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Home >> Subaru >> 2006 >> Baja Turbo, Automatic >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 18 (Manual Transmission And Differential) >> Manual Transmission Assembly >> Installation

Manual Transmission Assembly: Installation

WARNING: This page is about a different variant/trim than selected.
  1. Replace the differential side oil seal with a new one. (TURBO model) < Ref. to REPLACEMENT , DIFFERENTIAL SIDE RETAINER OIL SEAL. >
    NOTE: It is not necessary to replace the oil seal if a new one installed.
  2. Install the rear cushion rubber to transmission assembly.

    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. While releasing turn buckle of engine support assembly, raise upward transmission jack, and then return tilt of engine and transmission.

    ST 41099AA000 ENGINE SUPPORT ASSY

    Fig 1: Identifying ST 41099AA000 Engine Support Assy
    G04990851Courtesy of SUBARU OF AMERICA, INC.
  6. Install the transmission rear crossmember.

    Tightening torque: 

    T1: 75 N.m (7.7 kgf-m, 55.4 ft-lb) 

    T2: 140 N.m (14.3 kgf-m, 103 ft-lb) 

    T3: 35 N.m (3.6 kgf-m, 25.9 ft-lb) 

    Fig 2: Identifying Transmission Rear Crossmember Bolts
    G04990861Courtesy of SUBARU OF AMERICA, INC.
  7. Take off the transmission jack.
  8. Tighten the nuts which hold the lower side of transmission to engine.

    Tightening torque: 

    50 N.m (5.1 kgf-m, 36.9 ft-lb) 

    Fig 3: Locating Transmission Nuts
    G05002964Courtesy of SUBARU OF AMERICA, INC.
  9. Connect the engine and transmission.
    1. Install the starter.

      < Ref. to INSTALLATION , STARTER. >

    2. Tighten the bolt which holds right upper side of transmission to engine.

      Tightening torque: 

      50 N.m (5.1 kgf-m, 36.9 ft-lb) 

      Fig 4: Locating Transmission Bolts
      G05002959Courtesy of SUBARU OF AMERICA, INC.
  10. Remove the ST.
    Fig 5: Identifying ST 41099AA000 Engine Support Assy
    G04990851Courtesy of SUBARU OF AMERICA, INC.
  11. Install the pitching stopper.

    Tightening torque: 

    T1: 50 N.m (5.1 kgf-m, 37 ft-lb) 

    T2: 58 N.m (5.9 kgf-m, 43 ft-lb) 

    Fig 6: Identifying Pitching Stopper
    G04999662Courtesy of SUBARU OF AMERICA, INC.
  12. Lift-up the vehicle.
  13. Drive the spring pin into chamfered hole of drive shaft. (Non-TURBO model)
    NOTE: Always use a new spring pin.
    Fig 7: Installing Spring Pin Into Chamfered Hole Of Drive Shaft
    G04990866Courtesy of SUBARU OF AMERICA, INC.
  14. Replace the circlip with a new one, and insert the front drive shaft to transmission. (TURBO model) < Ref. to REMOVAL , Front Drive Shaft . >

    ST 28399SA010 FRONT DRIVE SHAFT OIL SEAL PROTECTOR

  15. Install the ball joints of lower arm into knuckle arm of housing, and tighten the installing bolts.

    Tightening torque: 

    49 N.m (5.0 kgf-m, 36 ft-lb) 

    Fig 8: Identifying Transverse Link And Ball Joint
    G04990867Courtesy of SUBARU OF AMERICA, INC.
  16. Install the stabilizer link from transverse link.

    Tightening torque: 

    30 N.m (3.1 kgf-m, 22.1 ft-lb) 

    Fig 9: Locating Stabilizer Link
    G05002975Courtesy of SUBARU OF AMERICA, INC.
  17. Install the gear shift rod and stay.
    1. Install the gear shift rod onto transmission.
      Fig 10: Identifying Gear Shift Rod And Stay
      G04990869Courtesy of SUBARU OF AMERICA, INC.
    2. Install the stay onto transmission.
  18. Install the propeller shaft. < Ref. to INSTALLATION , Propeller Shaft . >
  19. Install the heat shield cover. (If equipped)
  20. Install the hanger bracket on right side of transmission.
    Fig 11: Identifying Hanger Bracket
    G05002960Courtesy of SUBARU OF AMERICA, INC.
  21. Install the rear exhaust pipe and muffler.
  22. Install the front exhaust pipe and center exhaust pipe. (Non-TURBO model)

    < Ref. to INSTALLATION , FRONT EXHAUST PIPE. >

  23. Install the center exhaust pipe. (TURBO model) < Ref. to INSTALLATION , FRONT EXHAUST PIPE. >
  24. Install the under cover.
  25. Push the clutch release lever to fit the bearing into clutch cover. (TURBO model)
    Fig 12: Locating Clutch Release Lever
    G04990871Courtesy of SUBARU OF AMERICA, INC.
  26. Install the operating cylinder.

    Tightening torque: 

    37 N.m (3.8 kgf-m, 27.5 ft-lb) 

    Fig 13: Locating Operating Cylinder Bolts
    G04990849Courtesy of SUBARU OF AMERICA, INC.
  27. Connect the following connectors:
    1. Transmission ground cable

      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
  28. Install the air cleaner case stay. (Non-TURBO model)

    Tightening torque: 

    16 N.m (1.6 kgf-m, 11.6 ft-lb) 

  29. Install the air cleaner case or the air intake chamber and duct. (Non-TURBO model)
  30. Install the intercooler. (TURBO model)
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