLATION

16.

Install the turbine speed sensor. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Turbine Speed Sensor>INSTALLATION

17.

Install the transmission harness. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Transmission Harness>INSTALLATION

18.

Install the control valve body. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Control Valve Body>INSTALLATION

19.

Install the air breather hose. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Air Breather Hose>INSTALLATION

20.

Install the transmission body. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Transmission Assembly>INSTALLATION

CONTINUOUSLY VARIABLE TRANSMISSION(TR580) > Reduction Drive Gear　

INSPECTION

Check that there is no deformation, cracks or other damages.

CONTINUOUSLY VARIABLE TRANSMISSION(TR580) > Reduction Drive Gear　

ADJUSTMENT

1.

Remove the reduction drive gear shim.

2.

Install the transmission case, and secure it with four or five bolts.

Tightening torque:

22 N·m (2.2kgf-m, 16.2ft-lb)

3.

Measure depth “A” from the ST upper face to the reduction drive gear end face.

Preparation tool:

ST: GAUGE (499575400)

4.

Raise and hold the reduction drive gear.

5.

Measure depth “B” from the ST upper face to the reduction drive gear end face.

Preparation tool:

ST: GAUGE (499575400)

6.

Obtain the thickness of reduction drive gear shim using the following formula to select one to three reduction drive gear shims.

T mm = A − B − (0.05 — 0.25)

[T in = A − B − (0.002 — 0.01)]

T: Reduction drive gear shim thickness

A: Depth from the ST upper face to the reduction drive gear end surface

B: Depth from the ST upper face to the reduction drive gear end surface

0.05 — 0.25 mm (0.002 — 0.01 in): Clearance

CONTINUOUSLY VARIABLE TRANSMISSION(TR580) > Primary Pulley and Secondary Pulley　

REMOVAL

Always replace primary pulley and secondary pulley as a set because they are non-disassembled parts.

1.

Remove the transmission body. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Transmission Assembly>REMOVAL

2.

Remove the air breather hose. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Air Breather Hose>REMOVAL

3.

Remove the control valve body. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Control Valve Body>REMOVAL

4.

Remove the transmission harness. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Transmission Harness>REMOVAL

5.

Remove the turbine speed sensor. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Turbine Speed Sensor>REMOVAL

6.

Remove the secondary speed sensor. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Secondary Speed Sensor>REMOVAL

7.

Remove the primary speed sensor. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Primary Speed Sensor>REMOVAL

8.

Remove the inhibitor switch. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Inhibitor Switch>REMOVAL

9.

Remove the electric oil pump. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Electric Fluid Pump>REMOVAL

10.

Remove the extension case. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Extension Case>REMOVAL

11.

Remove the transfer clutch. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Transfer Clutch>REMOVAL

12.

Remove the transfer driven gear. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Transfer Driven Gear>REMOVAL

13.

Remove the parking pawl. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Parking Pawl>REMOVAL

14.

Remove the reduction driven gear. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Reduction Driven Gear>REMOVAL

15.

Remove the oil pan and oil strainer. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Oil Pan>REMOVAL

16.

Remove the transmission control device. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Transmission Control Device>REMOVAL

17.

Remove the transmission case. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Transmission Case>REMOVAL

18.

Remove the reduction drive gear. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Reduction Drive Gear>REMOVAL

19.

Set the ST to secondary pulley, expand the V groove, and then completely loosen the variator chain.

Preparation tool:

ST: EXPANDER PULLEY (18769AA010)

20.

Remove the chain guide.

(1)

Remove the chain guide from lubrication pipe.

(2)

While pushing the claw (A) down, slide the upper chain guide to the direction of the arrow and remove the chain guide.

(3)

Remove the lubrication pipe.

(4)

Remove the bolt securing the support rod.

(5)

Raise the support rod, and remove the chain guide. Then, remove the support rod.

Protect the primary pulley, secondary pulley and variator chain from scratching.

(6)

Move the chain guide to the secondary pulley side.

(7)

While pushing the claw (A) down, slide the upper chain guide to the direction of the arrow and remove the chain guide.

21.

Remove the bolt securing the primary pulley.

22.

Remove the primary pulley.

Cover the V grooves of primary pulley and secondary pulley with cloth to protect the primary pulley, secondary pulley and variator chain from scratching.

23.

Remove the variator chain and ST (EXPANDER PULLEY) from the secondary pulley.

24.

Remove the bolt securing the secondary pulley, and remove the secondary pulley.

25.

Remove the seal rings.

26.

Remove the seal rings.

CONTINUOUSLY VARIABLE TRANSMISSION(TR580) > Primary Pulley and Secondary Pulley　

INSTALLATION

1.

Select shims for primary pulley. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Primary Pulley and Secondary Pulley>ADJUSTMENT

2.

Install a new seal ring to the input shaft.

Apply CVTF to the seal rings.

3.

Install new seal rings to drive pinion retainer.

Apply CVTF to the seal rings.

4.

Install the selected shims to the primary pulley bearing catch surface.

5.

Install the secondary pulley to the drive pinion retainer.

6.

Install the secondary pulley securing bolts.

(1)

Tighten the three bolts until the seating surfaces contact the bearing retainer.

Be careful not to tilt the bearing retainer of the secondary pulley.
Apply CVTF to the bolt.

(A)

Secondary pulley

(B)

Bearing retainer

(2)

Tighten the bolts in the order of (A) → (B) → (C) → (B).

Tightening torque:

67.5N·m (6.9kgf-m, 49.8ft-lb)

7.

Place the variator chain on the V groove of the secondary pulley, set the ST and expand the V groove.

Preparation tool:

ST: EXPANDER PULLEY (18769AA010)

8.

Install the primary pulley together with the variator chain to the reverse brake housing.

Cover the V grooves of primary pulley and secondary pulley with cloth to protect the both pulleys and variator chain from scratching.

(1)

Intersect the V groove of primary pulley and the V groove of secondary pulley and install the secondary pulley while placing the variator chain on secondary pulley.

(2)

Install the primary pulley to the reverse brake housing so that the bolt hole of primary bearing retainer and the bolt hole of reverse brake housing are aligned.

9.

Install the primary pulley bolt.

Apply CVTF to the bolt.

Tightening torque:

21 N·m (2.1kgf-m, 15.5ft-lb)

10.

Install the chain guide.

(1)

Install the chain guide to the variator chain, and move it to the primary pulley side.

(2)

Place the support rod inside of the variator chain.

Protect the primary pulley, secondary pulley and variator chain from scratching.

(3)

Hold the support rod, and install the chain guide to the support rod.

(4)

Install the bolt securing the support rod.

Tightening torque:

21 N·m (2.1kgf-m, 15.5ft-lb)

(5)

Install the lubrication pipe.

Tightening torque:

21 N·m (2.1kgf-m, 15.5ft-lb)

(6)

Install the chain guide to the lubrication pipe.

(7)

Remove the ST (EXPANDER PULLEY).

11.

Install the reduction drive gear. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Reduction Drive Gear>INSTALLATION

12.

Select the reduction drive gear shim. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Reduction Drive Gear>ADJUSTMENT

13.

Install the transmission case. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Transmission Case>INSTALLATION

14.

Install the transmission control device. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Transmission Control Device>INSTALLATION

15.

Install the oil strainer and oil pan. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Oil Pan>INSTALLATION

16.

Install the reduction driven gear. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Reduction Driven Gear>INSTALLATION

17.

Install the parking pawl. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Parking Pawl>INSTALLATION

18.

Install the transfer driven gear. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Transfer Driven Gear>INSTALLATION

19.

Install the transfer clutch. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Transfer Clutch>INSTALLATION

20.

Install the extension case. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Extension Case>INSTALLATION

21.

Install the electric oil pump. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Electric Fluid Pump>INSTALLATION

22.

Install the inhibitor switch. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Inhibitor Switch>INSTALLATION

23.

Install the secondary speed sensor. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Secondary Speed Sensor>INSTALLATION

24.

Install the primary speed sensor. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Primary Speed Sensor>INSTALLATION

25.

Install the turbine speed sensor. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Turbine Speed Sensor>INSTALLATION

26.

Install the transmission harness. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Transmission Harness>INSTALLATION

27.

Install the control valve body. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Control Valve Body>INSTALLATION

28.

Install the air breather hose. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Air Breather Hose>INSTALLATION

29.

Install the transmission body. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Transmission Assembly>INSTALLATION

CONTINUOUSLY VARIABLE TRANSMISSION(TR580) > Primary Pulley and Secondary Pulley　

INSPECTION

1.

Check for oil leaks.

2.

Check that there is no deformation, cracks or other damages.

3.

Check the ball bearing for seizure.

4.

Check the ball bearing for abnormal noise.

5.

Check the ball bearing for smooth rotation.

Apply CVTF to the ball bearing.

CONTINUOUSLY VARIABLE TRANSMISSION(TR580) > Primary Pulley and Secondary Pulley　

ADJUSTMENT

1. PROCEDURE IN REPLACEMENT OF PRIMARY AND SECONDARY PULLEY, OR IN REPLACEMENT OF PRIMARY PULLEY, SECONDARY PULLEY AND VARIATOR CHAIN

1.

Measure depth “Lp” from the ST upper face to the primary pulley bearing catch surface at several points and calculate the average.

Preparation tool:

ST: GAUGE (499575400)

2.

Measure the depth “Ls” from the ST upper face to the secondary pulley bearing catch surface at several points and calculate the average.

Preparation tool:

ST: GAUGE (499575400)

3.

Calculate the following formula.

