Forester 19myty Pubno - G8240be Version - 008

13/6/2019 FORESTER 19MY PubNo: G8240BE Version: 008
CONTINUOUSLY VARIABLE TRANSMISSION(TR580)
CVT(TR580)
1. General Description
2. CVTF
3. Differential Gear Oil
4. AWD ON/OFF Switching Mode
5. Road Test
6. Stall Test
7. Time Lag Test
8. Secondary Pressure (Line Pressure) Test
9. Transfer Clutch Pressure Test
10. Transmission Assembly
11. Transmission Mounting System
12. Extension Case Oil Seal
13. Differential Side Retainer Oil Seal
14. Inhibitor Switch
15. Turbine Speed Sensor
16. Secondary Speed Sensor
17. Primary Speed Sensor
18. Secondary Pressure Sensor
19. Oil Pan
20. Control Valve Body
21. Electric Fluid Pump
22. Transmission Harness
23. X MODE Switch
24. Transmission Control Module (TCM)
25. Relay and Fuse
26. CVTF Cooler (With Warmer Function)
27. Air Breather Hose
28. Drive Plate
29. Torque Converter
30. Preparation for Overhaul
31. Extension Case
32. Transfer Clutch
33. Transfer Driven Gear
34. Transfer Drive Gear
35. Parking Pawl
36. Reduction Driven Gear
37. Transmission Control Device
38. Transmission Case
39. CVTF Filter
40. Reduction Drive Gear
41. Primary Pulley and Secondary Pulley
42. Variator Chain
43. Reverse Brake
44. Forward Clutch
https://techinfo.subaru.com/stis/diag/2019/Forester/contents/data/print/s505.html 1/276
45. Drive Pinion

46. Front Differential
47. Oil Pump Chain
48. Oil Pump
49. Converter Case
50. AT learning
51. Symptoms and causes
CONTINUOUSLY VARIABLE TRANSMISSION(TR580) > General Description

SPECIFICATION
Forward continuously
Type variable speed
change, 1-reverse
Forward 3.600 — 0.512
Gear ratio
Rev 3.687
Transmission Number of forward Drive plate 3
pcs.
clutch plates Driven plate 3
Number of reverse Drive plate 4
pcs.
brake plates Driven plate 4
L (US qt, Imp 11.74 — 12.24 (12.4
CVTF capacity
qt) — 12.9, 10.3 — 10.8)
Symmetric, 3-
element, single stage,
Type
2-phase torque
converter
Nominal mm (in) 236 (9.29)
Torque converter
Sprag type one-way
Clutch
clutch
Stall torque ratio 2.18
Stall speed (at sea D range 1,950 — 2,550
r/min
level) R range 1,850 — 2,450
Type Internal gear pump
Driving method Chain drive
Oil pump
Inner rotor 8
Number of teeth pcs.
Outer rotor 9
Type Multi-plate transfer
Electronic hydraulic
Control method
type
Transfer
Number of transfer Drive plate 5
pcs.
clutch plates Driven plate 5
Gear ratio 1.000
Type of gear Hypoid gear
LSD type —
Gear ratio 3.700
Backlash between the differential bevel
Front differential mm (in) 0.13 — 0.18 (0.005 —
gear and differential bevel pinion
0.007)
Hypoid gear set backlash mm (in)
L (US qt, Imp 1.21 — 1.31 (1.3 —
Differential gear oil capacity
qt) 1.4, 1.1 — 1.2)
CVTF:
Refer to “RECOMMENDED MATERIALS” for CVTF. Ref. to RECOMMENDED MATERIALS>GREASE>CVTF.
Caution:
Always use specified CVTF. Using other fluid will cause malfunction.
Differential gear oil:
For the differential gear oil, refer to “RECOMMENDED MATERIALS”. Ref. to RECOMMENDED
MATERIALS>GREASE>DIFFERENTIAL GEAR OIL.
COMPONENT
1. TORQUE CONVERTER & CONVERTER CASE
T5
(14)
x2
(13)
(12)
x2
(10)
T4 (11)
(9)
(8)
T6 (7)
(15) T1
(6)
T2 (5) (16)
(17)
(5)
T2
(6)
(1) (19)
(18)
T8
(4) (24) T3
T4
x8 (23)
x4 x15
(20)
(2)
(3)
(22)
(21)
T2
T7 T6
CVT11386
(1) Drive plate (13) Air breather cap Tightening torque: N·m (kgf-m,
ft-lb)
(2) Reinforcement drive plate (14) Pitching stopper bracket T1: 18 (1.8, 13.3)
(3) Torque converter (15) O-ring T2: 22 (2.2, 16.2)
(4) Seal ring (16) Stud bolt T3: 22.5 (2.3, 16.6)
(5) O-ring (17) O-ring T4: 25 (2.5, 18.4)
(6) Plug (18) O-ring T5: 41 (4.2, 30.2)
(7) Gasket (19) Plug T6: 50 (5.1, 36.9)
(8) Filler plug (20) Gasket T7: 70 (7.1, 51.6)
(9) O-ring (21) Overflow plug T8: Ref. to CONTINUOUSLY
VARIABLE
TRANSMISSION(TR580)>Driv
e 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
(11)
(7) (9)
(6)
(5) (12)
(4)
(2) (3)
(10)
T2
x4
x10
(8) T1
(1)
CVT11214
(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
(8)
(9) T2
(12) (14)
(10) T1
(13)
(11) (15)
T4
(23)
(24) T4 x3
(7)
T5 (5)
(6)
T5 T5
(5) (10)
(11)
(17)
(4) (16)
(11)
(10)
T4
(3)
x2 (18)
(2)
(19)
(1)
T4
T3
(13)
(5) T5
(23) (20)
(25) (21)
(22)
T2
(24)
(26) (11)
(27) T5 (23)
(24)
(29) (28) T5
CVT11295
(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 T2: 13 (1.3, 9.6)
(line pressure))
(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
T2
(1)
(2)
T3 x12
(3)
(4)
T6 x7
(5)
(6)
x2
(6)
(7)
(8)
(9)
T4
x2
(10)
(11)
T5 x12
T1
(12)
CVT11215
(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: Ref. to CONTINUOUSLY
VARIABLE
TRANSMISSION(TR580)>Cont
rol Valve
Body>INSTALLATION.
5. REVERSE BRAKE
(7)
(4)
(5)
(3)
(2)
(1)
(6)
T1
(14)
(13)
(16) (17)
(12)
(11) (15)
(10)
x6
(9)
(8)
T2
CVT11218
(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
(6)
(5)
(4)
(3)
(2)
(1)
(16)
(15)
(12)
(13)
(11)
(10)
(9)
(8)
(7) (14)
(27)
(26)
(25)
(24)
(23)
(22)
(21)
(20)
(19)
(18)
(17)
CVT11219
(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
(11)
T4
T5
(12)
x2 x2
(8)
(9) (13) (14) (15)
T5
x2 (10)
(7)
T1 x2
T3
(16)
(6)
(5) x4
T2
(4)
T2
(3)
(1)
(2)
CVT11297
(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 bracket T2: 7 (0.7, 5.2)
(4) Detent spring (12) Cable plate T3: 9 (0.9, 6.6)
(5) Separator plate (13) Return spring T4: 18 (1.8, 13.3)
(6) Manual valve (14) Parking pawl T5: 25 (2.5, 18.4)
(7) Spring pin (15) Shaft
(8) Shifter arm (16) Parking support
8. PRIMARY PULLEY & SECONDARY PULLEY, VARIATOR CHAIN AND REDUCTION DRIVE GEAR
(3)
(4)
T2
T2 (2)
(1) x2
(8)
(9)
T2
(8)
(5)
(13)
(12)
(6) (11)
(7)
(6)
T3
(10)
x3
(14)
T1 x3
CVT11221
(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
(4) (6) (9)

(10) (11)
(7)
(8) (10)
(6) (9)
(1) C
(3) A
(8)
(7)
B
(5) (28)
(2)
(27)
A
(24)
T4
C B T3 (23)
(22)
(26)
(21)
(16) (25)
x2
x8
(16) T3
(13) x4
(12)
(20) (29)
(30)
(15)
(14) (31)
(17)
T2 (32) (31)
T1 (30)
(19)
(29)
(18)
(32)
T2
CVT11222
(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: Ref. to CONTINUOUSLY
VARIABLE
TRANSMISSION(TR580)>Driv
e 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) (29) Differential side retainer oil
inner race seal
(15) Taper roller bearing (front) (30) Differential side retainer
outer race
∗: 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
(8)
(7)
(5)
(6)
(1) (4)
T5
(3)
(2)
x3 (27)
(26)
(25)
T1
(24)
(23)
(9) (22)
(21)
(20)
(19)
(15)
(17)
(16)
(32)
(14) T3
(13)
(31)
(12) (18) (30)
(29)
(11)
(10)
T2
T4 (33)
(28)
(34)
x12
T3
CVT11223
(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
T2
x3
(1)
(2)
(3)
(3)
(4)
(4) T1
T1
(5)
T2
x3
(6)
(4)
T1 (3)
CVT11298
(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)
T1
x2
x5
T1 (2) T2
T4
(3)
T3
(4)
(5)
T1
(7)
(6)
(8)
T5
(9)
(11) (10)
(12)
T1
T1
CVT11299
(1) Transmission case cover (7) O-ring Tightening torque: N·m (kgf-m,
(rear) ft-lb)
(2) Transmission case cover (8) Secondary pressure sensor T1: 7 (0.7, 3.7)
(front)
(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)
(6) (2)
T
(2)
(5) x2
(4) (8)
(7)
(4)
(4) T
x2
(2)
(4)
(3)
(1)
(2)
CVT11213
(1) Water hose (inlet) (5) CVTF outlet hose Tightening torque: N·m (kgf-m,
ft-lb)
(2) Hose clamp (6) Water hose (outlet) T: 23 (2.3, 17.0)
(3) CVTF inlet hose (7) CVTF cooler (with warmer
feature)
(4) Hose clamp (8) CVTF cooler bracket
14. TRANSMISSION CONTROL MODULE
T
x2
(1)
CVT11301
(1) Transmission control module Tightening torque: N·m (kgf-m,

(TCM) ft-lb)
T: 7 (0.7, 5.3)
15. TRANSMISSION MOUNTING
(2)
x4
T2
(3)
T4
T3
(1) (4)
x4 T5
x6
T1
CVT11622
(1) Pitching stopper (3) Transmission rear Tightening torque: N·m (kgf-m,
crossmember 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)

CAUTION
When performing service operation, refer to “Repair Contents” in “General Description”. Ref. to 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 cable from battery.
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.

PREPARATION TOOL
1. SPECIAL TOOL
ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS
398177700 INSTALLER Used for installing the ball bearing
of the transfer clutch and
transmission case.
Used for installing the taper roller
bearing (front) outer race of drive
pinion.
Used for installing the drive pinion
plug.
ST-398177700
398497701 SEAT Used for removing and installing the

side bearing inner race of the front
differential.
ST-398497701
398527700 PULLER ASSY Used for removing the extension

case oil seal.
Used for removing the ball bearing
of transmission case.
Used together with CLAW
(18760AA000) when removing the
ball bearing of transmission case.
Used for removing the taper roller
ST-398527700 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.
ST-398673600

399513600 INSTALLER Used for removing the ball bearing of
drive sprocket.
ST-399513600
498057300 OIL SEAL Used for installing the extension case

INSTALLER oil seal.
ST-498057300
498077000 REMOVER Used for removing the side bearing

inner race of the front differential.
ST-498077000
498077300 REMOVER Used for removing ball bearing of

reduction driven gear.
ST-498077300
498077400 REMOVER Used for removing the ball bearing of

transfer driven gear.
ST-498077400

498077600 REMOVER Used for removing the ball bearing of
drive sprocket.
ST-498077600
498247001 MAGNET BASE Used for adjusting backlash of the

differential bevel gear and
differential bevel pinion.
Used for adjusting hypoid gear set
backlash.
Used together with DIAL GAUGE
(498247100).
ST-498247001
498247100 DIAL GAUGE Used for adjusting backlash of the

differential bevel gear and
differential bevel pinion.
backlash.
Used together with MAGNET BASE
(498247001).
ST-498247100
498255400 PLATE Used for adjusting hypoid gear set

backlash.
ST-498255400
498277200 STOPPER SET Used for removing and installing

transmission body.
ST-498277200

498497300 CRANKSHAFT Used for removing and installing the
STOPPER drive plate.
ST-498497300
498515500 REMOVER Used for removing the taper roller

bearing (front) inner race of the drive
pinion and drive pinion shim.
ST-498515500
498575400 OIL PRESSURE Used for measuring the transfer clutch

GAUGE ASSY pressure.
ST-498575400
498897700 OIL PRESSURE Used for measuring the secondary

ADAPTER SET pressure (line pressure).
ST-498897700
498937110 HOLDER Used for removing and installing the

drive pinion lock nut.
Used for adjusting drive pinion
preload.
backlash.
Used together with ADAPTER
(499787500).
ST-498937110 Used together with WRENCH
(499787700).

499267300 STOPPER PIN Used for adjusting the inhibitor
switch.
ST-499267300
499277100 BUSHING 1-2 Used for installing the ball bearing

INSTALLER of reduction driven gear.
Used for installing the ball bearing
of the transmission case.
代替画像1 Used for installing the side bearing
この画像は代替画像です
499277200 INSTALLER Used for installing the ball bearing of

the transfer clutch.
ST-499277200
499575400 GAUGE Used for measuring the end play.
ST-499575400
ST-499575500

ST-499575600
499755502 PRESS SNAP Used for installing the drive sprocket

RING ball bearing.
ST-499755502
499755602 PRESS SNAP Used for installing the drive pinion

RING retainer plug.
Used for installing the oil seal of the
oil pump chain cover.
ST-499755602
499757002 INSTALLER Used for removing ball bearing of

reduction driven gear.
Used for installing the parking gear.
Used for installing the transfer drive
gear.
ST-499757002
499787500 ADAPTER Used for removing and installing the

preload.
Used together with HOLDER
(498937110).
Used together with WRENCH
(499787700).
ST-499787500

499787700 WRENCH Used for removing and installing the
preload.
backlash.
Used together with ADAPTER
(499787500).
ST-499787700 Used together with HOLDER
(498937110).
499987003 SOCKET Used for removing and installing the
WRENCH (35) lock nut of reduction driven gear.
ST-499987003
899580100 INSTALLER Used for installing the ball bearing

of the transfer driven gear.
bearing (front) inner race of drive
pinion.
ST-899580100
899864100 REMOVER Used for removing and installing the

ball bearing of the transfer driven
gear.
Used for removing the parking gear
and transfer drive gear.
Used for removing the side bearing
ST-899864100
899904100 STRAIGHT PIN Used for removing the spring pin of

REMOVER the differential case.
ST-899904100

927130000 EXTENSION Used for installing the taper roller
DRIVE SHAFT bearing (front) inner race of drive
pinion.
ST-927130000
927720000 HOUSING Used for installing drive pinion

BUSHING retainer oil seal.
INSTALLER AND
REMOVER
ST-927720000
18270AA040 SOCKET Used for removing and installing the

test plug (transfer clutch pressure).
ST18270AA040
18270KA020 SOCKET (E20) Used for removing and installing the

drive pinion retainer.
ST18270KA020
18334AA000 PULLEY Used for removing and installing the

