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Primary Pulley and Secondary Pulley: Installation

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

Always replace the primary pulley, secondary pulley and variator chain as a set. 

  1. Install a new seal ring.
    NOTE:
    • Apply CVTF to the seal rings. 
    • Do not stretch the seal ring more than necessary. 
    G13936207Courtesy of SUBARU OF AMERICA, INC.
  2. When replacing the primary pulley and secondary pulley, select the primary pulley shim.
    1. Using the ST, measure the height "H1" from the ST end face to the primary pulley bearing catch surface.
      NOTE:

      Measure at four points and calculate the average. 

      Preparation tool: 

      ST: GAUGE (499575400)

      G13936209Courtesy of SUBARU OF AMERICA, INC.
    2. Measure the height "H2" from the ST end face to the secondary pulley bearing catch surface.
      NOTE:

      Measure at four points and calculate the average. 

      G13936210Courtesy of SUBARU OF AMERICA, INC.
    3. Using the following calculation and selection criteria table, select an appropriate thickness of the primary pulley shim.
    NOTE:

    Adjust using 1 - 2 pieces. 

    C = B - A + H1 - H2 - 31.137 mm (1.2259 in)

    C Pulley alignment mm (in)
    H1 Measured value (mm (in)) of step (1)
    H2 Measured value (mm (in)) of step (2)
    A Specified primary pulley dimension*
    B Specified secondary pulley dimension*
    31.137 mm (1.2259 in) Constant

    *: The specified dimensions of the primary pulley and secondary pulley are stamped only on repair parts.

    Primary pulley shim selection criteria table for calculated values 

    Pulley alignment mm (in) Thickness of primary pulley shim mm (in)
    -0.007 - 0.049 (-0.0003 - 0.002) No shims
    0.050 - 0.149 (0.002 - 0.006) 0.1 (0.004)
    0.150 - 0.249 (0.006 - 0.010) 0.2 (0.008)
    0.250 - 0.349 (0.010 - 0.014) 0.3 (0.012)
    0.350 - 0.449 (0.014 - 0.018) 0.4 (0.016)
    0.450 - 0.549 (0.018 - 0.022) 0.5 (0.020)
    0.550 - 0.649 (0.022 - 0.026) 0.6 (0.024)
    0.650 - 0.749 (0.026 - 0.029) 0.7 (0.028)
    0.750 - 0.849 (0.029 - 0.033) 0.8 (0.031)
    0.850 - 0.949 (0.033 - 0.037) 0.9 (0.035)
    0.950 - 1.049 (0.037 - 0.041) 1.0 (0.039)
    1.050 - 1.149 (0.041 - 0.045) 1.1 (0.043)
    1.150 - 1.163 (0.045 - 0.046) 1.2 (0.047)
  3. Install the secondary pulley.
    1. Temporarily install the secondary pulley.
      NOTE:
      • Apply CVTF to the threaded portion of the bolts and seat surface. 
      • Be careful not to tilt the bearing retainer. 
      • Tighten the bolt (a) to the position where any part of the seat surface contacts. 
      G13936211Courtesy of SUBARU OF AMERICA, INC.
    2. Tighten the bolts in the numerical order as shown in the figure.

    Tightening torque: 

    67.5 N.m (6.9 kgf-m, 49.8 ft-lb)

    Fig 1: Secondary Pulley Bolts Tightening Sequence
    G13936212Courtesy of SUBARU OF AMERICA, INC.
  4. Set the variator chain to the secondary pulley.
  5. Using the ST, expand the chain groove of the secondary pulley.
    • When using EXPANDER PULLEY (18769AA030)

      Preparation tool: 

      ST: EXPANDER PULLEY (18769AA030)

      G13936213Courtesy of SUBARU OF AMERICA, INC.
    • When replacing EXPANDER PULLEY (18769AA010) and LOCK PLATE (16047AA000)

    Preparation tool: 

    ST1: EXPANDER PULLEY (18769AA010)

    ST2: LOCK PLATE (16047AA000)

    G13936214Courtesy of SUBARU OF AMERICA, INC.
  6. Install the primary pulley.
    1. Set the primary pulley shim.
      G13936205Courtesy of SUBARU OF AMERICA, INC.
    2. Intersect the chain groove of primary pulley and the chain groove of secondary pulley, and set the primary pulley while placing the variator chain on the primary pulley.
      G13936204Courtesy of SUBARU OF AMERICA, INC.
    3. Align the bolt hole of primary bearing retainer and the bolt hole of reverse brake housing, and install the bolt to secure the primary pulley.
    NOTE:

    Apply CVTF to the threaded portion of the bolts and seat surface. 

    Tightening torque: 

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

    G13936203Courtesy of SUBARU OF AMERICA, INC.
  7. Install the chain guide.
    1. Install the chain guide (B) to the variator chain (A).
    2. Place the support rod (C) on the variator chain inside and install the chain guide (B).
      G13936218Courtesy of SUBARU OF AMERICA, INC.
    3. Install the bolt securing the support rod.
      NOTE:

      Apply CVTF to the threaded portion of the bolts and seat surface. 

      Tightening torque: 

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

      G13936219Courtesy of SUBARU OF AMERICA, INC.
    4. Install the chain guide (B) to the variator chain (A).
    5. Place the lubrication pipe (C) on the variator chain inside and install the chain guide (B).
      G13936220Courtesy of SUBARU OF AMERICA, INC.
    6. Install the bolt to secure the lubrication pipe.
      NOTE:

      Apply CVTF to the threaded portion of the bolts and seat surface. 

      Tightening torque: 

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

      G13936221Courtesy of SUBARU OF AMERICA, INC.
    7. Remove the ST (EXPANDER PULLEY).
    NOTE:

    When LOCK PLATE (16047AA000) was used, restore EXPANDER PULLEY (18769AA010) to its original state. 

  8. Install the reduction drive gear. Ref. to CONTINUOUSLY VARIABLE TRANSMISSION (TR580 CROSSTREK)>REDUCTION DRIVE GEAR>INSTALLATION .
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