Calculation formula:

T (mm) = B − A + Lp − Ls −31.079

[T (in) = B − A + Lp − Ls −1.224]

T: Pulley alignment

A: Specified primary pulley dimension

B: Specified secondary pulley dimension

Lp: Depth from the ST upper face to the primary pulley bearing catch surface

Ls: Depth from the ST upper face to the secondary pulley bearing catch surface

31.079 mm (1.224in): Constant

Pulley alignment T mm (in)	Thickness of primary pulley shim mm (in)
-0.034 — 0.049 (-0.001 — 0.002)	No shims
0.050 — 0.149 (0.002 — 0.006)	0.1 (0.004)
0.150 — 0.249 (0.006 — 0.010)	0.2 (0.008)
0.250 — 0.349 (0.010 — 0.014)	0.3 (0.012)
0.350 — 0.449 (0.014 — 0.018)	0.4 (0.016)
0.450 — 0.549 (0.018 — 0.022)	0.5 (0.020)
0.550 — 0.649 (0.022 — 0.026)	0.6 (0.024)
0.650 — 0.749 (0.026 — 0.029)	0.7 (0.028)
0.750 — 0.849 (0.029 — 0.033)	0.8 (0.031)
0.850 — 0.949 (0.033 — 0.037)	0.9 (0.035)
0.950 — 1.049 (0.037 — 0.041)	1.0 (0.039)
1.050 — 1.149 (0.041 — 0.045)	1.1 (0.043)
1.150 — 1.191 (0.045 — 0.047)	1.2 (0.047)

4.

Select one to two primary pulley shims so that the total thickness meets the value obtained from step 3.

2. PROCEDURE WHEN REPLACING ONLY DRIVE PINION RETAINER OR REVERSE BRAKE HOUSING

1.

Measure and record the thickness of primary pulley shim before replacement.

2.

Using the current drive pinion retainer, measure depth “Lp1” from the ST upper face to the primary pulley bearing catch surface at several points and calculate the average.

Preparation tool:

ST: GAUGE (499575400)

3.

Using the current drive pinion retainer or current reverse brake housing, measure the depth “Ls1” from the ST upper face to the secondary pulley bearing catch surface at several points and calculate the average.

Preparation tool:

ST: GAUGE (499575400)

4.

Calculate the “LD1” using the following formula and record it.

Calculation formula:

LD1 mm (in) = Ls1 − Lp1

LD1: Height from the primary pulley bearing catch surface to the secondary pulley bearing catch surface

Lp1: Depth from the ST upper face to the primary pulley bearing catch surface

Ls1: Depth from the ST upper face to the secondary pulley bearing catch surface

5.

Using the new drive pinion retainer or new reverse brake housing, measure the depth “Lp2” from the ST upper face to the primary pulley bearing catch surface at several points and calculate the average.

Preparation tool:

ST: GAUGE (499575400)

6.

Using the new drive pinion retainer or new reverse brake housing, measure the depth “Ls2” from the ST upper face to the secondary pulley bearing catch surface at several points and calculate the average.

Preparation tool:

ST: GAUGE (499575400)

7.

Calculate the “LD2” using the following formula and record it.

Calculation formula:

LD2 mm (in) = Ls2 − Lp2

LD2: Height from the primary pulley bearing catch surface to the secondary pulley bearing catch surface

Lp2: Depth from the ST upper face to the primary pulley bearing catch surface

Ls2: Depth from the ST upper face to the secondary pulley bearing catch surface

8.

Calculate the difference of the case using the following formula with the recorded values of “LD1” and “LD2”, and select the primary pulley shim.

Calculation formula: T1 mm (in) = LD1 − LD2 or T2 mm (in) = LD2 − LD1

T1, T2: Difference between new drive pinion retainer or new reverse brake housing and drive pinion retainer before replacement or reverse brake housing before replacement

LD1: Calculated value of drive pinion retainer before replacement or reverse brake housing before replacement

LD2: Calculated value of new drive pinion retainer or new reverse brake housing

Difference of the case (T1) mm (in)	Selection method of primary pulley shim
0 — 0.050 (0 — 0.00197)	Select a new shim of the same thickness with the shim that is used on the primary pulley side of the current reverse brake housing.
0.051 — 0.150 (0.00201 — 0.00591)	Select a shim which is 0.1 mm (0.004in) thicker than the shim that is used on the primary pulley side of the current reverse brake housing.
0.151 — 0.250 (0.00594 — 0.00984)	Select a shim which is 0.2 mm (0.008in) thicker than the shim that is used on the primary pulley side of the current reverse brake housing.
0.251 — 0.350 (0.00988 — 0.01378)	Select a shim which is 0.3 mm (0.012in) thicker than the shim that is used on the primary pulley side of the current reverse brake housing.
0.351 — 0.450 (0.01382 — 0.01772)	Select a shim which is 0.4 mm (0.016in) thicker than the shim that is used on the primary pulley side of the current reverse brake housing.
0.451 — 0.550 (0.01776 — 0.02165)	Select a shim which is 0.5 mm (0.020in) thicker than the shim that is used on the primary pulley side of the current reverse brake housing.
0.551 — 0.600 (0.02169 — 0.02362)	Select a shim which is 0.6 mm (0.024in) thicker than the shim that is used on the primary pulley side of the current reverse brake housing.

Difference of the case (T2) mm (in)	Selection method of primary pulley shim
0 — 0.050 (0 — 0.00197)	Select a new shim of the same thickness with the shim that is used on the primary pulley side of the current reverse brake housing.
0.051 — 0.150 (0.00201 — 0.00591)	Select a shim which is 0.1 mm (0.004in) thinner than the shim that is used on the primary pulley side of the current reverse brake housing.
0.151 — 0.250 (0.00594 — 0.00984)	Select a shim which is 0.2 mm (0.008in) thinner than the shim that is used on the primary pulley side of the current reverse brake housing.
0.251 — 0.350 (0.00988 — 0.01378)	Select a shim which is 0.3 mm (0.012in) thinner than the shim that is used on the primary pulley side of the current reverse brake housing.
0.351 — 0.450 (0.01382 — 0.01772)	Select a shim which is 0.4 mm (0.016in) thinner than the shim that is used on the primary pulley side of the current reverse brake housing.
0.451 — 0.550 (0.01776 — 0.02165)	Select a shim which is 0.5 mm (0.020in) thinner than the shim that is used on the primary pulley side of the current reverse brake housing.
0.551 — 0.600 (0.02169 — 0.02362)	Select a shim which is 0.6 mm (0.024in) thinner than the shim that is used on the primary pulley side of the current reverse brake housing.

CONTINUOUSLY VARIABLE TRANSMISSION(TR580) > Variator Chain　

SPECIFICATION

Refer to the “Primary Pulley & Secondary Pulley” section for removal and installation procedures.

CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Primary Pulley and Secondary Pulley>REMOVAL
CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Primary Pulley and Secondary Pulley>INSTALLATION

CONTINUOUSLY VARIABLE TRANSMISSION(TR580) > Reverse Brake　

REMOVAL

1.

Remove the transmission body. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Transmission Assembly>REMOVAL

2.

Remove the air breather hose. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Air Breather Hose>REMOVAL

3.

Remove the control valve body. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Control Valve Body>REMOVAL

4.

Remove the transmission harness. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Transmission Harness>REMOVAL

5.

Remove the turbine speed sensor. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Turbine Speed Sensor>REMOVAL

6.

Remove the secondary speed sensor. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Secondary Speed Sensor>REMOVAL

7.

Remove the primary speed sensor. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Primary Speed Sensor>REMOVAL

8.

Remove the inhibitor switch. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Inhibitor Switch>REMOVAL

9.

Remove the electric oil pump. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Electric Fluid Pump>REMOVAL

10.

Remove the extension case. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Extension Case>REMOVAL

11.

Remove the transfer clutch. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Transfer Clutch>REMOVAL

12.

Remove the transfer driven gear. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Transfer Driven Gear>REMOVAL

13.

Remove the parking pawl. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Parking Pawl>REMOVAL

14.

Remove the reduction driven gear. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Reduction Driven Gear>REMOVAL

15.

Remove the oil pan and oil strainer. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Oil Pan>REMOVAL

16.

Remove the transmission control device. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Transmission Control Device>REMOVAL

17.

Remove the transmission case. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Transmission Case>REMOVAL

18.

Remove the reduction drive gear. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Reduction Drive Gear>REMOVAL

19.

Remove the primary pulley, secondary pulley and variator chain. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Primary Pulley and Secondary Pulley>REMOVAL

20.

Remove the manual valve body and separator plate.

21.

Remove the oil guide (B) and lubrication pipe (A).

22.

Remove the O-rings.

23.

Remove the reverse brake.

24.

Remove the O-rings.

CONTINUOUSLY VARIABLE TRANSMISSION(TR580) > Reverse Brake　

INSTALLATION

1.

Select a washer. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Forward Clutch>ADJUSTMENT

2.

Install the selected washer to the reverse brake housing.

3.

Install the thrust bearing to the reverse brake housing.

Make sure to install in the right direction.

4.

Install the internal gear to the reverse brake housing.

5.

Install a new O-ring to drive pinion retainer.

Apply CVTF to the O-rings.

6.

Install the reverse brake and internal gear as a unit to the drive pinion retainer.

Slowly rotate the input shaft by hand to engage the internal gear and pinion gear of planetary carrier.

Tightening torque:

37 N·m (3.8kgf-m, 27.3ft-lb)

7.

Install a new O-ring to the lubrication pipe.

Apply CVTF to the O-rings.

8.

Install the lubrication pipe and oil guide.

Tightening torque:

16 N·m (1.6kgf-m, 11.8ft-lb)

9.

Install the manual valve body and separator plate.

Apply CVTF to the bolt.

