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Transaxle Reassembly

  1. Install interlock plungers between 1st-2nd and 3rd-4th fork rod holes, and between 3rd-4th and reverse fork rod holes. Install reverse shifter lever, reverse idler gear and reverse idler shaft (from rear side). Drive in pin.
  2. Install reverse arm fork spring, ball and interlock plunger into reverse fork rod arm. Insert reverse fork rod into hole in reverse fork rod arm. Install snap ring. Install check ball, spring, gasket and plug. Tighten to 13-15 ft. lbs. (18-21 N.m).
  3. Position reverse shifter rod toward reverse side. Measure clearance between reverse idler gear and transaxle case. If clearance is not .236-.295" (6.0-7.5 mm), select and install appropriate reverse shifter lever. See REVERSE SHIFTER LEVER SELECTION  table.
  4. Set reverse shifter rod to Neutral position. Measure clearance between reverse idler gear and case. If clearance is not 0-.020" (0-.50 mm), select and install washer(s). See IDLER GEAR WASHER SELECTION  table.
    REVERSE SHIFTER LEVER SELECTION

    Part No. ID No. Remarks
    32820AA000 0 Farther From Case Wall
    32820AA010 - Standard
    32820AA020 2 Closer To Case Wall
    IDLER GEAR WASHER SELECTION

    Part No. Thickness - In. (mm)
    803020151 .016 (0.40)
    803020152 .043 (1.10)
    803020153 .059 (1.50)
    803020154 .075 (1.90)
    803020155 .091 (2.30)
  5. Install 1st-2nd shifter fork and fork rod into case. Align holes in rod and fork. Drive in NEW pin. Install interlock plunger into 3rd-4th fork rod. Install together with 3rd-4th shifter fork into case. Align holes in rod and fork. Drive in NEW pin.
  6. Install 5th shifter fork onto reverse fork rod. Align holes. Drive in pin. Install check balls, springs, gaskets and plugs. Tighten to 13-15 ft. lbs. (18-21 N.m). Install washer, speedometer shaft, vehicle speed sensor, oil seal, speedometer driven gear and snap ring.
  7. Upper number on drive pinion is match number for mating gear. Lower number is for shim adjustment. If no lower number is shown, value is zero.
  8. Loosen bolts on Gauge Assembly (499917500). Adjust until scale indicates .5 when plate end and scale end are even.
  9. Install drive pinion shaft assembly (without shim) into right case. Tighten bearing bolts to 19-24 ft. lbs. (26-32 N.m). Position gauge by inserting gauge pin into case hole. Slide gauge toward pinion. Measure distance at point where it matches with end of drive pinion. See Fig 1.
  10. Determine thickness of drive pinion shim by adding or subtracting value on drive pinion shaft to value indicated on gauge. Add if pinion shaft value is prefixed with a plus (+), or subtract if prefixed with a minus (-). Select 1-3 shims for value determined. See DRIVE PINION SHIM SELECTION  table. Remove drive pinion shaft from case.
    Fig 1: Determining Drive Pinion Shim Thickness
    G93I25492Courtesy of SUBARU OF AMERICA, INC.
  11. Wrap tape around drive axle splines. Install differential assembly into left hand case. Wrap tape around mainshaft splines. Install needle bearing and oil seal onto mainshaft assembly. Apply grease to oil seal lip. Install mainshaft into case. Engage locating pin with hole in needle bearing outer race.
  12. Install drive pinion shaft assembly and selected shims. Engage locating pin of case with hole in bearing outer race. Position mainshaft assembly and drive pinion shaft assembly so there is no clearance between them when moved to front. Select appropriate 1st-2nd, 3rd-4th and 5th shifter forks so coupling sleeves and reverse driven gear are positioned in center of synchronizing mechanisms. See Fig 2, Fig 3 and Fig 4 . See appropriate SHIFT FORK SELECTION table.
    DRIVE PINION SHIM SELECTION

    Part No. Thickness - In. (mm)
    32295AA031 .006 (0.15)
    32295AA041 .007 (0.17)
    32295AA051 .008 (0.20)
    32295AA061 .009 (0.22)
    32295AA071 .010 (0.25)
    32295AA081 .011 (0.27)
    32295AA091 .012 (0.30)
    32295AA101 .020 (0.50)
    SHIFT FORK SELECTION - 1ST-2ND SHIFTER FORK

    Part No. ID No. Remarks
    32804AA060 1 Moves .008" (.20 mm) Closer To 1st Gear
    32804AA070 - Positions In Center
    32804AA080 3 Moves .008" (.20 mm) Closer To 2nd Gear
    SHIFT FORK SELECTION - 3RD-4TH SHIFTER FORK

    Part No. ID No. Remarks
    32804AA060 1 Moves .008" (.20 mm) Closer To 4th Gear
    32804AA070 - Positions In Center
    32804AA100 3 Moves .008" (.20 mm) Closer To 3rd Gear
    SHIFT FORK SELECTION - 5TH SHIFTER FORK

