Primary Pulley and Secondary Pulley: Removal

WARNING: This page is about a different variant/trim than selected.

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

Remove the transmission assembly. <Ref. to REMOVAL , Automatic Transmission Assembly.>
Remove the air breather hose. <Ref. to REMOVAL , Air Breather Hose.>
Remove the control valve body. <Ref. to REMOVAL , Control Valve Body.>
Remove the transmission harness. <Ref. to REMOVAL , Transmission Harness.>
Remove the turbine speed sensor. <Ref. to REMOVAL , Turbine Speed Sensor.>
Remove the secondary speed sensor. <Ref. to REMOVAL , Secondary Speed Sensor.>
Remove the primary speed sensor. <Ref. to REMOVAL , Primary Speed Sensor.>
Remove the inhibitor switch. <Ref. to REMOVAL , Inhibitor Switch.>
Remove the extension case. <Ref. to REMOVAL , Extension Case.>
Remove the transfer clutch assembly. <Ref. to REMOVAL , Transfer Clutch.>
Remove the transfer driven gear assembly. <Ref. to REMOVAL , Transfer Driven Gear.>
Remove the parking pawl. <Ref. to REMOVAL , Parking Pawl.>
Remove the reduction driven gear assembly. <Ref. to REMOVAL , Reduction Driven Gear.>
Remove the oil pan and oil strainer. <Ref. to REMOVAL , Oil Pan and Strainer.>
Remove the transmission control device. <Ref. to REMOVAL , Transmission Control Device.>
Remove the transmission case. <Ref. to REMOVAL , Transmission Case.>
Remove the reduction drive gear. <Ref. to REMOVAL , Reduction Drive Gear.>
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: Setting Expander Pulley To Secondary Pulley (18769AA010)
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 Claws
  Courtesy of SUBARU OF AMERICA, INC.
3. Remove the lubrication pipe.
  
  Fig 3: Locating Lubrication Pipe 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: Supporting Rod To Remove Chain Guide
  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 Claws
  Courtesy of SUBARU OF AMERICA, INC.
8. Remove the support rod.
CAUTION: Protect the both pulleys and variator chain from scratching.

Fig 8: 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: Primary And Secondary Pulley
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 Seal Ring Of Drive Pinion Retainer
Courtesy of SUBARU OF AMERICA, INC.
Remove the seal ring from the input shaft.

Fig 13: Locating Seal Ring Of Input Shaft

Courtesy of SUBARU OF AMERICA, INC.