Subaru BRZ 2013 · Service Manual Drive train

Automatic transmission unit

Components Inspection Removal / installation

AUTOMATIC TRANSMISSION / TRANSAXLE
AUTOMATIC TRANSMISSION UNIT
EXPLODED VIEW
DISASSEMBLY
1. Removal of refill plug
(1) Remove the refill plug.
(2) Remove the O-ring from the refill plug.
2. Removal of transmission control shaft lever RH
(1) Remove the nut, spring washer, and transmission control shaft lever RH from the neutral start switch ASSY.
3. Removal of neutral start switch ASSY
(1) Use a flat tip screwdriver to bend the tab of the lock washer.
(2) Remove the nut and lock washer.
(3) Remove the bolt and neutral start switch ASSY from the automatic transmission case SUB-ASSY.
NOTE:
Be sure to keep the manual valve lever shaft from rotating before installation of the neutral start switch ASSY so as to prevent the detent spring from being detached from the manual valve lever shaft.
4. Removal of oil cooler tube union
(1) Remove 2 oil cooler tube unions from the automatic transmission case SUB-ASSY.
5. Removal of transmission revolution sensor
(1) Remove 2 bolts and 2 transmission revolution sensors from the automatic transmission case SUB-ASSY.
(2) Remove 2 O-rings from the 2 transmission revolution sensors.
6. Removal of automatic transmission breather tube
(1) Remove 2 bolts to remove the automatic transmission breather tube from the automatic transmission case SUB-ASSY.
7. Removal of automatic transmission case plug
(1) Remove 5 automatic transmission case plugs from the automatic transmission case SUB-ASSY.
(2) Remove 5 O-rings from the 5 automatic transmission case plugs.
(3) Remove the automatic transmission case plug from the automatic transmission case SUB-ASSY using a TORX socket wrench T55.
(4) Remove the O-ring from the automatic transmission case plug.
8. Removal of automatic transmission housing
(1) Remove 10 bolts to remove the automatic transmission housing from the automatic transmission case SUB-ASSY.
9. Removal of extension housing dust deflector
(1) Use a brass bar and a hammer to lightly tap the extension housing dust deflector and remove it from the extension housing SUB-ASSY.
CAUTION:
Be careful not to damage the extension housing SUB-ASSY.
10. Removal of extension housing SUB-ASSY
(1) Remove the 6 bolts.
(2) Use a flat tip screwdriver to remove the extension housing SUB-ASSY from the automatic transmission case SUB-ASSY.
Captions in illustration
*1
 Protective tape
CAUTION:
Be careful not to scratch the mating surface of the extension housing SUB-ASSY and the automatic transmission case SUB-ASSY.
NOTE:
Wrap the tip of a flat tip screwdriver with tape before using it.
11. Removal of transmission case adapter radial ball bearing
(1) Remove the snap ring from the extension housing SUB-ASSY.
(2) Remove the transmission case adapter radial ball bearing from the extension housing SUB-ASSY.
13. Removal of output shaft thrust bearing
(1) Remove the snap ring from the output shaft of the rear planetary gear ASSY.
(2) Remove the rear output shaft thrust bearing race, output shaft thrust bearing, and output shaft thrust bearing race.
18. Removal of transmission case gasket
(1) Remove 3 transmission case gaskets from the automatic transmission case SUB-ASSY.
19. Removal of brake drum gasket
(1) Remove 3 brake drum gaskets from the automatic transmission case SUB-ASSY.
21. Removal of C-2 accumulator piston
(1) Blow compressed air into the oil hole to remove the C-2 accumulator piston and spring from the automatic transmission case SUB-ASSY.
CAUTION:
Be careful as the C-3 and B-3 accumulator pistons may jump out.
(2) Remove 2 O-rings from the C-2 accumulator piston.
(3) Use a flat tip screwdriver to remove the snap ring and spring SUB-ASSY from the C-2 accumulator piston.
CAUTION:
Be careful not to damage the C-2 accumulator piston.
NOTE:
Wrap the tip of a flat tip screwdriver with tape before using it.
22. Removal of B-3 accumulator piston
(1) Blow compressed air into the oil hole to remove the B-3 accumulator piston and spring from the automatic transmission case SUB-ASSY.