WRENCH PIN lock nut of reduction driven gear.
SET Used together with PULLEY
WRENCH (18355AA000).
ST18334AA000

18355AA000 PULLEY Used for removing and installing the
WRENCH lock nut of reduction driven gear.
Used together with PULLEY
WRENCH PIN SET (18334AA000).
ST18355AA000
18460AA040 CHECK BOARD Used for measuring voltage and

resistance of TCM terminals.
ST18460AA040
18632AA000 STAND ASSY Used for disassembling and

assembling the transmission body.
ST18632AA000
18657AA000 INSTALLER Used for installing the transmission

case oil seal.
ST18657AA000
18658AA020 WRENCH COMPL Used for removing and installing the

RETAINER differential side retainer.
ST18658AA020

18675AA000 DIFFERENTIAL Used for installing the differential side
SIDE OIL SEAL retainer oil seal.
INSTALLER
ST18675AA000
18681AA060 OIL PRESSURE Used for measuring the secondary

GAUGE pressure (line pressure).
ADAPTER Note:
Used together with the genuine
O-ring (part No. 806908150).
ST18681AA060
18723AA000 REMOVER Used for removing the ball bearing

of transfer clutch.
Used together with BEARING
REMOVER (18767AA010).
ST18723AA000
18760AA000 CLAW Used for removing the ball bearing

of transmission case.
Used together with PULLER ASSY
(398527700).
ST18760AA000
18761AA010 SHEET SPECIAL Used for removing and installing valve

TOOL cover.
ST18761AA010

18762AA001 COMPRESSOR Used for disassembling and
SPECIAL TOOL assembling transfer clutch and
reverse brake.
COMPRESSOR SPECIAL TOOL
(18762AA000) can also be used.
ST18762AA001
18762AA010 COMPRESSOR Used for removing and installing snap

SPECIAL TOOL ring of forward clutch.
ST18762AA010
18763AA000 COMPRESSOR Used for adjusting hypoid gear set

SHAFT backlash.
ST18763AA000
18767AA010 BEARING Used for removing the ball bearing

REMOVER of transfer clutch.
Used together with REMOVER
(18723AA000).
ST18767AA010
18769AA010 EXPANDER Used for removing and installing the

PULLEY secondary pulley.
ST18769AA010

18801AA000 OIL PRESSURE Used for measuring the secondary
GAUGE ASSY pressure (line pressure).
ST18801AA000
20099AE020 INSTALLER Used for installing the taper roller

bearing (rear) outer race of drive
pinion.
ST-20099AE020
28499TC010 PRESS SNAP Used for installing the ball bearing

RING of the transmission case.
bearing (front) outer race of drive
pinion.
ST28499TC010
34099AC020 ADAPTER HOSE Used for measuring the transfer clutch

B pressure.
Note:
Used with genuine union screw
(Part No. 801914010) and gasket
(Part No. 803914060).
ST34099AC020
41099AA012 ENGINE Used for removing and installing

SUPPORT transmission body.
BRACKET Used together with ENGINE
SUPPORT (41099AA020).
ST41099AA012

41099AA020 ENGINE Used for removing and installing
SUPPORT transmission body.
Used together with ENGINE
SUPPORT BRACKET (41099AA012).
ST41099AA020
73099SG000 SPECIAL TOOL Used for installing the test plug

CONDENSER (transfer clutch pressure).
ST73099SG000
— SUBARU Used for setting of each function and

SELECT troubleshooting for electrical system.
MONITOR 4 Note:
For detailed operation procedures,
refer to “Help” of application.
STSSM4
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 assembling the reverse brake and
forward clutch.
Used together with magnet stand.
Magnet stand Used for assembling the reverse brake and
forward clutch.
Used together with dial gauge.
DST-i Used together with Subaru Select Monitor 4.
CONTINUOUSLY VARIABLE TRANSMISSION(TR580) > CVTF

INSPECTION
Caution:
When inspecting CVTF level, observe the specified CVTF temperature.
Do not add CVTF at a cold condition since the oil may blow out.
Note:
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.
Note:
For detailed operation procedures, refer to “Help” of application.
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).
Caution:
Make sure to perform the CVTF inspection while [ATF Temp.] is within the range 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.
Note:
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.
CVT11175
8. If the CVTF level is below the bottom of the filler plug hole, check for oil leakage, and add specified CVTF.
Caution:
Always use specified CVTF. Using fluid other than specified CVTF will cause malfunction.
CVTF:
Ref. to RECOMMENDED MATERIALS>GREASE>CVTF.
9. Using a new gasket, install the filler plug.
Tightening torque:
50 N·m (5.1 kgf-m, 36.9 ft-lb)
CONTINUOUSLY VARIABLE TRANSMISSION(TR580) > CVTF

REPLACEMENT
Caution:
Note:
When there is no severe conditions or intrusion of water, etc., replacement of CVTF is unnecessary.
1. Remove the filler plug.
CVT11175
2. Loose the drain plug to drain CVTF.

SK-*AE
CVT11176
3. Check the CVTF condition.

Note:
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 Replace CVTF and check if the
the transmission body. 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 mixed in 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 (3.2 kgf-m, 22.9 ft-lb)
5. Pour the specified CVTF to the bottom end of filler plug hole.
Caution:
Always use specified CVTF. Using fluid other than specified CVTF will cause malfunction.
CVTF:
Ref. to RECOMMENDED MATERIALS>GREASE>CVTF.

6. Temporarily tighten the filler plug.
7. Check the CVTF level. Ref. to CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>CVTF>INSPECTION.
CONTINUOUSLY VARIABLE TRANSMISSION(TR580) > Differential Gear Oil

INSPECTION
Caution:
CVT11178
2. Remove the overflow plug.

Note:
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.
SK-*AE
CVT11179
3. Fill the differential gear oil through the filler plug hole, and let the oil flow out of the overflow plug.
Ref. to RECOMMENDED MATERIALS>GREASE>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 (5.1 kgf-m, 36.9 ft-lb)
5. Using a new gasket, install the filler plug.
Tightening torque:
50 N·m (5.1 kgf-m, 36.9 ft-lb)
CONTINUOUSLY VARIABLE TRANSMISSION(TR580) > Differential Gear Oil

REPLACEMENT
Caution:
CVT11178
2. Drain the differential gear oil by loosening the drain plug using TORX® bit T70.
SK-*AE
CVT11177
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 (7.1 kgf-m, 51.6 ft-lb)
5. Fill the differential gear oil from the filler plug hole.
Ref. to RECOMMENDED MATERIALS>GREASE>DIFFERENTIAL GEAR OIL.
Differential gear oil capacity:
Ref. to CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>General Description>SPECIFICATION.
6. Check the differential gear oil level. Ref. to CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Differential Gear
Oil>INSPECTION.
CONTINUOUSLY VARIABLE TRANSMISSION(TR580) > AWD ON/OFF Switching Mode

PROCEDURE
Caution:
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”.

Note:
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.]
Note:
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
Caution:
Always observe the local traffic laws when performing the test.
Note:
Turn OFF the X mode switch and perform inspection. (Model with X mode switch)
1. D RANGE SHIFT FUNCTION

1. From halting condition, accelerate with 1/4 or less of the accelerator opening angle, and make sure that the engine speed is
950 — 1,400 r/min while driving on the level road at 50 km/h (31 MPH).
Caution:
Make sure to route the Subaru Select Monitor wires so that they do not disturb the driving.
Note:
4. Display [Vehicle Speed] and [Actual Gear Ratio].
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.
Caution:
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 “4th speed of manual mode” [50 — 60 km/h (31 — 37 MPH)], and shift down from 4th to 3rd.
Drive in “3rd speed of manual mode” [40 — 50 km/h (25 — 31 MPH)], and shift down from 3rd to 2nd.
Drive in “2nd speed of manual mode” [20 — 30 km/h (12 — 19 MPH)], and shift down from 2nd to 1st.
• 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.
Caution:
Release the parking brake while being prepared to depress the brake pedal anytime.
6. NOISE AND VIBRATION

Make sure to check that noise and vibration do not occur during driving at a constant speed, accelerating, decelerating and
manual shift operation.
7. Auto Start Stop

Note:
3. Display [ATF Temp.] and [Emphasized idle stop request].
4. Warm up the engine until [ATF Temp.] reaches 60°C (140°F) or more.
Note:
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].
Note:
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].
Note:
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) five times, and then check that no shock occurs during engine
restarting.
CONTINUOUSLY VARIABLE TRANSMISSION(TR580) > Stall Test

INSPECTION
Warning:
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. Place wheel chocks at the front and rear of all wheels and engage the parking brake.
Note:
4. Display [ATF Temp.] and [Engine Speed].
6. Check the engine oil level. Ref. to LUBRICATION(H4DO)>Engine Oil>INSPECTION.
7. Check the engine coolant level. Ref. to COOLING(H4DO)>Engine Coolant>INSPECTION.
9. Warm up until [ATF Temp.] reaches to 60 — 80°C (140 — 176°F).
10. Turn OFF the pre-collision brake function. (Models with EyeSight)
12. Depress the accelerator pedal to the full while fully depressing the foot brake pedal with your left foot.
Caution:
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.
13. 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
Insufficient engine output
Lower than standard value
Torque converter malfunction
Forward clutch slippage
Secondary pressure (line pressure) is low.
D Variator chain malfunction
Higher than standard value Torque converter malfunction
Control valve body malfunction
TCM malfunction
Damaged harness and harness connector
14. Shift the select lever to “N range”, and idle the engine for one minute or more.
15. 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
Insufficient engine output
Lower than standard value
Torque converter malfunction
Reverse brake slippage
Secondary pressure (line pressure) is low.
R Variator chain malfunction
Higher than standard value Torque converter malfunction
TCM malfunction
Damaged harness and harness connector
CONTINUOUSLY VARIABLE TRANSMISSION(TR580) > Time Lag Test

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

Note:
5. Apply the parking brake.
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.
Note:
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
Learning 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
Learning incomplete
CONTINUOUSLY VARIABLE TRANSMISSION(TR580) > Secondary Pressure (Line Pressure) Test

LOCATION
SK-*AE
(A)
CVT11336
(A) Test plug (secondary pressure

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

INSPECTION
Warning:
During the secondary pressure (line pressure) test, confirm safety in the vicinity and make sure no person is around
the vehicle.
Caution:
1. Remove the test plug (secondary pressure (line pressure)), and install ST1, ST2 and ST3.
Caution:
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.
Note:
Use the ST1 with genuine O-ring (part No. 806908150) attached.
Preparation tool:
ST1: OIL PRESSURE GAUGE ADAPTER (18681AA060)
ST2: OIL PRESSURE ADAPTER SET (498897700)
ST3: OIL PRESSURE GAUGE ASSY (18801AA000)
CVT00750
ST1
ST3
ST2
CVT10001
2. Set the gauge so that it can be seen from the driver’s seat.
Note:
11. Warm up until [ATF Temperature] reaches to 60 — 80°C (140 — 176°F).
13. Record the secondary pressure (line pressure) with the engine idling.
Note:
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)
15. Depress the accelerator pedal to the full while fully depressing the foot brake pedal with your left foot.
Caution:
Do not perform this procedure for over 5 seconds at a time.
16. 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)
18. 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)
19. 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.
Caution:
Due to flowing out of CVTF, quickly install the test plug (secondary pressure (line pressure)).
Note:
Apply CVTF to the O-rings.
Tightening torque:
13 N·m (1.3 kgf-m, 9.6 ft-lb)
CONTINUOUSLY VARIABLE TRANSMISSION(TR580) > Transfer Clutch Pressure Test

LOCATION
SK-*AE
(A)
CVT11337
(A) Test plug (transfer clutch

pressure)
CONTINUOUSLY VARIABLE TRANSMISSION(TR580) > Transfer Clutch Pressure Test

INSPECTION
Warning:
During the transfer clutch pressure test, confirm safety in the vicinity and make sure no person is around the
vehicle.
Caution:
1. Remove the rear exhaust pipe. Ref. to EXHAUST(H4DO)>Rear Exhaust Pipe>REMOVAL.

2. Remove the crossmember support rear LH. Ref. to FRONT SUSPENSION>Crossmember Support>REMOVAL.
3. Set the transmission jack under the transmission.
4. Remove the bolt securing the transmission rear crossmember.
CVT10262
5. Tilt the transmission body to the position where the test plug (transfer clutch pressure) can be removed.
Caution:
Be careful not to damage the propeller shaft.
6. Using the ST, remove the test plug (transfer clutch pressure).
Caution:
Use cloth to catch CVTF in order to prevent it from splashing.
Preparation tool:
ST: SOCKET (18270AA040)
ST
CVT00612
7. Attach the ST1 and ST2.

Caution:
Be careful when setting the tool so that the ST1 does not touch the exhaust pipe.
Note:
Use ST1 with genuine gasket (Part No. 803914060) and union screw (Part No. 801914010) attached.
Preparation tool:
ST1: ADAPTER HOSE B (34099AC020)
ST2: OIL PRESSURE GAUGE ASSY (498575400)
ST1
ST1
CVT11315
ST2
ST1
ST2
CVT00753
8. Install the transmission rear crossmember.

Tightening torque:
70 N·m (7.1 kgf-m, 51.6 ft-lb)
9. Remove the transmission jack.
10. Install the rear exhaust pipe. Ref. to EXHAUST(H4DO)>Rear Exhaust Pipe>INSTALLATION.
Note:
Reuse the new gasket at this point.
11. Set the gauge so that it can be seen from the driver’s seat.
Note:
15. Display [ATF Temp.] and [Transfer Duty Ratio].
22. Turn OFF the X mode switch. (Model with X mode switch)
23. Record the transfer clutch pressure with the engine idling.
Specification:
0 kPa (0 kgf/cm2, 0 psi)
24. Switch to FWD mode. Ref. to CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>AWD ON/OFF Switching
Mode>PROCEDURE.
25. Shift the select lever to “D range”, and depress and hold the brake pedal.
26. When the engine speed stabilizes, record the transfer clutch pressure.
Specification:
kPa (0 kgf/cm2, 0 psi)
27. Switch to AWD mode. Ref. to CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>AWD ON/OFF Switching
Mode>PROCEDURE.
28. While fully depressing the brake pedal with your left foot, depress the accelerator pedal until [Transfer Duty Ratio] becomes
60%.
Caution:
29. 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. Depress the accelerator pedal to the full while fully depressing the brake pedal with your left foot.
Caution:
33. 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)
35. Remove the rear exhaust pipe. Ref. to EXHAUST(H4DO)>Rear Exhaust Pipe>REMOVAL.
37. Remove the bolt securing the transmission rear crossmember.
CVT10262
38. Tilt the transmission body to the position where the test plug (transfer clutch pressure) can be installed.
Caution:
Be careful not to damage the propeller shaft.
39. 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.
Note:
40. 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 (2.2 kgf-m, 16.2 ft-lb) × L/ (100 mm (3.94 in) +L)
T: Tightening torque
L: Effective length of torque wrench
Note:
If the effective length of the torque wrench used is unknown, consult the manufacturer of
the torque wrench.
(a) (b)
(c) (d) (e)
CO-03173
(a) Effective length of the ST2

(b) Effective length of the torque wrench
(c) Center of drive angle of the ST2
(d) Center of drive angle of the torque wrench
(e) Center of the position where a force is applied by hand
ST2
ST1
CVT00479

Tightening torque:
70 N·m (7.1 kgf-m, 51.6 ft-lb)
43. Install the crossmember support rear LH. Ref. to FRONT SUSPENSION>Crossmember Support>INSTALLATION.
44. Install the rear exhaust pipe. Ref. to EXHAUST(H4DO)>Rear Exhaust Pipe>INSTALLATION.
CONTINUOUSLY VARIABLE TRANSMISSION(TR580) > Transmission Assembly

REMOVAL
1. Release the parking brake.

