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Manual Transmission Assembly: Installation

  1. Replace the differential side retainer oil seal. Refer to REPLACEMENT  .
    NOTE: Be sure to replace the differential side retainer oil seal after removing the front drive shaft.

    ST 18675AA000 DIFFERENTIAL SIDE OIL SEAL INSTALLER

    Fig 1: Identifying Differential Side Oil Seal Installer
    G05002972Courtesy of SUBARU OF AMERICA, INC.
  2. Install the transmission cushion rubber to the transmission assembly, and tighten bolt (A).
  3. Install the transmission cushion rubber to the center crossmember, and tighten the nut (B).

    Tightening torque: 

    Bolt (A) 

    35 N.m (3.6 kgf-m, 25.8 ft-lb) 

    Nut (B) 

    35 N.m (3.6 kgf-m, 25.8 ft-lb) 

    Fig 2: Identifying Center Crossmember Nuts
    G06652276Courtesy of SUBARU OF AMERICA, INC.
  4. Tap the transmission hanger in the rear side of transmission with a rubber hammer to bend it until it is in close contact with the transmission case.
    CAUTION: Do not apply excessive load or impact to the transmission case.
    Fig 3: Identifying Transmission Hanger In Rear Side Of Transmission
    G06652277Courtesy of SUBARU OF AMERICA, INC.
  5. Install the transmission onto the engine.
    CAUTION: This operation requires at least two persons.
    NOTE: Keep the engine level.
    1. Lift up the transmission gradually using a transmission jack.
    2. Engage at the spline section.
      NOTE: Be careful not to hit the main shaft against the clutch housing cover.
  6. Temporarily tighten the bolts and nuts which hold lower side of transmission to engine.
  7. Install the front crossmember and rear crossmember.

    Tightening torque: 

    T1: 75 N.m (7.6 kgf-m, 55.3 ft-lb) 

    T2: 140 N.m (14.3 kgf-m, 103.3 ft-lb) 

    Fig 4: Front Crossmember And Rear Crossmember Mounting Bolts With Torque Specification
    G06652278Courtesy of SUBARU OF AMERICA, INC.
  8. Take out the transmission jack.
  9. Tighten the bolts and nuts which hold the lower side of transmission to the engine.

    Tightening torque: 

    50 N.m (5.1 kgf-m, 36.9 ft-lb) 

    Fig 5: Locating Transmission Lower Side Holding Bolts And Nuts
    G05002964Courtesy of SUBARU OF AMERICA, INC.
  10. Lower the vehicle.
  11. Install the two mounting bolts on the upper side of the transmission.

    Tightening torque: 

    50 N.m (5.1 kgf-m, 36.9 ft-lb) 

    Fig 6: Locating Transmission Upper Side Mounting Bolts
    G05335715Courtesy of SUBARU OF AMERICA, INC.
  12. Remove the ST (ENGINE HANGER).
  13. Install the transmission main mounting bracket.
    NOTE: Incline the engine, and install the transmission main mounting bracket for the left side of the vehicle first.

    Tightening torque: 

    75 N.m (7.6 kgf-m, 55.3 ft-lb) 

    Fig 7: Locating Transmission Main Mounting Bracket Bolts
    G06652270Courtesy of SUBARU OF AMERICA, INC.
  14. Attach the ST (ENGINE HANGER) again.
  15. Remove the bolts from ST (SPECIAL TOOL H4).
    Fig 8: Locating Special Tool H4 Attaching Bolts
    G07915042Courtesy of SUBARU OF AMERICA, INC.
  16. Remove the bolt and nut to remove ST (SPECIAL TOOL H4).
  17. Temporarily attach the front cushion rubber with bolts.
    Fig 9: Locating Front Cushion Rubber Mounting Bolts
    G07915056Courtesy of SUBARU OF AMERICA, INC.
  18. Install the bolt and nut to the front cushion rubber.
  19. Tighten the bolts and nuts of front cushion rubber.
    NOTE: Always start tightening from the bolts on the engine side.