CAUTION:
Be careful as the C-3 accumulator piston may jump out.
(2) Remove 2 O-rings from the B-3 accumulator piston.
(3) Use a flat tip screwdriver to remove the snap ring and spring SUB-ASSY from the B-3 accumulator piston.
CAUTION:
Be careful not to damage the B-3 accumulator piston.
NOTE:
Wrap the tip of a flat tip screwdriver with tape before using it.
23. Removal of C-3 accumulator piston
(1) Blow compressed air into the oil hole to remove the C-3 accumulator piston and 2 springs from the automatic transmission case SUB-ASSY.
(2) Remove 2 O-rings from the C-3 accumulator piston.
24. Removal of B-1 accumulator valve
(1) Remove the B-1 accumulator valve and spring from the automatic transmission case SUB-ASSY.
25. Removal of parking lock pole bracket
(1) Remove 3 bolts to remove the parking lock pole bracket from the automatic transmission case SUB-ASSY.
26. Removal of parking lock rod SUB-ASSY
(1) Remove the parking lock rod SUB-ASSY from the manual valve lever SUB-ASSY.
30. Setting of automatic transmission case SUB-ASSY
(1) Place the automatic transmission case SUB-ASSY on a pipe or tube approx. 125 mm {4.92 in} in inner diameter.
CAUTION:
Place it on a level surface.
36. Removal of reverse clutch reaction sleeve
(1) Remove the reverse clutch reaction sleeve from the reverse clutch hub SUB-ASSY.
39. Removal of coast clutch hub SUB-ASSY
(1) Remove the coast clutch hub SUB-ASSY from the reverse clutch drum SUB-ASSY.
43. Removal of input shaft
(1) Remove the thrust needle roller bearing and input shaft rear thrust bearing race from the input shaft.
Captions in illustration
*1
 Thrust needle roller bearing
*2
 Input shaft rear thrust bearing race
(2) Remove the input shaft from the reverse clutch drum SUB-ASSY.
44. Removal of clutch drum oil seal ring
(1) Remove the 4 clutch drum oil seal rings from the input shaft.
47. Removal of reverse clutch flange
(1) Remove the reverse clutch flange from the reverse clutch drum SUB-ASSY.
49. Removal of No.3 clutch balancer
(1) Place the SST on the No.3 clutch balancer and press the reverse clutch return spring SUB-ASSY using a press.
SST     09387-00070
(2) Remove the snap ring.
(3) Remove the No.3 clutch balancer.
54. Removal of No.3 brake cylinder
(1) Remove the snap ring from the automatic transmission case SUB-ASSY.
(2) Remove the No.3 brake cylinder from the automatic transmission case SUB-ASSY.
58. Removal of front planetary ring gear
(1) Remove the front planetary ring gear from the automatic transmission case SUB-ASSY.
62. Removal of No.1 brake piston
(1) Hold the No.1 brake piston and blow compressed air (392 kPa {4.0 kgf/cm2, 57 psi}) to the No.1 brake cylinder, then remove the No.1 brake piston.
NOTE:
If the piston does not jump out by compressed air, use needle nose pliers to pick the piston up and take it out.
(2) Remove 2 O-rings from the No.1 brake piston.
64. Removal of No.2 brake piston
(1) Hold the No.2 brake piston and blow compressed air (392 kPa {4.0 kgf/cm2, 57 psi}) to the transmission case, then remove the No.2 brake piston and No.2 brake cylinder.
NOTE:
If the piston does not jump out by compressed air, use needle nose pliers to pick the piston up and take it out.
(2) Remove the No.2 brake piston from the No.2 brake cylinder.
(3) Remove 2 O-rings from the No.2 brake piston.
66. Removal of intermediate shaft
(1) Remove the snap ring from the automatic transmission case SUB-ASSY.
(2) Remove the intermediate shaft together with the No.3 one-way clutch ASSY from the automatic transmission case SUB-ASSY.
69. Removal of brake plate stopper spring
(1) Remove the brake plate stopper spring from the automatic transmission case SUB-ASSY.
73. Removal of brake apply tube
(1) Remove the brake apply tube from the automatic transmission case SUB-ASSY.
