Primary Pulley and Secondary Pulley: Removal

NOTE: Always replace primary pulley and secondary pulley as an assembly because they are non-disassembled parts.

Remove the transmission assembly from the vehicle. Refer to REMOVAL .
Remove the air breather hose. Refer to REMOVAL .
Remove the control valve body. Refer to REMOVAL .
Remove the transmission harness. Refer to REMOVAL .
Remove the turbine speed sensor. Refer to REMOVAL .
Remove the secondary speed sensor. Refer to REMOVAL .
Remove the primary speed sensor. Refer to REMOVAL .
Remove the inhibitor switch. Refer to REMOVAL .
Remove the extension case. Refer to REMOVAL .
Remove the transfer clutch assembly. Refer to REMOVAL .
Remove the transfer driven gear assembly. Refer to REMOVAL .
Remove the parking pawl. Refer to REMOVAL .
Remove the reduction driven gear assembly. Refer to REMOVAL .
Remove the oil pan and oil strainer. Refer to REMOVAL .
Remove the transmission control device. Refer to REMOVAL .
Remove the transmission case. Refer to REMOVAL .
Remove the reduction drive gear. Refer to REMOVAL .
Set the ST to secondary pulley, expand the V groove of pulley, and then completely loosen the variator chain.
ST 18769AA010 EXPANDER PULLEY

Fig 1: Expanding V Groove Of Pulley Using Special Tool
Courtesy of SUBARU OF AMERICA, INC.
Remove the chain guide.
1. Remove the chain guide from lubrication pipe.
2. Detach the four claws to remove the chain guide.
  
  Fig 2: Locating Chain Guide Claws
  Courtesy of SUBARU OF AMERICA, INC.
3. Remove the lubrication pipe.
  
  Fig 3: Locating Lubrication Pipe Mounting Bolt
  Courtesy of SUBARU OF AMERICA, INC.
4. Remove the support rod mounting bolts.
  
  Fig 4: Locating Support Rod Mounting Bolt
  Courtesy of SUBARU OF AMERICA, INC.
5. Raise the support rod to remove the chain guide.
  
  Fig 5: Identifying Support Rod
  Courtesy of SUBARU OF AMERICA, INC.
6. Move the chain guide to the secondary pulley side.
  
  Fig 6: Moving Chain Guide To Secondary Pulley Side
  Courtesy of SUBARU OF AMERICA, INC.
7. Detach the four claws to remove the chain guide.
  
  Fig 7: Locating Chain Guide Claws
  Courtesy of SUBARU OF AMERICA, INC.
8. Remove the support rod.
  CAUTION: Protect the both pulleys and variator chain from scratching.
  
  Fig 8: Identifying Support Rod
  Courtesy of SUBARU OF AMERICA, INC.
Remove the primary pulley mounting bolt.

Fig 9: Locating Primary Pulley Mounting Bolts
Courtesy of SUBARU OF AMERICA, INC.
Remove the primary pulley from the reverse brake housing and intersect the V groove of secondary pulley and the V groove of primary pulley. Remove the variator chain from primary pulley, and remove the primary pulley.
CAUTION: Cover the V grooves of secondary pulley and primary pulley with cloth to protect the both pulleys and variator chain from scratching.

Fig 10: Removing/Installing Primary Pulley From Reverse Brake Housing Using Tool
Courtesy of SUBARU OF AMERICA, INC.
Remove the ST (EXPANDER PULLEY) from the secondary pulley.
Remove the variator chain from secondary pulley.
Remove the secondary pulley mounting bolts, and remove the secondary pulley.

Fig 11: Locating Secondary Pulley Mounting Bolts
Courtesy of SUBARU OF AMERICA, INC.
Remove the seal ring from drive pinion retainer.

Fig 12: Locating Drive Pinion Retainer Seal Ring
Courtesy of SUBARU OF AMERICA, INC.
Remove the seal ring from the input shaft.

Fig 13: Locating Input Shaft Seal Ring
Courtesy of SUBARU OF AMERICA, INC.