Transmission Unit Assembly: Assembly

Installation of gear shift fork shaft No. 3
1. Install the gear shift fork shaft No. 3 to the gear shift fork No. 3 with a new bolt.
  Standard value: T=19.5N.m {198.8kgf.cm} {14.4ft.lbf}
  
  Fig 1: Installing Gear Shift Fork Shaft No. 3
  Courtesy of SUBARU OF AMERICA, INC.
Installation of gear shift fork shaft No. 1
1. Install the gear shift fork shaft No. 1 to the gear shift fork No. 1 with a new bolt.
  Standard value: T=19.5N.m {198.8kgf.cm} {14.4ft.lbf}
  
  Fig 2: Locating Gear Shift Fork Shaft No. 1 Bolt
  Courtesy of SUBARU OF AMERICA, INC.
2. Install a new shaft snap ring.
  
  Fig 3: Installing Shaft Snap Ring
  Courtesy of SUBARU OF AMERICA, INC.
3. Install the gear shift fork shaft No. 1 and the gear shift fork No. 1 as a unit to the gear shift fork shaft No. 3 and the gear shift fork No. 3.
  
  Fig 4: Installing Gear Shift Fork Shaft No. 1
  Courtesy of SUBARU OF AMERICA, INC.
4. Install a new shaft snap ring.
  
  Fig 5: Installing Shaft Snap Ring
  Courtesy of SUBARU OF AMERICA, INC.
Installation of gear shift fork shaft No. 2
1. Install the gear shift fork shaft No. 2 to the gear shift fork No. 2 with a new bolt.
  Standard value: T=19.5N.m {198.8kgf.cm} {14.4ft.lbf}
  
  Fig 6: Locating Gear Shift Fork Shaft No. 2 Bolt
  Courtesy of SUBARU OF AMERICA, INC.
2. Install a new shaft snap ring.
  
  Fig 7: Installing Shaft Snap Ring
  Courtesy of SUBARU OF AMERICA, INC.
Installation of transmission front bearing retainer oil seal
1. Use the SST to install a new transmission front bearing retainer oil seal.
  SST 09950-60010 (09951-00420), 09950-70010 (09951-07100)
  
  Standard value: 11.1 to 11.9 mm {0.437 to 0.469 in} (from end face of bearing retainer FR)
  CAUTION:
  - Do not damage the lip of the transmission front bearing retainer oil seal.
  - Do not damage the bearing retainer FR.
2. Apply manual transmission oil to the lip of the transmission front bearing retainer oil seal.
  NOTE: Be sure to use the recommended product or the substitute product for manual transmission oil. (Refer to MANUAL TRANSMISSION OIL )
  
  Fig 8: Installing Transmission Front Bearing Retainer Oil Seal
  Courtesy of SUBARU OF AMERICA, INC.
Installation of reverse idler gear shaft
1. Apply manual transmission oil to the reverse idler gear shaft and install the reverse idler gear shaft to the reverse idler gear.
  NOTE: Be sure to use the recommended product or the substitute product for manual transmission oil. (Refer to MANUAL TRANSMISSION OIL )
  
  Fig 9: Installing Reverse Idler Gear Shaft
  Courtesy of SUBARU OF AMERICA, INC.
Installation of input shaft
1. Apply manual transmission oil to the needle roller bearing of the input shaft, and install the input shaft to the output shaft.
  NOTE: Be sure to use the recommended product or the substitute product for manual transmission oil. (Refer to MANUAL TRANSMISSION OIL )
  
  Fig 10: Installing Input Shaft
  Courtesy of SUBARU OF AMERICA, INC.
Installation of counter shaft
1. Install the input shaft, output shaft, counter shaft, reverse idler gear, reverse idler gear shaft, gear shift fork shaft No. 1, gear shift fork shaft No. 2, and gear shift fork shaft No. 3 as a unit to the clutch housing.
  
  Fig 11: Installing Counter Shaft
  Courtesy of SUBARU OF AMERICA, INC.
2. Temporarily tighten the reverse idler gear shaft with a new bolt via a new gasket. (Clutch housing side)
  
  Fig 12: Locating Reverse Idler Gear Shaft Bolt
  Courtesy of SUBARU OF AMERICA, INC.
3. Use the SST to install 2 new shaft snap rings.
  SST 499895400
  
  NOTE: Install the shaft snap rings on the input shaft side and the counter shaft side.
  