    Tightening torque: 

    T1: 25 N.m (2.5 kgf-m, 18.4 ft-lb) 

    T2: 45 N.m (4.6 kgf-m, 33.2 ft-lb) 

    Fig 10: Front Cushion Rubber Mounting Bolts With Torque Specification
    G06652282Courtesy of SUBARU OF AMERICA, INC.
  20. Remove the ST (ENGINE HANGER) from the vehicle.
  21. Install the stopper rod.

    Tightening torque: 

    36 N.m (3.7 kgf-m, 26.6 ft-lb) 

    Fig 11: Locating Stopper Rod Mounting Bolts
    G06652267Courtesy of SUBARU OF AMERICA, INC.
  22. Tighten the nuts connecting the engine mount and the transmission main mounting bracket.

    Tightening torque: 

    45 N.m (4.6 kgf-m, 33.2 ft-lb) 

    Fig 12: Locating Transmission Main Mounting Bracket Nuts
    G06652264Courtesy of SUBARU OF AMERICA, INC.
  23. Remove the engine hanger rear for turbo model and install the engine hanger rear for non-turbo model. (non-turbo model)

    Tightening torque: 

    16 N.m (1.6 kgf-m, 11.8 ft-lb) 

  24. Install the starter. Refer to STARTER .
  25. Install the operating cylinder.

    Tightening torque: 

    37 N.m (3.8 kgf-m, 27.3 ft-lb) 

    Fig 13: Locating Operating Cylinder Mounting Bolts
    G06652261Courtesy of SUBARU OF AMERICA, INC.
  26. Lift up the vehicle.
  27. Install the front drive shaft into the transmission. Refer to FRONT DRIVE SHAFT .
  28. Insert the front arm ball joint into the housing lower part. Refer to FRONT BALL JOINT .
  29. Attach the stabilizer link to the front arm. Refer to FRONT STABILIZER .
  30. Install the MT gear shift cable and MT gear select cable to MT gear shift lever. Refer to MT GEAR SHIFT LEVER .
    CAUTION:
    • Do not bend MT gear shift cable and MT gear select cable at a sharp angle.
    • Always use new MT gear select cable if the cable is removed from selector lever COMPL of transmission side.
  31. Install the propeller shaft. Refer to PROPELLER SHAFT .
  32. Install the steering shaft universal joint. Refer to UNIVERSAL JOINT .
  33. Install the heat shield cover. Refer to HEAT SHIELD COVER .
  34. Install the front, center and rear exhaust pipe. (non-turbo model) Refer to FRONT EXHAUST PIPE . Refer to CENTER EXHAUST PIPE . Refer to REAR EXHAUST PIPE .
  35. Install the center and rear exhaust pipe. (turbo model) Refer to CENTER EXHAUST PIPE . Refer to REAR EXHAUST PIPE .
  36. Install the front under cover. Refer to FRONT UNDER COVER .
  37. Lower the vehicle.
  38. Install the throttle body. (non-turbo model) Refer to STARTER .
  39. Connect the following connectors.
    1. Transmission radio ground terminal

      Tightening torque: 

      13 N.m (1.3 kgf-m, 9.6 ft-lb) 

    2. Neutral position switch connector (Brown)
    3. Back-up light switch connector (Gray)
    4. Engine harness connectors
  40. Fill transmission gear oil through the transmission oil level gauge hole. Refer to Transmission Gear Oil  .
  41. Install the air intake boot assembly. (non-turbo model) Refer to AIR INTAKE BOOT .
  42. Install the intercooler and the intercooler stay. (turbo model) Refer to INTERCOOLER .
  43. Attach the grille bracket.
    Fig 14: Locating Grille Bracket Attaching Clips
    G06651507Courtesy of SUBARU OF AMERICA, INC.
  44. Install the air intake duct. Refer to AIR INTAKE DUCT . Refer to AIR INTAKE DUCT .
  45. Install the collector cover. (turbo model)
  46. Install the front wheels.
  47. Connect the battery ground terminal.
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