Tightening torque:

9 N·m (0.9kgf-m, 6.6ft-lb)

10.

Install the primary pulley, secondary pulley and variator chain. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Primary Pulley and Secondary Pulley>INSTALLATION

11.

Select shims for pulley alignment. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Primary Pulley and Secondary Pulley>ADJUSTMENT

12.

Install the reduction drive gear. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Reduction Drive Gear>INSTALLATION

13.

Install the transmission case. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Transmission Case>INSTALLATION

14.

Install the transmission control device. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Transmission Control Device>INSTALLATION

15.

Install the oil strainer and oil pan. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Oil Pan>INSTALLATION

16.

Install the reduction driven gear. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Reduction Driven Gear>INSTALLATION

17.

Install the parking pawl. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Parking Pawl>INSTALLATION

18.

Install the transfer driven gear. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Transfer Driven Gear>INSTALLATION

19.

Install the transfer clutch. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Transfer Clutch>INSTALLATION

20.

Install the extension case. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Extension Case>INSTALLATION

21.

Install the electric oil pump. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Electric Fluid Pump>INSTALLATION

22.

Install the inhibitor switch. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Inhibitor Switch>INSTALLATION

23.

Install the secondary speed sensor. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Secondary Speed Sensor>INSTALLATION

24.

Install the primary speed sensor. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Primary Speed Sensor>INSTALLATION

25.

Install the turbine speed sensor. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Turbine Speed Sensor>INSTALLATION

26.

Install the transmission harness. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Transmission Harness>INSTALLATION

27.

Install the control valve body. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Control Valve Body>INSTALLATION

28.

Install the air breather hose. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Air Breather Hose>INSTALLATION

29.

Install the transmission body. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Transmission Assembly>INSTALLATION

CONTINUOUSLY VARIABLE TRANSMISSION(TR580) > Reverse Brake　

DISASSEMBLY

1.

Remove the snap ring, and then remove the retaining plate, drive plate, driven plate and dish plate.

2.

Compress the return spring using the ST and a press to remove the snap ring.

Preparation tool:

ST: COMPRESSOR SPECIAL TOOL (18762AA001)

3.

Remove the ST, and remove the spring retainer.

4.

Remove the return spring.

5.

Remove the reverse brake piston by blowing compressed air from reverse brake housing hole.

CONTINUOUSLY VARIABLE TRANSMISSION(TR580) > Reverse Brake　

ASSEMBLY

1.

Install the reverse brake piston.

Apply CVTF to the sealing area of reverse brake piston.

2.

Install the return spring.

3.

Install the spring retainer.

4.

Compress the return spring using the ST and a press to install the snap ring.

Preparation tool:

ST: COMPRESSOR SPECIAL TOOL (18762AA001)

5.

Check the operation of reverse brake piston by blowing compressed air from reverse brake housing hole.

6.

Place the driven plate, drive plate and retaining plate neatly in this order on surface table.

7.

Set the dial gauge to retaining plate, and read its scale.

The value, which is read in the gauge at this time, is zero point.

8.

Scale and record the weight “Z” of a flat board which will be put on retaining plate.

Use a stiff board which does not bend against load as a flat board to be put on retaining plate.
Use a flat board weighing less than 29 N (3.0 kgf, 6.5 lb).

9.

Put the flat board on retaining plate.

10.

Using the following formula, read the push/pull gauge and calculate “N”.

N = 29 N (3.0 kgf, 6.5 lb) − Z

29 N (3.0 kgf, 6.5 lb): Load applied to clutch plate

Z: Flat board weight

11.

Press the center of retaining plate by applying a force of “N” using push/pull gauge, and then measure and record the compression amount “A”.

Measure at four points with a 90° interval and calculate the average.

(A)

Drive plate

(B)

Driven plate

(C)

Retaining plate

12.

Install the dish plate, drive plate, driven plate, retaining plate and snap ring to the reverse brake housing.

Make sure to install in the right direction.

13.

Measure and record the clearance “B” between the retaining plate and snap ring.

14.

Calculate the piston stroke “S” with A and B dimensions recorded before.

S mm (in) = A + B

S: Piston stroke

A: Compression amount of drive plate and dish plate

B: Clearance between retaining plate and snap ring

Specification:

1.8 — 2.2 mm (0.071 — 0.087in)

Service limit:

2.4 mm (0.094in)

15.

If it exceeds the limit, using a new drive plate, select the retaining plate so that the piston stroke is within the standard value.

CONTINUOUSLY VARIABLE TRANSMISSION(TR580) > Reverse Brake　

INSPECTION

1.

Check that there is no deformation, cracks or other damages.

2.

Check the driven plate for discoloration (burnt color).

3.

Make sure the clearance between retaining plate and snap ring of reverse brake is within the limit. If it exceeds the limit, replace with a new drive plate and select and adjust the retaining plate within the standard value. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Reverse Brake>ASSEMBLY

CONTINUOUSLY VARIABLE TRANSMISSION(TR580) > Forward Clutch　

REMOVAL

1.

Remove the transmission body. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Transmission Assembly>REMOVAL

2.

Remove the air breather hose. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Air Breather Hose>REMOVAL

3.

Remove the control valve body. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Control Valve Body>REMOVAL

4.

Remove the transmission harness. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Transmission Harness>REMOVAL

5.

Remove the turbine speed sensor. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Turbine Speed Sensor>REMOVAL

6.

Remove the secondary speed sensor. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Secondary Speed Sensor>REMOVAL

7.

Remove the primary speed sensor. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Primary Speed Sensor>REMOVAL

8.

Remove the inhibitor switch. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Inhibitor Switch>REMOVAL

9.

Remove the electric oil pump. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Electric Fluid Pump>REMOVAL

10.

Remove the extension case. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Extension Case>REMOVAL

11.

Remove the transfer clutch. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Transfer Clutch>REMOVAL

12.

Remove the transfer driven gear. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Transfer Driven Gear>REMOVAL

13.

Remove the parking pawl. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Parking Pawl>REMOVAL

14.

Remove the reduction driven gear. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Reduction Driven Gear>REMOVAL

15.

Remove the oil pan and oil strainer. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Oil Pan>REMOVAL

16.

Remove the transmission control device. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Transmission Control Device>REMOVAL

17.

Remove the transmission case. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Transmission Case>REMOVAL

18.

Remove the reduction drive gear. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Reduction Drive Gear>REMOVAL

19.

Remove the primary pulley, secondary pulley and variator chain. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Primary Pulley and Secondary Pulley>REMOVAL

20.

Remove the reverse brake. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Reverse Brake>REMOVAL

21.

Remove the thrust bearing.

22.

Remove the planetary carrier.

23.

Remove the thrust bearing and sun gear.

24.

Remove the forward clutch.

25.

Remove the thrust bearing (A) and seal ring.

CONTINUOUSLY VARIABLE TRANSMISSION(TR580) > Forward Clutch　

INSTALLATION

1.

Install the thrust bearing to the converter case.

Make sure to install in the right direction.

2.

Install new seal rings to the input shaft and forward clutch drum.

Apply CVTF to the seal rings.

3.

Install the forward clutch.

4.

Install the sun gear.

Face the end face of the sun gear to the reverse brake side as shown in the figure.

5.

Install the thrust bearing to the sun gear.

Make sure to install in the right direction.

6.

Install the planetary carrier.

7.

Install the thrust bearing.

Make sure to install in the right direction.

8.

Select a washer. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Forward Clutch>ADJUSTMENT

9.

Install the reverse brake. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Reverse Brake>INSTALLATION

10.

Install the primary pulley, secondary pulley and variator chain. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Primary Pulley and Secondary Pulley>INSTALLATION

11.

Install the reduction drive gear. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Reduction Drive Gear>INSTALLATION

12.

Install the transmission case. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Transmission Case>INSTALLATION

13.

Install the transmission control device. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Transmission Control Device>INSTALLATION

14.

Install the oil strainer and oil pan. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Oil Pan>INSTALLATION

15.

Install the reduction driven gear. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Reduction Driven Gear>INSTALLATION

16.

Install the parking pawl. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Parking Pawl>INSTALLATION

17.

Install the transfer driven gear. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Transfer Driven Gear>INSTALLATION

18.

Install the transfer clutch. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Transfer Clutch>INSTALLATION

19.

Install the extension case. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Extension Case>INSTALLATION

20.

Install the electric oil pump. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Electric Fluid Pump>INSTALLATION

21.

Install the inhibitor switch. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Inhibitor Switch>INSTALLATION

22.

Install the secondary speed sensor. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Secondary Speed Sensor>INSTALLATION

23.

Install the primary speed sensor. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Primary Speed Sensor>INSTALLATION

24.

Install the turbine speed sensor. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Turbine Speed Sensor>INSTALLATION

25.

Install the transmission harness. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Transmission Harness>INSTALLATION

26.

Install the control valve body. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Control Valve Body>INSTALLATION

27.

Install the air breather hose. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Air Breather Hose>INSTALLATION

28.

Install the transmission body. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Transmission Assembly>INSTALLATION

CONTINUOUSLY VARIABLE TRANSMISSION(TR580) > Forward Clutch　

DISASSEMBLY

1. FORWARD CLUTCH

1.

Remove the snap ring, and then remove the retaining plate, drive plate, driven plate and dish plate.

2.

Compress the return spring using the ST1, ST2 and a press to remove the snap ring.

Preparation tool:

ST1: COMPRESSOR SPECIAL TOOL (18762AA010)

ST2: COMPRESSOR (398673600)

3.

Remove the chamber and snap ring.

4.

Remove the return spring.

5.

Remove the forward clutch piston by blowing compressed air from the forward clutch carrier hole.

