Service Manuals, User Guides, Schematic Diagrams or docs for : . Car Manuals Subaru Forester 1999-2004 Approved Subaru Forester 1999-2000 AUTOMATIC TRANSMISSION MSA5T0128A34686

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MSA5T0128A34686


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                                TORQUE CONVERTER CLUTCH CASE
                                                                                     Automatic Transmission

18. Torque Converter Clutch                               4) Disconnect transmission harness connector
                                                          from stay.
Case
                                                          NOTE :
A : REMOVAL S5,o2o6A,e                                    Lift-up lever behind the connector and disconnect
1) Extract the torque converter clutch assembly .         it from stay.
                                      6) Disconnect the air breather hose . 
                                                       7) Remove the oil charger pipe . 
                                                       8) Remove the oil cooler inlet and outlet pipes.
pump shaft.
                                                       
  Note that oil pump shaft also comes out.
                                                       9) Separation of torque converter clutch case and
                                                       transmission case sections
                                                       CAUTION :
                                                       * Be careful not to damage the oil seal and
                                                       bushing inside the torque converter clutch
                                                       case by the oil pump cover.
                                                       9 Be careful not to lose the rubber seal.
                                                       NOTE :
                                                       Separate these cases while tapping lightly on the
                                                       housing.
                                         B3M2020

2) Remove the input shaft.




                                                       10) Wrap the axle shaft serration with vinyl tape.

3) Remove pitching stopper bracket.




                                                            (A)   Vinyl tape


   (A)   Pitching stopper bracket




                                                   AT59
                                        TORQUE CONVERTER CLUTCH CASE
Automatic Transmission

11) Remove the differential side retainer with ST.                            B : INSTALLATION SS,oz~
CAUTION:                                                                  1) Check the appearance of each component and
Hold the differential case assembly by hand to                            clean.
avoid damaging retainer mounting hole of the
torque converter clutch case and speedometer                              CAUTION :
gears.                                                                    Make sure each part is free of harmful cuts,
                                                                          damage and other faults .
ST 499787000 WRENCH ASSY
12) Extract the axle shaft with ST1 and ST2.                              2) Force-fit the oil seal to the torque converter
CAUTION:                                                                  clutch case with ST.
                                                                          ST 398437700 DRIFT
Do not reuse the circlip .
ST1 499095500 REMOVER
ST2 499247300 INSTALLER

             :qvv

                     Y--~~                    `~~~~~\




                                                        \
                         \,l\~/I\   ~   ST1

                                                            ~--'i-
                     i
                          ;~    ST2                                       3) Install the differential assembly to the case,
                                                             G3M0956      paying special attention not to damage the inside
                                                                          of the case (particularly, the differential side
13) Remove the differential assembly .
                                                                          retainer contact surface) .
CAUTION :
* Remove the seal pipe if it is attached. (Reus-
ing is not allowed.)
* Be careful not to damage the retainer mount-
ing hole of the torque converter clutch case.




                                                                                (A)   Differential assembly

                                                                          4) Install the circlip to the axle shaft, insert the
                                                                          shaft into the differential assembly, and tap it into
                                                                          position with a plastic hammer.
   (A)   Seal pipe
                                                                          CAUTION:
14) Remove the oil seal from torque converter                             e If no play is felt, check whether the shaft is
clutch case .                                                             fully inserted. If shaft insertion is correct,
                                                                          replace the axle shaft.
                                                                          e Be sure to use a new circlip.
                                                                          Thrust play:
                                                                              0.3-0.5mm (0.012-0.020 in)




                                                                       AT60
                             TORQUE CONVERTER CLUTCH CASE
                                                                                           Automatic Transmission

5) Wrap vinyl tape around the splined portion of            9) Install the rubber seal to the torque converter
the axle shaft.                                             clutch case .
                                                            CAUTION :
                                                            Be careful not to lose the rubber seal.




    (A)   Vinyl tape

6) Install the oil seal and outer race (taper roller
bearing) to the differential side retainer. Then               (A)   Rubber seal
screw in the retainer and the O-ring after coating          10) Apply proper amount of liquid gasket to the
the threads with oil.                                       entire torque converter clutch case mating surface.
CAUTION:                                                    Liquid gasket:
" Pay attention not to damage the oil seal lips .                THREE BOND 1215
" Do not confuse the RH and LH oil seals.
" Keep the O-ring removed from the retainer.              NOTE :
                                                          Make sure that the rubber seal and seal pipe are
7) Using ST, install the left and right side retainers.   fitted in position.

ST 499787000 WRENCH ASSY
8) Install the seal pipe to the torque converter
clutch case.
CAUTION :
Be sure to use a new seal pipe.




                                                               (A)   THREE BOND (Part No . 1215)
                                                               (B)   Rubber seal




   (A)    Seal pipe




                                                     AT61
                              TORQUE CONVERTER CLUTCH CASE
Automatic Transmission

11) Install the torque converter clutch case assem-        16) Install the pitching stopper bracket.
bly to the transmission case assembly, and secure          Tightening torque:
with six bolts and four nuts .                                 41 N~m (4.2 kgf-m, 30.4 ft-Ib)
CAUTION:
When installing, be careful not to damage the
torque converter clutch case bushing and oil
seal.
Tightening torque:
    41 N-m (4.2 kgf-m, 30.4 ft-Ib)




                                                              (A)   Pitching stopper

                                                           17) Insert the input shaft while turning lightly by
                                                           hand .
                                                           CAUTION:
                                                           Be careful not to damage the bushing .
12) Install air breather hose .                               50-55 mm (1.97-2.17 in)
13) Insert inhibitor switch and transmission con-
nector into stay.
14) Install the oil cooler pipes. 
15) Install the oil charger pipe with O-ring . 




                                                           18) Install the torque converter clutch assembly.
                                                           

                                                           C : INSPECTION s5.o
                                                           Measure the backlash and adjust to within specifi-
                                                           cations. 




                                                      AT62



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