Primary Pulley and Secondary Pulley: Removal

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

1. Remove the transmission assembly from the vehicle. Ref. to CONTINUOUSLY VARIABLE TRANSMISSION (TR690)>Automatic Transmission Assembly>REMOVAL .
2. Remove the air breather hose. Ref. to CONTINUOUSLY VARIABLE TRANSMISSION (TR690)>Air Breather Hose>REMOVAL .
3. Remove the oil pan and control valve body. Ref. to CONTINUOUSLY VARIABLE TRANSMISSION (TR690)>Control Valve Body>REMOVAL .
4. Remove the transmission harness. Ref. to CONTINUOUSLY VARIABLE TRANSMISSION (TR690)>Transmission Harness>REMOVAL .
5. Remove the extension case. Ref. to CONTINUOUSLY VARIABLE TRANSMISSION (TR690)>Extension Case>REMOVAL .
6. Remove the rear drive shaft. Ref. to CONTINUOUSLY VARIABLE TRANSMISSION (TR690)>Rear Drive Shaft>REMOVAL .
7. Remove the transfer clutch assembly. Ref. to CONTINUOUSLY VARIABLE TRANSMISSION (TR690)>Transfer Clutch>REMOVAL .
8. Remove the transfer reduction driven gear assembly. Ref. to CONTINUOUSLY VARIABLE TRANSMISSION (TR690)>Transfer Reduction Driven Gear>REMOVAL .
9. Remove the intermediate case. Ref. to CONTINUOUSLY VARIABLE TRANSMISSION (TR690)>Intermediate Case>REMOVAL .
10. Remove the forward clutch assembly. Ref. to CONTINUOUSLY VARIABLE TRANSMISSION (TR690)>Forward Clutch Assembly>REMOVAL .
11. Remove the transmission case. Ref. to CONTINUOUSLY VARIABLE TRANSMISSION (TR690)>Transmission Case>REMOVAL .
12. Set the ST to the secondary pulley, and expand the V groove of pulley until the variator chain gets completely loose.

    ST 18769AA000 EXPANDER PULLEY 

    Fig 1: Setting Special Tool Onto Secondary Pulley

    Courtesy of SUBARU OF AMERICA, INC.
13. Remove the chain guide from lubrication pipe and support rod.
14. Remove the lubrication pipe and support rod.
    Fig 2: Identifying Primary And Secondary Pulley Lubrication Pipes And Support Rods

    Courtesy of SUBARU OF AMERICA, INC.
15. Detach the four claws to remove the two chain guides.
    Fig 3: Locating Primary And Secondary Pulley Chain Guide Claws

    Courtesy of SUBARU OF AMERICA, INC.
16. Remove the secondary pulley mounting bolt.
    Fig 4: Locating Secondary Pulley Mounting Bolts

    Courtesy of SUBARU OF AMERICA, INC.
17. Remove the secondary pulley from drive pinion retainer and intersect the V groove of secondary pulley and V groove of primary pulley. Remove the variator chain from secondary pulley and remove the secondary 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 5: Covering Primary And Secondary Pulley V Grooves Using Cloth

    Courtesy of SUBARU OF AMERICA, INC.
18. Remove the variator chain from primary pulley.
19. Remove the primary pulley mounting bolt.
    Fig 6: Locating Primary Pulley Mounting Bolts

    Courtesy of SUBARU OF AMERICA, INC.
20. Remove the primary pulley.
21. Remove the two seal rings from drive pinion retainer.
    Fig 7: Locating Drive Pinion Retainer Seal Ring

    Courtesy of SUBARU OF AMERICA, INC.
22. Remove the two seal rings from primary pulley.

Fig 8: Locating Primary Pulley Seal Rings

Courtesy of SUBARU OF AMERICA, INC.