2. PLANETARY CARRIER

Disassemble the balance oil guide only.

1.

Remove the snap ring.

2.

Remove the balance oil guide.

3. INTERNAL GEAR

1.

Remove the snap ring.

2.

Remove the thrust gear plate.

CONTINUOUSLY VARIABLE TRANSMISSION(TR580) > Forward Clutch　

ASSEMBLY

1. FORWARD CLUTCH

1.

Install the forward clutch piston to forward clutch drum.

Apply CVTF to the seal of forward clutch piston.

2.

Install the return spring.

3.

Install the chamber and set the snap ring.

Apply CVTF to the sealing area of chamber.

4.

Compress the return spring using the ST1, ST2 and a press to install the snap ring.

Preparation tool:

ST1: COMPRESSOR SPECIAL TOOL (18762AA010)

ST2: COMPRESSOR (398673600)

5.

Check the operation of forward clutch piston by blowing compressed air from forward clutch carrier hole.

6.

Place the driven plate, drive plate and retaining plate neatly in this order on surface table.

7.

Set the dial gauge to retaining plate, and read its scale.

The value, which is read in the gauge at this time, is zero point.

8.

Scale and record the weight “Z” of a flat board which will be put on retaining plate.

Use a stiff board which does not bend against load as a flat board to be put on retaining plate.
Use a flat board weighing less than 52 N (5.3 kgf, 11.7 lb).

9.

Put the flat board on retaining plate.

10.

Using the following formula, read the push/pull gauge, and calculate “N”.

N = 52 N (5.3 kgf, 11.7 lb) − Z

52 N (5.3 kgf, 11.7 lb): Load applied to clutch plate

Z: Flat board weight

11.

Press the center of retaining plate by applying a force of “N” using push/pull gauge, and then measure the compression amount “A”.

Measure at four points with a 90° interval and calculate the average.

(A)

Driven plate

(B)

Drive plate

(C)

Retaining plate

12.

Install the dish plate, drive plate, driven plate and retaining plate in order, and install the snap ring.

Make sure to install in the right direction.

13.

Measure and record the clearance “B” between the retaining plate and snap ring.

14.

Calculate the piston stroke “S” with A and B dimensions recorded before.

S mm (in) = A + B

S: Piston stroke

A: Compression amount of drive plate and dish plate

B: Clearance between retaining plate and snap ring

Specification:

1.0 — 1.4 mm (0.040 — 0.055in)

Service limit:

1.6 mm (0.063in)

15.

If it exceeds the limit, using a new drive plate, select the retaining plate so that the piston stroke is within the standard value.

2. PLANETARY CARRIER

1.

Install the balance oil guide.

2.

Install the snap ring.

3. INTERNAL GEAR

1.

Install the thrust gear plate.

2.

Install the snap ring.

CONTINUOUSLY VARIABLE TRANSMISSION(TR580) > Forward Clutch　

INSPECTION

1.

Check that there is no deformation, cracks or other damages.

2.

Check the driven plate for discoloration (burnt color).

CONTINUOUSLY VARIABLE TRANSMISSION(TR580) > Forward Clutch　

ADJUSTMENT

1.

Install the thrust bearing to the internal gear.

Make sure to install in the right direction.

2.

Measure depth “A” from the ST upper face to the washer mounting surface.

Preparation tool:

ST: GAUGE (499575600)

3.

Measure the height “B” from the ST upper face to the mating surface of the drive pinion retainer.

Preparation tool:

ST: GAUGE (499575600)

4.

Calculate the following formula.

T mm = A − B − (0.35 — 0.70)

[T in = A − B − (0.014 — 0.028)]

T: Washer thickness

A: Depth from the ST upper face to the washer mounting surface

B: Height from ST upper face to the drive pinion retainer mating surface

0.35 — 0.70 mm (0.014 — 0.028in): Clearance

CONTINUOUSLY VARIABLE TRANSMISSION(TR580) > Drive Pinion　

REMOVAL

1.

Remove the transmission body. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Transmission Assembly>REMOVAL

2.

Remove the air breather hose. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Air Breather Hose>REMOVAL

3.

Remove the control valve body. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Control Valve Body>REMOVAL

4.

Remove the transmission harness. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Transmission Harness>REMOVAL

5.

Remove the turbine speed sensor. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Turbine Speed Sensor>REMOVAL

6.

Remove the secondary speed sensor. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Secondary Speed Sensor>REMOVAL

7.

Remove the primary speed sensor. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Primary Speed Sensor>REMOVAL

8.

Remove the inhibitor switch. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Inhibitor Switch>REMOVAL

9.

Remove the electric oil pump. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Electric Fluid Pump>REMOVAL

10.

Remove the extension case. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Extension Case>REMOVAL

11.

Remove the transfer clutch. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Transfer Clutch>REMOVAL

12.

Remove the transfer driven gear. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Transfer Driven Gear>REMOVAL

13.

Remove the parking pawl. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Parking Pawl>REMOVAL

14.

Remove the reduction driven gear. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Reduction Driven Gear>REMOVAL

15.

Remove the oil pan and oil strainer. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Oil Pan>REMOVAL

16.

Remove the transmission control device. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Transmission Control Device>REMOVAL

17.

Remove the transmission case. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Transmission Case>REMOVAL

18.

Remove the reduction drive gear. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Reduction Drive Gear>REMOVAL

19.

Remove the primary pulley, secondary pulley and variator chain. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Primary Pulley and Secondary Pulley>REMOVAL

20.

Remove the reverse brake. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Reverse Brake>REMOVAL

21.

Remove the forward clutch. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Forward Clutch>REMOVAL

22.

Using the ST, remove the drive pinion retainer.

Preparation tool:

ST: SOCKET (E20) (18270KA020)

23.

Remove the O-rings.

24.

Remove the liquid gasket from the drive pinion retainer and converter case.

CONTINUOUSLY VARIABLE TRANSMISSION(TR580) > Drive Pinion　

INSTALLATION

1.

Adjust backlash and tooth contact of the hypoid gear set. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Front Differential>ADJUSTMENT

2.

Install a new O-ring to converter case.

Apply CVTF to the O-rings.

3.

Apply liquid gasket to the mating surface of the drive pinion retainer as shown in the figure, and temporarily install the drive pinion retainer.

Before applying liquid gasket, degrease the old liquid gasket seal surface of the drive pinion retainer and converter case.
Install within 5 min. after applying liquid gasket.

Liquid gasket:

THREE BOND 1215B or equivalent

4.

Tighten the bolt using the ST.

Preparation tool:

ST: SOCKET (E20) (18270KA020)

Tightening torque:

43 N·m (4.4kgf-m, 31.7ft-lb)

(A)

M10 × 54

(B)

M10 × 45

(C)

M10 × 33

5.

Install the forward clutch. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Forward Clutch>INSTALLATION

6.

Install the reverse brake. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Reverse Brake>INSTALLATION

7.

Install the primary pulley, secondary pulley and variator chain. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Primary Pulley and Secondary Pulley>INSTALLATION

8.

Install the reduction drive gear. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Reduction Drive Gear>INSTALLATION

9.

Install the transmission case. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Transmission Case>INSTALLATION

10.

Install the transmission control device. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Transmission Control Device>INSTALLATION

11.

Install the oil strainer and oil pan. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Oil Pan>INSTALLATION

12.

Install the reduction driven gear. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Reduction Driven Gear>INSTALLATION

13.

Install the parking pawl. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Parking Pawl>INSTALLATION

14.

Install the transfer driven gear. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Transfer Driven Gear>INSTALLATION

15.

Install the transfer clutch. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Transfer Clutch>INSTALLATION

16.

Install the extension case. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Extension Case>INSTALLATION

17.

Install the electric oil pump. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Electric Fluid Pump>INSTALLATION

18.

Install the inhibitor switch. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Inhibitor Switch>INSTALLATION

19.

Install the secondary speed sensor. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Secondary Speed Sensor>INSTALLATION

20.

Install the primary speed sensor. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Primary Speed Sensor>INSTALLATION

21.

Install the turbine speed sensor. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Turbine Speed Sensor>INSTALLATION

22.

Install the transmission harness. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Transmission Harness>INSTALLATION

23.

Install the control valve body. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Control Valve Body>INSTALLATION

24.

Install the air breather hose. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Air Breather Hose>INSTALLATION

25.

Install the transmission body. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Transmission Assembly>INSTALLATION

CONTINUOUSLY VARIABLE TRANSMISSION(TR580) > Drive Pinion　

DISASSEMBLY

1.

Flatten the tab of the lock nut.

2.

Using ST1, ST2 and ST3, fix at the spline portion of drive pinion to remove the lock nut.

Preparation tool:

ST1: ADAPTER (499787500)

ST2: WRENCH (499787700)

ST3: HOLDER (498937110)

3.

Remove the drive pinion.

4.

Using the round bar with diameter of 36 mm (1.42in) or 37 mm (1.46in) and a press, remove the taper roller bearing (rear) inner race and plug.

5.

Remove the drive pinion washer.

6.

Remove the drive pinion spacer.

7.

Remove the O-rings.

8.

Using the ST and a press, remove the taper roller bearing (front) inner race and the drive pinion shim.

Preparation tool:

ST: REMOVER (498515500)

9.

Using the ST, remove the taper roller bearing (front) outer race and the taper roller bearing (rear) outer race.

Preparation tool:

ST: PULLER ASSY (398527700)

10.

Remove the oil seal from the front side and the rear side.

Do not damage the fitting surface of oil seal.

11.

Remove the plug from drive pinion retainer.

CONTINUOUSLY VARIABLE TRANSMISSION(TR580) > Drive Pinion　

ASSEMBLY

1.

