Part 3 of 3
Contents
1. 1 3 0 1 9 4 0 7 8 8 1 0 8 0 1 5 8 0 7 T9 6 4 0 5 0 65 0 05 4 7 0 4 Page 85 of 90 Oil Pump Tightening torque N m kg m ft lb T1 25 2 2 5 0 2 18 1 1 4 T2 39 3 4 0 0 3 28 9 2 2 T3 33 3 3 4 0 3 24 6 2 2 T4 13 1 1 3 0 1 9 4 0 7 5 7 1 0 7 0 1 5 1 0 7 T6 113 5 11 5 0 5 83 2 3 6 Selective parts H 1 Retainer 2 Return spring 3 Pin 4 Friction ring 5 O ring 6 Camring 7 Vane ring B Vane 9 Rotor 10 Bushing 11 Oil pump cover 12 Thrust washer 13 Seal ring RI 14 Sealring H 15 Thrust needle bearing 16 Thrust washer 17 Air breather hose 18 Drive pinion shaft 19 Roller bearing 20 Shim 21 Test plug 22 Oil pump housing 23 Pin 24 Side seal 25 Contro piston 26 Plane seal 27 Gasket 28 O ring 29 Oil seal 30 Oil seal retainer 31 Sea 32 Lock washer 33 Locknut Page 86 of 90 Differential Case WON OW Bb An Tightening torque N m kg m ft Ib 1 57 67 5 8 6 8 42 49 T2 23 26 2 3 27 17 20 Straight pin Pinion shaft Differential case RH Differential case LH Taper roller bearing Oil seal LH O ring Differential side retainer Circlip Axle shaft Oil seal RH Speedometer drive gear Washer Differential beve pinion Differential bevel gear Selective parts Page 87 of 90 Torque Converter and Converter Case Pitching stopper bra2. Be careful not to cut or break the O ring Then tighten bolts Tightening torque 5 8 0 7 ft lb 8 1 N m 0 8 0 1 kg m 5 Secure five connectors 6 Install the oil cooler outlet pipe and secure with two bolts Fit the pipe into position Be careful to avoid twisting Tightening torque 5 8 0 7 ft lb 8 1 N m 0 8 0 1 kg m 7 Install the oil pan a Attach the magnet at the specified position b With gasket inserted secure the oil pan by tightening 20 bolts Tighten the bolts evenly Tightening torque 2 9 0 4ft lb 3 9 0 5N m 0 4 0 05kg m Page 74 of 90 Extension Case 1 Install the filter in the extension case Pay attention to the orientation of the filter 2 Install the transfer clutch valve assembly and secure with four bolts Tightening torque 5 8 0 7 ft lb 8 1 N m 0 8 0 1 kg m a Be sure to use a new gasket 3 Install the pipe and clamp securely 4 Install the transfer clutch assembly to the case a Be careful not to damage the seal rings b Insert the clutch assembly fully into position until the bearing shoulder bottoms Connection between Extension Case amp Transmission Case 1 Install the revolution sensor to the transmission case with one bolt AWD model only Tightening torque 5 1 0 7 ft lb 7 1 N m 0 7 0 1 kom 2 Install the reduction driven gear 3 Install the parking pawl and shaft set the select lever in the P range and tighten the drive pinion lock nut Afte
3. drive pinion hight adjusting shim in order to bring drive pinion close to crown gear Reduce thickness of drive pinion hight adjusting shim in order to move drive pinion away from crown gear Adjust as for flank contact Adjust as for face contact If tooth contact is correct mark the retainer position and loosen it After fitting the O ring screw the retainer to the marked position Then tighten the lock plate to the specified torque Tightening torque 17 20 ft lb 23 26 N m 2 3 2 7 kg m Page 66 of 90 11 Install the seal pipe to the converter case Be sure to use a new seal pipe 12 Install two oil seals to the oil seal retainer with INSTALLER 499247300 a Pay attention to the orientation of the oil seals b Be careful not to damage the seal lips If any damage is found replace with a new one 13 Attach the O ring to the oil seal retainer with petroleum jelly Install the seal to the oil pump housing bore 14 Install the oil seal retainer taking care not to damage the oil seal lips Then secure with three bolts Make sure the O ring is fitted correctly in position Tightening torque 5 1 0 7 ft lb 7 1 N m 0 7 0 1 kg m seal retainer 15 Apply petroleum jelly to the groove on the oil pump cover and install two R seal rings and two H seal rings a Fit the seal ring after compressing and rub petroleum jelly into the seal ring to avoid expansio
4. hearing noises that appear to be coming from the rear of the transmission remove the speed sensor at the rear of the transmission and check for the presence of metal particles It may mean the transfer clutch has begun to self destruct Source UberRoo SVX forum Page 89 of 90 TPS failure mode A partial failure of the TPS has been known to manifest itself as a flare in engine RPMs during the shift from 2 to 3 gear The likely cause is a partial failure in the resistive element of the TPS producing a drop out in the smooth change of voltage output to the TCU and ECU This dropout effectively signals the TCU that throttle pressure has gone to zero and therefore the TCU signals a reduced line pressure resulting in a slip during the shifting process Front differential failure There have been a few cases of the front differential housing failing with subsequent failure of the ring pinion gears likely from a part of the failed housing being introduced between the gear teeth There may or may not be a warning sound s After failure there will be a loud distinct and rhythmic thud thunk with each turn of the ring gear There has been some speculation that the failure might be induced by excessive torque being applied through the front differential if the transfer clutch is not fully functional Binding AWD system For those AWD Subaru owners experiencing binding in the transfer clutch system the addition of 4 oz of a limited slip differen