2. Disconnect the ground cable from battery. Ref. to REPAIR CONTENTS>NOTE > BATTERY.
3. Release the shift lock using a screwdriver, etc. and shift the select lever to the “N” range.
SK-*AE
P
R
N
M-D
CVT11166
4. Drain the CVTF. Ref. to CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>CVTF>REPLACEMENT.

5. Drain differential gear oil. Ref. to CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Differential Gear
Oil>REPLACEMENT.
6. Remove the clip from the air intake boot, and loosen the clamp.
SK-9AU
IN-10444
7. Remove the air intake boot, and place it aside so that it does not interfere with the work.
Caution:
Be careful not to pull out the PCV hose.
SK-9AU
IN-10427
8. Remove the CVTF cooler (with warmer feature).

Note:
(1) Disconnect the CVTF inlet hose and CVTF outlet hose.
SK-*AE
CVT11093
(2) Remove the CVTF cooler (with warmer feature), and move it aside so that it does not interfere with the operation.
Note:
Suspend from the vehicle body with rope, etc.
SK-*AE
CVT11091
(3) Remove the CVTF inlet hose (A) and CVTF outlet hose (B).
(B) (A)
CVT11260
9. Remove the engine rear hanger.
CVT10275
10. Disconnect the transmission harness connector.
CVT10266
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.
SK-*AE
(A) CVT11192
12. Remove the TCM. Ref. to CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Transmission Control Module
(TCM)>REMOVAL.
13. Remove the starter. Ref. to STARTING/CHARGING SYSTEMS(H4DO)>Starter>REMOVAL.
14. Separate the torque converter from drive plate.
(1) Remove the PCV hose. Ref. to 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.
SK-9AE (B)
(A)
ME-21704
(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.
SK-9AE
ME-21705
(4) Attach the ST to the converter case.

Preparation tool:
ST: STOPPER SET (498277200)
SK-9AE
ST
ME-21757
15. Remove the bolts which hold the upper side of the transmission.
AT-06591
16. Set the ST1 and ST2.

Preparation tool:
ST1: ENGINE SUPPORT BRACKET (41099AA012)
ST2: ENGINE SUPPORT (41099AA020)
ST2
ST1
CVT10286
17. Remove the front drive shaft. Ref. to PROPELLER SHAFT / DRIVE SHAFT / AXLE>Front Drive Shaft>REMOVAL.
18. Remove the propeller shaft. Ref. to PROPELLER SHAFT / DRIVE SHAFT / AXLE>Propeller Shaft>REMOVAL.
19. Remove the select cable from the transmission body.
Caution:
Do not apply excessive load while holding the part (a).
(a)
CS-10149
SK-*AE
CVT11094
20. Remove the exhaust hanger bracket.
CVT10312
21. Remove the bolts and nuts which hold the lower side of transmission.
AT-06598

Caution:
Make sure that the support plates of transmission jack do not touch the oil pan.
23. Remove the transmission rear crossmember.
CVT10316
24. While lowering the transmission jack gradually, fully retract the ST (ENGINE SUPPORT), and then tilt the engine rearward.
25. Remove the transmission body.
Note:
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.
CVT10318
27. Remove the transmission cover (rear).

SK-*AE
CVT11115
28. When overhauling the transmission body, refer to “Preparation for overhaul”. Ref. to CONTINUOUSLY VARIABLE
TRANSMISSION(TR580)>Preparation for Overhaul>PROCEDURE > BEFORE OVERHAUL.

INSTALLATION
1. When having overhauled the transmission body, refer to “Preparation for overhaul”. Ref. to CONTINUOUSLY VARIABLE
TRANSMISSION(TR580)>Preparation for Overhaul>PROCEDURE > AFTER OVERHAUL.
2. Replace the differential side retainer oil seal with a new part. Ref. to CONTINUOUSLY VARIABLE
TRANSMISSION(TR580)>Differential Side Retainer Oil Seal>REPLACEMENT.
3. Install the transmission case cover (rear).
Tightening torque:
8 N·m (0.8 kgf-m, 5.9 ft-lb)
4. Install the rear cushion rubber.
Tightening torque:
40 N·m (4.1 kgf-m, 29.5 ft-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.
Caution:
Do not apply extra overload or impact to the transmission case.
AT-06599
7. Install the transmission body.

Note:
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.
AT-06598

Tightening torque:
T1: 35 N·m (3.6 kgf-m, 25.8 ft-lb)
T2: 70 N·m (7.1 kgf-m, 51.6 ft-lb)
T2
T1
T2
CVT10317
10. Tighten the bolts and nuts which hold lower side of the transmission.
Tightening torque:
50 N·m (5.1 kgf-m, 36.9 ft-lb)
11. Install the exhaust hanger bracket.
Tightening torque:
23 N·m (2.3 kgf-m, 17.0 ft-lb)
12. Install the select cable to the transmission body.
Caution:
Tightening torque:
25 N·m (2.5 kgf-m, 18.4 ft-lb)
(a)
CS-10149
SK-*AE
CVT11094
13. Install the bolts which hold upper side of transmission.

Tightening torque:
50 N·m (5.1 kgf-m, 36.9 ft-lb)
AT-06591
14. Install the propeller shaft. Ref. to PROPELLER SHAFT / DRIVE SHAFT / AXLE>Propeller Shaft>INSTALLATION.
15. Install the front drive shaft. Ref. to 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.
Note:
Be careful not to drop the ST into the converter case when removing the ST.
SK-9AE
ST
ME-21757
(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.
Note:
Be careful not to drop bolts into the converter housing.
Tightening torque:
25 N·m (2.5 kgf-m, 18.4 ft-lb)
(3) Install the plug (B) to the service hole, and connect the connector (A).
SK-9AE (B)
(A)
ME-21704
(4) Install the PCV hose. Ref. to 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 (1.9 kgf-m, 14.0 ft-lb)
(2) Install the engine ground and the harness case.
Tightening torque:
19 N·m (1.9 kgf-m, 14.0 ft-lb)
SK-*AE
(A) CVT11192
19. Install the starter. Ref. to STARTING/CHARGING SYSTEMS(H4DO)>Starter>INSTALLATION.

20. Install the TCM. Ref. to CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Transmission Control Module
(TCM)>INSTALLATION.
21. Install the CVTF cooler (with warmer feature).
(1) Install a new CVTF inlet hose (A) and a new CVTF outlet hose (B).
(B) (A)
CVT11260
(2) Install the CVTF cooler (with warmer feature).

Tightening torque:
23 N·m (2.3 kgf-m, 17.0 ft-lb)
(3) Connect the CVTF inlet hose and CVTF outlet hose.
SK-*AE
CVT11093
22. Install the engine rear hanger.

Tightening torque:
21 N·m (2.1 kgf-m, 15.5 ft-lb)
23. Connect the transmission harness connector to the engine wiring harness.
24. Install the air intake boot. Ref. to INTAKE (INDUCTION)(H4DO)>Air Intake Boot>INSTALLATION.
26. Connect the battery ground terminal. Ref. to REPAIR CONTENTS>NOTE > BATTERY.
28. Fill differential gear oil. Ref. to CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Differential Gear Oil>REPLACEMENT.
29. Fill with CVTF. Ref. to CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>CVTF>REPLACEMENT.
30. Perform Clear AT learning value and AT learning mode using the Subaru Select Monitor. Ref. to CONTINUOUSLY
VARIABLE TRANSMISSION(TR580)>AT learning.
Note:
31. When the transmission body or hypoid gear set was replaced, perform the rear differential inspection mode using the Subaru
Select Monitor. Ref. to DIFFERENTIALS>Rear Differential Inspection Mode.
Note:
32. Perform the road test to make sure there is no fault. Ref. to CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Road
Test>INSPECTION.

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
SK-9AU
IN-10444
Caution:
SK-9AU
IN-10427
3. Remove the air breather hose bracket.
CVT10439
4. Remove the pitching stopper.
CVT10272
5. Remove the pitching stopper bracket.

Note:
Perform this procedure only when required.
CVT10276
2. TRANSMISSION REAR CROSSMEMBER AND REAR CUSHION RUBBER

2. Remove the front exhaust pipe. Ref. to EXHAUST(H4DO)>Front Exhaust Pipe>REMOVAL.
3. Remove the center exhaust cover.
SK-*AE
EX-10370

Caution:
Make sure that the support plates of transmission jack do not touch the oil pan.
5. Remove the transmission rear crossmember.
CVT10316
6. Remove the rear cushion rubber.
CVT10318

INSTALLATION
1. PITCHING STOPPER
1. Install the pitching stopper bracket.
Tightening torque:
41 N·m (4.2 kgf-m, 30.2 ft-lb)
CVT10276
2. Install the pitching stopper.

Tightening torque:
T1: 50 N·m (5.1 kgf-m, 36.9 ft-lb)
T2: 58 N·m (5.9 kgf-m, 42.8 ft-lb)
T2
T1
CVT10319
3. Install the air breather hose bracket.
CVT10439
2. TRANSMISSION REAR CROSSMEMBER AND REAR CUSHION RUBBER

1. Install the rear cushion rubber.
Tightening torque:
40 N·m (4.1 kgf-m, 29.5 ft-lb)
Tightening torque:
T1: 35 N·m (3.6 kgf-m, 25.8 ft-lb)
T2: 70 N·m (7.1 kgf-m, 51.6 ft-lb)
T2
T1
T2
CVT10317

4. Install the center exhaust cover.
Tightening torque:
18 N·m (1.8 kgf-m, 13.3 ft-lb)
SK-*AE
EX-10370
5. Install the front exhaust pipe. Ref. to EXHAUST(H4DO)>Front Exhaust Pipe>INSTALLATION.


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.

SK-*AE
P
R
N
M-D
CVT11166
4. Remove the propeller shaft. Ref. to PROPELLER SHAFT / DRIVE SHAFT / AXLE>Propeller Shaft>REMOVAL.
6. Using the ST, remove the extension case oil seal.
Preparation tool:
ST: PULLER ASSY (398527700)
SK-*AE
ST
CVT11235
7. Using the ST, install a new extension case oil seal.

Note:
Apply CVTF to the oil seal lip and peripheral surface.
Preparation tool:
ST: OIL SEAL INSTALLER (498057300)
SK-*AE
ST
CVT11234

9. Install the propeller shaft. Ref. to PROPELLER SHAFT / DRIVE SHAFT / AXLE>Propeller Shaft>INSTALLATION.
CONTINUOUSLY VARIABLE TRANSMISSION(TR580) > Extension Case Oil Seal

INSPECTION

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

REPLACEMENT
Note:
Perform this procedure only when removing the LH side.
2. Drain differential gear oil. Ref. to CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Differential Gear
Oil>REPLACEMENT.
3. Remove the front drive shaft. Ref. to PROPELLER SHAFT / DRIVE SHAFT / AXLE>Front Drive Shaft>REMOVAL.
4. Remove the differential side retainer oil seal using a flat tip screwdriver wrapped with vinyl tape, etc.
SK-*AE
CVT11314
5. Install the new differential side retainer oil seal using the ST.
Caution:
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.
Note:
Apply differential gear oil to the peripheral surface of differential side retainer oil seal and the inner
circumference of differential side retainer.
Apply differential gear oil to the differential side retainer oil seal lip.
Preparation tool:
ST: DIFFERENTIAL SIDE OIL SEAL INSTALLER (18675AA000)
ST
AT-06602
6. Install the front drive shaft. Ref. to PROPELLER SHAFT / DRIVE SHAFT / AXLE>Front Drive Shaft>INSTALLATION.
7. Fill differential gear oil. Ref. to CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Differential Gear Oil>REPLACEMENT.
CONTINUOUSLY VARIABLE TRANSMISSION(TR580) > Differential Side Retainer Oil Seal
INSPECTION

CONTINUOUSLY VARIABLE TRANSMISSION(TR580) > Inhibitor Switch

REMOVAL
SK-*AE
P
R
N
M-D
CVT11166
3. Remove the select cable from the transmission body.

Caution:
(a)
CS-10149
SK-*AE
CVT11094
4. Remove the spring pin (A) and remove the shifter arm (B).
SK-*AE
(B)
(A)
CVT11099
5. Disconnect the connector and remove the inhibitor switch.

SK-*AE
CVT11236

INSTALLATION
1. Temporarily connect the inhibitor switch, and connect the connector.

2. Install the shifter arm and fix with a new spring pin.
3. Install the select cable to the transmission body.
Caution:
Tightening torque:
25 N·m (2.5 kgf-m, 18.4 ft-lb)
(a)
CS-10149
SK-*AE
CVT11094
4. Adjust the inhibitor switch. Ref. to CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Inhibitor Switch>ADJUSTMENT.


INSPECTION
SK-9AU
IN-10444
Caution:
SK-9AU
IN-10427
CVT10266
5. Disconnect the ground cord.
CVT10273
6. Remove the pitching stopper. Ref. to CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Transmission Mounting

System>REMOVAL > PITCHING STOPPER.
7. Remove the transmission case cover (front).
CVT10283
8. Move the lock lever in the arrow direction while pressing the lock button (A), and disconnect the connector.
(A)
CVT10284
9. Set the ST between the TCM and transmission harness. Ref. to TRANSMISSION (DIAGNOSTICS)>General
Description>CAUTION.
Special tool:
CHECK BOARD (18460AA040)
10. Check the inhibitor switch signal circuit.
(1) Check the circuit of each range.

Note:
If faulty, check the transmission harness for open circuit or short circuit, or poor contact.
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32
33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
CVT11189
Terminal No. Inspection conditions Standard

38 — 42 P range
37 — 42 R range
Less than 1 Ω
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. Ref. to CONTINUOUSLY
VARIABLE TRANSMISSION(TR580)>Inhibitor Switch>ADJUSTMENT.
(C)
(A)
(B)
(A)
CVT10412
(A) 1.5° (B) Initial position (C) Continuity range
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32
33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
CVT11189

38 — 42 P range
37 — 42 R range
Less than 1 Ω
36 — 42 N range
35 — 42 D range
11. Check the neutral switch signal circuit and back-up light circuit.
SK-*AE
1 2 3 4 5
21 6 7 8 9 10 22
24 25
23 26
28 29
27 11 12 13 14 15 30
16 17 18 19 20
CVT11611
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

ADJUSTMENT
SK-*AE
P
R
N
M-D
CVT11166
2. Loosen the bolts holding the inhibitor switch.

3. Insert the ST into the holes of the shifter arm and inhibitor switch.
Note:
Set the parts so that the center points of the holes are aligned.
Preparation tool:
ST: STOPPER PIN (499267300)
ST
CVT00756
4. Tighten the bolts holding the inhibitor switch.