Install the plug to the drive pinion retainer with a new O-ring.

Apply CVTF to the O-rings.

Tightening torque:

22 N·m (2.2kgf-m, 16.2ft-lb)

2.

Using the ST, install the oil seal.

Apply CVTF to the press-fitting surface of oil seal and apply differential gear oil to the lip portion.
Make sure to install in the right direction.

Preparation tool:

ST: HOUSING BUSHING INSTALLER AND REMOVER (927720000)

(A)

2.8 mm (0.11in)

(B)

18.7 mm (0.74in)

3.

Select the drive pinion washer.

(1)

Measure width “A” of a new taper roller bearing (front) inner race.

(2)

Measure width “B” of a new taper roller bearing (rear) inner race.

(3)

Measure width “C” of the drive pinion spacer.

(4)

Install a new taper roller bearing (front) outer race using the ST1, ST2 and a press.

Preparation tool:

ST1: PRESS SNAP RING (28499TC010)

ST2: INSTALLER (398177700)

(5)

Install a new taper roller bearing (rear) outer race using the ST and a press.

Preparation tool:

ST: INSTALLER (20099AE020)

(6)

Place the drive pinion retainer on the surface plate, and install the taper roller bearing (rear) inner race to the taper roller bearing (rear) outer race.

Place the drive pinion retainer so that the mating surface of the drive pinion retainer (mating surface with the converter case) contacts the surface plate.

(7)

Measure the height “D” from the end face of the taper roller bearing (rear) inner race to the surface plate.

(8)

Install the taper roller bearing (front) inner race to the taper roller bearing (front) outer race.

(9)

Measure the depth “E” from the end face of the taper roller bearing (front) inner race to the end face of the ST.

Preparation tool:

ST: GAUGE (499575400)

(10)

Using following formula, select one to three drive pinion washers.

T mm = D − (A + B + C + E − 15) − (0±0.0125)

[T in = D − (A + B + C + E − 0.591) − (0±0.0005)]

A: Width of taper roller bearing (front) inner race

B: Width of taper roller bearing (rear) inner race

C: Width of drive pinion spacer

D: Height from end face of taper roller bearing (rear) inner race to surface plate

E: Depth from the end face of the taper roller bearing (front) inner race to the end face of the ST

15 mm (0.591in): Thickness of ST

T: Drive pinion washer thickness

0±0.0125 mm (0±0.0005in): Clearance

4.

Measure and record the drive pinion shim thickness to be reused. When reuse is not possible, select the drive pinion shim.

(1)

Using a precise round bar, measure the height “G” from the mating surface of transmission case of the converter case to the upper end of the round bar. Also, measure and record the diameter “M” of the round bar.

(2)

Using the following formula, calculate the height “A1” from the mating surface of the converter case and transmission case to the bottom end of the differential side retainer hole.

A1 mm = G − M

[A1 in = G − M]

G: Height from the mating surface of the converter case and transmission case to the upper end of the round bar

M: Diameter of the round bar

(3)

Measure the hole inner diameter “R” of differential side retainer of the converter case.

Perform the measurement at the contact surface of the side bearing outer race.

(4)

Using the following formula, calculate the hole radius “A2” of the differential side retainer.

A2 mm = R/2

[A2 in = R/2]

R: Hole inner diameter of differential side retainer of the converter case

(5)

Using the following formula, calculate the differential center distance “A” from the mating surface of the converter case and transmission case.

A mm = A1 + A2

[A in = A1 + A2]

(6)

Measure the depth “B1” from the ST to the mating surface of drive pinion retainer. Then, using the following formula, calculate the height “B” from the mating surface of transmission case of the converter case to the mating surface of drive pinion retainer.

Preparation tool:

ST: GAUGE (499575400)

B mm = B1 − 15

[B in = B1 − 0.591]

B1: Depth from ST to the drive pinion retainer mating surface

15 mm (0.591in): Thickness of ST

(7)

Using following formula, select one to three drive pinion shims.

T mm = (A − B + E − 15) − 90.8 + (0±0.0125)

[T in = (A − B + E − 0.591) − 3.575 + (0±0.0005)]

A: Differential center distance from the mating surface of the converter case and transmission case

B: Height from the mating surface of the converter case and transmission case to the mating surface of the drive pinion retainer

E: Depth from the end face of the taper roller bearing (front) inner race to the end face of the ST, measured in (9) in “3. Select the drive pinion washer”

15 mm (0.591in): Thickness of ST

T: Drive pinion shim thickness

90.8 mm (3.575in): Ideal distance from the differential center to the drive pinion end surface

0±0.0125 mm (0±0.0005in): Clearance

5.

Install the drive pinion shim that is reused for the drive pinion.

6.

Press-fit the taper roller bearing (front) inner race using the ST1, ST2 and a press.

Preparation tool:

ST1: INSTALLER (899580100)

ST2: EXTENSION DRIVE SHAFT (927130000)

7.

Install the drive pinion spacer.

Replace the O-ring with a new part after tooth contact inspection.

8.

Install the selected drive pinion washer.

9.

Insert the drive pinion into the drive pinion retainer.

Be careful not to damage the oil seal.

10.

Install the lock nut.

Apply differential gear oil to the threaded portion of the drive pinion.

11.

Using the ST1, ST2 and ST3, tighten the lock nut to the specified torque so that the initial load of the drive pinion is within the specified range.

Before inspecting the starting torque, apply differential gear oil to roller of bearing and rotate the taper roller bearing several times.

Tighten the lock nut while directly aligning ST2 and torque wrench.
If the initial load is not within the specified range, select the drive pinion washer, and repeat the step until the initial load is within the specified range.
When a thicker drive pinion washer is selected, the initial load decreases. When a thinner drive pinion washer is selected, the initial load increases.

Initial load:

5.1 — 17.1 N (0.5 — 1.7 kgf, 1.1 — 3.8 lbf)

Preparation tool:

ST1: ADAPTER (499787500)

ST2: WRENCH (499787700)

ST3: HOLDER (498937110)

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

T2 = L2/(L1 + L2) × T1

T1: 170 — 250 N·m (17.3 — 25.5kgf-m, 125.4 — 184.4ft-lb) [Specified tightening torque range]

T2: Tightening torque

L1: ST1 length 0.072 m (2.83in)

L2: Torque wrench length

Example:

Torque wrench length m (in)	Tightening torque N·m (kgf-m, ft-lb)
0.4 (15.75)	144 — 211 (14.7 — 21.5, 106.2 — 155.6)
0.45 (17.72)	147 — 215 (15.0 — 21.9, 108.4 — 158.6)
0.5 (19.69)	149 — 218 (15.2 — 22.2, 109.9 — 160.8)
0.55 (21.65)	150 — 221 (15.3 — 22.5, 110.6 — 163.0)

12.

Install the drive pinion retainer to the converter case, and check the backlash and tooth contact of the hypoid gear set. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Drive Pinion>ADJUSTMENT CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Front Differential>ADJUSTMENT

13.

Remove the drive pinion retainer from converter case. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Drive Pinion>REMOVAL

14.

Remove the drive pinion spacer from the drive pinion. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Drive Pinion>DISASSEMBLY

15.

Install a new O-ring.

Apply the differential gear oil to O-ring.

16.

Install the drive pinion spacer.

17.

Install the drive pinion washer.

18.

Insert the drive pinion.

Be careful not to damage the oil seal.

19.

Install a new lock nut.

Apply differential gear oil to the threaded portion of the drive pinion.

20.

Using the ST1, ST2 and ST3, tighten the lock nut to the specified torque so that the initial load of the drive pinion is within the specified range.

Before inspecting the initial load, apply differential gear oil to the roller of the taper roller bearing (front) and taper roller bearing (rear), and rotate the taper roller bearing several times.

Tighten the lock nut while directly aligning ST2 and torque wrench.
If the initial load is not within the specified range, select the drive pinion washer, and repeat the step until the initial load is within the specified range.
When a thicker drive pinion washer is selected, the initial load decreases. When a thinner drive pinion washer is selected, the initial load increases.

Initial load:

5.1 — 17.1 N (0.5 — 1.7 kgf, 1.1 — 3.8 lbf)

Preparation tool:

ST1: ADAPTER (499787500)

ST2: WRENCH (499787700)

ST3: HOLDER (498937110)

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

T2 = L2/(L1 + L2) × T1

T1: 170 — 250 N·m (17.3 — 25.5kgf-m, 125.4 — 184.4ft-lb) [Specified tightening torque range]

T2: Tightening torque

L1: ST1 length 0.072 m (2.83in)

L2: Torque wrench length

Example:

Torque wrench length m (in)	Tightening torque N·m (kgf-m, ft-lb)
0.4 (15.75)	144 — 211 (14.7 — 21.5, 106.2 — 155.6)
0.45 (17.72)	147 — 215 (15.0 — 21.9, 108.4 — 158.6)
0.5 (19.69)	149 — 218 (15.2 — 22.2, 109.9 — 160.8)
0.55 (21.65)	150 — 221 (15.3 — 22.5, 110.6 — 163.0)

21.

Crimp the lock nut.

22.

Install a new plug using ST1, ST2 and a press.

Preparation tool:

ST1: PRESS SNAP RING (499755602)

ST2: INSTALLER (398177700)

CONTINUOUSLY VARIABLE TRANSMISSION(TR580) > Drive Pinion　

INSPECTION

1.

Check that there is no deformation, cracks or other damages.

2.

Check the taper roller bearing for abnormal noise.

CONTINUOUSLY VARIABLE TRANSMISSION(TR580) > Drive Pinion　

ADJUSTMENT

1.