  Fig 13: Installing Shaft Snap Rings
  Courtesy of SUBARU OF AMERICA, INC.
Installation of bearing retainer FR
1. Apply Three Bond 1281 or equivalent continuously like beads to the position of the bearing retainer FR shown in the figure.
  
  Fig 14: Locating Bearing Retainer FR Adhesive Application Area
  Courtesy of SUBARU OF AMERICA, INC.
  
  CAUTION: Install within 10 minutes after applying seal gasket.
2. Apply Adhesive 1344 or equivalent to the 2 to 3 pitches from the tip of a new bolt.
  
  Fig 15: Applying Adhesive 1344 To Bolt
  Courtesy of SUBARU OF AMERICA, INC.
3. Install the bearing retainer FR with the 7 bolts.
  Standard value: T=17N.m {173kgf.cm} {12.5ft.lbf}
  
  CAUTION: Do not damage the lip of the bearing retainer FR oil seal.
  
  Fig 16: Locating Bearing Retainer FR Bolts
  Courtesy of SUBARU OF AMERICA, INC.
Installation of oil receiver pipe
1. Install the oil receiver pipe.
  CAUTION: Check that the tip of the oil receiver pipe is not lifted or disconnected.
  
  Fig 17: Installing Oil Receiver Pipe
  Courtesy of SUBARU OF AMERICA, INC.
Installation of transmission case
1. Apply Three Bond 1281 or equivalent continuously like beads to the position of the transmission case shown in the figure.
  
  Fig 18: Locating Transmission Case Adhesive Application Area
  Courtesy of SUBARU OF AMERICA, INC.
  
  CAUTION: Install within 10 minutes after applying seal gasket.
2. Check the position of the knock pin and install the transmission case.
  
  Fig 19: Installing Transmission Case
  Courtesy of SUBARU OF AMERICA, INC.
3. Apply Adhesive 1324 or equivalent to the 2 to 3 pitches from the tip of a new bolt.
  
  Fig 20: Applying Adhesive 1324 On Bolt
  Courtesy of SUBARU OF AMERICA, INC.
4. Install the transmission case and clamp with the 9 bolts.
  
  Fig 21: Locating Transmission Case Bolts And Clamp
  Courtesy of SUBARU OF AMERICA, INC.
  
  Standard value: T=29N.m {296kgf.cm} {21.4ft.lbf}
5. Install a new reverse idler gear shaft fixing bolt via a new gasket. (Transmission case side)
  Standard value: T=28N.m {286kgf.cm} {20.7ft.lbf}
  
  Fig 22: Locating Reverse Idler Gear Shaft Fixing Bolt
  Courtesy of SUBARU OF AMERICA, INC.
6. Tighten the reverse idler gear shaft fixing bolt. (Clutch housing side)
  Standard value: T=28N.m {286kgf.cm} {20.7ft.lbf}
  
  Fig 23: Locating Reverse Idler Gear Shaft Fixing Bolt
  Courtesy of SUBARU OF AMERICA, INC.
7. Use the SST to install a new shaft snap ring.
  SST 499895400
  
  Fig 24: Installing Shaft Snap Ring
  Courtesy of SUBARU OF AMERICA, INC.
Installation of bearing retainer RR
1. Install the shift arm pivot to the bearing retainer RR.
  
  Fig 25: Locating Shift Arm Pivot
  Courtesy of SUBARU OF AMERICA, INC.
2. Apply Adhesive 1324 or equivalent to the 2 to 3 pitches from the tip of a new bolt.
  
  Fig 26: Applying Adhesive 1324 To Bolt
  Courtesy of SUBARU OF AMERICA, INC.
3. Install the bearing retainer RR with 4 TORX bolts.
  Standard value: T=30N.m {306kgf.cm} {22.1ft.lbf}
  
  Fig 27: Locating Bearing Retainer RR Bolts
  Courtesy of SUBARU OF AMERICA, INC.
Installation of 6th gear thrust washer
1. Install the straight pin to the counter shaft.
  