Tightening torque:
5 N·m (0.5 kgf-m, 3.7 ft-lb)
CONTINUOUSLY VARIABLE TRANSMISSION(TR580) > Turbine Speed Sensor

LOCATION
SK-*AE
(A)
CVT11237
(A) Turbine speed sensor

REMOVAL
Caution:
If water or oil contacts the connector terminal of turbine speed sensor, replace it with a new part.
3. Disconnect the connector and remove the turbine speed sensor.
SK-*AE
CVT11238

INSTALLATION
Caution:
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.
Note:
Tightening torque:
7 N·m (0.7 kgf-m, 5.2 ft-lb)


INSPECTION

2. Check the output waveform and output voltage of the turbine speed sensor.
(1) Disconnect the ground cable from battery. Ref. to REPAIR CONTENTS>NOTE > BATTERY.
(2) Remove the clip from the air intake boot, and loosen the clamp.
SK-9AU
IN-10444
(3) Remove the air intake boot, and place it aside so that it does not interfere with the work.
Caution:
SK-9AU
IN-10427
(4) Disconnect the ground cord.
CVT10273
(5) Remove the pitching stopper. Ref. to CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Transmission Mounting
(6) Remove the transmission case cover (front).
CVT10283
(7) Move the lock lever in the arrow direction while pressing the lock button (A), and disconnect the connector.
(A)
CVT10284
(8) Set the ST between the TCM and transmission harness. Ref. to TRANSMISSION (DIAGNOSTICS)>General
Special tool:
(9) Install the air intake boot. Ref. to INTAKE (INDUCTION)(H4DO)>Air Intake Boot>INSTALLATION.
(10)Connect the battery ground terminal. Ref. to REPAIR CONTENTS>NOTE > BATTERY.
(11)Connect the probe of oscilloscope to ST.
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32
33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
CVT11189
Terminal No. Probe

12 +
26 −
(12)Start the engine and warm up completely.

(13)Check the output waveform and output voltage with engine idling.
Note:
For the output waveform and output voltage, refer to the “TRANSMISSION (DIAGNOSTICS)” section. Ref.
to TRANSMISSION (DIAGNOSTICS)>Transmission Control Module (TCM) I/O Signal>WAVEFORM > SENSOR.
(14)After inspection, install the related parts in the reverse order of removal.
CVT10293
Tightening torque:
7 N·m (0.7 kgf-m, 5.2 ft-lb)
CVT10283
Tightening torque:
32.3 N·m (3.3 kgf-m, 23.8 ft-lb)
CVT10273
CONTINUOUSLY VARIABLE TRANSMISSION(TR580) > Secondary Speed Sensor

LOCATION
SK-*AE
(A)
CVT11240
(A) Secondary speed sensor

REMOVAL
Caution:
If water or oil contacts the connector terminal of secondary speed sensor, replace it with a new part.
3. Disconnect the connector and remove the secondary speed sensor.
Note:
SK-*AE
CVT11241

INSTALLATION
Caution:
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.
Note:
Tightening torque:
7 N·m (0.7 kgf-m, 5.2 ft-lb)

INSPECTION

2. Check the output waveform and output voltage of the secondary speed sensor.
SK-9AU
IN-10444
Caution:
SK-9AU
IN-10427
CVT10273
CVT10283
(A)
CVT10284
Special tool:
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32
33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
CVT11189
Terminal No. Probe

13 +
26 −

(13)Lift up the vehicle.
Warning:
Lift up the vehicle until the tire bottom is 0.3 m (0.98 ft) 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.
Note:
CVT10293
Tightening torque:
7 N·m (0.7 kgf-m, 5.2 ft-lb)
CVT10283
Tightening torque:
32.3N·m (3.3 kgf-m, 23.8 ft-lb)
CVT10273
CONTINUOUSLY VARIABLE TRANSMISSION(TR580) > Primary Speed Sensor

LOCATION
SK-*AE
(A)
CVT11243
(A) Primary speed sensor

REMOVAL
Caution:
If water or oil contacts the connector terminal of primary speed sensor, replace it with a new part.
1. Remove the transmission body. Ref. to CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Transmission

Assembly>REMOVAL.
2. Disconnect the connector, and remove the primary speed sensor.
SK-*AE
CVT11244

INSTALLATION
Caution:
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.
Note:
Tightening torque:
7 N·m (0.7 kgf-m, 5.2 ft-lb)

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

INSPECTION

2. Check the output waveform and output voltage of the primary speed sensor.
SK-9AU
IN-10444
Caution:
SK-9AU
IN-10427
CVT10273
CVT10283
(A)
CVT10284
Special tool:
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32
33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
CVT11189
Terminal No. Probe

14 +
42 −

(13)Lift up the vehicle.
Warning:
Lift up the vehicle until the tire bottom is 0.3 m (0.98 ft) 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.
Note:
CVT10293
Tightening torque:
7 N·m (0.7 kgf-m, 5.2 ft-lb)
CVT10283
Tightening torque:
32.3N·m (3.3 kgf-m, 23.8 ft-lb)
CVT10273
CONTINUOUSLY VARIABLE TRANSMISSION(TR580) > Secondary Pressure Sensor

LOCATION
SK-*AE
(A)
CVT11245
(A) Secondary pressure sensor

REMOVAL
Caution:
If water or oil contacts the connector terminal of secondary pressure sensor, replace it with a new part.
3. Disconnect the connector and remove the secondary pressure sensor.
Note:
SK-*AE
CVT11246

INSTALLATION
Caution:
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.
Note:
Tightening torque:
39 N·m (4.0 kgf-m, 28.8 ft-lb)

INSPECTION

2. Check [secondary pressure sensor voltage.] of the secondary pressure sensor.
(1) Connect the Subaru Select Monitor.
Note:
(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.
(10)Check [secondary pressure sensor voltage.].
Specification:
Approx. 0.5 V
CONTINUOUSLY VARIABLE TRANSMISSION(TR580) > Oil Pan

REMOVAL
Caution:
If any CVTF adheres to the exhaust pipe, completely wipe it off to avoid emitting smoke and causing a fire.

2. Remove the bolts which hold the oil pan.
SK-*AE
CVT11107
3. Insert an oil pan seal cutter into the gap between oil pan and transmission case, and remove the oil pan.
Caution:
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.
Note:
Remove the iron powder, etc. from the magnet.
SK-*AE
CVT11247
5. Remove the liquid gasket from the oil pan and the transmission case.
6. Remove the oil strainer.
CVT00633
7. Remove the O-ring from oil strainer.

SK-*AE
CVT11108

INSTALLATION
1. Install a new O-ring to the oil strainer.

Note:
2. Install the oil strainer.
Tightening torque:
9 N·m (0.9 kgf-m, 6.6 ft-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.
Note:
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
Liquid gasket applying diameter:
1.4 mm (0.0551 in)
CVT11476
5. Tighten the bolts evenly.

Tightening torque:
5 N·m (0.5 kgf-m, 3.7 ft-lb)

INSPECTION

3. Check the oil passages for clogging.
CONTINUOUSLY VARIABLE TRANSMISSION(TR580) > Control Valve Body

REMOVAL
Note:
The control valve body is a non-disassembly part.
SK-9AU
IN-10444
Caution:
SK-9AU
IN-10427
4. Remove the TCM. Ref. to CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Transmission Control Module

(TCM)>REMOVAL.
CVT10266
6. Remove the ground cord and the air breather hose stay.
SK-*AE
CVT11535
7. Remove the clip and remove the ground terminal.
CVT10299
8. Clean the valve cover vicinity.

Caution:
Make sure that foreign matter does not get into the throttle body and connector terminals.
Note:
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. Ref. to FUEL INJECTION (FUEL
SYSTEMS)(H4DO)>Throttle Body>REMOVAL.
Note:
Do not disconnect the preheater hose.
10. Attach the ST.
Note:
The ST is included in the control valve body for repairs.
Preparation tool:
ST: SHEET SPECIAL TOOL (18761AA010)
ST
CVT10482
11. Remove the bolt securing the transmission harness.

SK-*AE
CVT11248
12. Remove the valve cover.
代替画像1
この画像は代替画像です
13. Disconnect the connector from the control valve body, and remove the transmission harness from the valve cover.
SK-*AE
CVT11253
14. Remove the O-rings.
AT-06796
15. Remove the gasket.

SK-*AE
CVT11254
16. Remove the control valve body.

Caution:
Do not remove any bolts other than specified in the figure.
CVT01259
CVT11317
18. Remove the liquid gasket from the mating surface of valve cover and transmission body.

INSTALLATION
1. Check the control valve body for foreign matter adhesion.

2. Set new O-rings.
Note:
CVT11317
3. Install the control valve body.

(1) Set the control valve body to the transmission body.
Caution:
Perform installation so that the O-ring is not displaced.
(2) Temporarily tighten the bolt (silver).
CVT11232
(3) Attach the bolt (black).

Tightening torque:
9 N·m (0.9 kgf-m, 6.6 ft-lb)
CVT11233
(4) Tighten the bolt (silver).
Tightening torque:
9 N·m (0.9 kgf-m, 6.6 ft-lb)
4. Install a new O-ring to the transmission harness.
Note:
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.
Note:
Before applying liquid gasket, degrease the old liquid gasket seal surface of the transmission body and valve
cover.
Liquid gasket:
THREE BOND 1215B or equivalent
CVT11613
7. Connect the connector to the control valve body.

8. Install the valve cover.
Caution:
Be careful not to catch the ST (SHEET SPECIAL TOOL).
Tightening torque:
8 N·m (0.8 kgf-m, 5.9 ft-lb)
9. Tighten the bolt which holds the transmission harness.
Tightening torque:
7 N·m (0.7 kgf-m, 5.2 ft-lb)
10. Remove the ST (SHEET SPECIAL TOOL).
11. Install the throttle body. Ref. to FUEL INJECTION (FUEL SYSTEMS)(H4DO)>Throttle Body>INSTALLATION.
12. Install the clip, and connect the ground terminal.
Tightening torque:
14 N·m (1.4 kgf-m, 10.3 ft-lb)
13. Install the ground cord and the air breather hose stay.
Tightening torque:
7 N·m (0.7 kgf-m, 5.2 ft-lb)
14. Connect the transmission harness connector to the engine wiring harness.
15. Install the TCM. Ref. to CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Transmission Control Module
(TCM)>INSTALLATION.
19. Perform AT learning mode using the Subaru Select Monitor. Ref. to CONTINUOUSLY VARIABLE
TRANSMISSION(TR580)>AT learning.
Note:

INSPECTION

3. Measure the resistance of each solenoid, sensor and ground wire.
Note:
Measurement should be performed at a temperature of 20°C (68°F).
5 4 3 2 1
10 9 8 7 6
CVT01262
Solenoid
Solenoid Terminal No. Standard
Primary UP solenoid 2 — Control valve body 10 — 13.5 Ω
Secondary solenoid 3 — Control valve body 5—7Ω
F&R clutch solenoid 4 — Control valve body 4—6Ω
Primary DOWN solenoid 7 — Control valve body 10 — 13.5 Ω
Lock-up duty solenoid 9 — Control valve body 10 — 13.5 Ω
AWD solenoid 10 — Control valve body 2 — 4.5 Ω
Sensor
Standard
Sensor Terminal No.
At 20°C (68°F)
Oil temperature sensor 1—6 Approx. 2.5 kΩ
Ground
Terminal No. Standard
8 — Control valve body Less than 1 Ω
CONTINUOUSLY VARIABLE TRANSMISSION(TR580) > Electric Fluid Pump

REMOVAL
4. Disconnect the connector and remove the electric oil pump.
Note:
SK-*AE
CVT11255
CVT00774

INSTALLATION
1. Install a new O-ring.

Note:
CVT00774
2. Install the electric oil pump, and connect the connector.

Tightening torque:
22 N·m (2.2 kgf-m, 16.2 ft-lb)

DISASSEMBLY
1. Remove the electric oil pump.
CVT00775
CVT11318
3. Remove the plug.
CVT00777

ASSEMBLY
1. Install the plugs with new O-rings.

Note:
Tightening torque:
16 N·m (1.6 kgf-m, 11.8 ft-lb)
Note:
3. Install the electric oil pump.
Tightening torque:
22 N·m (2.2 kgf-m, 16.2 ft-lb)

INSPECTION

3. Perform the road test (Auto Start Stop) and check that no shift shock occurs immediately after engine starting. Ref. to
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.

Note:
(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.
(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.
Note:
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

Assembly>REMOVAL.
2. Remove the air breather hose. Ref. to 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.
SK-*AE
CVT11256
4. Disconnect the connector from inhibitor switch.
CVT10303
5. Disconnect the ground terminal (valve cover side).
SK-*AE
CVT11259
6. Disconnect the transmission harness from the control valve body. Ref. to CONTINUOUSLY VARIABLE
TRANSMISSION(TR580)>Control Valve Body>REMOVAL.
7. Remove all clips and remove the transmission harness.

INSTALLATION
1. Set the transmission harness, and install the clip.

2. Connect the transmission harness to the control valve body. Ref. to CONTINUOUSLY VARIABLE
TRANSMISSION(TR580)>Control Valve Body>INSTALLATION.
3. Connect the ground terminal (valve cover side).
Tightening torque:
14 N·m (1.4 kgf-m, 10.3 ft-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 (1.3 kgf-m, 9.6 ft-lb)
SK-*AE
CVT11256
6. Install the air breather hose. Ref. to CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Air Breather
Hose>INSTALLATION.

INSPECTION

2. Check the terminal for rusting.
CONTINUOUSLY VARIABLE TRANSMISSION(TR580) > X MODE Switch

REMOVAL
SK-*AE
P
R
N
M-D
CVT11166
3. Remove the cover assembly front. Ref. to EXTERIOR/INTERIOR TRIM>Console Box>REMOVAL.

4. Remove the X mode switch.
SK-*AE
CVT11208

INSTALLATION
1. Install the X mode switch.

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

INSPECTION
SK-*AE
1 2 3 4
CVT11209
1. Check the resistance between connector terminals.

Counterclockwise (hold) 0Ω
1—4 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.
Caution:
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
Caution:
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. Ref. to 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. Ref. to STARTING/CHARGING SYSTEMS(H4DO)>Starter. Ref.
to FUEL INJECTION (FUEL SYSTEMS)(H4DO)>Fuel Pump Relay.
SK-9AU
IN-10444
Caution:
SK-9AU
IN-10427
4. Disconnect the ground cord.
CVT10273
5. Remove the pitching stopper. Ref. to CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Transmission Mounting

6. Remove the transmission case cover (front).
CVT10283
7. Move the lock lever in the arrow direction while pressing the lock button (A), and disconnect the connector.
(A)
CVT10284
8. Remove the TCM.
CVT10285
CONTINUOUSLY VARIABLE TRANSMISSION(TR580) > Transmission Control Module (TCM)

INSTALLATION
Caution:
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. Ref. to 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. Ref. to STARTING/CHARGING SYSTEMS(H4DO)>Starter. Ref.
to 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.
Note:
Move the lock lever and confirm that a clicking sound is heard.
3. Install the transmission case cover (front).
Note:
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.
CVT10293
Tightening torque:
7 N·m (0.7 kgf-m, 5.2 ft-lb)
CVT10283
4. Install the pitching stopper. Ref. to CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Transmission Mounting

System>INSTALLATION > PITCHING STOPPER.
5. Connect the ground cord.
Tightening torque:
32.3 N·m (3.3 kgf-m, 23.8 ft-lb)
CVT10273
8. Perform AT learning mode using the Subaru Select Monitor. Ref. to CONTINUOUSLY VARIABLE
TRANSMISSION(TR580)>AT learning.
Note:
CONTINUOUSLY VARIABLE TRANSMISSION(TR580) > Relay and Fuse

LOCATION
SK-*AE
(D)
(A)
(B)
(C)
CVT11207
(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
2. Check the resistance between terminals.
(3)
(3) (4)
(4)
(1) (2)
(2) (1)
CO-10121

Apply battery voltage between
3—4 Less than 1 Ω
terminals 1 and 2.
3—4 Always 1 MΩ or more
CONTINUOUSLY VARIABLE TRANSMISSION(TR580) > CVTF Cooler (With Warmer Function)

REMOVAL
Caution:
If CVTF and engine coolant spills over the engine, completely wipe it off to avoid emission of smoke and causing a
fire.
2. Drain engine coolant. Ref. to COOLING(H4DO)>Engine Coolant>REPLACEMENT.
SK-9AU
IN-10444
Caution:
SK-9AU
IN-10427
5. Remove the CVTF cooler (with warmer feature).

