automatic SUBARU TRIBECA 2009 1.G Service Workshop Manual

5AT-89
Front Differential Assembly
AUTOMATIC TRANSMISSION
2. SIDE RETAINER
NOTE:
Install the oil seal and O-ring of side retainer after
the adjustment of backlash and tooth contact.
1) Install the bearing outer race to side retainer.
2) Install a new oil seal using ST.
ST 18675AA000 DIFFERENTIAL SIDE OIL
SEAL INSTALLER
NOTE:
Apply oil to the oil seal lips.
3) Install a new O-ring.
E: INSPECTION
•Check each component for scratches, damage
or other faults.
•Measure the backlash, and then adjust it to be
within specification.
<Ref. to 5AT-89, ADJUSTMENT, Front Differential
Assembly.>
F: ADJUSTMENT
1) Using the ST, screw-in the retainer until resis-
tance is felt.
NOTE:
Screw in the RH side slightly deeper than the LH
side.
ST 18630AA010 WRENCH
2) Remove the oil pump cover.
3) Remove the liquid gasket from the mating sur-
face completely.
4) Install the oil pump cover to converter case, and
secure them with tightening four bolts evenly.
NOTE:
Use an old gasket or aluminum washer to prevent
damaging the mating surface of the housing.
Tightening torque:
41 N·m (4.2 kgf-m, 30.4 ft-lb)
5) Rotate the drive pinion ten times or more using
ST1 and ST2.
ST1 18667AA010 HOLDER
ST2 499787700 WRENCH
AT-00226
ST
AT-00219
AT-00227
ST
AT-01985
ST2ST1

5AT-90
Front Differential Assembly
AUTOMATIC TRANSMISSION
6) Tighten the LH retainer by rotating the shaft until
resistance is felt. Then loosen the retainer RH.
Keep tightening the retainer LH, and loosening the
retainer RH until the pinion shaft no longer be
turned. This is the “zero” state.
7) After the “zero” state is established, back off the
retainer LH 3 notches and secure it with the lock
plate. Then back off the retainer RH and retighten
until it stops. Rotate the drive pinion 2 or 3 times.
Tighten the retainer RH further 1-3/4 notches. This
sets the preload. Finally, secure the retainer with its
lock plate.
NOTE:
Turning the retainer by one tooth changes the
backlash approx. 0.05 mm (0.0020 in).
8) Turn the drive pinion several times using ST1,
and check to see if the backlash is within the spec-
ification using ST2, ST3, ST4 and ST5.
ST1 499787700 WRENCH
ST2 498247001 MAGNET BASE
ST3 498247100 DIAL GAUGE
ST4 499787500 ADAPTER
ST5 498255400 PLATE
Backlash:
0.10 — 0.15 mm (0.0039 — 0.0059 in)
9) Adjust the teeth contact of the front differential
and drive shaft. <Ref. to 5AT-83, ADJUSTMENT,
Drive Pinion Shaft Assembly.>
(A) Retainer
(A) Lock plate
(A) 0.05 mm (0.0020 in)
AT-01986
(A)
AT-01988
(A)
AT-01989
(A)

5AT-91
AT Main Case
AUTOMATIC TRANSMISSION
34.AT Main Case
A: REMOVAL
1) Remove the transmission assembly from vehicle
body. <Ref. to 5AT-34, REMOVAL, Automatic
Transmission Assembly.>
2) Pull out the torque converter assembly. <Ref. to
5AT-62, REMOVAL, Torque Converter Assembly.>
3) Remove the transmission harness connector
from stay.
4) Disconnect the air breather hose.
5) Remove the oil charge pipe. <Ref. to 5AT-61,
REMOVAL, Oil Charge Pipe.>
6) Remove the ATF filter inlet and outlet pipes.
<Ref. to 5AT-57, REMOVAL, ATF Cooler Pipe &
Hose.>
7) Remove the extension case. <Ref. to 5AT-63,
REMOVAL, Extension Case.>
8) Remove the center differential carrier. <Ref. to
5AT-71, REMOVAL, Center Differential Carrier.>
9) Remove the reduction driven gear. <Ref. to 5AT-
68, REMOVAL, Reduction Driven Gear.>
10) Separate the converter case from the transmis-
sion case. <Ref. to 5AT-75, REMOVAL, Converter
Case.>
11) Remove the control valve body. <Ref. to 5AT-
53, REMOVAL, Control Valve Body.>
12) Remove the oil pump cover.
<Ref. to 5AT-77, REMOVAL, Oil Pump Cover.>
NOTE:
The input clutch pack assembly and front sun gear
assembly are also removed together.
13) Remove the needle bearing of the middle carri-
er assembly.
14) Remove the middle carrier assembly.
15) Remove the rear carrier assembly.
AT-01990
AT-01991
AT-01992
AT-01993

