2021 Subaru Outback BaseFACTORY OEM SERVICE PROCEDURE

Intermediate Case: Installation

WARNING: This page is about a different variant/trim than selected.
  1. Install the CVTF filter.
    NOTE:
    • When reusing the CVTF filter, check the filter for clogging.
    • Install with the O-ring side (a) facing the intermediate case.
    • Apply CVTF to the O-rings.
    G13951241Courtesy of SUBARU OF AMERICA, INC.
  2. Select the washer for the forward clutch.
    1. Using the ST, measure the height "H1" from the ST end face to the reduction driven gear washer catch surface.

      Preparation tool: 

      ST: GAUGE (499575600)

      G13951242Courtesy of SUBARU OF AMERICA, INC.
    2. Install the thrust bearing.
      NOTE: Make sure to install in the right direction.
      G13951243Courtesy of SUBARU OF AMERICA, INC.
    3. Install the forward clutch to intermediate case.
    4. Using the ST, measure the height "H2" from the ST end face to the intermediate case mating surface.

      Preparation tool: 

      ST: GAUGE (499575600)

      G13951244Courtesy of SUBARU OF AMERICA, INC.
    5. Using the following calculation, select an appropriate washer thickness "T".
      NOTE: Adjust using 1 piece.

      T = (H1 - 15 mm (0.6 in)) - (H2 - 15 mm (0.6 in)) - 0.75 - 0.95 mm (0.030 - 0.037 in)

    T Washer thickness mm (in)
    H1 Measured value (mm (in)) of step (1)
    H2 Measured value (mm (in)) of step (4)
    15 mm (0.6 in) Thickness of ST
    0.75 - 0.95 mm (0.030 - 0.037 in) Clearance specification
  3. Install the washer.
    G13951245Courtesy of SUBARU OF AMERICA, INC.
  4. Install a new O-ring.
    NOTE: Apply CVTF to the O-rings.
    G13951246Courtesy of SUBARU OF AMERICA, INC.
  5. Apply liquid gasket to the mating surface of the transmission case as shown in the figure.
    NOTE:
    • Before applying liquid gasket, degrease the liquid gasket seal surfaces of the intermediate case and transmission case.
    • Install within 5 min. after applying liquid gasket.

    Preparation items: 

    Liquid gasket: THREE BOND 1215B or equivalent

    G13951247Courtesy of SUBARU OF AMERICA, INC.
  6. Install the intermediate case (A) and the forward clutch (B) as a single unit to the transmission case (C).
    CAUTION: Do not press-in forcibly because there is a possibility of offset on the reverse brake.
    G13951248Courtesy of SUBARU OF AMERICA, INC.
  7. Install the transmission hanger (A), and install the bolts which hold the intermediate case.
    CAUTION: Install the bolts after confirming close contact of the intermediate case and transmission case.

    Tightening torque: 

    25 N.m (2.5 kgf-m, 18.4 ft-lb)

    G13951249Courtesy of SUBARU OF AMERICA, INC.
  8. Install the electric oil pump. Ref. to CONTINUOUSLY VARIABLE TRANSMISSION (TR690)>ELECTRIC FLUID PUMP>INSTALLATION .
  9. Install the transfer reduction driven gear. Ref. to CONTINUOUSLY VARIABLE TRANSMISSION (TR690)>TRANSFER REDUCTION DRIVEN GEAR>INSTALLATION .
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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.