Note:
(1) Disconnect the CVTF inlet hose and CVTF outlet hose.
SK-*AE
CVT11093
(2) Disconnect the water hose (inlet) (A) and water hose (outlet) (B).
SK-*AE
(A)
(B)
CVT11173
(3) Remove the CVTF cooler (with warmer feature).
CVT10291
(4) Remove the CVTF inlet hose (A) and CVTF outlet hose (B).
(B) (A)
CVT11260
6. Remove the water hose (inlet).

Note:
Perform this procedure only when required.
(1) Remove the EGR cooler. Ref. to EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES)(H4DO)>EGR
Cooler>REMOVAL.
(2) Remove the water hose (inlet).
SK-9AE
CO-10246

INSTALLATION
1. Install the water hose (inlet).

(1) Install the water hose (inlet) to the thermostat cover.
(2) Install the EGR cooler. Ref. to EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES)(H4DO)>EGR
Cooler>INSTALLATION.
2. Install the CVTF cooler (with warmer feature).
(1) Install a new CVTF inlet hose (A) and a new CVTF outlet hose (B).
(B) (A)
CVT11260
(2) Install the CVTF cooler (with warmer feature).

Tightening torque:
23 N·m (2.3 kgf-m, 17.0 ft-lb)
(3) Connect the water hose (inlet) (A) and water hose (outlet) (B).
SK-*AE
(A)
(B)
CVT11173
(4) Connect the CVTF inlet hose and CVTF outlet hose.
SK-*AE
CVT11093
5. Fill engine coolant. Ref. to COOLING(H4DO)>Engine Coolant>REPLACEMENT.

DISASSEMBLY
1. Remove the bracket.
CVT10295

ASSEMBLY
1. Attach the bracket.

Tightening torque:
23 N·m (2.3 kgf-m, 17.0 ft-lb)
CVT10295

INSPECTION

2. Check for leaks.
CONTINUOUSLY VARIABLE TRANSMISSION(TR580) > Air Breather Hose

REMOVAL
1. FRONT DIFFERENTIAL SIDE

SK-9AU
IN-10444
Caution:
SK-9AU
IN-10427
3. Remove the air breather hose.
CVT11262
4. Remove the air breather cap.

SK-*AE
CVT11263
2. TRANSMISSION CASE SIDE

Assembly>REMOVAL.
2. Remove the air breather hose.
SK-*AE
CVT11264
3. Remove the air breather cap.
SK-*AE
CVT11263

INSTALLATION
1. FRONT DIFFERENTIAL SIDE

1. Install the air breather cap.
2. Install the air breather hose.
2. TRANSMISSION CASE SIDE

1. Install the air breather cap.
2. Install the air breather hose.
4. Install the air breather hose to the air breather hose bracket.
Note:
Assemble with the mark position facing in the direction shown in the figure.
CVT10441

INSPECTION

2. Check the hose for clogging.
CONTINUOUSLY VARIABLE TRANSMISSION(TR580) > Drive Plate

REMOVAL

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)
ST
CVT11265

INSTALLATION
1. Temporarily attach the reinforcement drive plate, drive plate and crankshaft position sensor plate, and set the ST.
Note:
Align the knock pin hole of the crankshaft position sensor plate to the knock pin of the crankshaft to secure the
knock pin.
Make sure to install in the right direction.
SK-*AE
x8
(C)
(B)
(A)
CVT11275
(A) Crankshaft position sensor (B) Drive plate (C) Reinforcement drive plate
plate
Preparation tool:
ST: CRANKSHAFT STOPPER (498497300)
ST
CVT11276
2. Tighten the bolts securing the drive plate.

(1) Tighten the bolts securing the drive plate.
Tightening torque:
30 N·m (3.1 kgf-m, 22.1 ft-lb)
(2) Using the angle gauge, tighten the bolts securing the drive plate to the specified angle.
Tightening angle:
30°— 35°

INSPECTION
CONTINUOUSLY VARIABLE TRANSMISSION(TR580) > Torque Converter

REMOVAL

Assembly>REMOVAL.
2. Remove the ST from converter case.
SK-9AE
ST
ME-21757
3. Pull out the torque converter horizontally.

Caution:
Do not scratch the inside of engaging parts.
CVT10394
4. Remove the O-ring from the input shaft.
SK-*AE
CVT11319

INSTALLATION
1. Install a new O-ring to the input shaft.

Note:
2. Install the torque converter.
Caution:
Do not damage the oil seal and O-ring.
Note:
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 (0.268 in) or less
CVT10395
4. Attach the ST to converter case.

Preparation tool:
ST: STOPPER SET (498277200)
SK-9AE
ST
ME-21757


INSPECTION
CONTINUOUSLY VARIABLE TRANSMISSION(TR580) > Preparation for Overhaul

PROCEDURE
1. BEFORE OVERHAUL
1. Remove the torque converter. Ref. to CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Torque Converter>REMOVAL.
2. Attach the ST.
Note:
When attaching the ST to the (a) positions, spacers or similar of 2.0 mm (0.08 in) or more in thickness are
necessary.
Preparation tool:
ST: STAND ASSY (18632AA000)
(a)
ST
ST
CVT11320
3. Place the transmission body.

Note:
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. Ref. to CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Torque
Converter>INSTALLATION.
2. Remove the filler plug (for overhaul), and refill approx. 10 L (2.6 US qt, 8.8 Imp qt) of CVTF.
Caution:
Always use specified CVTF. Using fluid other than specified CVTF will cause malfunction. Ref. to
RECOMMENDED MATERIALS>GREASE>CVTF.
CVT10308
3. Using a new gasket, install the filler plug (for overhaul).
Tightening torque:
50 N·m (5.1 kgf-m, 36.9 ft-lb)
CONTINUOUSLY VARIABLE TRANSMISSION(TR580) > Extension Case

REMOVAL

Assembly>REMOVAL.
2. Remove the electric oil pump. Ref. to CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Electric Fluid Pump>REMOVAL.
3. Remove the extension case and transmission hanger (A).
SK-*AE
(A)
CVT11322
4. Remove the O-ring from the transmission case.
AT-06937
5. Remove the liquid gasket from the extension case and the transmission case.

INSTALLATION
1. Select the transfer drive gear shim. Ref. to CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Reduction Driven
Gear>ADJUSTMENT.
2. Select the transfer driven gear shim. Ref. to 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.
Note:
6. Apply liquid gasket to the mating surface of the extension case as shown in the figure, and temporarily install the extension
case.
Note:
Before applying liquid gasket, degrease the old liquid gasket seal surfaces of the extension case and
transmission case.
Liquid gasket:
1.4 mm (0.0551 in)
CVT11477
7. Install the extension case to transmission hanger.

Tightening torque:
25 N·m (2.5 kgf-m, 18.4 ft-lb)
8. Install the electric oil pump. Ref. to CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Electric Fluid
Pump>INSTALLATION.

DISASSEMBLY
1. Remove the extension case oil seal from the extension case. Ref. to CONTINUOUSLY VARIABLE
TRANSMISSION(TR580)>Extension Case Oil Seal>REPLACEMENT.
2. Remove the dust cover from extension case.
SK-*AE
CVT11323
3. Remove all plugs.
CVT11324

ASSEMBLY
1. Install all plugs using new O-rings or gaskets.

Note:
Tightening torque:
T1: 22 N·m (2.2 kgf-m, 16.2 ft-lb)
T2: 35 N·m (3.6 kgf-m, 25.8 ft-lb)
T2
T1
AT-06406
2. Install the dust cover into extension case.

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

INSPECTION


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

REMOVAL

Assembly>REMOVAL.
3. Remove the extension case. Ref. to CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Extension Case>REMOVAL.
4. Remove the transfer clutch.
AT-06407
5. Remove the thrust bearing.
CVT01070
6. Remove the seal rings.
AT-06409
AT-06410

INSTALLATION
1. Install the thrust bearing.

Note:
CVT01073
2. Install the transfer clutch.
AT-06407
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.
Note:
Apply CVTF to the seal rings.
7. Install a new seal ring to the transfer driven gear.
Note:
8. Install the transfer clutch.
9. Install the extension case. Ref. to CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Extension Case>INSTALLATION.
Pump>INSTALLATION.

DISASSEMBLY
1. Remove the snap ring (A), and then remove the pressure plate, drive plate and driven plate.
(A)
AT-06411
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)
ST
(B)
(A)
AT-06412
3. Remove the return spring.
AT-06413
4. Remove the transfer clutch piston by blowing compressed air through transfer clutch hole.
Note:
Plug the holes through which the compressed air is not blown.
AT-06414
5. Remove the ball bearing using ST1, ST2 and a press.

Preparation tool:
ST1: BEARING REMOVER (18767AA010)
ST2: REMOVER (18723AA000)
ST2
ST1
AT-06415

ASSEMBLY
1. Install the transfer clutch piston.

Note:
Apply CVTF to the transfer clutch piston lip.
2. Install the return spring.
3. Install the transfer clutch piston seal (B).
Note:
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
(B)
(A)
AT-06412
5. Install the pressure plate and transfer clutch plate set, and then install the snap ring (A).
(A)
AT-06411
6. Blow compressed air through transfer clutch hole, and check the transfer clutch piston operation.
Note:
Plug the holes through which the compressed air is not blown.
AT-06414
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 — 0.043 in)
Service limit:
1.3 mm (0.051 in)
AT-06418
(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. Ref. to CONTINUOUSLY VARIABLE
TRANSMISSION(TR580)>Transfer Clutch>INSPECTION.
10. Install a new ball bearing using ST1, ST2 and a press.
Note:
Apply CVTF to the ball bearing.
Preparation tool:
ST1: INSTALLER (398177700)
ST2
ST1
AT-06417

INSPECTION

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 — 0.043 in)
Service limit:
1.3 mm (0.051 in)
AT-06418
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.

ADJUSTMENT
1. Install the transfer clutch to the extension case with the transfer driven gear shims and thrust bearings removed.
AT-07020

Note:
CVT00988
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)
ST
ST
AT-06419
4. Using the ST, measure the height “B” from the transmission case mating surface to the end of ST.
Preparation tool:
ST: GAUGE (499575500)
ST
ST
AT-06420
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 — 0.01 in): Clearance
CONTINUOUSLY VARIABLE TRANSMISSION(TR580) > Transfer Driven Gear

REMOVAL

Assembly>REMOVAL.
4. Remove the transfer clutch. Ref. to CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Transfer Clutch>REMOVAL.
5. Remove the transfer driven gear.
CVT01072
AT-06410

INSTALLATION
1. Install the transfer driven gear.

2. Install the transfer clutch. Ref. to CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Transfer Clutch>INSTALLATION.
3. Select the transfer driven gear shim. Ref. to CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Transfer
Clutch>ADJUSTMENT.
Pump>INSTALLATION.
DISASSEMBLY

Preparation tool:
ST1: REMOVER (498077400)
ST2: REMOVER (899864100)
ST1
ST2
AT-06423

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

Note:
Preparation tool:
ST: INSTALLER (899580100)
ST
AT-06424

INSPECTION

2. Check the ball bearing for smooth rotation.
3. Check the ball bearing for excessive looseness.

ADJUSTMENT
Note:
When the transfer driven gear or ball bearing is replaced, select the transfer driven gear shim. Ref. to
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.

Ref. to CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Reduction Driven Gear>DISASSEMBLY.
Ref. to CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Reduction Driven Gear>ASSEMBLY.
CONTINUOUSLY VARIABLE TRANSMISSION(TR580) > Parking Pawl

REMOVAL

Assembly>REMOVAL.
2. Shift the inhibitor switch to “N range”.
Note:
Align the holes of the shifter arm and inhibitor switch.
5. Remove the parking pawl shaft (A), return spring (B) and parking pawl (C).
(A)
(C) (B) CVT01071

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).
Note:
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).
(a)
(b)
(C) (B) (A) CVT00802

Pump>INSTALLATION.

INSPECTION
CONTINUOUSLY VARIABLE TRANSMISSION(TR580) > Reduction Driven Gear

REMOVAL

Assembly>REMOVAL.
5. Remove the transfer driven gear. Ref. to CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Transfer Driven
Gear>REMOVAL.
6. Remove the parking pawl. Ref. to CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Parking Pawl>REMOVAL.
7. Remove the reduction driven gear and oil spacer.
CVT11325

INSTALLATION
1. Install the reduction driven gear and oil spacer.

Tightening torque:
17 N·m (1.7 kgf-m, 12.5 ft-lb)
2. Select the transfer drive gear shim. Ref. to CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Reduction Driven
Gear>ADJUSTMENT.
3. Install the parking pawl. Ref. to 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. Ref. to CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Transfer Driven
Gear>INSTALLATION.
Pump>INSTALLATION.

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.
Caution:
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)
ST2
ST1
ST3
CVT10329

Preparation tool:
ST2: REMOVER (498077300)
ST1
ST2
AT-06429
4. Using the ST and a press, remove the parking gear and transfer drive gear.
Preparation tool:
ST: REMOVER (899864100)
ST
AT-06430
5. Remove the snap ring from reduction driven gear.

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

Note:
Apply CVTF to the press-fitting surface of the parking gear.
Preparation tool:
ST
CVT10330
2. Using the ST and a press, install the transfer drive gear.

Note:
Apply CVTF to the press-fitting surface of the transfer drive gear.
Preparation tool:
ST
AT-06433
3. Using the ST and a press, install a new ball bearing.

Note:
Preparation tool:
ST: BUSHING 1-2 INSTALLER (499277100)
ST
AT-06434
4. Using the ST1, ST2 and ST3, counter the rotation of the reduction driven gear, and install a new lock nut.
Caution:
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 (9.7 kgf-m, 70.1 ft-lb)
ST2
ST1
ST3
CVT10329
5. Crimp the lock nut so that the dimension of A becomes 18.9 mm (0.74 in) or less.
Caution:
Do not allow the lock nut to be cracked during crimping operation.
A A
CVT01057
6. Install the snap ring.