5. lb 39 3 N m 4 0 0 3 kg m 9 Tighten the drain plugs Tightening torque Differential 32 5 2 2 ft lb 44 3 N m 4 5 0 3 kg m ATF 18 1 1 4 ft Ib 25 2 N m 2 5 0 2 kg m 10 Install the air breather hose 11 Insert the input shaft while turning lightly by hand Be careful not to damage the bushing 12 Install the torque converter assembly a Clean out any rust from the center of the flex plate on the engine side Clean any excess paint especially for a rebuilt torque converter at the mating point Neglecting this may cause failure of the front oil pump bushing It would be a good idea to dry fit the torque converter to the drive flex plate to ensure there is no binding b Fill the torque converter with ATF Install the oil pump shaft to the torque converter Make sure the clip fits securely in its groove c Holding the torque converter assembly by hand carefully install it to the converter case Be careful not to damage the bushing In addition to avoid undue contact between the oil pump shaft bushing and stator shaft portion of the oil pump cover d Rotate the shaft lightly by hand to engage the splines securely Do this several times to ensure the torque converter is fully seated The usual process has the torque converter going in what feels like all the way then after rotating the converter while lightly pressing inward you feel it go in about another half inch Page 77 of 90 Transaxle Installation Pro
6. parts indicated by an asterisk in the following pages 2 5 mm 10 098 in Forward clutch drum 12 Install the forward clutch drum assembly a Install carefully while rotating the drum slowly paying special attention not to damage the seal ring b Installation is complete when the drum recedes 0 098 in 2 5mm from the inner race surface 13 Assemble the overrunning clutch hub a Join the thrust needle bearing and thrust washer with petroleum jelly and then install them together b Make sure that the splines are engaged correctly Thrust washer Thrust needie bearing 14 Install the one way clutch outer race assembly Make sure the forward clutch splines are engaged correctly 3 5 mm 0 138 in Thrust washer Overrunning dutch hub 15 Assemble the rear internal gear a Join the thrust needle bearing and thrust washer to the gear with petroleum jelly and install the gear while rotating it b Securely engage the bearing with the dog of the overrunning clutch hub Installation is complete when the snap ring top surface of the forward clutch drum recedes approximately 0 138 in 3 5 mm Page 70 of 90 16 Install the rear planetary carrier Attach the thrust needle bearing to the inside of the carrier with petroleum jelly Then install the carrier while rotating slowly 17 Install the rear sun gear Install the gear with the oil hole facing up Front planetary carrier drum 1
7. 39 Lip seal Meee Tightening torque N m kg m ft Ib 25 2 2 5 0 2 18 1 1 4 81 of 90 High Clutch and Planetary Gear OWA WN 17 18 19 20 21 22 23 24 25 26 27 28 Selective parts High clutch drum Lathe cut seal ring Piston Lathe cut sea ring Spring retainer Snap ring Driven plate Thinner Drive plate Driven plate Thicker Retaining plate Snap ring Thrust needle bearing High clutch hub Thrust needle bearing Front sun gear Thrust needle bearing Front planetary carrier Thrust needle bearing Rear sun gear Thrust needie bearing Rear planetary carrier Thrust needle bearing Rear internal gear Thrust washer Snap ring One way clutch 3 4 One way clutch outer race 3 4 Overrunning clutch hub fen 3 Page 82 of 90 Reverse Clutch and Brake Band Selective parts Brake band Reverse clutch drum Lip seal Piston Lathe cut seal ring Spring Spring Spring retainer Snap ring 10 Dish plate 11 Driven plate 12 Drive plate 13 Retaining plate 14 Snap ring 15 Lock nut 16 Brake band adjusting screw 17 Strut 18 Band servo piston 19 Spring 20 Lathe cut seal ring 21 Band servo piston 1 2 22 O ring 23 Retainer 24 O ring 25 Spring 26 Retainer 27 Circlip 28 Lathe cut seal ring 29 Band servo piston 3 4 30 O ring 31 OD servo retainer 32 Snap ring 33 Lathe cut seal ring DO AO Ob OH a Tigh
