LEMON Manuals: Even more car manuals for everyone
Home >> Subaru >> 2004 >> Forester XT, Standard >> Repair and Diagnosis >> Transmission >> Manual Trans >> Manual Transmission And Differential >> Manual Transmission Assembly >> Installation

Manual Transmission Assembly: Installation

  1. Replace the differential side retainer oil seal with a new one. < Ref. to REPLACEMENT . >
    NOTE: When pulling out the front drive shaft, always replace the differential side retainer oil seal.
  2. Install the rear cushion rubber to transmission assembly.
    1. Tightening torque: 35 N.m (3.57 kgf-m, 25.8 ft-lb) 
  3. Install the clutch release lever and bearing onto transmission. (Turbo model) < Ref. to INSTALLATION , Release Bearing and Lever . >
  4. Install the transmission onto engine.
    1. Gradually raise the transmission with transmission jack.
    2. Engage them at splines.
    NOTE: Be careful not to strike the main shaft against clutch cover.
  5. Install the transmission rear crossmember.

    Tightening torque: 

    1. T1: 70 N.m (7.1 kgf-m, 51 ft-lb) 
    2. T2: 140 N.m (14.3 kgf-m, 103 ft-lb) 
    Fig 1: Identifying Transmission Rear Crossmember
    G00937226Courtesy of SUBARU OF AMERICA, INC.
  6. Take off the transmission jack.
  7. Tighten the nuts and bolts which hold lower side of transmission to engine.
    1. Tightening torque: 50 N.m (5.1 kgf-m, 36.9 ft-lb) 
    Fig 2: Tightening Nuts And Bolts Holding Lower Side Of Transmission To Engine
    G00937227Courtesy of SUBARU OF AMERICA, INC.
  8. Connect the engine and transmission.
    1. Install the starter. < Ref. to INSTALLATION , Starter . >
    2. Tighten the bolt which holds upper side of transmission to engine.
    1. Tightening torque: 50 N.m (5.1 kgf-m, 36.9 ft-lb) 
    Fig 3: Tightening Bolt Holding Upper Side Of Transmission To Engine
    G00937228Courtesy of SUBARU OF AMERICA, INC.
  9. Remove the ST.
    Fig 4: Identifying ST
    G00937229Courtesy of SUBARU OF AMERICA, INC.
  10. Install the pitching stopper.

    Tightening torque: 

    1. T1: 50 N.m (5.1 kgf-m, 37 ft-lb) 
    2. T2: 58 N.m (5.9 kgf-m, 43 ft-lb) 
    Fig 5: Identifying Pitching Stopper
    G00937230Courtesy of SUBARU OF AMERICA, INC.
  11. Lift-up the vehicle.
  12. Install the front drive shaft into transmission. < Ref. to INSTALLATION , Front Drive Shaft . >
  13. Install the ball joints of lower arm into knuckle arm of housing, and tighten the identifying bolts.
    1. Tightening torque: 49 N.m (5.0 kgf-m, 36 ft-lb) 
    Fig 6: Tightening Ball Joint Bolt
    G00937231Courtesy of SUBARU OF AMERICA, INC.
  14. Install the stabilizer link from transverse link.
    1. Tightening torque: 45 N.m (4.6 kgf-m, 33.2 ft-lb) 
    Fig 7: Identifying Stabilizer Link
    G00937232Courtesy of SUBARU OF AMERICA, INC.
  15. Install the gear shift rod and stay.
    1. Install the gear shift rod onto transmission.
      1. Tightening torque: 18 N.m (1.8 kgf-m, 13.0 ft-lb) 
      Fig 8: Identifying Gear Shift Rod And Stay
      G00937233Courtesy of SUBARU OF AMERICA, INC.
    2. Install the stay onto transmission.
      1. Tightening torque: 18 N.m (1.8 kgf-m, 13.0 ft-lb) 
  16. Install the propeller shaft. < Ref. to INSTALLATION , Propeller Shaft . >
  17. Install the heat shield cover.
  18. Install the hanger bracket on right side of transmission.
    Fig 9: Identifying Hanger Bracket On Right Side Of Transmission
    G00937234Courtesy of SUBARU OF AMERICA, INC.
  19. Install the rear exhaust pipe and muffler.
  20. Install the front exhaust pipe and center exhaust pipe. < Ref. to INSTALLATION , Front Exhaust Pipe . >
  21. Install the center exhaust pipe. (Turbo model) < Ref. to INSTALLATION , Center Exhaust Pipe . >
  22. Install the under cover.
  23. Push clutch release lever to fit bearing into clutch cover.
  24. Install the operating cylinder.
    1. Tightening torque: 37 N.m (3.8 kgf-m, 27.5 ft-lb) 
    • NON-TURBO MODEL
      Fig 10: Identifying Operating Cylinder (Non-Turbo Model)
      G00937235Courtesy of SUBARU OF AMERICA, INC.
    • TURBO MODEL
      Fig 11: Identifying Operating Cylinder (Turbo Model)
      G00937236Courtesy of SUBARU OF AMERICA, INC.
  25. Connect the following connectors:
    1. Transmission ground cable
      1. Tightening torque: 13 N.m (1.3 kgf-m, 9.4 ft-lb) 
    2. Vehicle speed sensor connector
    3. Neutral position switch connector
    4. Back up light switch connector
  26. Install the air cleaner case stay.
  27. Install the air cleaner case and duct. < Ref. to INSTALLATION , Air Cleaner Case . > and < Ref. to INSTALLATION , Air Intake Duct . >
  28. Install the intercooler. (TURBO MODEL) < Ref. to INSTALLATION , Intercooler . >
  29. Fill gear oil into the gauge hole. < Ref. to REPLACEMENT . >
    1. Tightening torque: 16 N.m (1.6 kgf-m, 11.6 ft-lb) 
  30. Install the air intake chamber and duct.
  31. Connect the battery ground cable to battery.
  32. Take off the vehicle from lift.
scientia non olet · About LEMON Manuals