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Transmission Case: Installation

  1. Wipe off grease, oil and dust on the mating surfaces of transmission cases with cleaning solvent.
  2. Install the front differential assembly.
  3. Install the main shaft assembly for single-range. Install the transmission case knock pin into the knock pin hole of needle bearing.
  4. Install the drive pinion shaft assembly. Install the transmission case knock pin into the roller bearing knock pin hole.
  5. Apply liquid gasket, then join the right side and left side of the case together.

    Liquid gasket: 

    THREE BOND 1215 (Part No. 004403007) or equivalent 

    Fig 1: Applying Liquid Gasket
    G06652371Courtesy of SUBARU OF AMERICA, INC.
  6. With brackets and clips as shown in the figure, tighten the seventeen bolts.
    NOTE: Match the cases together so that the drive pinion shim and input shaft holder shims are not caught between the cases.

    Tightening torque: 

    8 mm bolt 

    25 N.m (2.5 kgf-m, 18.4 ft-lb) 

    10 mm bolt 

    40 N.m (4.1 kgf-m, 29.5 ft-lb) 

    Fig 2: Identifying Transmission Case Bolts Tightening Sequence
    G05003047Courtesy of SUBARU OF AMERICA, INC.
  7. Tighten the taper roller bearing mounting bolts.

    Tightening torque: 

    30 N.m (3.1 kgf-m, 22.1 ft-lb) 

    Fig 3: Tightening Taper Roller Bearing Mounting Bolts
    G06652366Courtesy of SUBARU OF AMERICA, INC.
  8. Perform backlash adjustment of the hypoid gear and preload measurement of the roller bearing.
    NOTE: Attach the ST on drive pinion assembly.

    ST 18667AA020 HOLDER

    Fig 4: Attaching ST On Drive Pinion Assembly
    G06652374Courtesy of SUBARU OF AMERICA, INC.
  9. Place the transmission with the left side of case facing downward, and put ST1 on bearing cup.
  10. Screw the retainer assembly from the bottom into left case using ST2. Fit the ST3 on transmission main shaft. Shift the gear into 4th or 5th, and turn the shaft several times. Screw in the retainer while rotating the ST3 until a slight resistance is felt on ST2.

    This is the contact point of the hypoid gear and the drive pinion shaft. Repeat the above sequence several times to ensure the contact point.

    ST1 399780104 WEIGHT

    ST2 18630AA010 WRENCH COMPL RETAINER

    ST3 499927100 HANDLE

    Fig 5: Screwing Retainer Assembly From Bottom Into Left Case Using ST2
    G06652375Courtesy of SUBARU OF AMERICA, INC.
  11. Remove the weight, and screw in the retainer without the O-ring on the upper side, and stop at the point where a slight resistance is felt.
    NOTE: In this condition, the backlash between hypoid gear and drive pinion shaft is zero.

    ST 18630AA010 WRENCH COMPL RETAINER

    Fig 6: Identifying Wrench Compl Retainer (ST 18630AA010)
    G06652376Courtesy of SUBARU OF AMERICA, INC.
  12. Loosen the retainer on the lower side by 3 notches, and turn the retainer on the upper side by the same amount in order to apply backlash.
  13. Rotate the retainer of the upper side additionally by 1 notch in order to apply preload on taper roller bearing.
  14. Temporarily attach both the upper and lower lock plates, and put marks both the retainer and lock plate for later readjustment.
    NOTE: If it is hard to install the lock plates, reverse the sides and install them.
  15. Turn the transmission main shaft several times while tapping around the retainer lightly with plastic hammer.
  16. Inspect and adjust backlash and tooth contact of the hypoid gear. Refer to Front Differential Assembly  .
  17. After checking the tooth contact of the hypoid gears, remove the lock plate. Then loosen the retainer until the O-ring groove appears. Fit the O-ring into the groove and tighten the retainer into the position before it was loosened.

    Install the lock plate.

    NOTE:
    • When loosening the retainer, record the number of the turns made.
    • Perform this operation for both upper and lower retainers.
    • Use new O-rings.

    Tightening torque: 

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

    Fig 7: Installing Lock Plate
    G05003052Courtesy of SUBARU OF AMERICA, INC.
  18. Select a main shaft rear plate. Refer to Main Shaft Assembly for Single-Range  .
  19. Install the clutch release lever and bearing. Refer to RELEASE BEARING AND LEVER .
  20. Install the transfer case together with the extension case assembly. Refer to Transfer Case and Extension Case Assembly  .
  21. Install the manual transmission assembly to the vehicle. Refer to Manual Transmission Assembly  .
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