8. 8 Install the front planetary carrier Attach the thrust needle bearings to both sides of the carrier with petroleum jelly Install the carrier carefully while aligning with the splines of the forward clutch drum and while rotating the pinion Thrust needie bearing 19 Install the front sun gear Attach the thrust needle bearing to the gear and install the gear while turning slowly Front sun gear Thrust needie bearing 20 Install the high clutch hub Attach the thrust needle bearing to the hub with petroleum jelly and install the hub by correctly engaging the splines of the front planetary carrier High duth ASSY 21 Install the high clutch assembly Correctly engage the high clutch hub and clutch splines Page 71 of 90 22 Install the reverse clutch assembly Engage the high clutch outer spline with the reverse clutch spline and the front sun gear with the cut out portion of the reverse clutch drum correctly when installing Brake band 23 Install the brake band assembly a Be careful not to damage the brake band when installing b Install the strut to the band servo piston stem Then tighten it temporarily to avoid tilting the band 24 Adjustment of total endplay a Measure the distance from the transmission case mating surface to the recessed portion of the high clutch drum and the distance to the top surface of the reverse clutch drum b Measure the distance from the oil p
9. Do not confuse the RH and LH oil seals c Keep the O ring removed from the retainer 9 Using the HANDLE 499787000 screw in the retainer until light contact is felt Screw in the RH side slightly deeper than the LH side 10 Hypoid gear backlash adjustment and tooth contact check a Assemble the drive pinion assembly to the oil pump housing a 1 Be careful not to bend the shims a 2 Be careful not to force the pinion against the housing bore Page 64 of 90 b Tighten four bolts to secure the roller bearing Tightening torque 28 9 2 2 ft lb 39 3N m 4 0 0 3 kg m c Install the oil pump housing assembly to the converter case and secure evenly by tightening four bolts Tightening torque 24 6 2 2 ft lb 33 3 N m 3 4 0 3 kg m c 1 Thoroughly remove the liquid gasket from the case mating surface beforehand c 2 Use an old gasket or an aluminum washer so as not to damage the mating surface of the housing WRENCH 4997871001 7 HOLDER 1498937100 m d Turn the drive pinion several times Then screw in the LH side retainer until light contact is felt e Repeat this operation several times to confirm the position where light contact is felt This is called the backlash zero state f Screw in the RH side retainer until light contact is felt g Apply the lock plate Then screw out the LH side retainer by three teeth of the plate Screw in the RH side retainer by the same amount Turning the
10. EAT Modifications Updated Information 16 90 94 MAY 94 Speedometer Cable Adapter 16 59 94 APR 94 Prevention of Planetary Gear Failure 16 58 94 94 A T 4EAT Modifications 16 56 93 93 Auxiliary Filter Kit 16 57 93 93 A T Cooler Hose Kit 16 54 92 NOV 92 A T 4EAT Gear Reduction Driven Shaft Replacement 18 03 92 SEP 92 Service Manual Updates Throttle Sensor Specifications 16 52 92 APR 92 A T 4EAT Reduction Gear amp Transfer Gear Installation 16 50 92 MAR92 A T 4EAT One Way Clutch Operation 16 49 91 DEC 91 A T 4 FWD amp AWD Brake Band Adjustment My thanks are extended to Subaru for making the SVX a unique sports coupe Lee 2004 Because the sources providing references assistance and or inspiration have not been contacted for release this document in whole or part may not be sold or used for commercial purposes This document was created as an educational paper for myself and others Page 90 of 90
11. Part 3 Transaxle Assembly Converter Case Section PRESS 1 Check the appearance of each component and clean Make 499827000 sure each part is free of harmful cuts damage and other faults 2 Install the washer and snap ring to the speedometer shaft and set the oil seal Then force fit the shaft to the converter case e Ar le IN 3 Install the speedometer driven gear to the speedometer shaft iit AN and secure with a snap ring gear O Zw pua s A X K MAN Bo UZE A j SN KK E AK k 25 lr TONS 4 Force fit the oil seal to the converter case 5 Install the differential assembly to the case paying special attention not to damage the speedometer gears drive and driven and the inside of the case particularly the differential side retainer contact surface 6 Install the snap ring to the axle shaft insert the shaft into the differential assembly and tap it into position with a plastic hammer Thrust play Approx 0 012 0 020 in 0 3 mm 0 5 mm a If no play is felt check whether the shaft is fully inserted If shaft insertion is correct replace the axle shaft b Be sure to use a new snap ring 7 Wrap vinyl tape around the splined portion of the axle shaft 8 Install the oil seal and outer race taper roller bearing to the differential side retainer Then screw in the retainer after coating the threads with oil a Pay attention not to damage the oil seal lips b