74. Removal of 1st & reverse brake piston
(1) Hold the 1st & reverse brake piston and blow compressed air (392 kPa {4.0 kgf/cm2, 57 psi}) to the transmission case, then remove the 1st & reverse brake piston.
NOTE:
If the piston does not jump out by compressed air, use needle nose pliers to pick the piston up and take it out.
(2) Remove the O-ring from the 1st & reverse brake piston.
75. Removal of brake reaction sleeve
(1) Use the SST to remove the brake reaction sleeve from the automatic transmission case SUB-ASSY.
SST     09350-07080
(2) Remove 2 O-rings from the brake reaction sleeve.
76. Removal of No.4 brake piston
(1) Use the SST to remove the No.4 brake piston from the automatic transmission case SUB-ASSY.
SST     09350-07090
(2) Remove 2 O-rings from the No.4 brake piston.
UNIT INSPECTION
1. Check of 1st & reverse brake return spring SUB-ASSY
(1) Measure the free length of the spring including the spring seat.
Normal free length :  23.74mm {0.935in}
If the measured free length is shorter than the normal free length, replace the 1st & reverse brake return spring SUB-ASSY.
2. Check of rear planetary gear ASSY
(1) Use a feeler gauge to measure the rear planetary gear pinion thrust clearance.
Normal clearance :  0.2 to 0.6 mm {0.00788 to 0.0236 in}
If the measured clearance is larger than the normal clearance, replace the rear planetary gear ASSY.
(2) Measure the inner diameter of the rear planetary gear bushing.
Normal inner diameter :  18.025mm {0.710in}
If the measured inner diameter is larger than the normal inner diameter, replace the rear planetary gear ASSY.
3. Check of No.4 brake pack clearance
(1) Apply compressed air (392 kPa {4.0 kgf/cm2, 57 psi}), release the air gun, and then check that the 1st & reverse brake piston moves smoothly.
(2) Measure the height difference (dimension A) between the upper surface of the brake apply tube and the No.4 brake flange contact surface at both ends of the diameter of the 1st & reverse brake piston, and calculate the average.
CAUTION:
The 1st & reverse brake piston must be installed to the end face of the transmission case securely.
NOTE:
Dimension A = 23.32 to 24.18 mm {0.919 to 0.951 in}
(3) While applying a pressure of 4.9 N {0.5 kgf, 1.1 lbf} or less, use a caliper to measure the total thickness of the 2 No.4 brake flanges, 4 No.4 brake plates, and 5 No.4 brake discs (dimension B) at both ends of the diameter, and calculate the average.
NOTE:
Dimension B = 23.64 to 26.00 mm {0.931 to 1.023 in}
Pack clearance = dimension A - dimension B - 0.18 mm {0.0071 in} + 1.8 mm {0.0709 in}
Pack clearance :  0.5 to 0.8 mm {0.0197 to 0.0315 in}
(4) If the pack clearance is out of the normal range, select a No.4 brake flange with the pack clearance within the normal range and install it.
NOTE:
There are 8 types of No.4 brake flanges that can be used for pack clearance adjustment. Select the one with the most suitable thickness.
Thickness H
Part number
 Mark
 Thickness H
30098AB380
 0
 0mm {0in}
30098AB390
 2
 0.2mm {0.00787in}
30098AB400
 4
 0.4mm {0.0157in}
30098AB410
 6
 0.6mm {0.0236in}
30098AB420
 8
 0.8mm {0.0315in}
30098AB430
 10
 1.0mm {0.0394in}
30098AB440
 12
 1.2mm {0.0472in}
30098AB450
 14
 1.4mm {0.0551in}
4. Check of No.4 brake disc
(1) Check for wear and seizing on the sliding surfaces of the disc, plate, and flange.
Replace them as required.
CAUTION:
·If the disc lining is peeling or discolored, or if even a part of the printed number is damaged, replace the all discs.
·Soak new discs in ATF for at least 15 minutes before the assembly.
5. Check of intermediate shaft
(1) Use a dial gauge to check the runout of the intermediate shaft.
Normal runout :  0.03mm {0.00118in}
If the runout is larger than the normal value, replace the intermediate shaft with a new one.
