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Home >> Subaru >> 2009 >> Outback i, Standard >> Repair and Diagnosis >> Transmission >> Manual Trans >> Manual Transmission And Differential 5MT >> Manual Transmission Assembly >> Removal

Manual Transmission Assembly: Removal

  1. Set the vehicle on a lift.
  2. Open the front hood fully, and support with stay.
  3. Disconnect the ground cable from the battery.
  4. Drain transmission gear oil completely. Ref. to REPLACEMENT , Transmission Gear Oil.
  5. Remove the air intake chamber and intake boot. (Non-turbo model) Ref. to REMOVAL , Air Intake Chamber.
  6. Remove the air intake chamber stay. (Non-turbo model)
    Fig 1: Identifying Air Intake Chamber Stay
    G04990847Courtesy of SUBARU OF AMERICA, INC.
  7. Remove the intercooler. (Turbo model) Ref. to REMOVAL , Intercooler.
  8. Disconnect the connector back-up light switch & neutral position switch.
    • Non-turbo model
      Fig 2: Identifying Connector Back-Up Light Switch And Neutral Position Switch (Non-Turbo Model)
      G06337939Courtesy of SUBARU OF AMERICA, INC.
    • Turbo model
      Fig 3: Identifying Connector Back-Up Light Switch And Neutral Position Switch (Turbo Model)
      G05002992Courtesy of SUBARU OF AMERICA, INC.
  9. Disconnect the ground cable.
    Fig 4: Identifying Ground Cable
    G06337941Courtesy of SUBARU OF AMERICA, INC.
  10. Remove the starter. Ref. to REMOVAL , Starter.
  11. Remove the operating cylinder from the transmission, and suspend on a wire.
    Fig 5: Locating Operating Cylinder Bolts
    G05020128Courtesy of SUBARU OF AMERICA, INC.
  12. Remove the pitching stopper.
    Fig 6: Identifying Pitching Stopper
    G05342089Courtesy of SUBARU OF AMERICA, INC.
  13. Set the ST.

    ST 41099AC000 ENGINE SUPPORT ASSY

    Fig 7: Identifying ST 41099AC000 Engine Support Assembly
    G05002958Courtesy of SUBARU OF AMERICA, INC.
  14. Lift up the vehicle.
  15. Remove the front and center exhaust pipes. (Non-turbo model) Ref. to REMOVAL , Center Exhaust Pipe.
  16. Remove the center exhaust pipe. (Turbo model) Ref. to REMOVAL , Center Exhaust Pipe.
  17. Remove the rear exhaust pipe and muffler.
    • Non-turbo model

      Ref. to REMOVAL , Rear Exhaust Pipe. Ref. to REMOVAL , Muffler.

    • Turbo model

      Ref. to REMOVAL , Rear Exhaust Pipe. Ref. to REMOVAL , Muffler.

      CAUTION: When removing the exhaust pipes, be careful each exhaust pipe does not drop out.
  18. Remove the bolts which hold upper side of transmission to engine.
    Fig 8: Locating Upper Side Of Transmission Bolts
    G05335715Courtesy of SUBARU OF AMERICA, INC.
  19. Remove the heat shield cover.
    Fig 9: Identifying Heat Shield Cover
    G05661238Courtesy of SUBARU OF AMERICA, INC.
  20. Remove the hanger bracket from the right side of transmission.
    Fig 10: Identifying Hanger Bracket
    G05002960Courtesy of SUBARU OF AMERICA, INC.
  21. Remove the propeller shaft. Ref. to REMOVAL , Propeller Shaft.
  22. Remove the gear shift rod and the stay from the transmission.
    1. Disconnect the stay from the transmission.
    2. Remove the gear shift rod from the transmission.
      Fig 11: Identifying Gear Shift Rod And Stay
      G06337948Courtesy of SUBARU OF AMERICA, INC.
  23. Remove the stabilizer link from the front arm.
    Fig 12: Locating Stabilizer Link
    G05342093Courtesy of SUBARU OF AMERICA, INC.
  24. Remove the bolt securing the ball joint of the front arm to the housing, then separate the front arms and the housing.
    Fig 13: Locating Ball Joint Bolt
    G06337950Courtesy of SUBARU OF AMERICA, INC.
  25. Using a crowbar, remove the left and right front drive shaft from the transmission.
    Fig 14: Removing Front Drive Shaft From Transmission
    G06337951Courtesy of SUBARU OF AMERICA, INC.
  26. Remove the bolts and nuts which hold lower side of transmission to engine.
    Fig 15: Locating Bolts And Nuts
    G05002964Courtesy of SUBARU OF AMERICA, INC.
  27. Place the transmission jack under the transmission.
    CAUTION: Always support the transmission case with a transmission jack.
    Fig 16: Placing Transmission Jack Under Transmission
    G05002965Courtesy of SUBARU OF AMERICA, INC.
  28. Remove the front crossmember and rear crossmember from the vehicle.
    Fig 17: Locating Front Crossmember And Rear Crossmember
    G05956396Courtesy of SUBARU OF AMERICA, INC.
  29. Tighten the turnbuckle of the ST while lowering the transmission jack, to tilt the engine assembly towards the back.
  30. Remove the transmission.
    NOTE: Move the transmission jack towards the rear until the main shaft is withdrawn from the clutch disc.
  31. Separate the transmission assembly from the transmission cushion rubber.