Using the ST, install the drive pinion retainer.

Preparation tool:

ST: SOCKET (E20) (18270KA020)

Tightening torque:

43 N·m (4.4kgf-m, 31.7ft-lb)

(A)

M10 × 54

(B)

M10 × 45

(C)

M10 × 33

2.

Rotate the drive pinion several times using ST1 and ST2.

Preparation tool:

ST1: HOLDER (498937110)

ST2: WRENCH (499787700)

3.

Adjust the hypoid gear set backlash. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Front Differential>ADJUSTMENT

4.

Using the ST, remove the drive pinion retainer.

Preparation tool:

ST: SOCKET (E20) (18270KA020)

5.

Apply lead-free red dye evenly on the both sides of three to four teeth of the 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, readjust the backlash of hypoid gear or the thickness of the drive pinion shim. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Front Differential>ADJUSTMENT

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

Correct tooth contact

Check item: Tooth contact surface is slightly shifted toward the toe side (A) under a no-load condition. (When driving, it moves towards the heel side (B).)
Face contact

Check item: Backlash is too large.

Contact pattern

Adjustment: Increase thickness of the drive pinion shim according to the procedures for moving the drive pinion closer to the driven gear.
Flank contact

Check item: Backlash is too small.

Contact pattern

Adjustment: Reduce the thickness of the drive pinion shim according to the procedures for moving the drive pinion away from the driven gear side.
Toe contact (inside contact)

Check item: Teeth contact area is too small.

Contact pattern

Adjustment: Reduce the thickness of the drive pinion shim according to the procedures for moving the drive pinion away from the driven gear side.
Heel contact (outside end contact)

Check item: Teeth contact area is too small.

Contact pattern

Adjustment: Increase thickness of the drive pinion shim according to the procedures for moving the drive pinion closer to the driven gear.

6.

Using the ST, loosen the differential side retainer until the mounting groove of the O-ring appears, and then install a new O-ring.

When loosening the differential side retainer, record the number of the turns made.
Perform this for both left and right differential side retainers.
Apply the differential gear oil to O-ring.

Preparation tool:

ST: WRENCH COMPL RETAINER (18658AA021)

7.

Using the ST, tighten the differential side retainer to the position before it is loosened.

Preparation tool:

ST: WRENCH COMPL RETAINER (18658AA021)

8.

Replace the differential side retainer oil seal with a new part. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Differential Side Retainer Oil Seal

9.

Install the lock plate (A).

Tightening torque:

25 N·m (2.5kgf-m, 18.4ft-lb)

CONTINUOUSLY VARIABLE TRANSMISSION(TR580) > Front Differential　

REMOVAL

1.

Remove the transmission body. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Transmission Assembly>REMOVAL

2.

Remove the air breather hose. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Air Breather Hose>REMOVAL

3.

Remove the control valve body. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Control Valve Body>REMOVAL

4.

Remove the transmission harness. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Transmission Harness>REMOVAL

5.

Remove the turbine speed sensor. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Turbine Speed Sensor>REMOVAL

6.

Remove the secondary speed sensor. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Secondary Speed Sensor>REMOVAL

7.

Remove the primary speed sensor. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Primary Speed Sensor>REMOVAL

8.

Remove the inhibitor switch. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Inhibitor Switch>REMOVAL

9.

Remove the electric oil pump. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Electric Fluid Pump>REMOVAL

10.

Remove the extension case. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Extension Case>REMOVAL

11.

Remove the transfer clutch. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Transfer Clutch>REMOVAL

12.

Remove the transfer driven gear. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Transfer Driven Gear>REMOVAL

13.

Remove the parking pawl. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Parking Pawl>REMOVAL

14.

Remove the reduction driven gear. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Reduction Driven Gear>REMOVAL

15.

Remove the oil pan and oil strainer. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Oil Pan>REMOVAL

16.

Remove the transmission control device. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Transmission Control Device>REMOVAL

17.

Remove the transmission case. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Transmission Case>REMOVAL

18.

Remove the reduction drive gear. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Reduction Drive Gear>REMOVAL

19.

Remove the primary pulley, secondary pulley and variator chain. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Primary Pulley and Secondary Pulley>REMOVAL

20.

Remove the reverse brake. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Reverse Brake>REMOVAL

21.

Remove the forward clutch. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Forward Clutch>REMOVAL

22.

Remove the drive pinion. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Drive Pinion>REMOVAL

23.

Remove the oil baffle.

24.

Remove the lock plate (A).

25.

Remove the differential side retainers using the ST.

When the wrench COMPL retainer interferes with the converter case, align the cutout portion with the interference part.
Support the differential case by hand while being careful not to damage the attachment section of the differential side retainer.
Keep the left and right differential side retainers and left and right side bearing outer races by attaching tags or in similar ways.

Preparation tool:

ST: WRENCH COMPL RETAINER (18658AA021)

26.

Remove the differential case while being careful not to damage the attachment section of the differential side retainer.

27.

Remove the oil seals and O-rings from differential side retainer. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Front Differential>DISASSEMBLY > DIFFERENTIAL SIDE RETAINER

CONTINUOUSLY VARIABLE TRANSMISSION(TR580) > Front Differential　

INSTALLATION

1.

Install the side bearing outer race.

2.

Install the differential case.

Be careful not to damage the inside of the case (especially the mounting surface of the differential side retainers).

3.

Temporarily install the differential side retainers using the ST.

Preparation tool:

ST: WRENCH COMPL RETAINER (18658AA021)

4.

Adjust the hypoid gear set backlash. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Front Differential>ADJUSTMENT

5.

Inspect and adjust the tooth contact. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Drive Pinion>ADJUSTMENT

6.

Using the ST, loosen the differential side retainer until the mounting groove of the new O-ring appears, and then install the O-ring.

When loosening the differential side retainer, record the number of the turns made.
Perform this for both left and right differential side retainers.
Apply the differential gear oil to O-ring.

Preparation tool:

ST: WRENCH COMPL RETAINER (18658AA021)

7.

Using the ST, tighten the differential side retainer to the position before it is loosened.

Preparation tool:

ST: WRENCH COMPL RETAINER (18658AA021)

8.

Install the oil seal to the differential side retainer. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Differential Side Retainer Oil Seal

9.

Install the lock plate (A).

Tightening torque:

25 N·m (2.5kgf-m, 18.4ft-lb)

10.

Install the oil baffle.

11.

Install the drive pinion. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Drive Pinion>INSTALLATION

12.

Install the forward clutch. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Forward Clutch>INSTALLATION

13.

Install the reverse brake. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Reverse Brake>INSTALLATION

14.

Install the primary pulley, secondary pulley and variator chain. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Primary Pulley and Secondary Pulley>INSTALLATION

15.

Install the reduction drive gear. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Reduction Drive Gear>INSTALLATION

16.

Install the transmission case. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Transmission Case>INSTALLATION

17.

Install the transmission control device. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Transmission Control Device>INSTALLATION

18.

Install the oil strainer and oil pan. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Oil Pan>INSTALLATION

19.

Install the reduction driven gear. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Reduction Driven Gear>INSTALLATION

20.

Install the parking pawl. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Parking Pawl>INSTALLATION

21.

Install the transfer driven gear. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Transfer Driven Gear>INSTALLATION

22.

Install the transfer clutch. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Transfer Clutch>INSTALLATION

23.

Install the extension case. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Extension Case>INSTALLATION

24.

Install the electric oil pump. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Electric Fluid Pump>INSTALLATION

25.

Install the inhibitor switch. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Inhibitor Switch>INSTALLATION

26.

Install the secondary speed sensor. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Secondary Speed Sensor>INSTALLATION

27.

Install the primary speed sensor. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Primary Speed Sensor>INSTALLATION

28.

Install the turbine speed sensor. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Turbine Speed Sensor>INSTALLATION

29.

Install the transmission harness. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Transmission Harness>INSTALLATION

30.

Install the control valve body. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Control Valve Body>INSTALLATION

31.

Install the air breather hose. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Air Breather Hose>INSTALLATION

32.

Install the transmission body. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Transmission Assembly>INSTALLATION

CONTINUOUSLY VARIABLE TRANSMISSION(TR580) > Front Differential　

DISASSEMBLY

1. DIFFERENTIAL CASE

1.

Remove the side bearing inner race using ST1, ST2, ST3 and a press.

Preparation tool:

ST1: REMOVER (498077000)

ST2: REMOVER (899864100)

ST3: SEAT (398497701)

2.

Using the ST, remove the spring pin.

Preparation tool:

ST: STRAIGHT PIN REMOVER (899904100)

3.

Remove the pinion shaft, and remove the differential bevel pinion, differential bevel gear and washer.

(A)	Pinion shaft	(C)	Differential bevel pinion	(D)	Washer
(B)	Differential bevel gear

2. DIFFERENTIAL SIDE RETAINER

1.

Remove the O-rings.

2.

Remove the differential side retainer oil seal.

CONTINUOUSLY VARIABLE TRANSMISSION(TR580) > Front Differential　

ASSEMBLY

1. DIFFERENTIAL CASE

1.

Install the differential bevel gear and differential bevel pinion together with the washer, and install the pinion shaft.

Apply differential gear oil on the sliding portion of the washer, differential bevel gear, and pinion shaft.

(A)	Pinion shaft	(C)	Differential bevel pinion	(D)	Washer
(B)	Differential bevel gear

2.

Measure the backlash between the differential bevel gear and differential bevel pinion, and select a washer.

(1)

Install the ST to the differential case.

The ST is a SUBARU genuine part.

Preparation tool:

ST: Axle shaft (38415AA070)

(2)

Using a dial gauge and a magnet stand, measure the backlash by inserting the dial gauge through the window of differential case.