(2) Use a micrometer to check the outer diameters of the intermediate shaft at the positions shown in the figure.
Normal diameter: A
:  22.962 to 22.975 mm {0.9041 to 0.9045 in} B
:  27.759 to 27.775 mm {1.0929 to 1.0935 in}
If the outer diameter is smaller than the normal value, replace the intermediate shaft with a new one.
7. Check of center planetary gear ASSY
(1) Measure the center planetary gear pinion thrust clearance.
Normal clearance :  0.12 to 0.68 mm {0.00473 to 0.0267 in}
If the measured clearance is larger than the normal clearance, replace the center planetary gear ASSY.
8. Check of No.2 brake disc
(1) Check for wear and seizing on the sliding surfaces of the disc, plate, and flange.
Replace them as required.
CAUTION:
·If the disc lining is peeling or discolored, or if even a part of the printed number is damaged, replace the all discs.
·Soak new discs in ATF for at least 15 minutes before the assembly.
9. Check of No.2 brake piston return spring SUB-ASSY
(1) Measure the free length of the spring including the spring seat.
Normal free length :  22.66mm {0.892in}
If the measured free length is shorter than the normal free length, replace the No.2 brake piston return spring SUB-ASSY.
11. Check of brake piston return spring SUB-ASSY
(1) Measure the free length of the spring including the spring seat.
Normal free length :  17.05mm {0.671in}
If the measured free length is shorter than the normal free length, replace the brake piston return spring SUB-ASSY.
12. Check of front planetary gear ASSY
(1) Measure the front planetary gear pinion thrust clearance.
Normal clearance :  0.20 to 0.60 mm {0.00788 to 0.0236 in}
If the measured clearance is larger than the normal clearance, replace the front planetary gear ASSY.
(2) Measure the inner diameter of the front planetary gear bushing.
Normal inner diameter :  48.78mm {1.92in}
If the measured inner diameter is larger than the normal inner diameter, replace the front planetary gear ASSY.
15. Check of No.1 brake disc
(1) Check for wear and seizing on the sliding surfaces of the disc, plate, and flange.
Replace them as required.
CAUTION:
·If the disc lining is peeling or discolored, or if even a part of the groove is damaged, replace the all discs.
·Soak new discs in ATF for at least 15 minutes before the assembly.
16. Check of No.3 brake piston return spring SUB-ASSY
(1) Measure the free length of the spring including the spring seat.
Normal free length :  15.72mm {0.619in}
If the measured free length is shorter than the normal free length, replace the No.3 brake piston return spring set SUB-ASSY.
17. Check of No.3 brake disc set
(1) Check for wear and seizing on the sliding surfaces of the disc, plate, and flange.
Replace them as required.
CAUTION:
·If the disc lining is peeling or discolored, or if even a part of the printed number is damaged, replace the all discs.
·Soak new discs in ATF for at least 15 minutes before the assembly.
21. Check of direct clutch return spring SUB-ASSY
(1) Measure the free length of the spring including the spring seat.
Normal free length :  20.02mm {0.788in}
If the measured free length is shorter than the normal free length, replace the direct clutch return spring SUB-ASSY.
22. Check of reverse clutch return spring SUB-ASSY
(1) Measure the free length of the spring including the spring seat.
Normal free length :  21.03mm {0.828in}
If the measured free length is shorter than the normal free length, replace the reverse clutch return spring SUB-ASSY.
23. Check of No.2 clutch disc (direct clutch disc)
(1) Check for wear and seizing on the sliding surfaces of the disc, plate, and flange.
Replace them as required.
CAUTION:
·If the disc lining is peeling or discolored, or if even a part of the printed number is damaged, replace the all discs.
·Soak new discs in ATF for at least 15 minutes before the assembly.
26. Check of forward clutch return spring SUB-ASSY
(1) Use a caliper gauge to measure the free length of the spring including the spring seat.
Normal free length :  26.29mm {1.04in}
If the measured free length is shorter than the normal free length, replace the forward clutch return spring SUB-ASSY.
27. Check of No.4 clutch disc (coast clutch disc)
(1) Check for wear and seizing on the sliding surfaces of the disc, plate, and flange.
Replace them as required.