5AT-92
AT Main Case
AUTOMATIC TRANSMISSION
16) Remove the middle & rear sun gear assembly.
17) Remove the thrust needle bearing of high & low
reverse clutch.
18) Remove the high & low reverse clutch assem-
bly.
19) Remove the direct clutch assembly.
20) Remove the snap ring of reverse brake.
21) Remove the retaining plate.
22) Remove the leaf spring.
23) Take out the drive plate, driven plate and dish
plate.
AT-01994
AT-01995
AT-01996(A) Leaf spring
AT-01997
AT-01998
B'B
B' B
(A)
(A)AT-03364

5AT-93
AT Main Case
AUTOMATIC TRANSMISSION
24) Remove the snap ring of the reverse brake
spring retainer.
ST1 18762AA000 COMPRESSOR SPECIAL
TOOL
ST2 18765AA000 COMPRESSOR SUPPORT
ST3 18763AA000 COMPRESSOR SHAFT
25) Remove the spring retainer.
26) Remove the return spring.
27) Apply compressed air.
28) Remove the reverse brake piston.
B: INSTALLATION
1) Install the reverse brake piston.
NOTE:
Apply ATF onto the piston sliding surface.
ST1 18762AA000 COMPRESSOR SPECIAL
TOOL
ST2 18765AA000 COMPRESSOR SUPPORT
ST3 18763AA000 COMPRESSOR SHAFT
2) Install the return spring.
AT-02000
ST3
ST2
ST1
AT-02001
AT-02002
AT-02004
AT-02005
AT-02002

5AT-94
AT Main Case
AUTOMATIC TRANSMISSION
3) Install the spring retainer and snap ring.
ST1 18762AA000COMPRESSOR SPECIAL TOOL
ST2 18765AA000 COMPRESSOR SUPPORT
ST3 18763AA000 COMPRESSOR SHAFT
4) Install the dish plate.
NOTE:
When installing, make sure that the identification
mark is facing the front side of transmission.
5) Install the drive plate and driven plate.
6) Install the leaf spring.
7) Install the retaining plate.
8) Install the snap ring of the reverse brake.
9) Perform the clearance check of reverse brake.
(1) Measure the clearance between retainer
plate and snap ring using thickness gauge.
Specification:
0.7 — 1.1 mm (0.028 — 0.043 in)
(2) If it is out of specification, select a suitable
retainer plate from the following table and as-
semble it.
10) Install the direct clutch assembly.
(A) Leaf spring
AT-02000
ST3
ST2
ST1
B'B
B' B
(A)
(A)AT-03364
Retainer plate
Par t N o. Thickness mm (in)
31567AB100 4.2 (0.165)
31567AB170 4.4 (0.173)
31567AB180 4.6 (0.181)
31567AB190 4.8 (0.189)
31567AB200 5.0 (0.197)
AT-01998
AT-02372
AT-01997

5AT-95
AT Main Case
AUTOMATIC TRANSMISSION
11) Install the high & low reverse clutch assembly.
12) Install the thrust needle bearing of the high &
low reverse clutch.
13) Install the middle & rear sun gear assembly.
14) Install the rear carrier assembly.
15) Install the middle carrier assembly.
AT-01996
AT-01995
AT-01994
AT-01993
AT-01992

5AT-96
AT Main Case
AUTOMATIC TRANSMISSION
16) Install the thrust needle bearing of middle carri-
er assembly.
17) Measure the total end play, and select the
bearing. <Ref. to 5AT-99, ADJUSTMENT, AT Main
Case.>
18) Install the impact clutch pack assembly to oil
pump cover.
19) Install the thrust needle bearing.
20) Turn the transmission sideways.
21) Install the oil pump cover.
(1) Apply ATF to the O-ring of input clutch shaft.
(2) Install the oil pump cover to AT main case
while supporting the input clutch shaft and oil
pump housing with your hand.
(3) Make sure the rear end of drive pinion shaft
is engaged to the spline of reduction driven
gear.
(4) Protect the input clutch shaft with a cloth,
and rotate to engage the spline of the input
clutch and rear carrier using pliers.
NOTE:
Work with pressing the oil pump cover.
(5) Combine the oil pump cover with transmis-
sion main case.
Tightening torque:
41 N·m (4.2 kgf-m, 30.4 ft-lb)
22) Install the center differential carrier. <Ref. to
5AT-71, INSTALLATION, Center Differential Carri-
er.>
23) Install the reduction driven gear. <Ref. to 5AT-
68, INSTALLATION, Reduction Driven Gear.>
(A) Impact clutch pack ASSY
(B) Front sun gear ASSY
AT-01991
AT-02006
(A)
(B)
AT-01990
(A) Drive pinion shaft
(A) Cloth
AT-02092(A)
AT-02046(A)
AT-01976