When measuring, fix the differential bevel pinion in place with a screwdriver covered with cloth, or a similar tool.

Specification:

0.13 — 0.18 mm (0.0051 — 0.0071in)

(3)

If the value is not within specification, select a suitable washer and replace it.

3.

Align the pinion shaft and differential case holes, and install a new spring pin to the position shown in the figure.

4.

Using the ST1, ST2 and a press, install the side bearing inner race.

Preparation tool:

ST1: BUSHING 1-2 INSTALLER (499277100)

ST2: SEAT (398497701)

2. DIFFERENTIAL SIDE RETAINER

1.

Install the new differential side retainer oil seal using the ST.

Apply differential gear oil to the differential side retainer oil seal lip.
Since the differential side retainer oil seal has an identification mark (R or L), be careful not to mix up the RH and LH when installing.

Preparation tool:

ST: DIFFERENTIAL SIDE OIL SEAL INSTALLER (18675AA000)

2.

Install a new O-ring.

Apply the differential gear oil to O-ring.

CONTINUOUSLY VARIABLE TRANSMISSION(TR580) > Front Differential　

INSPECTION

Check that there is no deformation, cracks or other damages.

CONTINUOUSLY VARIABLE TRANSMISSION(TR580) > Front Differential　

ADJUSTMENT

1.

Using the ST, screw-in the differential side retainer until resistance is felt.

RH side should be screwed-in more than LH side.

Preparation tool:

ST: WRENCH COMPL RETAINER (18658AA021)

2.

Using the ST, install the drive pinion retainer.

Preparation tool:

ST: SOCKET (E20) (18270KA020)

Tightening torque:

43 N·m (4.4kgf-m, 31.7ft-lb)

(A)

M10 × 54

(B)

M10 × 45

(C)

M10 × 33

3.

Rotate the drive pinion ten times or more using ST1 and ST2.

Preparation tool:

ST1: HOLDER (498937110)

ST2: WRENCH (499787700)

4.

While rotating the drive pinion, tighten the LH differential side retainer and loosen the RH side until it does not rotate anymore. The backlash is “zero” when the drive pinion comes to the point where it doesn’t rotate.

5.

After reaching the “zero” state, loosen the LH differential side retainer by 3 notches and secure it with the lock plate. Retighten until the RH differential side retainer stops. Rotate the drive pinion 2 or 3 times. Tighten the RH differential side retainer further 1-3/4 notches. This sets the preload. Finally, secure the differential side retainer with the lock plate.

Turning the differential side retainer by one notch (A) changes the backlash approx. 0.05 mm (0.0020in).

6.

Insert the ST (Axle Shaft) into the right and left sides of differential case.

The ST (Axle Shaft) is a SUBARU genuine part.

7.

Install the ST to the drive pinion retainer, and wrap the drive pinion with cloth and pinch with vise pliers. Using a tie-wrap or a wire, fix the vise pliers to the ST.

Make sure the drive pinion does not move.

Preparation tool:

ST: COMPRESSOR SHAFT (18763AA000)

8.

Check that the backlash of hypoid gear set is within specification using the ST, a dial gauge and a magnet stand.

Preparation tool:

ST: PLATE (498255400)

Specification:

0.13 — 0.18 mm (0.005 — 0.007in)

9.

Adjust the tooth contact of hypoid gear set. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Drive Pinion>ADJUSTMENT

CONTINUOUSLY VARIABLE TRANSMISSION(TR580) > Oil Pump Chain　

REMOVAL

1.

Remove the transmission body. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Transmission Assembly>REMOVAL

2.

Remove the torque converter. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Torque Converter>REMOVAL

3.

Remove the oil pump chain, oil pump sprocket, driven sprocket and oil pump chain cover.

Oil pump chain cover may be hard to remove because the driven sprocket is installed to the shaft side of the oil pump. In this case, remove it while holding the driven sprocket by hand.

4.

Remove the seal rings.

5.

Remove the driven sprocket from oil pump chain cover to remove the oil pump chain.

The driven sprocket is a non-disassembly part.
If the ball bearing is removed from the driven sprocket, replace it with a new part.

6.

Remove the snap ring.

7.

Remove the drive sprocket.

8.

Remove the oil seal.

9.

Remove the liquid gasket from the oil pump chain cover and the converter case.

CONTINUOUSLY VARIABLE TRANSMISSION(TR580) > Oil Pump Chain　

INSTALLATION

1.

Install a new oil seal using ST.

Apply CVTF to the press-fitting area.

Preparation tool:

ST: HOUSING BUSHING INSTALLER AND REMOVER (927720000)

2.

Install the drive sprocket.

3.

Install the snap ring.

Install the snap ring so that its cutout portion is fitted into the snap ring groove of the oil pump chain cover and within the fitting area (A).

4.

Place the oil pump chain on drive sprocket.

5.

Place the oil pump chain on driven sprocket and install the driven sprocket to oil pump chain cover.

6.

Install a new seal ring.

Apply CVTF to the seal rings.

7.

Apply liquid gasket to the mating surface of the oil pump chain cover as shown in the figure, and temporarily install the oil pump chain cover.

Do not apply liquid gasket at the arrowed hole.

Before applying liquid gasket, degrease the old liquid gasket seal surface of the oil pump chain cover and converter case.
Install within 5 min. after applying liquid gasket.

Liquid gasket:

THREE BOND 1215B or equivalent

8.

Install the oil pump chain cover.

Tightening torque:

21 N·m (2.1kgf-m, 15.5ft-lb)

9.

Install the torque converter. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Torque Converter>INSTALLATION

10.

Install the transmission body. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Transmission Assembly>INSTALLATION

CONTINUOUSLY VARIABLE TRANSMISSION(TR580) > Oil Pump Chain　

DISASSEMBLY

1. DRIVE SPROCKET

1.

Remove the snap ring.

2.

Remove the ball bearing using ST1, ST2 and a press.

Preparation tool:

ST1: REMOVER (498077600)

ST2: INSTALLER (399513600)

CONTINUOUSLY VARIABLE TRANSMISSION(TR580) > Oil Pump Chain　

ASSEMBLY

1. DRIVE SPROCKET

1.

Using the ST and a press, install a new ball bearing.

Apply CVTF to the press-fitting area.

Preparation tool:

ST: PRESS SNAP RING (499755502)

2.

Install the snap ring.

CONTINUOUSLY VARIABLE TRANSMISSION(TR580) > Oil Pump Chain　

INSPECTION

1.

Check for oil leaks.

2.

Check that there is no deformation, cracks or other damages.

3.

Check the ball bearing for seizure.

4.

Check the ball bearing for abnormal noise.

5.

Check the ball bearing for smooth rotation.

Apply CVTF to the ball bearing.

CONTINUOUSLY VARIABLE TRANSMISSION(TR580) > Oil Pump　

REMOVAL

1.

Remove the transmission body. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Transmission Assembly>REMOVAL

2.

Remove the torque converter. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Torque Converter>REMOVAL

3.

Remove the oil pump chain cover. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Oil Pump Chain>REMOVAL

4.

Remove the oil pump and the plate.

5.

Remove the O-rings.

CONTINUOUSLY VARIABLE TRANSMISSION(TR580) > Oil Pump　

INSTALLATION

1.

Install a new O-ring.

Apply CVTF to the O-rings.

2.

Install the plate and the oil pump.

Apply CVTF to the bolt.

Tightening torque:

8.5N·m (0.9kgf-m, 6.3ft-lb)

3.

Install the oil pump chain cover. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Oil Pump Chain>INSTALLATION

4.

Install the torque converter. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Torque Converter>INSTALLATION

5.

Install the transmission body. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Transmission Assembly>INSTALLATION

CONTINUOUSLY VARIABLE TRANSMISSION(TR580) > Oil Pump　

INSPECTION

1.

Check that there is no deformation, cracks or other damages.

2.

Check the oil pump shaft for looseness.

3.

Rotate the oil pump shaft by hand, and check for noise.

4.

Rotate the oil pump shaft by hand, and check for smooth rotation.

5.

Check oil strainer for clogging.

(1)

Measure the secondary pressure (line pressure). CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Secondary Pressure (Line Pressure) Test>INSPECTION

(2)

Remove the oil pan and oil strainer. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Oil Pan>REMOVAL

(3)

Check oil strainer for clogging.

When oil strainer has no clogging, replace the oil pump.

CONTINUOUSLY VARIABLE TRANSMISSION(TR580) > Converter Case　

REMOVAL

1.

Remove the transmission body. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Transmission Assembly>REMOVAL

2.

Remove the air breather hose. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Air Breather Hose>REMOVAL

3.

Remove the control valve body. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Control Valve Body>REMOVAL

4.

Remove the transmission harness. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Transmission Harness>REMOVAL

5.

Remove the turbine speed sensor. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Turbine Speed Sensor>REMOVAL

6.

Remove the secondary speed sensor. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Secondary Speed Sensor>REMOVAL

7.

Remove the primary speed sensor. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Primary Speed Sensor>REMOVAL

8.

Remove the inhibitor switch. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Inhibitor Switch>REMOVAL

9.

Remove the electric oil pump. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Electric Fluid Pump>REMOVAL

10.

Remove the extension case. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Extension Case>REMOVAL

11.

Remove the transfer clutch. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Transfer Clutch>REMOVAL

12.

Remove the transfer driven gear. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Transfer Driven Gear>REMOVAL

13.

Remove the parking pawl. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Parking Pawl>REMOVAL

14.

Remove the reduction driven gear. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Reduction Driven Gear>REMOVAL

15.