    Part No. Identification No. Remarks
    32804AA060 1 Moves .008" (.20 mm) Closer To 5th Gear
    32804AA070 - Positions In Center
    32804AA100 3 Moves .008" (.20 mm) Away From 5th Gear
    Fig 2: Selecting 1st-2nd Shifter Fork
    G93J25493Courtesy of SUBARU OF AMERICA, INC.
    Fig 3: Selecting 3rd-4th Shifter Fork
    G93A25494Courtesy of SUBARU OF AMERICA, INC.
    Fig 4: Selecting 5th Shifter Fork
    G93B25495Courtesy of SUBARU OF AMERICA, INC.
  13. Measure rod end clearances "A" and "B". See Fig 5. Clearance "A" should be .020-.059" (.50-1.5 mm). Clearance "B" should be .024-.055" (.60-1.4 mm). If clearances are not as specified, replace rod or fork as necessary.
  14. Clean and apply liquid gasket to transaxle case mating surfaces. Assemble case halves. Ensure drive pinion shim and input shaft holder shim are not caught between case halves, and countergear and speedometer gear are meshed.
  15. Insert transaxle case bolts from bottom. Tighten nuts on top. Tighten 8-mm bolts to 17-19 ft. lbs. (23-26 N.m) and 10-mm bolts to 27-31 ft. lbs. (36-42 N.m), in sequence. See Fig 6. Tighten ball bearing bolts to 19-24 ft. lbs. (26-32 N.m).
    Fig 5: Measuring Rod End Clearance
    G96A29827Courtesy of SUBARU OF AMERICA, INC.
    Fig 6: Case Bolt Tightening Sequence
    G93D25497Courtesy of SUBARU OF AMERICA, INC.
  16. Position transmission with left side down. Install Weight (399780104) onto bearing cup. Screw retainer into left case from bottom. Install Handle (499927100) onto main shaft.
  17. Shift transmission into 4th or 5th gear. Rotate shaft several times. Screw in retainer while turning handle until resistance occurs. This is contact point of hypoid gear and drive pinion shaft.
  18. Remove weight. Screw in retainer (without "O" ring) into upper side. Stop when resistance occurs. Backlash between hypoid gear and drive pinion is now zero. Install lock plates. Loosen retainer on lower side by 1 1/2 notches. Tighten upper side retainer by same amount to adjust backlash.
  19. Tighten upper side retainer one notch to apply preload to roller bearing. Temporarily tighten upper and lower lock plates. Rotate mainshaft 12-15 times while tapping retainer lightly to seat bearings.
  20. Install dial gauge through oil drain hole so plunger contacts tooth surface at right angle. Backlash should be .005-.007" (.13-.18 mm). If backlash is outside specified range, rotate upper retainer to adjust.
  21. Apply thin coat of Red lead to both tooth surfaces of 3 or 4 teeth of hypoid gear. Rotate mainshaft until definite contact pattern appears. See Fig 7.
  22. Mark retainers and lock plates. Loosen retainers until "O" ring grooves appear. Install "O" rings into grooves. Retighten retainers to marked positions. Tighten lock plate bolts to 16-20 ft. lbs. (22-27 N.m).
  23. Tap end of mainshaft lightly to ensure zero clearance between main case and bearing. Measure bearing protrusion "A" from surface. See Fig 8. Select and install mainshaft rear plate. See MAINSHAFT REAR PLATE SPECIFICATIONS  table. Install clutch release lever and bearing.
    Fig 7: Determining Gear Tooth Contact Pattern
    G93E25498Courtesy of SUBARU OF AMERICA, INC.
    Fig 8: Measuring Ball Bearing Protrusion
    G93F25499Courtesy of SUBARU OF AMERICA, INC.
    MAINSHAFT REAR PLATE SPECIFICATIONS (1)

    Part No. ID No. Dimension "A" - In. (mm)
    32294AA041 1 .1575-.1626 (4.00-4.13)
    32294AA051 2 .1524-.1571 (3.87-4.00)
    (1) Use appropriate plate for measured dimension "A".
  24. Install rear case assembly. Tighten bolts to 17-19 ft. lbs. (23-26 N.m). Install transfer case with extension housing. Tighten bolts to 17-19 ft. lbs. (23-26 N.m). Fasten selector arm to shifter arm with shifter fork screw. Ensure shifter arm engages rod pawl, and selector arm engages with reverse check sleeve.
  25. Shift transmission into 3rd gear. Shifter arm should move easily toward 1st-2nd gear side, but heavily toward reverse gear side. Adjust so heavy stroke is a little more than light stroke by installing adjuster shim between sleeve assembly and case. Shims are available in thicknesses of .006" (.15 mm) and .012" (.30 mm). If shims alone do not adjust clearance, replace reverse detent shaft. See REVERSE DETENT SHAFT SPECIFICATIONS  table.
  26. Set shifter arm to 5th gear position, and then to reverse gear to verify operation of reverse check mechanism. Verify arm returns to Neutral when released from Reverse. If arm does not return to Neutral, replace reverse check plate. See REVERSE CHECK PLATE SPECIFICATIONS  table. Install transfer cover. Tighten bolts to 10.5-12.7 ft. lbs. (14.2-17.2 N.m).
REVERSE DETENT SHAFT SPECIFICATIONS

Part No. ID Mark Remarks
32188AA020 A Closer To 1st Gear
32188AA002 None Or B Standard
32188AA030 C Closer To Reverse Gear
REVERSE CHECK PLATE SPECIFICATIONS

Part No. ID No. Angle "B" Remarks
32189AA000 0 28° Closer To 5th
32189AA010 1 31° Closer To 5th
32189AA020 2 34° Standard
32189AA030 3 37° Closer To Reverse
32189AA040 4 40° Closer To Reverse
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