INSPECTION

3. Check the ball bearing for excessive looseness.

ADJUSTMENT
1. Measure the height “A” from the ST upper face to the ball bearing catch surface.
Preparation tool:
ST: GAUGE (499575600)
ST
ST
AT-06435
2. Measure the height “B” from the ST to the mating surface of the transmission case.
Preparation tool:
ST: GAUGE (499575600)
ST
ST
CVT10445
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 — 0.01 in): Clearance
CONTINUOUSLY VARIABLE TRANSMISSION(TR580) > Transmission Control Device

REMOVAL

Assembly>REMOVAL.
2. Remove the inhibitor switch. Ref. to CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Inhibitor Switch>REMOVAL.
3. Remove the oil pan and oil strainer. Ref. to CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Oil Pan>REMOVAL.
4. Shift the manual plate to “N range”, and remove the spring pin.
Note:
Prevent the spring pin from dropping using paper towel, etc.
CVT00264
5. Remove the detent spring.
CVT00265
6. Remove the bolt securing the shifter arm shaft, and remove the shifter arm shaft.
Note:
Do not damage the lip of oil seal press-fitted in the transmission case.
CVT00267
7. Remove the shift connecting rod (C) of manual valve.

8. Remove the parking rod (A) and manual plate (B).
(A)
(C)
(B)
CVT00268
9. Remove the manual valve.
CVT00269
11. Remove the parking support.
AT-06442

INSTALLATION
1. Install the parking support.

Tightening torque:
25 N·m (2.5 kgf-m, 18.4 ft-lb)
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.
(A)
(C)
(B)
CVT00268
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.
Note:
Do not damage the lip of oil seal press-fitted in the transmission case.
Tightening torque:
7 N·m (0.7 kgf-m, 5.2 ft-lb)
7. Install the detent spring.
Tightening torque:
7 N·m (0.7 kgf-m, 5.2 ft-lb)
8. Install a new spring pin.
9. Install the inhibitor switch. Ref. to CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Inhibitor Switch>INSTALLATION.
10. Install the oil strainer and oil pan. Ref. to CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Oil Pan>INSTALLATION.

INSPECTION
CONTINUOUSLY VARIABLE TRANSMISSION(TR580) > Transmission Case

REMOVAL

Assembly>REMOVAL.
3. Remove the control valve body. Ref. to CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Control Valve
Body>REMOVAL.
4. Remove the transmission harness. Ref. to CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Transmission
Harness>REMOVAL.
5. Remove the turbine speed sensor. Ref. to CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Turbine Speed
Sensor>REMOVAL.
6. Remove the secondary speed sensor. Ref. to CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Secondary Speed
Sensor>REMOVAL.
7. Remove the primary speed sensor. Ref. to CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Primary Speed
Sensor>REMOVAL.
Gear>REMOVAL.
14. Remove the reduction driven gear. Ref. to CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Reduction Driven
Gear>REMOVAL.
16. Remove the transmission control device. Ref. to CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Transmission
Control Device>REMOVAL.
17. Remove the bolt securing the oil baffle.
CVT00729
18. Remove the oil cooler pipe.
AT-06736
19. Remove the transmission case.

SK-*AE
CVT11327
20. Remove the oil pressure pipe and the oil baffle.
CVT00804
AT-06754
22. Remove the seal ring from the transmission case.
CVT10331
23. Remove the liquid gasket from the transmission case and converter case.

INSTALLATION
1. Select the reduction drive gear shim. Ref. to 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.
Note:
4. Install a new seal ring to the transmission case.
Note:
5. Install a new O-ring to the oil pressure pipe.
Note:
6. Temporarily install the oil baffle with bolts, and then install the oil pressure pipe.
CVT00803
7. Apply liquid gasket to the mating surface of the transmission case as shown in the figure, and temporarily install the
transmission case.
Note:
Before applying liquid gasket, degrease the old liquid gasket seal surface of the transmission case and
converter case.
Liquid gasket:
1.4 mm (0.0551 in)
CVT11478
8. Tighten the bolts evenly.

Tightening torque:
22 N·m (2.2 kgf-m, 16.2 ft-lb)
9. Install the oil cooler pipe using a new O-ring.
Note:
Tightening torque:
25 N·m (2.5 kgf-m, 18.4 ft-lb)
10. Tighten the bolt securing the oil baffle, and install the remaining bolts.
Tightening torque:
16 N·m (1.6 kgf-m, 11.8 ft-lb)
11. Install the transmission control device. Ref. to CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Transmission Control
Device>INSTALLATION.
12. Install the oil pan and oil strainer. Ref. to CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Oil Pan>INSTALLATION.
13. Install the reduction driven gear. Ref. to CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Reduction Driven
Gear>INSTALLATION.
Gear>INSTALLATION.
Pump>INSTALLATION.
20. Install the secondary speed sensor. Ref. to CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Secondary Speed
Sensor>INSTALLATION.
21. Install the primary speed sensor. Ref. to CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Primary Speed
22. Install the turbine speed sensor. Ref. to CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Turbine Speed
23. Install the transmission harness. Ref. to CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Transmission
Harness>INSTALLATION.
24. Install the control valve body. Ref. to CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Control Valve
Body>INSTALLATION.
Hose>INSTALLATION.

DISASSEMBLY
1. Remove the oil stopper plate.
CVT00728
2. Remove the plug, and remove the oil control valve holder.
(A)
CVT00808
(A) Oil control valve holder
3. Remove the O-ring from the oil control valve holder.

CVT01426
5. Remove the oil seal using a screwdriver wrapped with cloth etc.
CVT00991
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)
ST1
ST2
(A)
AT-06447
(2) Remove the ball bearing of the secondary pulley using the ST1 and ST2.
Preparation tool:
ST1: PULLER ASSY (398527700)
ST2: CLAW (18760AA000)
ST1
ST2
CVT10332
7. Remove the oil guide.
AT-06450
8. Remove the roller bearing.
CVT10396
CVT10397
10. Remove the CVTF filter cover and gasket.
CVT11328
11. Remove the CVTF filter.
AT-06452

ASSEMBLY
1. Install the CVTF filter with its O-ring side faced to the transmission case side.
Note:
2. Using a new gasket, install the CVTF filter cover.
Tightening torque:
17 N·m (1.7 kgf-m, 12.5 ft-lb)
3. Install a new oil seal using ST.
Note:
Apply CVTF to the oil seal lip and press-fitting surface.
Preparation tool:
ST: INSTALLER (18657AA000)
ST
AT-06651
4. Using a new O-ring, install the oil control valve holder, and install the plug.
Note:
Tightening torque:
50 N·m (5.1 kgf-m, 36.9 ft-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.
Caution:
Insert wooden pieces between the contacting surfaces of the vise and the bearing race to prevent bearing
race damage.
CVT10224
(2) Measure the height “A” of the spring pin.

Specification:
4.4 mm (0.173 in) or less
CVT10225
7. Install the ball bearing (secondary pulley side) using ST1, ST2, ST3 and a press.
Note:
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)
ST3: PRESS SNAP RING (28499TC010)
ST1
ST2
ST3
CVT10226
(A)
(B)
(B)
CVT10227
8. Install the plugs using new O-rings and new gaskets.

Note:
For the plug (a), fill the CVTF, and then tighten the plug using a new gasket.
Tightening torque:
T1: 13 N·m (1.3 kgf-m, 9.6 ft-lb)
T2: 22 N·m (2.2 kgf-m, 16.2 ft-lb)
T3: 50 N·m (5.1 kgf-m, 36.9 ft-lb)
T1 T2 T3
(a)
T2
T2
T3
T3 T1
CVT11329
9. Install the oil stopper plate.
Caution:
Always use a new MEC (Micro-encapsulated) bolt.
Tightening torque:
9 N·m (0.9 kgf-m, 6.6 ft-lb)
Note:
CVT10390
11. Install the roller bearing.

INSPECTION

3. Check the bearings for smooth operation.
4. Check all the bearings for seizure.

ADJUSTMENT
Note:
When replacing the transmission case with a new part, perform the following adjustment.
Select the transfer driven gear shim. Ref. to CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Transfer
Clutch>ADJUSTMENT.
Select the transfer drive gear shim. Ref. to CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Reduction Driven
Gear>ADJUSTMENT.
Select the reduction drive gear shim. Ref. to CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Reduction Drive
Gear>ADJUSTMENT.
CONTINUOUSLY VARIABLE TRANSMISSION(TR580) > CVTF Filter

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

Caution:
During installation, check if a large quantity of wear debris or metal particles are in CVTF and CVTF filter.
Ref. to CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Transmission Case>DISASSEMBLY.
Ref. to CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Transmission Case>ASSEMBLY.
CONTINUOUSLY VARIABLE TRANSMISSION(TR580) > Reduction Drive Gear

REMOVAL

Assembly>REMOVAL.
Body>REMOVAL.
Harness>REMOVAL.
Sensor>REMOVAL.
Sensor>REMOVAL.
Sensor>REMOVAL.
Gear>REMOVAL.
Gear>REMOVAL.
17. Remove the transmission case. Ref. to CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Transmission
Case>REMOVAL.
18. Remove the reduction drive gear shim.
CVT11331
19. Remove the reduction drive gear.
AT-06453

INSTALLATION
1. Install the reduction drive gear.
AT-06453
Gear>ADJUSTMENT.
3. Install the selected reduction drive gear shim.
4. Install the transmission case. Ref. to CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Transmission
Case>INSTALLATION.
Gear>INSTALLATION.
Gear>INSTALLATION.
Pump>INSTALLATION.
Body>INSTALLATION.
Hose>INSTALLATION.

INSPECTION

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 (2.2 kgf-m, 16.2 ft-lb)
3. Measure depth “A” from the ST upper face to the reduction drive gear end face.
Preparation tool:
ST: GAUGE (499575400)
ST
A
ST
AT-06719
4. Raise and hold the reduction drive gear.
AT-06720
5. Measure depth “B” from the ST upper face to the reduction drive gear end face.
Preparation tool:
ST: GAUGE (499575400)
ST
B
ST
AT-06721
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
Note:
Always replace primary pulley and secondary pulley as a set because they are non-disassembled parts.

Assembly>REMOVAL.
Body>REMOVAL.
Harness>REMOVAL.
Sensor>REMOVAL.
Sensor>REMOVAL.
Sensor>REMOVAL.
Gear>REMOVAL.
Gear>REMOVAL.
Case>REMOVAL.
18. Remove the reduction drive gear. Ref. to 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)
ST
AT-06454
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.
(A)
CVT10348
(3) Remove the lubrication pipe.
AT-06656
(4) Remove the bolt securing the support rod.
CVT10349
(5) Raise the support rod, and remove the chain guide. Then, remove the support rod.
Caution:
Protect the primary pulley, secondary pulley and variator chain from scratching.
CVT10350
(6) Move the chain guide to the secondary pulley side.
CVT10351
(7) While pushing the claw (A) down, slide the upper chain guide to the direction of the arrow and remove the chain guide.
(A)
CVT10358
21. Remove the bolt securing the primary pulley.
AT-06679
22. Remove the primary pulley.

Caution:
Cover the V grooves of primary pulley and secondary pulley with cloth to protect the primary pulley, secondary
pulley and variator chain from scratching.
AT-06879
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.
CVT00815
AT-06713
CVT10183

INSTALLATION
1. Select shims for primary pulley. Ref. to CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Primary Pulley and
Secondary Pulley>ADJUSTMENT.
2. Install a new seal ring to the input shaft.
Note:
3. Install new seal rings to drive pinion retainer.
Note:
4. Install the selected shims to the primary pulley bearing catch surface.
5. Install the secondary pulley to the drive pinion retainer.
CVT00818
6. Install the secondary pulley securing bolts.

(1) Tighten the three bolts until the seating surfaces contact the bearing retainer.
Note:
Be careful not to tilt the bearing retainer of the secondary pulley.
Apply CVTF to the bolt.
(A)
(B)
AT-06716
(A) Secondary pulley (B) Bearing retainer
(2) Tighten the bolts in the order of (A) → (B) → (C) → (B).
Tightening torque:
67.5 N·m (6.9 kgf-m, 49.8 ft-lb)
(C)
(A)
(B)
CVT00819
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)
ST
AT-06883
8. Install the primary pulley together with the variator chain to the reverse brake housing.
Caution:
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.
AT-06879
(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.
Note:
Tightening torque:
21 N·m (2.1 kgf-m, 15.5 ft-lb)
AT-06679
10. Install the chain guide.

(1) Install the chain guide to the variator chain, and move it to the primary pulley side.
CVT10367
(2) Place the support rod inside of the variator chain.

Caution:
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.
CVT10352
(4) Install the bolt securing the support rod.

Tightening torque:
21 N·m (2.1 kgf-m, 15.5 ft-lb)
(5) Install the lubrication pipe.
Tightening torque:
21 N·m (2.1 kgf-m, 15.5 ft-lb)
(6) Install the chain guide to the lubrication pipe.
CVT10353
(7) Remove the ST (EXPANDER PULLEY).

11. Install the reduction drive gear. Ref. to CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Reduction Drive
Gear>INSTALLATION.
Gear>ADJUSTMENT.
Case>INSTALLATION.
Gear>INSTALLATION.
Gear>INSTALLATION.
Pump>INSTALLATION.
Body>INSTALLATION.
Hose>INSTALLATION.

INSPECTION

3. Check the ball bearing for seizure.
4. Check the ball bearing for abnormal noise.
Note:

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)
ST
Lp
ST
AT-06885
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)
ST
ST Ls
AT-06884
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 (1.224 in): Constant
Pulley alignment Thickness of primary pulley shim
T mm (in) 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)
ST
Lp1
ST
AT-06888
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)
ST
ST Ls1
AT-06887
4. Calculate the “LD1” using the following formula and record it.
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)
ST
Lp2
ST
AT-06890
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)
ST
ST Ls2
AT-06889
7. Calculate the “LD2” using the following formula and record it.
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
Selection method of primary pulley shim
(T1) mm (in)
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 Select a shim which is 0.1 mm (0.004 in) thicker than the shim that is
— 0.00591) used on the primary pulley side of the current reverse brake housing.

(T1) mm (in)

(T2) mm (in)
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 Select a shim which is 0.1 mm (0.004 in) thinner than the shim that is
CONTINUOUSLY VARIABLE TRANSMISSION(TR580) > Variator Chain

SPECIFICATION
Refer to the “Primary Pulley & Secondary Pulley” section for removal and installation procedures.
Ref. to CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Primary Pulley and Secondary Pulley>REMOVAL.
Ref. to CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Primary Pulley and Secondary Pulley>INSTALLATION.
CONTINUOUSLY VARIABLE TRANSMISSION(TR580) > Reverse Brake

REMOVAL

Assembly>REMOVAL.
Body>REMOVAL.
Harness>REMOVAL.
Sensor>REMOVAL.
Sensor>REMOVAL.
Sensor>REMOVAL.
Gear>REMOVAL.
Gear>REMOVAL.
Case>REMOVAL.
Gear>REMOVAL.
19. Remove the primary pulley, secondary pulley and variator chain. Ref. to CONTINUOUSLY VARIABLE
TRANSMISSION(TR580)>Primary Pulley and Secondary Pulley>REMOVAL.
20. Remove the manual valve body and separator plate.
AT-06461
21. Remove the oil guide (B) and lubrication pipe (A).
(B)
(A)
AT-06752
AT-06764
23. Remove the reverse brake.

SK-*AE
CVT11334
AT-06462

INSTALLATION
1. Select a washer. Ref. to CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Forward Clutch>ADJUSTMENT.