CAUTION:
·If the disc lining is peeling or discolored, or if even a part of the printed number is damaged, replace the all discs.
·Soak new discs in ATF for at least 15 minutes before the assembly.
29. Check of No.1 clutch disc (forward clutch disc)
(1) Check for wear and seizing on the sliding surfaces of the disc, plate, and flange.
Replace them as required.
CAUTION:
·If the disc lining is peeling or discolored, or if even a part of the printed number is damaged, replace the all discs.
·Soak new discs in ATF for at least 15 minutes before the assembly.
31. Check of forward clutch hub SUB-ASSY
(1) Use a caliper gauge to check the inner diameter of the forward clutch hub bushing.
Normal inner diameter :  23.037 to 23.062 mm {0.9070 to 0.9079 in}
If the measured inner diameter is longer than the normal inner diameter, replace the forward clutch hub SUB-ASSY.
32. Check of No.3 clutch disc
(1) Check for wear and seizing on the sliding surfaces of the disc, plate, and flange.
Replace them as required.
CAUTION:
·If the disc lining is peeling or discolored, or if even a part of the printed number is damaged, replace the all discs.
·Soak new discs in ATF for at least 15 minutes before the assembly.
33. Check of reverse clutch hub SUB-ASSY
(1) Measure the inner diameter of the reverse clutch hub bushing.
Normal inner diameter :  33.312 to 33.337 mm {1.3115 to 1.3125 in}
If the measured inner diameter is longer than the normal inner diameter, replace the reverse clutch hub SUB-ASSY.
ASSEMBLY
6. Installation of brake apply tube
(1) Install the brake apply tube so that the protrusion fits into the groove of the automatic transmission case SUB-ASSY as shown in the figure.
CAUTION:
·Engage the claw of the 1st & reverse brake piston with the protrusion of the brake apply tube.
·Peep through the rear side rotation sensor installation hole to check that the inside of the transmission case can be seen.
10. Installation of brake plate stopper spring
(1) Install the brake plate stopper spring to the automatic transmission case SUB-ASSY.
13. Installation of intermediate shaft
(1) Install the No.3 one-way clutch ASSY to the automatic transmission case SUB-ASSY.
(2) Install the snap ring to the automatic transmission case SUB-ASSY.
NOTE:
Install the joint of the snap ring toward the control valve side.
18. Installation of No.1 brake piston
(1) Apply ATF to 2 new O-rings and install them to the No.1 brake piston.
Captions in illustration
*1
 O-ring
(2) Press the No.1 brake piston into the No.1 brake cylinder.
CAUTION:
Be careful not to damage the O-ring.
21. Installation of front planetary ring gear
(1) Install the front planetary ring gear to the automatic transmission case SUB-ASSY.
24. Installation of No.1 brake disc
(1) Install No.1 brake flange, 3 No.1 brake discs, and 3 No.1 brake plates to the automatic transmission case SUB-ASSY.
Captions in illustration
*1
 No.1 brake plate
*2
 No.1 brake disc
*3
 No.1 brake flange
Installation order :  *1 - *2 - *1 - *2 - *1 - *2 - *3
CAUTION:
Check that the disc, plate, and flange are installed in the correct order.
27. Installation of No.3 brake cylinder
(1) Install the No.3 brake cylinder to the automatic transmission case SUB-ASSY.
(2) Check that the oil pressure apply hole of the No.3 brake cylinder is aligned with the oil pressure apply hole of the automatic transmission case SUB-ASSY.
(3) Install the snap ring to the automatic transmission case SUB-ASSY.
NOTE:
Install the joint of the snap ring toward the control valve side.
35. Installation of reverse clutch flange
(1) Install the reverse clutch flange to the reverse clutch drum SUB-ASSY.
45. Installation of clutch drum oil seal ring
(1) Apply ATF to 4 new clutch drum oil seal rings.
(2) Push out both ends of the 4 clutch drum oil seal rings all together and install them to the input shaft groove.
CAUTION:
Do not stretch the ring ends excessively.
NOTE:
After installing the clutch drum oil seal rings, check that they can rotate smoothly.
46. Installation of input shaft
(1) Install the input shaft to the reverse clutch drum SUB-ASSY.
