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HOMESERVICE MANUALSSUBARU1991JUSTY GL, 2D HATCHBACK, 1.2 7, AUTOMATIC CVTREPAIR AND DIAGNOSIS (SINGLE PAGE)TRANSMISSIONAUTOMATIC TRANSOVERHAUL - ECVTTRANSAXLE REASSEMBLYNOTES
1991 Subaru Justy GL, 2D Hatchback, 1.2 7, Automatic CVT

Transaxle Reassembly: Notes

1991 Subaru Justy GL, 2D Hatchback, 1.2 7, Automatic CVTSECTION Notes
  1. Install side case to Stand (499935600). Install pilot pipe to side case and face straight-pin toward center of pulleys. Install seal ring on secondary guide using Seal Ring Guide (499305500).
  2. Clean and dress mating surface of side case. Install Gauge (499575700) to side case. See Fig 1. Using depth micrometer, measure depth between gauge top surface and mounting portion of primary pulley bearing ("Lp"). Measure between gauge top surface and mounting portion of secondary pulley bearing ("Ls"). See Fig 1. Measure in 4 positions and average results.
  3. Calculate thickness of shim using values measured and equation: X=A-(B+Lp-Ls)+.002"-.963". "A"= indicated primary pulley dimension and "B"= indicated secondary pulley dimension. Select appropriate shim. See SECONDARY PULLEY SHIM SPECIFICATION  table. Install shim on secondary pulley bearing mounting surface.
    SECONDARY PULLEY SHIM SPECIFICATION

    "X"-In. (mm) Part No. Thickness In. (mm) (Calculated Dimension)
    0-.001 (0-.05) Not Used 0 (0)
    .001-.006 (.05-.15) 803054021 .004 (.10)
    .006-.009 (.15-.25) 803054022 .008 (.20)
    .009-.014 (.25-.35) 803054023 .012 (.30)
    .014-.018 (.35-.45) 803054024 .016 (.40)
    .018-.022 (.45-.55) 803054025 .020 (.50)
    .022-.026 (.55-.65) 803054026 .024 (.60)
  4. Clean and dress mating surface of transmission case. Install gauge to transmission case. See Fig 4. Measure depth "C" between gauge top surface and recess for snap ring at 2.76" (70.0 mm) hole using depth gauge. Measure at 4 positions and average readings.
    Fig 1: Measuring Pulley Bearing Depth
    G93B24068Courtesy of SUBARU OF AMERICA, INC.
RENDER: 1.0x

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When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

  • • You smell fuel, burning insulation, or see smoke.
  • • Brakes feel soft, pull hard to one side, or make grinding noises.
  • • The engine overheats, stalls repeatedly, or misfires under load.
  • • You are missing required tools, torque specs, or safe lifting equipment.
  • • You are not confident in the next step or safety outcome.