12. arts Snap ring Pressure plate Drive plate Driven plate Thrust needle bearing Snap ring Spring retainer CP Lathe cut seal ring Transfer clutch piston Lathe cut seal ring Needle bearing Rear drive shaft Bal bearing Seal ring Revolution sensor 40 0 Pilot valve pipe Duty sol C transfer Gasket Plate Filter Gasket Roller bearing Extension case Bushing Oil seal Dust seal Page 79 of 90 Reduction gear 1 Seal ring 2 Bushing 3 Reduction drive shaft 4 Plug 5 Ball bearing 6 Reduction drive gear 7 Snap ring 8 Orive pinion shaft 9 Reduction driven gear 10 Lock washer 11 Lock nut 12 Reduction drive gear 13 Ball bearing 14 Snap ring Tightening torque N m kg m ft Ib T 98 5 10 0 5 723 3 6 Page 80 of 90 Forward Clutch and Low amp Reverse Brake Snap ring Retaining plate Drive plate Driven plate Dish plate Snap ring Retaining plate Drive plate Driven plate Dish plate Snap ring Spring retainer Spring Lathe cut seal ring Overrunning piston Lip seal Forward piston Lip seal Lathe cut seal ring Forward clutch drum e rn Needle bearing Snap ring One way clutch 1 2 Snap ring Snap ring Retaining plate Drive plate Driven plate Snap ring Thrust needle bearing Needle bearing Seal ring Thrust needle bearing One way clutch inner race 1 2 Spring retainer CP Socket boit Low amp reverse piston 38 Lathe cut seal ring
13. baru svx net forum listed some few of its members in these credits and am very sorry could not remember list all who have helped me but whom undoubtedly still plagiarized As an example one member who has given me lots of advice but received no credit in this document is Harvey 2 Dropping Resistor The TCU code for a failed solenoid A is frequently caused by a failure of the dropping resistor The resistor is found on the inner fender wall behind the battery The value of the OEM resistor is specified between 9 and 15 ohms and has a 20 watt rating Some SVX owners have deliberately removed the dropping resistor from the circuit to increase the crispness of shifting However this act will cause the blinking power light condition on start up with the potential to hide other trouble codes Note Use this recommendation for changing the dropping resistor only after you consider carefully and judge it for yourself Also the article referenced below was not tailored to the SVX automatic transmission but was of a general nature concerning dropping resistors and shift solenoids An article in the Gears magazine May 2002 published by the Automatic Transmission Rebuilder s Association ATRA suggested that for both crisp shifting and continued health of the duty solenoid a minimum current of approximately 0 2 amps should flow The article also stated that a current flow of more than 1 0 amp could shorten the life of the solenoid The s
14. cedure Note Always use NEW roll pins when reinstalling axle shafts Tighten bolts to specification see table below Did you fill the torque converter with ATF before putting it in the case Did you put the torque converter back in the transmission then turn it a bit and get it to seat in about a half inch more If your answer to either of these is no then STOP and make sure it is taken care of before proceeding further cannot stress this enough if the torque converter is not fully seated you will ruin the pump when the transmission is mated to the engine If it starts up with a dry torque converter there is a good chance to blow out some internal oil seals 1 If the engine rotated forward when the transmission was removed you will have to find a way to correct the alignment Depending on the engine tilt in one direction you may not clear the power steering gear the other and you will not have the necessary clearance to mate the engine to the transaxle Support transmission with a transmission jack Mate transmission to engine ensuring the transmission slides fully on to the studs on the back of the engine block Be cautious to avoid damage to the steering rack and associated hoses fittings etc Install nuts holding lower side of transmission to engine Install bolts securing rear cross member to body Connect ATF cooler hoses from pipes on the transmission left side near firewall 2 Pull out on knuckle to give you some free space and i
