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Transmission Case: Installation

WARNING: This page is about a different variant/trim than selected.
  1. Wipe off grease, oil and dust on the mating surfaces of transmission cases with cleaning solvent.
  2. Install the shifter fork and rod. Ref. to MANUAL TRANSMISSION AND DIFFERENTIAL (6MT)>Shifter Fork and Rod>INSTALLATION .
  3. Install the reverse idler gear. Ref. to MANUAL TRANSMISSION AND DIFFERENTIAL (6MT)>Reverse Idler Gear>INSTALLATION .
  4. Select the drive pinion shim. Ref. to MANUAL TRANSMISSION AND DIFFERENTIAL (6MT)>Drive Pinion Shaft Assembly>INSTALLATION .
  5. Install the taper roller bearing outer race to the transmission case LH side, and install the differential side retainer with the O-ring removed.
  6. Install the front differential assembly.
  7. Install the main shaft assembly.
    NOTE: Align to install the needle bearing knock pin hole to the transmission case knock pin.
  8. Install the selected drive pinion shims and drive pinion shaft assembly.
    NOTE: Align the roller bearing knock pin hole to the transmission case knock pin.
  9. 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 

    40 N.m (4.1 kgf-m, 29.5 ft-lb)

    Fig 1: Transmission Case Mounting Bolts Tightening Sequence
    G05003047Courtesy of SUBARU OF AMERICA, INC.
  10. Install the taper roller bearing outer race to the RH side of the transmission case.
  11. Tighten the bearing mounting bolts.

    Tightening torque: 

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

    Fig 2: Identifying Taper Roller Bearing Outer Race Mounting Bolts
    G08582026Courtesy of SUBARU OF AMERICA, INC.
  12. Perform backlash adjustment of the hypoid driven gear and preload adjustment of the taper roller bearing.
    1. Attach the ST on drive pinion shaft assembly.

      ST 18667AA020 HOLDER 

      Fig 3: Attaching ST On Drive Pinion Shaft Assembly
      G08582027Courtesy of SUBARU OF AMERICA, INC.
    2. Place the transmission case with the LH side facing downward, and put ST1 on the taper roller bearing outer race.
    3. Screw in the differential side retainer from the bottom into LH side case using ST2. Fit the ST3 on the main shaft. Shift the gear into 4th or 5th, and turn the shaft several times. Screw in the side retainer while rotating the ST3 until a slight resistance is felt on ST2.

      This is the contact point of the hypoid driven 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 Differential Side Retainer
      G09482649Courtesy of SUBARU OF AMERICA, INC.
    4. Remove the WEIGHT, and screw in the differential 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 driven gear and drive pinion shaft is zero.
      ST 18630AA010 WRENCH COMPL RETAINER 
      Fig 5: Removing Weight And Screw In Differential Side Retainer Without O-Ring Into RH Side Of Transmission Case
      G09482650Courtesy of SUBARU OF AMERICA, INC.
    5. Loosen the differential 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 3 notches in order to apply backlash.
    6. Screw in the differential side retainer of the RH side of the transmission case additionally by 1 notch in order to apply preload on taper roller bearing.
    7. Temporarily tighten both the retainer lock plates LH and RH, and put marks on both the differential 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 differential side retainer lightly with plastic hammer.
  13. Inspect and adjust backlash and tooth contact of the hypoid driven gear. Ref. to MANUAL TRANSMISSION AND DIFFERENTIAL (6MT)>Front Differential Assembly>INSPECTION .
  14. Separate the transmission case into left and right parts. Ref. to MANUAL TRANSMISSION AND DIFFERENTIAL (6MT)>Transmission Case>REMOVAL .
  15. Check each shifter fork. Ref. to MANUAL TRANSMISSION AND DIFFERENTIAL (6MT)>Shifter Fork and Rod>INSPECTION .
  16. Select a main shaft rear plate. Ref. to MANUAL TRANSMISSION AND DIFFERENTIAL (6MT)>Main Shaft Assembly>ADJUSTMENT .
  17. Install the front oil guide.
    NOTE: Fit in all the way.
    Fig 6: Identifying Front Oil Guide
    G08582024Courtesy of SUBARU OF AMERICA, INC.
  18. Apply liquid gasket, then join the right side and left side of the case together.

    Liquid gasket: 

    THREE BOND 1215B or equivalent

    Fig 7: Identifying Liquid Gasket Applying Area On Right Side And Left Side Of Case Together
    G08582031Courtesy of SUBARU OF AMERICA, INC.
  19. Tighten 17 bolts with brackets and clips as shown in the figure.
    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 

    40 N.m (4.1 kgf-m, 29.5 ft-lb)

    Fig 8: Transmission Case Mounting Bolts Tightening Sequence
    G05003047Courtesy of SUBARU OF AMERICA, INC.
  20. Tighten the bearing mounting bolts.

    Tightening torque: 

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

    Fig 9: Identifying Taper Roller Bearing Outer Race Mounting Bolts
    G08582026Courtesy of SUBARU OF AMERICA, INC.
  21. Remove the retainer lock plate, and loosen the differential side retainer until the groove of the O-ring appears. Fit the O-ring into the groove and tighten the side retainer into the position where it was not loosened.
    NOTE:
    • When loosening the side retainer, record the number of the turns made.
    • Perform this for both left and right side retainers.
    • Use new O-rings.
    • Apply transmission gear oil to O-ring.
  22. Install the retainer lock plate.

    Tightening torque: 

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

    Fig 10: Identifying Retainer Lock Plate Bolts With Torque Specification
    G09482655Courtesy of SUBARU OF AMERICA, INC.
  23. Install the transfer case together with the extension case assembly. Ref. to MANUAL TRANSMISSION AND DIFFERENTIAL (6MT)>Transfer Case and Extension Case Assembly>INSTALLATION .
  24. Install the clutch release lever and release bearing. Ref. to CLUTCH SYSTEM>Release Bearing and Lever>INSTALLATION .
  25. Install the manual transmission assembly to the vehicle. Ref. to MANUAL TRANSMISSION AND DIFFERENTIAL (6MT)>Manual Transmission Assembly>INSTALLATION .
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