Transmission Case: Installation

WARNING: This page is about a different variant/trim than selected.

Wipe off grease, oil and dust on the mating surfaces of transmission cases with white gasoline.
Install the front differential assembly.
Install the main shaft assembly for single-range. Install the transmission case knock pin into needle bearing knock pin hole.
Install the drive pinion shaft assembly.
Install the transmission case knock pin into roller bearing knock pin hole.
Apply liquid gasket, and then put the case RH and LH together.
Liquid gasket:

THREE BOND 1215 (Part No. 004403007) or equivalent
Tighten seventeen bolts with bracket, clip, etc. as shown in Fig 1 .
NOTE: Insert the bolts from the bottom and tighten nuts on the top.

Tightening torque:

8 mm bolt

25 N.m (2.5 kgf-m, 18.1 ft-lb)

*10 mm bolt

39 N.m (4.0 kgf-m, 28.9 ft-lb)

Fig 1: Tightening Nuts On Top
Courtesy of SUBARU OF AMERICA, INC.
Tighten the ball bearing mounting bolts.
Tightening torque:

30 N.m (3.1 kgf-m, 22.1 ft-lb)

Fig 2: Tightening Ball Bearing Mounting Bolts
Courtesy of SUBARU OF AMERICA, INC.
Backlash adjustment of hypoid gear and preload adjustment of roller bearing.
NOTE: Set the ST on drive pinion assembly.

ST 498427100 STOPPER

Fig 3: Setting ST On Drive Pinion Assembly
Courtesy of SUBARU OF AMERICA, INC.
Place the transmission with the left side of case facing downward, and put ST1 on bearing cup.
Screw the retainer assembly into left case from the bottom with 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 turning ST3 until a slight resistance is felt on ST2.
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 ASSY

ST3 499927100 HANDLE

Fig 4: Putting ST1 On Bearing Cup
Courtesy of SUBARU OF AMERICA, INC.
Remove the weight, and screw in the retainer without O-ring on the upper side and stop at the point where slight resistance is felt.
NOTE: At this condition, the backlash between hypoid gear and drive pinion shaft is zero.

ST 499787000 WRENCH ASSY

Fig 5: Identifying ST 499787000 Wrench Assy
Courtesy of SUBARU OF AMERICA, INC.
Install the lock plate. Loosen the retainer on the lower side by 1-1/2 notches from lock plate, and turn 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.
Turn in the retainer on the upper side additionally by 1 notch in order to apply preload on taper roller bearing.
Tighten temporarily both the upper and lower lock plates and mark both holder and lock plate for later readjustment.
Turn the transmission main shaft several times while tapping around retainer lightly with plastic hammer.
Inspect and adjust the backlash and tooth contact of hypoid gear. < Ref. to , INSPECTION , Front Differential Assembly. >
After checking the tooth contact of hypoid gears, remove the lock plate. Then loosen the retainer until the O-ring groove appears. Fit O-ring into the groove and tighten the retainer into the position where retainer has been tightened in.
Tighten the lock plate.

NOTE: Carry out this job on both upper and lower retainers.

Tightening torque:

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

Fig 6: Tightening Lock Plate
Courtesy of SUBARU OF AMERICA, INC.
Selecting of main shaft rear plate: < Ref. to , ADJUSTMENT , Main Shaft Assembly for Single-Range. >
Install the clutch release lever and bearing. < Ref. to INSTALLATION , Release Bearing and Lever. >
Install the transfer case with extension case assembly. < Ref. to , INSTALLATION , Transfer Case and Extension Case Assembly. >
Install the manual transmission assembly into vehicle. < Ref. to , INSTALLATION , Manual Transmission Assembly. >