Transmission Case: Installation

WARNING: This page is about a different car, the 2013 Subaru Forester. However, it is still accessible from the selected car via links, so may be relevant.

Wipe off grease, oil and dust on the mating surfaces of transmission cases with cleaning solvent.
Install the shifter fork and rod. < Refer to INSTALLATION , Shifter Fork and Rod. >
Select the drive pinion shim. < Refer to INSTALLATION , Drive Pinion Shaft Assembly. >
Install the differential side retainer, from which the bearing outer race and O-ring have already been removed, to the transmission case LH side.
Install the front differential assembly.
Install the main shaft assembly for single-range.
NOTE: Align to install the knock pin hole of needle bearing to the transmission case knock pin.
Install the selected drive pinion shims and drive pinion shaft assembly.
NOTE: Align to install the roller bearing knock pin hole to the transmission case knock pin.
Tighten the left and right side of the transmission case with the 17 mounting bolts.
NOTE:
- Insert bolts (11) and (16) from the LH side of the transmission case.
- Match the cases together so that the drive pinion shims are not caught between the cases.
Tightening torque:

8 mm bolt

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

* 10 mm bolt

39 N.m (4.0 kgf-m, 28.8 ft-lb)

Fig 1: Identifying Transmission Case Bolts Tightening Sequence
Courtesy of SUBARU OF AMERICA, INC.
Tighten the roller bearing mounting bolts.
Tightening torque:

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

Fig 2: Identifying Bearing Mounting Bolts
Courtesy of SUBARU OF AMERICA, INC.
Perform backlash adjustment of the hypoid gear and preload adjustment of the roller bearing.
1. Attach the ST on drive pinion assembly.
  ST 498427100 STOPPER
  
  Fig 3: Attaching ST On Drive Pinion Assembly
  Courtesy of SUBARU OF AMERICA, INC.
2. Place the transmission case with the LH side facing downward, and put ST1 on the bearing outer race.
3. Screw the side retainer from the bottom into left case using 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 rotating the ST3 until a slight resistance is felt on ST2.
  This is the contact point of the hypoid gear and the drive pinion shaft. Repeat the above sequence several times to ensure the contact point.
  
  ST1 399780104 WEIGHT
  
  ST2 18630AA010 WRENCH COMPL RETAINER
  
  ST3 499927100 HANDLE
  
  Fig 4: Screwing Retainer Assembly From Bottom Into Left Case Using ST2
  Courtesy of SUBARU OF AMERICA, INC.
4. Remove the WEIGHT, and screw in the side retainer without the O-ring into the RH side of the transmission case, and stop at the point where a slight resistance is felt.
  NOTE: In this condition, the backlash between hypoid gear and drive pinion shaft is zero.
  
  ST 18630AA010 WRENCH COMPL RETAINER
  
  Fig 5: Identifying Wrench Compl Retainer
  Courtesy of SUBARU OF AMERICA, INC.
5. Loosen the side retainer on the LH side of the transmission case by 3 notches, and turn the side retainer on the RH side of the transmission case by the same notches in order to apply backlash.
6. Screw in the side retainer of the RH side of the transmission case additionally by 1 notch in order to apply preload on taper roller bearing.
7. Tighten temporarily both the upper and lower lock plates, and put marks on both the side retainer and lock plate for later readjustment.
  NOTE: If it is hard to install the lock plates, reverse the sides and install them.
8. Turn the transmission main shaft several times while tapping around the retainer lightly with plastic hammer.
Inspect and adjust backlash and tooth contact of the hypoid gear. < Refer to INSPECTION , Front Differential Assembly. >
Separate the transmission case into left and right parts. < Refer to REMOVAL , Transmission Case. >
Check each shifter fork. < Refer to INSPECTION , Shifter Fork and Rod. >
Apply liquid gasket, then join the right side and left side of the case together.
Liquid gasket:

THREE BOND 1215 (Part No. 004403007) or equivalent

Fig 6: Identifying Liquid Gasket Applying Area
Courtesy of SUBARU OF AMERICA, INC.
With brackets and clips as shown in the figure, tighten the seventeen bolts.
NOTE:
- Insert bolts (11) and (16) from the LH side of the transmission case.
- Match the cases together so that the drive pinion shims are not caught between the cases.
Tightening torque:

8 mm bolt

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

* 10 mm bolt

39 N.m (4.0 kgf-m, 28.8 ft-lb)

Fig 7: Identifying Tightening Sequence Of Bolts
Courtesy of SUBARU OF AMERICA, INC.
Tighten the bearing mounting bolts.
Tightening torque:

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

Fig 8: Tightening Bearing Mounting Bolts
Courtesy of SUBARU OF AMERICA, INC.
Remove the lock plate. Then loosen the retainer until the O-ring groove appears. Fit the O-ring into the groove and tighten the retainer into the position where it was not loosened.
NOTE:
- When loosening the retainer, record the number of the turns made.
- Perform this for both left and right side retainers.
- Use new O-rings.
Install the lock plate.
Tightening torque:

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

Fig 9: Lock Plate And Bolts With Torque Specification
Courtesy of SUBARU OF AMERICA, INC.
Select a main shaft rear plate. < Refer to ADJUSTMENT , Main Shaft Assembly for Single-Range. >
Install the clutch release lever and bearing. < Refer to INSTALLATION , Release Bearing and Lever. >
Install the transfer case together with the extension case assembly. < Refer to INSTALLATION , Transfer Case and Extension Case Assembly. >
Install the manual transmission assembly to the vehicle. < Refer to INSTALLATION , Manual Transmission Assembly. >