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Manual Transmission Assembly: Removal

  1. Set the vehicle on a lift.
  2. Remove the front wheels.
  3. Open the front hood completely.
  4. Remove the collector cover.
  5. Remove the air intake duct. Ref. to REMOVAL , Air Intake Duct. Ref. to REMOVAL , Air Intake Duct.
  6. Remove the 10 clips and detach the grille bracket.
    Fig 1: Locating Grille Bracket Clips
    G06651507Courtesy of SUBARU OF AMERICA, INC.
  7. Disconnect the ground cable from battery.
  8. Remove the air intake boot assembly, (non-turbo model) Ref. to REMOVAL , Air Intake Boot.
  9. Remove the intercooler and the intercooler stay. (turbo model) Ref. to REMOVAL , Intercooler.
  10. Disconnect the engine harness connector.
    • Non-turbo model
      Fig 2: Identifying Engine Harness Connector - Non-Turbo Model
      G06652255Courtesy of SUBARU OF AMERICA, INC.
    • Turbo model
      Fig 3: Identifying Engine Harness Connector - Turbo Model
      G06652256Courtesy of SUBARU OF AMERICA, INC.
  11. Disconnect the connector of back-up light switch and neutral position switch.
    • Non-turbo model
      Fig 4: Identifying Back-Up Light Switch And Neutral Position Switch - Non-Turbo Model
      G06652257Courtesy of SUBARU OF AMERICA, INC.
    • Turbo model
      Fig 5: Identifying Back-Up Light Switch And Neutral Position Switch - Turbo Model
      G06652258Courtesy of SUBARU OF AMERICA, INC.
  12. Disconnect the ground cable.
    • Non-turbo model
      Fig 6: Identifying Ground Cable - Non-Turbo Model
      G06652259Courtesy of SUBARU OF AMERICA, INC.
    • Turbo model
      Fig 7: Identifying Ground Cable - Turbo Model
      G06652260Courtesy of SUBARU OF AMERICA, INC.
  13. Remove the throttle body, (non-turbo model) Ref. to REMOVAL , Throttle Body.
  14. Remove the starter. Ref. to REMOVAL , Starter.
  15. Remove the operating cylinder from the transmission, and hang it with a wire or the like.
    Fig 8: Locating Cylinder Bolts
    G06652261Courtesy of SUBARU OF AMERICA, INC.
  16. Lift up the vehicle.
  17. Remove the front under cover. Ref. to REMOVAL , Front Under Cover.
  18. Drain transmission gear oil completely. Ref. to REPLACEMENT , Transmission Gear Oil.
  19. Remove the front, center and rear exhaust pipes, (non-turbo model) Ref. to REMOVAL , Front Exhaust Pipe. Ref. to REMOVAL , Center Exhaust Pipe. Ref. to REMOVAL , Rear Exhaust Pipe.
  20. Remove the center and rear exhaust pipes. (turbo model) Ref. to REMOVAL , Center Exhaust Pipe. Ref. to REMOVAL , Rear Exhaust Pipe.
    CAUTION: When removing the exhaust pipes, make sure that each exhaust pipe does not drop off.
  21. Remove the heat shield cover.
    Fig 9: Identifying Heat Shield Cover
    G05661238Courtesy of SUBARU OF AMERICA, INC.
  22. Remove the steering shaft universal joint. Ref. to REMOVAL , Universal Joint.
  23. Remove the propeller shaft. Ref. to REMOVAL , Propeller Shaft.
  24. Remove the MT gear shift cable and MT gear select cable from MT gear shift lever. Ref. to REMOVAL , MT Gear Shift Lever.
    CAUTION:
    • Do not bend MT gear shift cable and MT gear select cable at a sharp angle.
    • Disconnect the MT gear shift cable and MT gear select cable at the MT gear shift lever side.
    • Always use new MT gear select cable if the cable is removed from selector lever COM PL of transmission side.
  25. Remove the stabilizer link from the front arm. Ref. to REMOVAL , Front Stabilize.
  26. Remove the bolts which secure front arm ball joint to the housing, and separate the front arm and housing. Ref. to REMOVAL , Front Ball Joint.
  27. Separate the front drive shafts on both sides from the transmission. Ref. to REMOVAL , Front Drive Shaft.
  28. Lower the vehicle.
  29. Remove the engine hanger rear, and install the engine hanger rear for turbo model, (non-turbo model)