  Fig 28: Locating Counter Shaft Straight Pin
  Courtesy of SUBARU OF AMERICA, INC.
2. Apply manual transmission oil to the 6th gear thrust washer, and install the 6th gear thrust washer to the counter shaft.
  NOTE: Be sure to use the recommended product or the substitute product for manual transmission oil. (Refer to MANUAL TRANSMISSION OIL )
  
  Fig 29: Installing 6th Gear Thrust Washer To Counter Shaft
  Courtesy of SUBARU OF AMERICA, INC.
Installation of needle roller bearing
1. Apply manual transmission oil to the needle roller bearing and install the needle roller bearing to the counter shaft.
  NOTE: Be sure to use the recommended product or the substitute product for manual transmission oil. (Refer to MANUAL TRANSMISSION OIL )
  
  Fig 30: Installing Needle Roller Bearing
  Courtesy of SUBARU OF AMERICA, INC.
Installation of counter shaft 6th gear
1. Apply manual transmission oil to the counter shaft 6th gear, and install the counter shaft 6th gear to the counter shaft.
  NOTE: Be sure to use the recommended product or the substitute product for manual transmission oil. (Refer to MANUAL TRANSMISSION OIL )
  
  Fig 31: Installing Counter Shaft 6th Gear
  Courtesy of SUBARU OF AMERICA, INC.
Installation of synchronizer ring No. 2
1. Apply manual transmission oil to the synchronizer ring No. 2, and install the synchronizer ring No. 2 to the counter shaft.
  NOTE: Be sure to use the recommended product or the substitute product for manual transmission oil. (Refer to MANUAL TRANSMISSION OIL )
  
  Fig 32: Installing Synchronizer Ring No. 2
  Courtesy of SUBARU OF AMERICA, INC.
Installation of transmission hub sleeve No. 4
1. Apply manual transmission oil to the sliding area of the transmission clutch hub No. 4.
  NOTE: Be sure to use the recommended product or the substitute product for manual transmission oil. (Refer to MANUAL TRANSMISSION OIL )
2. Install the transmission hub sleeve No. 4 to the transmission clutch hub No. 4, and install the 3 balls after installing the 3 synchromesh shifting keys No. 1 and the 3 synchromesh shifting key springs No. 1 as a unit.
  
  Fig 33: Installing Transmission Hub Sleeve No. 4, Balls, Synchromesh Shifting Keys No. 1 And Synchromesh Shifting Key Springs No. 1
  Courtesy of SUBARU OF AMERICA, INC.
  NOTE:
  - Install the balls while pressing the synchromesh shifting key spring No. 1.
  - After the installation, settle the synchromesh shifting key spring No. 1.
3. Install a new hole snap ring.
  
  Fig 34: Installing Hole Snap Ring
  Courtesy of SUBARU OF AMERICA, INC.
Installation of transmission clutch hub No. 4
1. Use the SST to install the transmission clutch hub No. 4, transmission hub sleeve No. 4, and gear shift fork No. 4 as a unit.
  SST 18682AA000
  
  Fig 35: Installing Transmission Clutch Hub No. 4
  Courtesy of SUBARU OF AMERICA, INC.

Installation of shaft snap ring

Select a shaft snap ring so that the thrust clearance between the transmission clutch hub No. 4 and the snap ring is within the standard value.

Standard value: 0 to 0.1 mm {0 to 0.00394 in}

NOTE: Select a shaft snap ring with the maximum thickness that can be installed.

Fig 36: Selecting Shaft Snap Ring

Courtesy of SUBARU OF AMERICA, INC.

Shaft snap ring type

SHAFT SNAP RING SPECIFICATION

Item number	Thickness mm {in}	Identification
17005AA230	2.8 {0.110}	A
17005AA240	2.85 {0.11220}	B
17005AA250	2.90 {0.11417}	C
17005AA260	2.95 {0.11614}	D
17005AA270	3.00 {0.11811}	E
17005AA280	3.05 {0.12007}	F

Install a new shaft snap ring to the counter shaft.

Fig 37: Installing Shaft Snap Ring To Counter Shaft
Courtesy of SUBARU OF AMERICA, INC.

Installation of gear shift head No. 2
1. Install the gear shift head No. 2 to the gear shift fork shaft No. 2.
2. Install a new slotted spring pin to the gear shift fork shaft No. 2.
  CAUTION: Do not drive in the pin excessively.
  Standard value: 0 mm {0 in} (from end face of gear shift head No. 2)
  
  Fig 38: Installing Gear Shift Head No. 2
  Courtesy of SUBARU OF AMERICA, INC.
Installation of 5th shift head
1. Install the compression spring to the 5th shift head, and install the 5th shift head to the gear shift fork shaft No. 3 while pressing the ball with the pin punch 5.
  