15. cket Oil level gauge O ring Oi seal Snap ring z4 Ou bk WH rz Clip Bushing Oil pump shaft Bushing Seal pipe Speedometer driven gear Snap ring Drain plug Oil sea B Bushing Torque converter case Torque converter O ring Spring pin Input shaft Seal Tightening torque N m kg m ft lb T1 44 3 4 5 0 3 32 5 2 2 T2 33 3 3 4 0 3 24 6 2 2 T3 39 3 4 0 0 3 28 9 2 2 Fig 104 91 Page 88 of 90 Appendix Credits Tips amp Misc Ramblings 1 Credit amp References a The photos of the 4EAT came from the Subaru site www endwrench com as well as being the inspiration of much of the text in the opening portion of the General Information section b Alarge part of this document is derivative from a publication put out by the Automatic Transmission Service Group ATSG no date of place of publishing ATSG in turn thanks Subaru for illustrations and information Although no reproduction notice was present and no copyrights or trademarks are found in the ATSG publication would be remiss if credit was not given to these organizations c General notes on the use of a pressure gauge are derivative from a TSB put out by the Automatic Transmission Repair Association ATRA d need to make an apology to some SVX owners out there could not have gotten this far in working on the SVX without the help and support of the members from the SVX forum www su
16. g torque 24 6 2 2 ft Ib 33 3 N m 3 4 0 3 kg m Mating Converter Case to Transmission Case 1 Apply proper amount of liquid gasket Three bond 1215 suggested to the entire converter case mating surface Make sure that the rubber seal and seal pipe are fitted in position 2 Install the converter case assembly to the transmission case assembly and secure with six bolts and four nuts When installing be careful not to damage the converter case bushing Rubber s al and oil seal Tightening torque 24 6 2 2ft Ib 33 x 3N m 3 4 0 3kg m Page 73 of 90 Installing the Control Valve Oil Pan D CH S TR 59 Accumulator piston 3 4 A 2 Install and route the transmission harness Be careful not to qu pu Accumulator piston 1 2 damage the harness 1 Install four accumulators Be careful not to confuse the springs and installation positions 3 Install the control valve assembly a Set the select lever in range 2 b Install the control valve by engaging the manual valve and manual lever then tighten the 18 bolts Tightening torque 5 8 0 7 ft lb 8 1 N m 0 8 0 1 kg m b 1 Be careful not to pinch the harness roll the gasket b 2 Tighten the control valve mounting bolts evenly The oil strainer filter and pipe will not be in place at this point this is just the only illustration for all the bolts 18 Oil strainer 4 Install the oil strainer to the control valve
17. he case and tighten three bolts temporarily b Insert the range selector lever into the shaft and tighten T gt Range select lever the nut a ow I Tightening torque 28 9 2 2 ft lb OC eee E Page 76 of 90 With the selector lever set to N adjust the inhibitor switch so that the hole of range selector lever is aligned with the inhibitor switch hole d With hole aligned tighten three bolts to secure the inhibitor switch Tightening torque 2 5 0 4 ft lb 3 4 0 5 N m 0 35 0 05 kom STOPPER PIN 3 Clip the following cords and harness OM a Transmission harness b Inhibitor switch cord c Revolution sensor cord AWD only 4 Install the oil cooler outlet pipe Tightening torque 22 8 2 5 ft lb 30 9 3 4 N m 3 15 0 35 kg m 5 Install the oil cooler inlet pipe Be sure to use a new aluminum washer Tightening torque 18 1 1 4 ft lb 25 2 N m 2 5 0 2 kg m 6 Install the oil charge pipe Be careful not to damage the O ring Tightening torque 22 8 2 5 ft lb 30 9 3 4 N m 3 15 0 35 kg m 7 Adjustment of brake band After tightening the brake band adjusting screw to 6 5 ft Ib 9 N m 0 9 kg m torque back it off three full turns Then secure with a lock nut When tightening the lock nut be careful not to turn the adjusting screw Lock nut tightening torque 18 21 ft lb 25 28 N m 2 5 2 9 kg m 8 Install the pitching stopper Tightening torque 28 9 2 2 ft
18. n b The R seal ring has a large diameter while has small diameter 16 Install the rubber seal to the converter case Be careful not to lose the rubber seal Transmission Case DRIFT 1398487700 1 Press fit the roller bearing to the transmission case Roller bearing Page 67 of 90 2 Using a plastic hammer force fit the oil seal 3 Install the manual plate and shaft and secure with a spring pin a Be careful not to damage the oil seal lip b After installation make sure of smooth movement 4 Assemble the manual lever and parking rod to the inside shaft and secure with a nut Tightening torque 28 9 2 2 ft lb 39 3 N m 4 0 0 3 kg m 5 Install the detent manual spring Position the spring so that its center is aligned with the center of the manual plate Tightening torque 4 3 0 7 ft lb 6 1 N m 0 6 0 1 kom 6 Install the lathe cut seal ring and lip seal to the I D O D of the low amp reverse piston Then install the piston into the case with a press a Be careful not to tilt the piston when installing b Be careful not to damage the lip seal m INSTALLER 398497701 loner race 7 Install the one way clutch inner race parr a Using a press install the thrust needle bearing to the inner race Use the PULLEY ASSEMBLY 398527700 for removal b Install four seal rings Apply petroleum jelly to the groove of the inner race and to the seal ring af