    Tightening torque: 

    16 N.m (1.6 kgf-m, 11.8 ft-lb) 

    Part No. 10004AA180 Engine hanger rear

    Fig 10: Identifying Engine Hanger Rear ST (10004Aa180)
    G06652263Courtesy of SUBARU OF AMERICA, INC.
  30. Remove the nuts connecting the engine mounting and the transmission main mounting bracket.
    Fig 11: Locating Engine Mounting And Transmission Main Mounting Bracket
    G06652264Courtesy of SUBARU OF AMERICA, INC.
  31. Set the ST on the vehicle and hang the engine.
    CAUTION:
    • Set the ST so that the chain does not contact the sensor and other parts while hanging the engine.
    • Set the arms of ST (ENGINE HANGER) at the locations shown in the figure.

    ST1 99099AJ000 SPECIAL TOOL ENGINE HANGER

    ST2 99099AJ010 SPECIAL TOOL CHAIN BALANCER

    GENERAL TOOL Sling chain

    GENERAL TOOL Screw shackle

    Fig 12: Identifying ST1 Special Tool Engine Hanger (99099AJ000) On Vehicle
    G06652265Courtesy of SUBARU OF AMERICA, INC.
    Fig 13: Identifying ST2 Special Tool Chain Balancer (99099AJ010) On Vehicle
    G06651960Courtesy of SUBARU OF AMERICA, INC.
  32. Remove the stopper rod.
    Fig 14: Locating Stopper Rod Bolts
    G06652267Courtesy of SUBARU OF AMERICA, INC.
  33. Remove the front cushion rubbers.
    Fig 15: Locating Front Cushion Rubbers Bolts
    G06652268Courtesy of SUBARU OF AMERICA, INC.
  34. Attach the ST with the front cushion rubber mounting bolts and nuts.
    CAUTION: Do not tighten the nuts on the engine mount excessively, or the engine mounting bracket may be deformed.

    Tightening torque: 

    25 N.m (2.5 kgf-m, 18.4 ft-lb) 

    ST 41099AJ000 SPECIAL TOOL H4

    Fig 16: Identifying ST Special Tool H4 Bolts (41099AJ000)
    G06652269Courtesy of SUBARU OF AMERICA, INC.
  35. Remove the ST (ENGINE HANGER).
    NOTE: Operation is less efficient with the ST (ENGINE HANGER) attached. Remove it temporarily.
  36. Remove the transmission main mounting bracket.
    Fig 17: Locating Transmission Main Mounting Bracket Bolts
    G06652270Courtesy of SUBARU OF AMERICA, INC.
  37. Remove the bolts which hold upper side of transmission to engine.
    Fig 18: Identifying Upper Side Transmission Bolts
    G05335715Courtesy of SUBARU OF AMERICA, INC.
  38. Attach the ST (ENGINE HANGER) again.
  39. Lift up the vehicle.
  40. Remove the bolts and nuts which hold lower side of transmission to engine.
    Fig 19: Identifying Lower Side Transmission Bolts
    G05002964Courtesy of SUBARU OF AMERICA, INC.
  41. Place the transmission jack under the transmission.
    CAUTION: Always support the transmission case with a transmission jack.
    Fig 20: Supporting Transmission Case With Transmission Jack
    G05002965Courtesy of SUBARU OF AMERICA, INC.
  42. Remove the front crossmember and rear cross-member from the vehicle.
    Fig 21: Locating Front Crossmember And Rear Cross-Member Bolts
    G06652274Courtesy of SUBARU OF AMERICA, INC.
  43. Remove the transmission while lowering the transmission jack.
    NOTE: Move the transmission jack towards the rear until the main shaft is withdrawn from the clutch disc.
  44. Separate the transmission assembly from the transmission cushion rubber.
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