  Fig 39: Installing Compression Spring And Ball To 5th Shift Head
  Courtesy of SUBARU OF AMERICA, INC.
2. Install the washer.
  
  Fig 40: Locating Washer
  Courtesy of SUBARU OF AMERICA, INC.
3. Install a new shaft snap ring to the gear shift fork shaft No. 3.
  
  Fig 41: Installing Shaft Snap Ring To Gear Shift Fork Shaft No. 3
  Courtesy of SUBARU OF AMERICA, INC.
Installation of gear shift fork shaft No. 3
1. Insert the gear shift fork shaft No. 3 in the direction shown in the figure, install the ball and the compression spring, and tighten a new head straight screw plug.
  Standard value: T=19N.m {194kgf.cm} {14.0ft.lbf}
  
  Fig 42: Installing Gear Shift Fork Shaft No. 3
  Courtesy of SUBARU OF AMERICA, INC.
Installation of shift arm
1. Install the shift arm to the shift arm pivot.
  
  Fig 43: Installing Shift Arm To Shift Arm Pivot
  Courtesy of SUBARU OF AMERICA, INC.
2. Install a new E-ring to the shift arm pivot.
  
  Fig 44: Installing E-Ring To Shift Arm Pivot
  Courtesy of SUBARU OF AMERICA, INC.
Installation of gear shift fork shaft No. 2
1. Install 2 balls to the gear shift fork shaft No. 3.
  
  Fig 45: Installing Gear Shift Fork Shaft No. 2
  Courtesy of SUBARU OF AMERICA, INC.
2. Insert the gear shift fork shaft No. 2 in the direction shown in the figure, install the ball and the compression spring, and tighten 2 new head straight screw plugs.
  Standard value: T=19N.m {194kgf.cm} {14.0ft.lbf}
  
  Fig 46: Installing Ball And Compression Spring And New Head Straight Screw Plugs
  Courtesy of SUBARU OF AMERICA, INC.
3. Install a new bolt to the gear shift fork shaft No. 2.
  Standard value: T=19.5N.m {198.8kgf.cm} {14.4ft.lbf}
  
  Fig 47: Locating Gear Shift Fork Shaft No. 2 Bolt
  Courtesy of SUBARU OF AMERICA, INC.
Installation of gear shift head No. 3
1. Install the gear shift head No. 3 to the gear shift fork shaft No. 3.
  NOTE: Install while rotating the gear shift head No. 3 so as to insert the shift arm in the groove of the gear shift head No. 3.
2. Install a new slotted spring pin to the gear shift fork shaft No. 3.
  CAUTION: Do not drive in the pin excessively.
  Standard value: 0 mm {0 in} (from end face of gear shift head No. 3)
  
  Fig 48: Installing Gear Shift Head No. 3
  Courtesy of SUBARU OF AMERICA, INC.
Installation of gear shift head No. 1
1. Install the gear shift head No. 1 to the gear shift fork shaft No. 1.
2. Install a new slotted spring pin to the gear shift fork shaft No. 1.
  CAUTION: Do not drive in the pin excessively.
  Standard value: 0 mm {0 in} (from end face of gear shift head No. 1)
  
  Fig 49: Installing Gear Shift Head No. 1
  Courtesy of SUBARU OF AMERICA, INC.
Installation of shift inner lever FR
1. Apply Adhesive 1324 or equivalent to the 2 to 3 pitches from the tip of a new bolt.
  
  Fig 50: Applying Adhesive 1324 To Bolt
  Courtesy of SUBARU OF AMERICA, INC.
2. Install the shift inner lever FR to the shift shaft with a new bolt.
  Standard value: T=33.3N.m {339.5kgf.cm} {24.6ft.lbf}
  
  Fig 51: Locating Shift Shaft Bolt
  Courtesy of SUBARU OF AMERICA, INC.
Installation of shift inner lock block No. 1
1. Install the shift inner lock block No. 1 to the shift shaft.
  
  Fig 52: Installing Shift Inner Lock Block No. 1
  Courtesy of SUBARU OF AMERICA, INC.
Installation of shift shaft
1. Slide and install the shift shaft and the shift inner lock block No. 1.
  
  Fig 53: Installing Shift Shaft
  Courtesy of SUBARU OF AMERICA, INC.
Installation of extension housing oil receiver pipe No. 1
1. Install the straight pin.
  