19. nstall axle shaft onto transmission Reverse the three bolt trick or ball joint work done when removing transmission for the three bolt trick install the single inner bolt first and then the two outer bolts it is much easier this way Install new spring pin holding axle shaft to front differential drive shaft 3 Install performance rod Install selector cable bracket on body Install selector cable to selector lever assembly Install drive shaft in transmission Install bolts holding drive shaft center support bearing to body Install drive shaft to companion flange bolts of rear differential 4 Install front exhaust pipes and rear catalyst converter Install front exhaust cover Install engine undercover Lower vehicle 5 Install transmission and differential dipsticks Install bolts holding right upper side of transmission to engine 6 Remove engine support Rotate the torque converter to match torque converter to drive plate rotating engine as necessary Remember my caution about fully seating the torque converter in the case The torque converter must be able to freely spin using only finger pressure at the service hole If it does not then the torque converter was not fully seated Proceeding beyond this point WILL ruin the ATF oil pump and require dismantling and overhaul again Install torque converter to drive flex plate bolts Install starter Connect starter wiring Install torque converter service hole plug 7 Connect left and
20. r tightening stake the lock nut securely Tightening torque 72 3 3 6ft lb 98 5Nem 10 0 5kg m 4 Install the reduction drive gear assembly Insert the assembly fully into position until the bearing shoulder bottoms 5 Adjustment of extension end play a Measure the distance from the transmission case mating surface to the reduction drive gear end surface AWD model Measure the distance from the transmission case mating surface to the bearing end face b Measure the distance from the extension case mating surface to the rear drive shaft end face AWD model Measure the distance from the cover case mating surface to the bearing mounting surface Rear drive shaft e wo Wm e E aa Reduction drive gear Page 75 of 90 Calculation equation Unit mm T L 0 4 Q 0 05 to 0 25 T Thickness of thrust bearing AWD model Thickness of Al washer L Distance of rear drive shaft end face from extension case mating surface AWD model Depth of bearing mounting face from cover case mating surface Q Height of reduction drive gear end surface from transmission case mating surface AWD model Height of bearing end face from transmission case mating surface 0 4 Thickness of gasket 0 05 to 0 25 Standard value of end play 6 Installation of extension case AWD cover case FWD and transmission case AWD model a Attach the selected thrust needle bearing to the end surface of reduction drive gear
21. retainer by one tooth changes the backlash about 0 0020 in 0 05 mm h Temporarily tighten the LH side lock plate i Screw in the RH side retainer another 1 75 teeth Then tighten the lock plate temporarily j Turn the drive pinion several rotations and check to see if the backlash is within the standard value After confirming that the backlash is correct check the tooth contact Backlash 0 0051 0 0071 in 0 13 0 18 mm WRENCH 499787100 ve MAGNET BASE 498247001 DIAL GAUGE 4982471001 Page 65 of 90 Apply red lead evenly to the surfaces of three or four teeth of the crown gear Rotate the drive pinion in the forward and reverse directions several times Then remove the oil pump housing and check the tooth contact pattern If tooth contact is improper readjust the backlash or shim thickness Correct tooth contact Tooth contact pattern slightly shifted toward toe under no load rotation When loaded contact pattern moves toward heel Face contact Backlash is too large Flank contact Backlash is too small Toe contact Inside end contact Hee contact Outside end contact Contact pattern This may cause noise and chipping at tooth ends This may cause noise and stepped wear on surfaces Contact area is small This may cause chipping at toe ends Contact area is small This may cause chipping at heel ends Corrective action increase thickness of