Remove the oil pan and oil strainer. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Oil Pan>REMOVAL

16.

Remove the transmission control device. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Transmission Control Device>REMOVAL

17.

Remove the transmission case. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Transmission Case>REMOVAL

18.

Remove the reduction drive gear. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Reduction Drive Gear>REMOVAL

19.

Remove the primary pulley, secondary pulley and variator chain. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Primary Pulley and Secondary Pulley>REMOVAL

20.

Remove the reverse brake. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Reverse Brake>REMOVAL

21.

Remove the forward clutch. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Forward Clutch>REMOVAL

22.

Remove the drive pinion. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Drive Pinion>REMOVAL

23.

Remove the front differential. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Front Differential>REMOVAL

24.

Remove the oil pump chain cover. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Oil Pump Chain>REMOVAL

25.

Remove the oil pump. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Oil Pump>REMOVAL

CONTINUOUSLY VARIABLE TRANSMISSION(TR580) > Converter Case　

INSTALLATION

1.

Install the oil pump. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Oil Pump>INSTALLATION

2.

Install the oil pump chain cover. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Oil Pump Chain>INSTALLATION

3.

Install the front differential. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Front Differential>INSTALLATION

4.

Install the drive pinion. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Drive Pinion>INSTALLATION

5.

Install the forward clutch. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Forward Clutch>INSTALLATION

6.

Install the reverse brake. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Reverse Brake>INSTALLATION

7.

Install the primary pulley, secondary pulley and variator chain. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Primary Pulley and Secondary Pulley>INSTALLATION

8.

Install the reduction drive gear. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Reduction Drive Gear>INSTALLATION

9.

Install the transmission case. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Transmission Case>INSTALLATION

10.

Install the transmission control device. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Transmission Control Device>INSTALLATION

11.

Install the oil strainer and oil pan. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Oil Pan>INSTALLATION

12.

Install the reduction driven gear. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Reduction Driven Gear>INSTALLATION

13.

Install the parking pawl. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Parking Pawl>INSTALLATION

14.

Install the transfer driven gear. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Transfer Driven Gear>INSTALLATION

15.

Install the transfer clutch. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Transfer Clutch>INSTALLATION

16.

Install the extension case. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Extension Case>INSTALLATION

17.

Install the electric oil pump. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Electric Fluid Pump>INSTALLATION

18.

Install the inhibitor switch. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Inhibitor Switch>INSTALLATION

19.

Install the secondary speed sensor. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Secondary Speed Sensor>INSTALLATION

20.

Install the primary speed sensor. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Primary Speed Sensor>INSTALLATION

21.

Install the turbine speed sensor. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Turbine Speed Sensor>INSTALLATION

22.

Install the transmission harness. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Transmission Harness>INSTALLATION

23.

Install the control valve body. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Control Valve Body>INSTALLATION

24.

Install the air breather hose. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Air Breather Hose>INSTALLATION

25.

Install the transmission body. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Transmission Assembly>INSTALLATION

CONTINUOUSLY VARIABLE TRANSMISSION(TR580) > Converter Case　

DISASSEMBLY

1.

Remove the filler plug, drain plug and overflow plug. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Differential Gear Oil>REPLACEMENT

2.

Remove all plugs.

3.

Remove the stud bolt.

CONTINUOUSLY VARIABLE TRANSMISSION(TR580) > Converter Case　

ASSEMBLY

1.

Install the stud bolt.

Tightening torque:

18 N·m (2.5kgf-m, 18.4ft-lb)

After tightening, check that the protruding portion (a) is within the standard.

Specification:

25.0 — 28.7 mm (0.98 — 1.13in)

2.

Install the drain plug.

Tightening torque:

70 N·m (7.1kgf-m, 51.6ft-lb)

3.

Temporarily attach the filler plug and overflow plug.

4.

Install the plugs with new O-rings.

Apply CVTF to the O-rings.

Tightening torque:

T1: 22 N·m (2.2kgf-m, 16.2ft-lb)

T2: 22.5N·m (2.3kgf-m, 16.6ft-lb)

CONTINUOUSLY VARIABLE TRANSMISSION(TR580) > Converter Case　

INSPECTION

1.

Check for oil leaks.

2.

Check that there is no deformation, cracks or other damages.

CONTINUOUSLY VARIABLE TRANSMISSION(TR580) > AT learning　

PROCEDURE

When replacement of TCM/replacement or disassembly of transmission body/replacement of control valve body/clearing AT leaning value is executed, perform AT learning mode.
Do not turn the power of the Subaru Select Monitor OFF during work, and do not disconnect the data link connector.

1. PREPARATION FOR LEARNING

1.

Warm up or cool down until [ATF Temp.] displayed on the Subaru Select Monitor is 40 — 65°C (104 — 149°F).

2.

After stopping the vehicle, shift the select lever to “P range”.

3.

Apply the parking brake.

4.

Lift up the vehicle.

While working, be sure to keep the lower edge of the tires 0.3m (0.98ft) or more above the ground as vehicle will vibrate.

5.

Connect the Subaru Select Monitor.

6.

Turn the ignition switch to ON.

7.

Turn off all systems causing an electrical load, such as headlights, A/C, seat heater and rear defogger, etc.

2. CLEAR AT LEARNING VALUE

Be sure to perform the AT learning mode after performing Clear AT learning value.

1.

On [Start] screen, select [Diagnosis].

2.

On [Vehicle selection] screen, enter vehicle information and select [Set].

3.

On [Main Menu] screen, select [Each System].

4.

On [Select System] screen, select [Transmission Control System].

5.

On [Select Function] screen, select [Work Support].

6.

On [Work Support] screen, select [Clear AT learning value].

7.

Follow the messages displayed on the screen when working.

8.

When [Clear completed. Turn off the ignition switch. Execute AT learning again.] is displayed, Clear AT learning value is completed.

3. AT LEARNING MODE

AT learning mode is performed with the vehicle lifted, without actually running the vehicle.

1.

On [Start] screen, select [Diagnosis].

2.

On [Vehicle selection] screen, enter vehicle information and select [Set].

3.

On [Main Menu] screen, select [Each System].

4.

On [Select System] screen, select [Transmission Control System].

5.

On [Select Function] screen, select [Work Support].

6.

On [Work Support] screen, select [AT learning mode].

7.

Follow the messages displayed on the screen when working.

8.

When [AT learning normally ended.] is displayed, AT learning mode is completed.

If communication error occurs during learning, retry the “AT learning mode” from the beginning.
If the message [Execute AT learning again after fixing troubles of the vehicle] is displayed during learning, select [OK] to display the List of Diagnostics Trouble Code. After repairing the locations indicated by the DTC, start the “AT learning mode” over from the beginning.
When communication error occurs during learning, select lever does not shift occasionally. If select lever does not shift, turn the ignition switch to OFF before operating the select lever.

If the message [AT learning ended abnormally. Try again from the beginning.] is displayed, start the “AT learning mode” over from the beginning.

Display

Main causes for abnormal termination

[AT learning ended abnormally. Try again from the beginning.]

Fault is detected during AT learning.
The accelerator pedal is depressed during AT learning.
An unspecified operation was performed during AT learning
ATF temperature becomes out of specification during AT learning.
Battery voltage is low.
The malfunction indicator light is lit.
Parking brake is not applied hard enough.
Brake pedal is not fully depressed.
Abnormal idle speed increase, etc.

CONTINUOUSLY VARIABLE TRANSMISSION(TR580) > Symptoms and causes　

INSPECTION

Symptoms	Problem parts etc.
Stall speed is low after warming-up, with select lever in “D range” or “R range”.	Engine control system
Engine speed rises up and the vehicle does not start, with select lever in “D range” or “R range”.	Engine control system Select cable CVTF Secondary pressure circuit Primary pulley & secondary pulley, variator chain and reduction drive gear Forward/reverse changeover section TCM Control valve body Inhibitor switch
Vehicle does not move by engine stall, with select lever in “D range” or “R range”.	Parking mechanism Select cable Torque converter Forward/reverse changeover section
Excessive shock occurs at starting, with select lever in “D range” or “R range”.	Secondary pressure circuit Primary pulley & secondary pulley, variator chain
Acceleration speed from standstill is insufficient, with select lever in “D range” or “R range”.	Control valve body Forward/reverse changeover section
Engine speed suddenly rises up during driving, with select lever in “D range” or “R range”.	Control valve body Secondary pressure circuit Primary pressure circuit
Vibration occurs during driving, with select lever in “D range” or “R range”.	Secondary pressure circuit Primary pressure circuit Forward/reverse changeover section Primary pulley & secondary pulley, variator chain Torque converter Hydraulic pressure circuit to torque converter Control valve body
Sudden braking occurs during driving, with select lever in “D range” or “R range”.	Secondary pressure circuit Primary pressure circuit Control valve body
During deceleration, lockup clutch does not disengage until just before halting, with select lever in “D range” or “R range”.	Control valve body Torque converter
Engine stalls with vehicle at a standstill, with select lever in “D range” or “R range”.	Engine control system Control valve body
Excessive lockup shock occurs during driving, with select lever in “D range”.	Control valve body
Slipping occurs at lockup, or lockup does not occur during driving, with select lever in “D range”.	Control valve body Lockup hydraulic circuit Torque converter
Excessive shift shock occurs when shifting the select lever from “N range” to “D range”, or from “N range” to “R range”.	Inhibitor switch Control valve body Forward/reverse changeover section
Vehicle does not keep at standstill with select lever in “P range”, or parking cannot be released when shifting from “P range” to another range.	Select cable Parking mechanism
Select lever does not shift smoothly.	Select cable Inhibitor switch Detent spring Manual plate