(2) Install the input shaft rear thrust bearing race and thrust needle roller bearing to the input shaft.
Captions in illustration
*1
 Thrust needle roller bearing
*2
 Input shaft rear thrust bearing race
Bearing and race diameter
Item
 Inner
 Outer
Thrust needle roller bearing
 50.8mm {1.999in}
 41.0mm {1.614in}
Input shaft rear thrust bearing race
 20.0mm {0.787in}
 35.6mm {1.402in}
48. Installation of coast clutch hub SUB-ASSY
(1) Install the coast clutch hub SUB-ASSY to the reverse clutch drum SUB-ASSY.
51. Installation of reverse clutch reaction sleeve
(1) Install the reverse clutch reaction sleeve to the reverse clutch hub SUB-ASSY.
57. Installation of manual valve lever shaft oil seal
(1) Tap 2 manual valve lever shaft oil seals lightly to insert them into the automatic transmission case SUB-ASSY using the SST and a hammer.
SST     18657AA010
(2) Apply auto fluid WS to the manual valve lever shaft oil seal lip.
60. Installation of parking lock rod SUB-ASSY
(1) Install the parking lock rod SUB-ASSY to the manual valve lever SUB-ASSY.
66. Installation of brake drum gasket
(1) Install 3 new brake drum gaskets to the automatic transmission case SUB-ASSY.
67. Installation of transmission case gasket
(1) Install 3 new transmission case gaskets on the automatic transmission case SUB-ASSY.
73. Installation of automatic transmission extension housing oil seal
(1) Tap the automatic transmission extension housing oil seal lightly to insert it into the extension housing SUB-ASSY using the SST and a hammer.
SST     09325-40010
Insertion depth :  5.4 to 5.8 mm {0.213 to 0.228 in}
(2) Apply auto fluid WS to the lip of the automatic transmission extension housing oil seal.
74. Installation of extension housing dust deflector
(1) Use the SST and a press to install a new extension housing dust deflector to the extension housing SUB-ASSY.
SST     398177700
75. Installation of transmission case adapter radial ball bearing
(1) Install the transmission case adapter radial ball bearing to the extension housing SUB-ASSY.
(2) Use snap ring pliers to install the snap ring to the extension housing SUB-ASSY.
78. Installation of automatic transmission case plug
(1) Apply ATF to a new O-ring and install it to the automatic transmission case plug.
(2) Use a TORX socket wrench T55 to install the automatic transmission case plug to the automatic transmission case SUB-ASSY.

Standard value:
Tightening torque=39N·m { 400kgf·cm} {28.8ft·lbf}
(3) Apply ATF to 5 new O-rings and install them to the 5 automatic transmission case plugs.
(4) Install the 5 automatic transmission case plugs to the automatic transmission case SUB-ASSY.

Standard value:
Tightening torque=7.4N·m { 75kgf·cm} {5.5ft·lbf}
79. Installation of automatic transmission breather tube
(1) Install the automatic transmission breather tube to the automatic transmission case SUB-ASSY with 6 bolts.

Standard value:
Tightening torque=5.4N·m { 55kgf·cm} {4.0ft·lbf}
80. Installation of transmission revolution sensor
(1) Apply ATF to 2 new O-rings and install them to the 2 transmission revolution sensors.
(2) Install the 2 transmission revolution sensors to the automatic transmission case SUB-ASSY with 2 bolts.

Standard value:
Tightening torque=5.4N·m { 55kgf·cm} {4.0ft·lbf}
81. Installation of transmission oil cooler
(1) Install the 2 oil cooler tube unions to the automatic transmission case SUB-ASSY.

Standard value:
Tightening torque=29.4N·m { 300kgf·cm} {21.7ft·lbf}
83. Installation of transmission control shaft lever RH
(1) Install the transmission control shaft lever RH to the neutral start switch ASSY with the spring washer and the nut.

Standard value:
Tightening torque=16N·m { 160kgf·cm} {11.8ft·lbf}
84. Installation of refill plug.
(1) Apply ATF to a new O-ring and install it to the refill plug.
(2) Install the refill plug.

Standard value:
Tightening torque=39N·m { 400kgf·cm} {28.8ft·lbf}