22. right O2 sensors Connect transmission harness connectors Connect transmission ground terminal connector Connect vehicle speed sensor 8 Install torque strut bracket along with bracket on transmission case Connect transmission air vent hoses Install strut dog bone Install air intake boot and throttle body cover Connect negative battery terminal 9 Fill with ATF and differential fluid remembering how much ATF was used for the torque converter subtract that from the ten quarts total would suggest you leave the ATF about one quart low until you are able to start the unit and execute a few simple tests then check again Remember this checking is done on the cold side of the stick See the drain amp refill instructions for final fluid amounts TORQUE SPECIFICATIONS TABLE Application Ft Lbs N m Cross member Bolts 27 49 37 66 Engine Mount Bracket Bolts 27 49 37 66 Engine Mount to Body Bolts 27 49 37 66 Torque Converter to Drive Plate Bolts 17 20 23 27 Torque Strut Bolt 31 46 42 62 Transaxle to Engine Bolts 34 40 46 54 Transaxle Mount to Body Bolts 27 49 37 66 Transverse Link to Cross member 54 69 73 94 Page 78 of 90 Component Diagrams Transfer and Extension Tightening torque N m kg m ft lb T1 7 1 0 7 0 1 5 1 0 7 2 8 1 0 8 0 1 5 8 0 7 T3 25 1 2 5 0 1 18 1 0 7 T4 13 1 1 3 0 1 9 4 0 7 D KR Selective p
23. tening torque N m kg m ft lb T 25 28 2 5 2 9 18 21 Page 83 of 90 Control Valve amp Harness Oo A Oo P GM d Clip Transmission harness O ring Duty sol A Line pressure Sol Assy Upper valve body Ball Upper separator plate Lower separator plate Lower valve body Duty sol B Lock up Pipe Revolution sensor 2WD Tightening torque N m kg m ft Ib 1 7 1 0 7 0 1 5 1 0 7 2 8 1 0 8 0 1 5 8 0 7 Page 84 of 90 Transmission Case Cover and Control Device Selective parts Air breather hose Oi level gauge Oi charge pipe Inhibitor switch Range select lever Manual shaft Manual plate Manual lever Snap ring Plug O ring Oi seal Releaf valve Pipe Roller bearing Transmission cover 2WDI Parking support Parking rod Return spring Shaft Parking pawl Inlet pipe Outlet pipe Spring O ring Accumulator piston N D O ring O ring Accumulator piston 2 3 Spring O ring Accumulator piston 1 2 O ring Spring O ring Accumulator piston 3 4 O ring Spring Magnet Gasket Oil pan Shim Tightening torque N m kg m ft lb T1 3 4 0 5 0 35 0 05 2 5 0 4 T2 39 3 4 0 0 3 28 9 2 2 T3 30 9 3 4 3 15 0 35 22 8 2 5 T4 6 1 0 6 0 1 4 3 0 7 5 25 2 2 5 0 2 18 1 1 4 T6 3 9 0 5 0 4 0 05 2 9 0 4 7 13 1
24. ter installation so that the seal ring will not expand Page 68 of 90 Place the spring retainer CP on the inner race Install the spring to the recessed portion of the piston Then tighten eight socket head bolts from the rear side of the transmission case Be sure to tighten evenly Tightening torque 18 1 1 4 ft lb 25 2 N m 2 5 0 2 kg m 8 Install the band servo sub assembly 9 Press the O D servo retainer into position and secure with a snap ring Perform the following operations with the transmission case set vertically on wooden blocks Snap ring Retaining plate Transmission Lip seal 10 Installation of the low amp reverse brake Dish plate Piston Bolt a Install two dish plates driven plates drive plates anda retaining plate and secure with a snap ring Pay attention to the orientation of the dish plate Clutch spring retainer b Apply compressed air intermittently to check for operation Forward clutch i Drive Plate SM y Driven Plate f Le BN Ic Pd e Page 69 of 90 c Check the clearance Selection of retaining plate Standard value 0 043 0 067 in 1 1 1 7 mm Allowable limit 0 106 in 2 7 mm 11 Install the thrust needle bearing to the inner race Refer to Location and installing direction of thrust needle bearing and washer for the orientation of the bearing Carefully check the orientation of all
25. tial additive to the ATF has been found to be an effective cure Source Green1995SVX SVX forum Synthetic ATF Subaru does NOT recommend the use of synthetic fluids in the SVX The premise seems to be that synthetics have a greater tendency to leak In practice no one Know that used a synthetic fluid from new condition has experienced a problem However many people changing to a synthetic with significant mileage do experience a problem This is most likely caused by the superior cleaning ability inherent in the synthetic oils used as base stock A layer of crud builds up behind the old seal assisting the seal with performing its sealing function After the synthetic ATF cleans away the crud the seal begins to leak As there are internal seals in addition to external ones the result could be transmission damage A arm hint Removal of the three A arm attachment bolts vice ball joint separation was first suggested by Beav on the SVX forum Negates the need to perform a front end alignment post transmission removal amp reinstallation Hint also works when it comes time to replace the axles because the CV joints failed 4 Subaru issued SVX transmission TSBs 16 63 99R AUG 00 4EAT Remanufactured Transaxle Available 16 63 99 APR 99 A T 4EAT Remanufactured Transaxle Program 11 51 97 DEC 97 AWD amp Full Time AWD Diagnostic Testing Precautions 16 62 97 97 Transfer Clutch Binding And Or Bucking On Turns 16 61 94 JUN 94 4