2. Install the selected washer to the reverse brake housing.
CVT00828
3. Install the thrust bearing to the reverse brake housing.

Note:
AT-06464
4. Install the internal gear to the reverse brake housing.
AT-06465
5. Install a new O-ring to drive pinion retainer.

Note:
6. Install the reverse brake and internal gear as a unit to the drive pinion retainer.
Note:
Slowly rotate the input shaft by hand to engage the internal gear and pinion gear of planetary carrier.
Tightening torque:
37 N·m (3.8 kgf-m, 27.3 ft-lb)
7. Install a new O-ring to the lubrication pipe.
Note:
8. Install the lubrication pipe and oil guide.
Tightening torque:
16 N·m (1.6 kgf-m, 11.8 ft-lb)
9. Install the manual valve body and separator plate.
Note:
Tightening torque:
9 N·m (0.9 kgf-m, 6.6 ft-lb)
10. Install the primary pulley, secondary pulley and variator chain. Ref. to CONTINUOUSLY VARIABLE
TRANSMISSION(TR580)>Primary Pulley and Secondary Pulley>INSTALLATION.
11. Select shims for pulley alignment. Ref. to CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Primary Pulley and
Secondary Pulley>ADJUSTMENT.
Gear>INSTALLATION.
Case>INSTALLATION.
Gear>INSTALLATION.
Gear>INSTALLATION.
Pump>INSTALLATION.
Body>INSTALLATION.
Hose>INSTALLATION.

DISASSEMBLY
1. Remove the snap ring, and then remove the retaining plate, drive plate, driven plate and dish plate.
CVT00821
2. Compress the return spring using the ST and a press to remove the snap ring.
Preparation tool:
ST
CVT00829
3. Remove the ST, and remove the spring retainer.
AT-06468
AT-06469
5. Remove the reverse brake piston by blowing compressed air from reverse brake housing hole.
CVT01455

ASSEMBLY
1. Install the reverse brake piston.

Note:
Apply CVTF to the sealing area of reverse brake piston.
CVT01456

3. Install the spring retainer.
4. Compress the return spring using the ST and a press to install the snap ring.
Preparation tool:
ST
CVT00829
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.
Note:
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.
Note:
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.
AT-05234
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”.
Note:
Measure at four points with a 90° interval and calculate the average.
A (C)
(A)
(B)
AT-06472
(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.
Note:
CVT00822
13. Measure and record the clearance “B” between the retaining plate and snap ring.
CVT00830
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 (0.094 in)
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.

INSPECTION

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. Ref. to CONTINUOUSLY
VARIABLE TRANSMISSION(TR580)>Reverse Brake>ASSEMBLY.
CONTINUOUSLY VARIABLE TRANSMISSION(TR580) > Forward Clutch

REMOVAL

Assembly>REMOVAL.
Body>REMOVAL.
Harness>REMOVAL.
Sensor>REMOVAL.
Sensor>REMOVAL.
Sensor>REMOVAL.
Gear>REMOVAL.
Gear>REMOVAL.
Case>REMOVAL.
Gear>REMOVAL.
20. Remove the reverse brake. Ref. to CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Reverse Brake>REMOVAL.
AT-06477
22. Remove the planetary carrier.
AT-06478
23. Remove the thrust bearing and sun gear.
AT-06479
24. Remove the forward clutch.
AT-06480
25. Remove the thrust bearing (A) and seal ring.
(A)
AT-06481

INSTALLATION
1. Install the thrust bearing to the converter case.

Note:
AT-06722
2. Install new seal rings to the input shaft and forward clutch drum.
Note:
3. Install the forward clutch.
4. Install the sun gear.
Note:
Face the end face of the sun gear to the reverse brake side as shown in the figure.
AT-06483
5. Install the thrust bearing to the sun gear.

Note:
6. Install the planetary carrier.
Note:
8. Select a washer. Ref. to CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Forward Clutch>ADJUSTMENT.
9. Install the reverse brake. Ref. to CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Reverse Brake>INSTALLATION.
Gear>INSTALLATION.
Case>INSTALLATION.
Gear>INSTALLATION.
Gear>INSTALLATION.
Pump>INSTALLATION.
Body>INSTALLATION.
Hose>INSTALLATION.

DISASSEMBLY
1. FORWARD CLUTCH
1. Remove the snap ring, and then remove the retaining plate, drive plate, driven plate and dish plate.
AT-06484
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)
ST2
ST1
AT-06485
3. Remove the chamber and snap ring.
AT-06486
AT-06487
5. Remove the forward clutch piston by blowing compressed air from the forward clutch carrier hole.
AT-06488
2. PLANETARY CARRIER
Note:
Disassemble the balance oil guide only.
1. Remove the snap ring.
AT-07026
2. Remove the balance oil guide.
3. INTERNAL GEAR
AT-06757
2. Remove the thrust gear plate.
AT-06759

ASSEMBLY
1. FORWARD CLUTCH
1. Install the forward clutch piston to forward clutch drum.
Note:
Apply CVTF to the seal of forward clutch piston.
AT-06489

3. Install the chamber and set the snap ring.
Note:
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)
ST2
ST1
AT-06485
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.
Note:
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.
Note:
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.
AT-05234
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”.
Note:
Measure at four points with a 90° interval and calculate the average.
A (C)
(A)
(B)
AT-06490
(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.
Note:
AT-06491
13. Measure and record the clearance “B” between the retaining plate and snap ring.
AT-06492
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 — 0.055 in)
Service limit:
1.6 mm (0.063 in)
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.
3. INTERNAL GEAR
1. Install the thrust gear plate.

INSPECTION


ADJUSTMENT
1. Install the thrust bearing to the internal gear.

Note:
AT-06808
2. Measure depth “A” from the ST upper face to the washer mounting surface.
Preparation tool:
ST: GAUGE (499575600)
ST
ST
AT-06804
3. Measure the height “B” from the ST upper face to the mating surface of the drive pinion retainer.
Preparation tool:
ST: GAUGE (499575600)
ST
ST
AT-06805
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 — 0.028 in): Clearance
CONTINUOUSLY VARIABLE TRANSMISSION(TR580) > Drive Pinion

REMOVAL

Assembly>REMOVAL.
Body>REMOVAL.
Harness>REMOVAL.
Sensor>REMOVAL.
Sensor>REMOVAL.
Sensor>REMOVAL.
Gear>REMOVAL.
Gear>REMOVAL.
Case>REMOVAL.
Gear>REMOVAL.
21. Remove the forward clutch. Ref. to CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Forward Clutch>REMOVAL.
22. Using the ST, remove the drive pinion retainer.
Preparation tool:
ST: SOCKET (E20) (18270KA020)
CVT11332
AT-06494
24. Remove the liquid gasket from the drive pinion retainer and converter case.

INSTALLATION
1. Adjust backlash and tooth contact of the hypoid gear set. Ref. to CONTINUOUSLY VARIABLE
TRANSMISSION(TR580)>Front Differential>ADJUSTMENT.
2. Install a new O-ring to converter case.
Note:
AT-06494
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.
Note:
Before applying liquid gasket, degrease the old liquid gasket seal surface of the drive pinion retainer and
converter case.
Liquid gasket:
1.4 mm (0.0551 in)
CVT11479
4. Tighten the bolt using the ST.

Preparation tool:
ST: SOCKET (E20) (18270KA020)
Tightening torque:
43 N·m (4.4 kgf-m, 31.7 ft-lb)
(B) (C)
(B)
(B)
(A)
(C) (B)
(C)
(B)
(C)
(B)
(B)
(A)
(B)
CVT11333
(A) M10 × 54 (B) M10 × 45 (C) M10 × 33
5. Install the forward clutch. Ref. to CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Forward Clutch>INSTALLATION.

Gear>INSTALLATION.
Case>INSTALLATION.
Gear>INSTALLATION.
Gear>INSTALLATION.
Pump>INSTALLATION.
Body>INSTALLATION.
Hose>INSTALLATION.

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)
ST1
ST3
ST2
AT-06497
3. Remove the drive pinion.
AT-06765
4. Using the round bar with diameter of 36 mm (1.42 in) or 37 mm (1.46 in) and a press, remove the taper roller bearing (rear)
inner race and plug.
AT-06756
5. Remove the drive pinion washer.
AT-06774
6. Remove the drive pinion spacer.
AT-06762
AT-06763
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)
ST
AT-06772
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)
ST ST
AT-06770
10. Remove the oil seal from the front side and the rear side.
Caution:
Do not damage the fitting surface of oil seal.
AT-06775
11. Remove the plug from drive pinion retainer.
AT-06779

ASSEMBLY
1. Install the plug to the drive pinion retainer with a new O-ring.
Note:
Tightening torque:
22 N·m (2.2 kgf-m, 16.2 ft-lb)
2. Using the ST, install the oil seal.
Note:
Apply CVTF to the oil seal press-fitting surface and lip.
Preparation tool:
ST: HOUSING BUSHING INSTALLER AND REMOVER (927720000)
ST ST
(A)
(B)
AT-06751
(A) 2.8 mm (0.11 in) (B) 18.7 mm (0.74 in)
3. Select the drive pinion washer.

(1) Measure width “A” of a new taper roller bearing (front) inner race.
AT-06749
(2) Measure width “B” of a new taper roller bearing (rear) inner race.
AT-06753
(3) Measure width “C” of the drive pinion spacer.
AT-06767
(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
ST1
AT-06778
(5) Install a new taper roller bearing (rear) outer race using the ST and a press.
Preparation tool:
ST: INSTALLER (20099AE020)
ST
AT-06777
(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.
Note:
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.
AT-06769
(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)
ST ST
AT-06768
(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 (0.591 in): Thickness of ST
T: Drive pinion washer thickness
0±0.0125 mm (0±0.0005 in): 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.
M
G
CVT10453
(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.
Note:
Perform the measurement at the contact surface of the side bearing outer race.
CVT10454
(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]
A2
A
A1
CVT10455
(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
ST
B1
CVT10456
(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”
T: Drive pinion shim thickness
90.8 mm (3.575 in): Ideal distance from the differential center to the drive pinion end surface
0±0.0125 mm (0±0.0005 in): Clearance
E
B
CVT10457
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:
ST2: EXTENSION DRIVE SHAFT (927130000)
ST1
ST2
AT-07013
7. Install the drive pinion spacer.

Note:
Replace the O-ring with a new part after tooth contact inspection.
AT-06762
8. Install the selected drive pinion washer.
AT-06774
9. Insert the drive pinion into the drive pinion retainer.

Caution:
Be careful not to damage the oil seal.
10. Install the lock nut.
Note:
Apply differential gear oil to the threaded portion of the drive pinion.
AT-06776
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.
Caution:
Before inspecting the starting torque, apply differential gear oil to roller of bearing and rotate the taper roller
bearing several times.
Note:
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 — 25.5 kgf-m, 125.4 — 184.4 ft-lb) [Specified tightening torque range]
T2: Tightening torque
L1: ST1 length 0.072 m (2.83 in)
L2: Torque wrench length
Example:
Torque wrench length Tightening torque
m (in) 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)
ST1
ST3
ST2
AT-06497
ST2
ST3
AT-07025
12. Install the drive pinion retainer to the converter case, and check the backlash and tooth contact of the hypoid gear set.
Ref. to CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Drive Pinion>ADJUSTMENT. Ref. to CONTINUOUSLY
VARIABLE TRANSMISSION(TR580)>Front Differential>ADJUSTMENT.
13. Remove the drive pinion retainer from converter case. Ref. to CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Drive
Pinion>REMOVAL.
14. Remove the drive pinion spacer from the drive pinion. Ref. to CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Drive
Pinion>DISASSEMBLY.
Note:
Apply the differential gear oil to O-ring.
AT-06763
16. Install the drive pinion spacer.
AT-06762
17. Install the drive pinion washer.
AT-06774
18. Insert the drive pinion.

Caution:
Be careful not to damage the oil seal.
AT-06765
19. Install a new lock nut.

Note:
Apply differential gear oil to the threaded portion of the drive pinion.
AT-06776
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.
Caution:
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.
Note:
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 — 25.5 kgf-m, 125.4 — 184.4 ft-lb) [Specified tightening torque range]
T2: Tightening torque
L1: ST1 length 0.072 m (2.83 in)
L2: Torque wrench length

Example:
Torque wrench length Tightening torque
m (in) 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)
ST1
ST3
ST2
AT-06497
ST2
ST3
AT-07025
21. Crimp the lock nut.

22. Install a new plug using ST1, ST2 and a press.
Preparation tool:
ST1: PRESS SNAP RING (499755602)
ST2
ST1
AT-06771

INSPECTION

2. Check the taper roller bearing for abnormal noise.

ADJUSTMENT
1. Using the ST, install the drive pinion retainer.

Preparation tool:
ST: SOCKET (E20) (18270KA020)
Tightening torque:
43 N·m (4.4 kgf-m, 31.7 ft-lb)
(B) (C)
(B)
(B)
(A)
(C) (B)
(C)
(B)
(C)
(B)
(B)
(A)
(B)
CVT11333
(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)
ST2
ST1
AT-06693
3. Adjust the hypoid gear set backlash. Ref. to 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. Ref.
to CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Front Differential>ADJUSTMENT.
Note:
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).)
(A)
(B)
AT-05367
Face contact
Check item: Backlash is too large.
Contact pattern
AT-05368
Adjustment: Increase thickness of the drive pinion shim according to the procedures for moving the drive pinion closer to
the driven gear.
AT-05369
Flank contact
Check item: Backlash is too small.
Contact pattern
AT-05370
Adjustment: Reduce the thickness of the drive pinion shim according to the procedures for moving the drive pinion away
from the driven gear side.
AT-05371
Toe contact (inside contact)

Check item: Teeth contact area is too small.
Contact pattern
AT-05372
Adjustment: Reduce the thickness of the drive pinion shim according to the procedures for moving the drive pinion away
from the driven gear side.
AT-05371
Heel contact (outside end contact)

Check item: Teeth contact area is too small.
Contact pattern
AT-05373
Adjustment: Increase thickness of the drive pinion shim according to the procedures for moving the drive pinion closer to
the driven gear.
AT-05369
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.
Note:
When loosening the differential side retainer, record the number of the turns made.
Perform this for both left and right differential side retainers.
Preparation tool:
ST: WRENCH COMPL RETAINER (18658AA020)
7. Using the ST, tighten the differential side retainer to the position before it is loosened.
Preparation tool:
8. Replace the differential side retainer oil seal with a new part. Ref. to CONTINUOUSLY VARIABLE
TRANSMISSION(TR580)>Differential Side Retainer Oil Seal.
9. Install the lock plate (A).
Tightening torque:
25 N·m (2.5 kgf-m, 18.4 ft-lb)
(A)
AT-06498
CONTINUOUSLY VARIABLE TRANSMISSION(TR580) > Front Differential

REMOVAL

Assembly>REMOVAL.
Body>REMOVAL.
Harness>REMOVAL.
Sensor>REMOVAL.
Sensor>REMOVAL.
Sensor>REMOVAL.
Gear>REMOVAL.
Gear>REMOVAL.
Case>REMOVAL.
Gear>REMOVAL.
22. Remove the drive pinion. Ref. to CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Drive Pinion>REMOVAL.
23. Remove the oil baffle.
CVT10354
24. Remove the lock plate (A).
(A)
AT-06498
25. Remove the differential side retainers using the ST.

