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Transmission Case: Installation

WARNING: This page is about a different variant/trim than selected.
  1. Wipe off grease, oil and dust on the mating surfaces of transmission cases with white gasoline.
  2. Install the front differential assembly.
  3. Install the main shaft assembly.

    Install needle bearing knock pin hole into transmission case knock pin.

  4. Install the drive pinion shaft assembly.

    Install roller bearing knock pin hole into transmission case knock pin.

  5. Apply liquid gasket, and then put case right side and left side together.

    Liquid gasket:  THREE BOND 1215 or equivalent

  6. Tighten 17 bolts with bracket, clip, etc. as shown in the figure.
    NOTE:
    • Insert bolts from the bottom and tighten nuts at the top.
    • Put cases together so that drive pinion shim and input shaft holder shim are not caught up in between.
    • Confirm that speedometer gear is meshed.

    Tightening torque: 

    1. 8 mm bolt:  25 N.m (2.5 kgf-m, 18.1 ft-lb)
    2. 10 mm bolt*:  39 N.m (4.0 kgf-m, 28.9 ft-lb)
    Fig 1: Tightening Transmission Case Bolts
    G02862943Courtesy of SUBARU OF AMERICA, INC.
  7. Tighten ball bearing attachment bolts.

    Tightening torque:  29 N.m (3.0 kgf-m, 21.7 ft-lb)

    Fig 2: Tightening Ball Bearing Attachment Bolts
    G02862944Courtesy of SUBARU OF AMERICA, INC.
  8. Backlash adjustment of hypoid gear and preload adjustment of roller bearing
    NOTE: Support drive pinion assembly with ST.

    ST 498427100:  STOPPER

    Fig 3: Supporting Drive Pinion Assembly With ST
    G02862945Courtesy of SUBARU OF AMERICA, INC.
  9. Place the transmission with case left side facing downward and put ST1 on bearing cup.
  10. Screw retainer assembly into left case from the bottom with ST2. Fit ST3 on the transmission main shaft. Shift gear into 4th or 5th and turn the shaft several times. Screw in the retainer while turning ST3 until a slight resistance is felt on ST. This is the contact point of hypoid gear and drive pinion shaft. Repeat the above sequence several times to ensure the contact point.

    ST1 399780104:  WEIGHT

    ST2 499787000:  WRENCH ASSEMBLY

    ST3 499927100:  HANDLE

    Fig 4: Placing Transmission With Case Left Side Facing Downward And Put ST 1 On Bearing Cup
    G02862946Courtesy of SUBARU OF AMERICA, INC.
  11. Remove weight and screw in retainer without O-ring on the upper side and stop at the point where slight resistance is felt.
    NOTE: At this point, the backlash between the hypoid gear and drive pinion shaft is zero.

    ST 499787000:  WRENCH ASSEMBLY

    Fig 5: Identifying ST 499787000 Wrench Assembly
    G02862947Courtesy of SUBARU OF AMERICA, INC.
  12. Fit lock plate. Loosen the retainer on the lower side by 1-1/2 notches of lock plate and turn in the retainer on the upper side by the same amount in order to obtain the backlash.
    NOTE: The notch on the lock plate moves by 1/2 notch if the plate is turned upside down.
  13. Turn in the retainer on the upper side additionally by 1 notch in order to apply preload on taper roller bearing.
  14. Tighten temporarily both the upper and lower lock plates and mark both holder and lock plate for later readjustment.
  15. Turn transmission main shaft several times while tapping around retainer lightly with plastic hammer.
  16. Inspect and adjust backlash and tooth contact of hypoid gear. Refer to INSPECTION under FRONT DIFFERENTIAL ASSEMBLY  .
  17. After checking the tooth contact of hypoid gears, remove the lock plate. Then loosen retainer until the O-ring groove appears. Fit O-ring into the groove and tighten retainer into the position where retainer has been tightened in. Tighten lock plate.
    NOTE: Carry out this job on both upper and lower retainers.

    Tightening torque: 

    1. T:  25 N.m (2.5 kgf-m, 18.1 ft-lb)
    Fig 6: Tightening Lock Plate Retainers
    G02862948Courtesy of SUBARU OF AMERICA, INC.
  18. Selecting of main shaft rear plate. Refer to ADJUSTMENT under MAIN SHAFT ASSEMBLY FOR SINGLE-RANGE  .
  19. Install clutch release lever and bearing. Refer to INSTALLATION under RELEASE BEARING AND LEVER .
  20. Install transfer case with extension case assembly. Refer to INSTALLATION under TRANSFER CASE AND EXTENSION CASE ASSEMBLY  .
  21. Install the manual transmission assembly into the vehicle. Refer to INSTALLATION under MANUAL TRANSMISSION ASSEMBLY  .
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