26. ump housing mating surface to the top surface of the oil pump cover with needle bearing and to the thrust surface of the reverse clutch Page 72 of 90 Equation for calculation Unit mm T L 0 4 Q 0 25 to 0 55 T Thickness of bearing race L Depth of the recess of high clutch drum from case mating surface Q Height of top surface of the oil pump cover with needle bearing from the mating surface of the housing 0 4 Thickness of gasket 0 25 to 0 55 Total end play standard value t M 0 4 m 0 55 to 0 9 t Thickness of thrust washer M Depth of top surface of reverse clutch drum from case mating surface m Height of reverse clutch thrust surface from housing mating surface 0 4 Thickness of gasket 0 55 to 0 9 Total end play standard value 25 Install the oil pump housing assembly a After completing endplay adjustment insert the bearing in the recess of the high clutch Attach the thrust washer to the oil pump cover with petroleum jelly b After correctly installing the gasket to the case mating surface carefully install the oil pump housing assembly Be careful to avoid hitting the drive pinion against the inside of the case b 1 Be careful not to damage the seal ring b 2 Be sure to use a new gasket Install both parts with dowel pins aligned Make sure no clearance exists at the mating surface Any clearance suggests a damaged seal ring d Secure the housing with two nuts Tightenin
27. with petroleum jelly b Set the parking return spring c Remove the transfer clutch from the extension case Set the needle bearing on the reduction drive shaft and then install transfer clutch to the transfer clutch hub Be sure to engage the spline teeth correctly d With gasket inserted between them install the extension case to the transmission case Be sure to use a new gasket d 1 After inserting the extension case halfway connect the connector for duty sol C Be careful not to jam the cord in the case d 2 Be careful not to damage the rear drive shaft seal ring e Tighten bolts to secure the case Tightening torque 18 1 1 4 ft lb 25 2 N m 2 5 0 2 kg m FWD model a Attach the selected aluminum washer to the cover case with petroleum jelly b Set the parking return spring c With gasket inserted between them install the cover case to the transmission case c 1 Be sure to use a new gasket c 2 Install the case while ensuring proper alignment of the bearing parking shaft and reduction driven gear d Tighten bolts to secure the case Tightening torque 18 1 1 4 ft lb 25 2 N m 2 5 0 2 kg m Installation of Exterior Parts 1 Install the revolution sensor AWD only Tightening torque 5 1 0 7 ft lb 7 1 N m 0 7 0 1 kom 2 Installation and adjustment of inhibitor switch uu a Install the inhibitor switch to the transmission case Fit the projecting portion of the switch in the recessed portion of t
28. ystem employed on the SVX could when at the limits of allowable specification 9 ohm resistor 1 5 ohm solenoid produce a current flow of over 1 0 amps Using the data found in the article and for those desiring an increased sporty feel to the shifts the dropping resistor may be changed to a value of approximately 60 ohm If you want to check the numbers yourself the dropping resistor sees alternator charging voltage while running 14 2v and the solenoid may have a resistance as low as 1 5 ohm Using V IR 14 2 0 2 X 1 5 so X269 5 ohm At the other end the solenoid may have a resistance of 4 5 ohm Using the same formula implies X266 5 ohm Therefore a value of 60 ohm should produce a safe margin in preserving adequate current flow while facilitating the crisp shifts desired This resistor should be specified with a minimum 5 watt rating 10 watts being the preferred value Finally the writer for ATRA claimed too little current through the solenoid would not exercise it enough potentially resulting in a seized solenoid Therefore a value much higher than 60 ohms should be avoided 3 Noises in the Night amp Other Scary Things Clunk in reverse A clunk or thud that is heard normally while in reverse and giving the car a bit of gas may mean its time for a new rear transmission mount Source aredubjay SVX forum Grinding from rear of transmission Failure of the AWD system should reveal a code in the TCU If it does not and you are
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