Note:
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
AT-06499
26. Remove the differential case while being careful not to damage the attachment section of the differential side retainer.
CVT10150
27. Remove the oil seals and O-rings from differential side retainer. Ref. to CONTINUOUSLY VARIABLE
TRANSMISSION(TR580)>Front Differential>DISASSEMBLY > DIFFERENTIAL SIDE RETAINER.

INSTALLATION
1. Install the side bearing outer race.

2. Install the differential case.
Note:
Be careful not to damage the inside of the case (especially the mounting surface of the differential side
retainers).
CVT10150
3. Temporarily install the differential side retainers using the ST.

Preparation tool:
ST
AT-06499
4. Adjust the hypoid gear set backlash. Ref. to CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Front
Differential>ADJUSTMENT.
5. Inspect and adjust the tooth contact. Ref. to 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.
Note:
When loosening the differential side retainer, record the number of the turns made.
Perform this for both left and right differential side retainers.
Preparation tool:
7. Using the ST, tighten the differential side retainer to the position before it is loosened.
Preparation tool:
8. Install the oil seal to the differential side retainer. Ref. to CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Differential
Side Retainer Oil Seal.
9. Install the lock plate (A).
Tightening torque:
25 N·m (2.5 kgf-m, 18.4 ft-lb)
(A)
AT-06498
10. Install the oil baffle.
CVT10355
11. Install the drive pinion. Ref. to CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Drive Pinion>INSTALLATION.
Gear>INSTALLATION.
Case>INSTALLATION.
Gear>INSTALLATION.
Gear>INSTALLATION.
Pump>INSTALLATION.
Body>INSTALLATION.
Hose>INSTALLATION.

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)
ST2 ST2
ST3
ST3
ST1
ST1
CVT10152
2. Using the ST, remove the spring pin.

Preparation tool:
ST: STRAIGHT PIN REMOVER (899904100)
ST
CVT10153
3. Remove the pinion shaft, and remove the differential bevel pinion, differential bevel gear and washer.
(D) (B) (C) (B) (D)
(A)
(C)
CVT10156
(A) Pinion shaft (C) Differential bevel pinion (D) Washer

(B) Differential bevel gear
2. DIFFERENTIAL SIDE RETAINER

AT-06684
2. Remove the differential side retainer oil seal.
AT-06685
ASSEMBLY
1. DIFFERENTIAL CASE
1. Install the differential bevel gear and differential bevel pinion together with the washer, and install the pinion shaft.
Note:
Apply differential gear oil on the sliding portion of the washer, differential bevel gear, and pinion shaft.
(D) (B) (C) (B) (D)
(A)
(C)
CVT10156
(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 SUBARU genuine axle shaft to differential case.
Part No. 38415AA070 AXLE SHAFT
(2) Using ST1 and ST2, insert the ST2 through the window of differential case, then measure the backlash.
Note:
When measuring, fix the differential bevel pinion in place with a screwdriver covered with cloth, or a similar
tool.
Preparation tool:
ST1: MAGNET BASE (498247001)
ST2: DIAL GAUGE (498247100)
Specification:
0.13 — 0.18 mm (0.0051 — 0.0071 in)
ST1
ST2
CVT10157
(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.
CVT11469
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)
ST1
ST2
CVT10155
2. DIFFERENTIAL SIDE RETAINER

1. Install the new differential side retainer oil seal using the ST.
Note:
Apply differential gear oil to the oil seal lip and press-fitting surface.
Oil seal has an identification mark (R, L). When installing oil seals, do not confuse the left and right.
Preparation tool:
ST: DIFFERENTIAL SIDE OIL SEAL INSTALLER (18675AA000)
ST
AT-06692

Note:
AT-06684

INSPECTION

ADJUSTMENT
1. Using the ST, screw-in the differential side retainer until resistance is felt.
Note:
RH side should be screwed-in more than LH side.
Preparation tool:
ST
AT-06499
2. Using the ST, install the drive pinion retainer.

Preparation tool:
ST: SOCKET (E20) (18270KA020)
Tightening torque:
43 N·m (4.4 kgf-m, 31.7 ft-lb)
(B) (C)
(B)
(B)
(A)
(C) (B)
(C)
(B)
(C)
(B)
(B)
(A)
(B)
CVT11333
(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)
ST2
ST1
AT-06693
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.
Note:
Turning the differential side retainer by one notch (A) changes the backlash approx. 0.05 mm (0.0020 in).
(A)
AT-06694
6. Insert the two SUBARU genuine axle shafts into differential case.
Part No. 38415AA070 Axle shaft
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.
Note:
Make sure the drive pinion does not move.
Preparation tool:
ST: COMPRESSOR SHAFT (18763AA000)
ST
AT-06695
8. Check the backlash of hypoid gear set is within specification using ST1, ST2 and ST3.
Preparation tool:
ST1: PLATE (498255400)
ST2: DIAL GAUGE (498247100)
ST3: MAGNET BASE (498247001)
Specification:
0.13 — 0.18 mm (0.005 — 0.007 in)
ST1
ST3
ST2
AT-06696
9. Adjust the tooth contact of hypoid gear set. Ref. to CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Drive
Pinion>ADJUSTMENT.
CONTINUOUSLY VARIABLE TRANSMISSION(TR580) > Oil Pump Chain

REMOVAL

Assembly>REMOVAL.
3. Remove the oil pump chain, oil pump sprocket, driven sprocket and oil pump chain cover.
Note:
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.
CVT00869
CVT00865
CVT10356
5. Remove the driven sprocket from oil pump chain cover to remove the oil pump chain.
Note:
The driven sprocket is a non-disassembly part.
If the ball bearing is removed from the driven sprocket, replace it with a new part.
AT-06698
AT-06699
7. Remove the drive sprocket.
AT-06700
8. Remove the oil seal.
AT-06701
9. Remove the liquid gasket from the oil pump chain cover and the converter case.

INSTALLATION
1. Install a new oil seal using ST.

Note:
Apply CVTF to the oil seal lip and press-fitting surface.
Preparation tool:
ST: PRESS SNAP RING (499755602)
ST
AT-06702
2. Install the drive sprocket.

Note:
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).
(A)
AT-07811
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.
Note:
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.
Caution:
Do not apply liquid gasket at the arrowed hole.
Note:
Before applying liquid gasket, degrease the old liquid gasket seal surface of the oil pump chain cover and
converter case.
Liquid gasket:
1.4 mm (0.0551 in)
CVT11480
8. Install the oil pump chain cover.

Tightening torque:
21 N·m (2.1 kgf-m, 15.5 ft-lb)

DISASSEMBLY
1. DRIVE SPROCKET
AT-06706

Preparation tool:
ST1: REMOVER (498077600)
ST2
ST1
AT-05411

ASSEMBLY
1. DRIVE SPROCKET
1. Using the ST and a press, install a new ball bearing.
Preparation tool:
ST: PRESS SNAP RING (499755502)
ST
AT-05412

INSPECTION

3. Check the ball bearing for seizure.
4. Check the ball bearing for abnormal noise.
Note:
CONTINUOUSLY VARIABLE TRANSMISSION(TR580) > Oil Pump

REMOVAL

Assembly>REMOVAL.
3. Remove the oil pump chain cover. Ref. to CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Oil Pump
Chain>REMOVAL.
4. Remove the oil pump and the plate.
CVT10357
AT-06708

INSTALLATION

Note:
2. Install the plate and the oil pump.
Note:
Tightening torque:
8.5 N·m (0.9 kgf-m, 6.3 ft-lb)
3. Install the oil pump chain cover. Ref. to CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Oil Pump
Chain>INSTALLATION.

INSPECTION

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). Ref. to CONTINUOUSLY VARIABLE
TRANSMISSION(TR580)>Secondary Pressure (Line Pressure) Test>INSPECTION.
(2) Remove the oil pan and oil strainer. Ref. to CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Oil Pan>REMOVAL.
(3) Check oil strainer for clogging.
Note:
When oil strainer has no clogging, replace the oil pump.
CONTINUOUSLY VARIABLE TRANSMISSION(TR580) > Converter Case

REMOVAL

Assembly>REMOVAL.
Body>REMOVAL.
Harness>REMOVAL.
Sensor>REMOVAL.
Sensor>REMOVAL.
Sensor>REMOVAL.
Gear>REMOVAL.
Gear>REMOVAL.
Case>REMOVAL.
Gear>REMOVAL.
22. Remove the drive pinion. Ref. to CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Drive Pinion>REMOVAL.
23. Remove the front differential. Ref. to CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Front Differential>REMOVAL.
24. Remove the oil pump chain cover. Ref. to CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Oil Pump
Chain>REMOVAL.
25. Remove the oil pump. Ref. to CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Oil Pump>REMOVAL.

INSTALLATION
1. Install the oil pump. Ref. to CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Oil Pump>INSTALLATION.

2. Install the oil pump chain cover. Ref. to CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Oil Pump
Chain>INSTALLATION.
3. Install the front differential. Ref. to CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Front
Differential>INSTALLATION.
4. Install the drive pinion. Ref. to CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Drive Pinion>INSTALLATION.
Gear>INSTALLATION.

Case>INSTALLATION.
Gear>INSTALLATION.
Gear>INSTALLATION.
Pump>INSTALLATION.
Body>INSTALLATION.
Hose>INSTALLATION.

DISASSEMBLY
1. Remove the filler plug, drain plug and overflow plug. Ref. to CONTINUOUSLY VARIABLE
TRANSMISSION(TR580)>Differential Gear Oil>REPLACEMENT.
AT-06709

ASSEMBLY
1. Install the drain plug.
Tightening torque:
70 N·m (7.1 kgf-m, 51.6 ft-lb)
2. Temporarily attach the filler plug and overflow plug.
3. Install the plugs with new O-rings.
Note:
Tightening torque:
T1: 22 N·m (2.2 kgf-m, 16.2 ft-lb)
T2: 22.5 N·m (2.3 kgf-m, 16.6 ft-lb)
T1
T1
T2
AT-06710

INSPECTION

CONTINUOUSLY VARIABLE TRANSMISSION(TR580) > AT learning

PROCEDURE
Caution:
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”.
4. Lift up the vehicle.
Caution:
While working, be sure to keep the lower edge of the tires 0.3 m (0.98 ft) or more above the ground as vehicle
will vibrate.
Note:
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

Caution:
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].
4. On [Select System] screen, select [Transmission Control System].
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
Note:
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].
4. On [Select System] screen, select [Transmission Control System].
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.
Note:
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 Fault is detected during AT learning.
the beginning.] 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 Engine control system
lever in “D range” or “R range”.
Engine control system
Select cable
CVTF
Secondary pressure circuit
Engine speed rises up and the vehicle does not Primary pulley & secondary pulley, variator
start, with select lever in “D range” or “R range”. chain and reduction drive gear
Forward/reverse changeover section
TCM
Control valve body
Inhibitor switch
Parking mechanism
Vehicle does not move by engine stall, with select Select cable
lever in “D range” or “R range”. Torque converter
Excessive shock occurs at starting, with select
Primary pulley & secondary pulley, variator
chain
Acceleration speed from standstill is insufficient, Control valve body
with select lever in “D range” or “R range”. Forward/reverse changeover section
Control valve body
Engine speed suddenly rises up during driving,
with select lever in “D range” or “R range”.
Primary pressure circuit
Vibration occurs during driving, with select lever Primary pulley & secondary pulley, variator
in “D range” or “R range”. chain
Torque converter
Hydraulic pressure circuit to torque converter
Control valve body
Sudden braking occurs during driving, with select
Control valve body
During deceleration, lockup clutch does not Control valve body
disengage until just before halting, with select Torque converter
Engine stalls with vehicle at a standstill, with Engine control system
select lever in “D range” or “R range”. Control valve body
Excessive lockup shock occurs during driving, Control valve body
with select lever in “D range”.
Slipping occurs at lockup, or lockup does not Control valve body
occur during driving, with select lever in “D Lockup hydraulic circuit
range”. Torque converter
Excessive shift shock occurs when shifting the Inhibitor switch
select lever from “N range” to “D range”, or from Control valve body
“N range” to “R range”. Forward/reverse changeover section
Symptoms Problem parts etc.

Vehicle does not keep at standstill with select Select cable
lever in “P range”, or parking cannot be released Parking mechanism
when shifting from “P range” to another range.
Select cable
Inhibitor switch
Select lever does not shift smoothly.
Detent spring
Manual plate

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13/6/2019 FORESTER 19MY PubNo: G8240BE Version: 008

CONTINUOUSLY VARIABLE TRANSMISSION(TR580)

45. Drive Pinion

CONTINUOUSLY VARIABLE TRANSMISSION(TR580) > General Description

CONTINUOUSLY VARIABLE TRANSMISSION(TR580) > General Description

1. TORQUE CONVERTER & CONVERTER CASE

4. CONTROL VALVE BODY

(1) O-ring (8) Snap ring (15) O-ring

(1) O-ring (10) Snap ring (19) Balance oil guide

7. TRANSMISSION CONTROL DEVICE

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

9. FRONT DIFFERENTIAL GEAR

(4) (6) (9)

(1) Hypoid gear set (16) Oil seal (31) O-ring

(12) Drive pinion shim (27) Lock nut

10. TRANSFER AND EXTENSION CASE

11. ELECTRIC OIL PUMP

12. TRANSMISSION HARNESS AND SENSOR

13. CVTF COOLER (WITH WARMER FEATURE)

14. TRANSMISSION CONTROL MODULE

(1) Transmission control module Tightening torque: N·m (kgf-m,

15. TRANSMISSION MOUNTING

CONTINUOUSLY VARIABLE TRANSMISSION(TR580) > General Description

CONTINUOUSLY VARIABLE TRANSMISSION(TR580) > General Description

398497701 SEAT Used for removing and installing the

398527700 PULLER ASSY Used for removing the extension

ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS

498057300 OIL SEAL Used for installing the extension case

498077000 REMOVER Used for removing the side bearing

498077300 REMOVER Used for removing ball bearing of

498077400 REMOVER Used for removing the ball bearing of

ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS

498247001 MAGNET BASE Used for adjusting backlash of the

498247100 DIAL GAUGE Used for adjusting backlash of the

498255400 PLATE Used for adjusting hypoid gear set

498277200 STOPPER SET Used for removing and installing

ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS

498515500 REMOVER Used for removing the taper roller

498575400 OIL PRESSURE Used for measuring the transfer clutch

498897700 OIL PRESSURE Used for measuring the secondary

498937110 HOLDER Used for removing and installing the

ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS

499277100 BUSHING 1-2 Used for installing the ball bearing

499277200 INSTALLER Used for installing the ball bearing of

499575400 GAUGE Used for measuring the end play.

499575500 GAUGE Used for measuring the end play.

ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS

499755502 PRESS SNAP Used for installing the drive sprocket

499755602 PRESS SNAP Used for installing the drive pinion

499757002 INSTALLER Used for removing ball bearing of

499787500 ADAPTER Used for removing and installing the

ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS

899580100 INSTALLER Used for installing the ball bearing

899864100 REMOVER Used for removing and installing the

899904100 STRAIGHT PIN Used for removing the spring pin of

ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS

927720000 HOUSING Used for installing drive pinion

18270AA040 SOCKET Used for removing and installing the

18270KA020 SOCKET (E20) Used for removing and installing the