5AT-97
AT Main Case
AUTOMATIC TRANSMISSION
24) Install the extension case. <Ref. to 5AT-63, IN-
STALLATION, Extension Case.>
25) Install the control valve body. <Ref. to 5AT-53,
INSTALLATION, Control Valve Body.>
26) Install the converter case assembly to the
transmission case assembly. <Ref. to 5AT-75, IN-
STALLATION, Converter Case.>
27) Install the air breather hose. <Ref. to 5AT-60,
INSTALLATION, Air Breather Hose.>
28) Install the ATF filter pipe. <Ref. to 5AT-58, IN-
STALLATION, ATF Cooler Pipe & Hose.>
29) Install the oil charge pipe together with an O-
ring. <Ref. to 5AT-61, INSTALLATION, Oil Charge
Pipe.>
30) Install the torque converter assembly. <Ref. to
5AT-62, INSTALLATION, Torque Converter As-
sembly.>
31) Install the transmission assembly to the vehi-
cle. <Ref. to 5AT-37, INSTALLATION, Automatic
Transmission Assembly.>
32) Perform Clear Memory 2 operation. <Ref. to
5AT(diag)-17, CLEAR MEMORY MODE, OPERA-
TION, Subaru Select Monitor.>
33) Perform the inspection with driving the vehicle
at the end of repair work, and make sure there is no
faulty as below;
•Excessive shift shock
•Oil leakage from the transmission body, etc.
•Occurrence of noise caused by interference etc.
NOTE:
If excessive shift shock is felt, execute advance op-
eration of learning control. <Ref. to 5AT(diag)-21,
PROCEDURE, Learning Control.>
C: DISASSEMBLY
1. INPUT CLUTCH PACK ASSEMBLY
1) Remove the front sun gear.
2) Remove the thrust bearing.
3) Remove the snap ring, and then remove the
front carrier.
4) Remove the input clutch assembly from rear in-
ternal gear.
D: ASSEMBLY
1. INPUT CLUTCH PACK ASSEMBLY
1) Assemble the input clutch assembly to rear inter-
nal gear.
2) Install the front carrier, and then install the snap
ring.
AT-02007
AT-02008
AT-02009
AT-02009
AT-02008

5AT-98
AT Main Case
AUTOMATIC TRANSMISSION
3) Install the thrust needle bearing.
4) Install the front sun gear.
E: INSPECTION
1. FRONT, MIDDLE & REAR PLANETARY
CARRIER ASSEMBLY
Check the following items.
•Visually inspect the tooth surface of planetary
gear, and replace with new one if damaged, broken
or excessively worn.
•Inspect the planetary carrier body for damage or
breakage.
2. INPUT CLUTCH
•Check the clearance of the input clutch. Measure
the clearance “L” between snap ring and retaining
plate using a thickness gauge. If it is out of specifi-
cation, replace the entire direct clutch assembly.
•Check for damage on the drive plate, driven plate
and snap ring, and replace the entire input clutch
assembly if damaged.
Specification:
0.7 — 1.1 mm (0.028 — 0.043 in)
3. HIGH & LOW REVERSE CLUTCH AS-
SEMBLY
•Check the clearance of the high & low reverse
clutch.
Measure the clearance “L” between snap ring and
retaining plate using a thickness gauge. If it is out of
specification, replace the entire high & low reverse
clutch assembly.
•Check for damage on the drive plate, driven plate
and snap ring, and replace the entire high & low re-
verse clutch assembly if damaged.
Specification:
1.8 — 2.2 mm (0.070 — 0.087 in)
4. DIRECT CLUTCH ASSEMBLY
•Check the clearance of direct clutch.
Measure the clearance “L” between snap ring and
retaining plate using a thickness gauge. If it is out of
specification, replace them as direct clutch assem-
bly.
•Check for damage on the drive plate, driven plate
and snap ring, and replace the entire direct clutch
assembly if damaged.
Specification:
0.6 — 1.0 mm (0.024 — 0.039 in)
5. REVERSE BRAKE
Check the following items.
•Drive plate facing for wear or damage
•Snap ring for wear, return spring for breakage,
and spring retainer for deformation
•Lip seal and D-ring for damage
•Piston operation
AT-02007
AT-03259
L
AT-02010
L
AT-02011
L