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Primary Pulley and Secondary Pulley: Installation

  1. Select shims for pulley alignment. Ref. to CONTINUOUSLY VARIABLE TRANSMISSION (TR690)>Primary Pulley and Secondary Pulley>ADJUSTMENT .
  2. Install the two seal rings to drive pinion retainer.
    NOTE:
    • Use a new seal ring.
    • Apply CVTF to the seal rings.
    • When installing the seal ring, do not expand the seal ring too much.
    Fig 1: Locating Drive Pinion Retainer Seal Ring
    G06654652Courtesy of SUBARU OF AMERICA, INC.
  3. Install the selected shims to the primary pulley bearing catch surface.
  4. Install the two seal rings to primary pulley.
    NOTE:
    • Use a new seal ring.
    • Apply CVTF to the seal rings.
    Fig 2: Locating Primary Pulley Seal Rings
    G06654653Courtesy of SUBARU OF AMERICA, INC.
  5. Install the primary pulley and adjust the position of bolt holes of primary bearing retainer and converter case to tighten the primary pulley bolt.
    NOTE: Use a new seal washer.

    Tightening torque: 

    21 N.m (2.1 kgf-m, 15.5 ft-lb)

    Fig 3: Locating Primary Pulley Bolts
    G06654651Courtesy of SUBARU OF AMERICA, INC.
  6. Set the ST to secondary pulley and expand the V groove of pulley.

    ST 18769AA000 EXPANDER PULLEY 

    Fig 4: Setting Special Tool Onto Secondary Pulley
    G06654657Courtesy of SUBARU OF AMERICA, INC.
  7. Place the variator chain on the primary pulley groove and attach the secondary pulley and variator chain together to the drive pinion retainer.
    CAUTION: Cover the V grooves of primary pulley and secondary pulley with cloth to protect the both pulleys and variator chain from scratching.
    1. Place the variator chain on primary pulley.
    2. 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.
      Fig 5: Covering Primary And Secondary Pulley V Grooves Using Cloth
      G06654650Courtesy of SUBARU OF AMERICA, INC.
    3. While aligning the bolt hole of secondary bearing retainer and the bolt hole of driving pinion retainer, install the secondary pulley to drive pinion retainer.
  8. Install the secondary pulley bolt.
    NOTE: Apply CVTF to the bolt.

    Tightening torque: 

    33 N.m (3.4 kgf-m, 24.3 ft-lb)

    Fig 6: Locating Secondary Pulley Bolts
    G09482219Courtesy of SUBARU OF AMERICA, INC.
  9. Install the chain guide.
    NOTE: Install it with two claws facing outward and with two claws facing inward.
    Fig 7: Locating Chain Guide Claws
    G09482218Courtesy of SUBARU OF AMERICA, INC.
  10. Engage the cutout portions of support rod and drive pinion retainer and install the support rod.
    Fig 8: Locating Support Rod Cutout Portion
    G09482231Courtesy of SUBARU OF AMERICA, INC.
  11. Engage the cutout portions of lubrication pipe and drive pinion retainer and install the lubrication pipe.
    Fig 9: Locating Primary And Secondary Pulley Lubrication Pipe Cutout Portion
    G09482232Courtesy of SUBARU OF AMERICA, INC.
  12. Install the chain guide so that the lubrication pipe and support rod run through between the protrusions of each chain guide. Then remove the ST (EXPANDER PULLEY).
    Fig 10: Locating Chain Guide Protrusion
    G09482233Courtesy of SUBARU OF AMERICA, INC.
  13. Install the O-ring to the lubrication pipe.
    NOTE: Use new O-rings.
  14. Install the lubrication pipe.
    Fig 11: Identifying Primary And Secondary Pulley Lubrication Pipe
    G09482234Courtesy of SUBARU OF AMERICA, INC.
  15. Install the transmission case. Ref. to CONTINUOUSLY VARIABLE TRANSMISSION (TR690)>Transmission Case>INSTALLATION .
  16. Install the forward clutch assembly. Ref. to CONTINUOUSLY VARIABLE TRANSMISSION (TR690)>Forward Clutch Assembly>INSTALLATION .
  17. Install the intermediate case. Ref. to CONTINUOUSLY VARIABLE TRANSMISSION (TR690)>Intermediate Case>INSTALLATION .
  18. Install the transfer reduction driven gear assembly. Ref. to CONTINUOUSLY VARIABLE TRANSMISSION (TR690)>Transfer Reduction Driven Gear>INSTALLATION .
  19. Install the transfer clutch assembly. Ref. to CONTINUOUSLY VARIABLE TRANSMISSION (TR690)>Transfer Clutch>INSTALLATION .
  20. Install the rear drive shaft. Ref. to CONTINUOUSLY VARIABLE TRANSMISSION (TR690)>Rear Drive Shaft>INSTALLATION .
  21. Install the extension case. Ref. to CONTINUOUSLY VARIABLE TRANSMISSION (TR690)>Extension Case>INSTALLATION .
  22. Install the transmission harness. Ref. to CONTINUOUSLY VARIABLE TRANSMISSION (TR690)>Transmission Harness>INSTALLATION .
  23. Install the control valve body and oil pan. Ref. to CONTINUOUSLY VARIABLE TRANSMISSION (TR690)>Control Valve Body>INSTALLATION .
  24. Install the air breather hose. Ref. to CONTINUOUSLY VARIABLE TRANSMISSION (TR690)>Air Breather Hose>INSTALLATION .
  25. Install the transmission assembly to the vehicle. Ref. to CONTINUOUSLY VARIABLE TRANSMISSION (TR690)>Automatic Transmission Assembly>INSTALLATION .
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