  Fig 54: Installing Straight Pin
  Courtesy of SUBARU OF AMERICA, INC.
2. Install the extension housing oil receiver pipe No. 1 and the stopper plate with a new bolt.
  Standard value: T=8.5N.m {87kgf.cm} {6.3ft.lbf}
  
  NOTE: Make sure the end of the oil receiver pipe No. 1 is inserted in the groove.
  
  Fig 55: Locating Extension Housing Oil Receiver Pipe Bolt No. 1
  Courtesy of SUBARU OF AMERICA, INC.
Installation of extension housing oil receiver pipe No. 2
1. Install the extension housing oil receiver pipe No. 2.
  
  Fig 56: Locating Extension Housing Oil Receiver Pipe Bolt No. 2
  Courtesy of SUBARU OF AMERICA, INC.
Installation of transmission extension housing oil seal
1. Apply manual transmission oil to the lip of a new transmission extension housing oil seal.
  NOTE: Be sure to use the recommended product or the substitute product for manual transmission oil. (Refer to MANUAL TRANSMISSION OIL )
2. Use the SST to install a new transmission extension housing oil seal.
  SST 09325-20010
  
  Standard value: 0.1 to 1.1 mm {0.00394 to 0.0433} (from end face of transmission extension housing sub-assembly (MTM))
  
  CAUTION: Do not damage the lip of the transmission extension housing oil seal.
  
  Fig 57: Installing Transmission Extension Housing Oil Seal
  Courtesy of SUBARU OF AMERICA, INC.
Installation of extension housing dust deflector
1. Use the SST to install a new extension housing dust deflector.
  SST 09950-60020 (09951-00750), 09950-70010 (09951-07100)
  
  NOTE: Drive in the deflector until it contacts the transmission extension housing sub-assembly (MTM).
  
  Fig 58: Installing Extension Housing Dust Deflector
  Courtesy of SUBARU OF AMERICA, INC.
Installation of extension housing rear oil seal
1. Use the SST to install a new extension housing rear oil seal.
  SST 18657AA040
  
  Standard value: 1.0 to 2.0 mm {0.0394 to 0.0787 in} (from end face of transmission extension housing sub-assembly (MTM))
  
  CAUTION: Do not damage the lip of the extension housing rear oil seal.
2. Apply manual transmission oil to the lip of the extension housing rear oil seal.
  NOTE: Be sure to use the recommended product or the substitute product for manual transmission oil. (Refer to MANUAL TRANSMISSION OIL )
  
  Fig 59: Installing Extension Housing Rear Oil Seal
  Courtesy of SUBARU OF AMERICA, INC.
Installation of transmission extension housing sub-assembly (MTM)
1. Apply Three Bond 1281 continuously like beads to the position of the transmission extension housing sub-assembly (MTM) shown in the figure.
  
  Fig 60: Locating Transmission Extension Housing Sub-Assembly Sealant Application Area
  Courtesy of SUBARU OF AMERICA, INC.
  CAUTION:
  - Install within 10 minutes after applying seal gasket.
  - Be sure to install the transmission extension housing sub-assembly (MTM) with the shift position in neutral status.
2. Install the transmission extension housing sub-assembly (MTM) and the clamp with the 8 new bolts.
  
  Fig 61: Locating Transmission Extension Housing Clamp And Bolts
  Courtesy of SUBARU OF AMERICA, INC.
  
  Standard value: T=29N.m {296kgf.cm} {21.4ft.lbf}
  
  CAUTION: Align the knock pin into the knock pin hole correctly.
3. Install a new bolt.
  Standard value: T=31N.m {316kgf.cm} {22.9ft.lbf}
  
  Fig 62: Locating Transmission Extension Housing Bolt
  Courtesy of SUBARU OF AMERICA, INC.
Holder installation
1. Install a new holder, compression spring, and lock ball pin.
  Standard value: T=39.2N.m {399.7kgf.cm} {28.9ft.lbf}
  
  Fig 63: Installing Holder, Compression Spring And Lock Ball Pin
  Courtesy of SUBARU OF AMERICA, INC.
Installation of lock ball pin
1. Install a new head straight screw plug, compression spring, and lock ball pin.
  Standard value: T=24.5N.m {249.8kgf.cm} {18.1ft.lbf}
  
  Fig 64: Installing Head Straight Screw Plug, Compression Spring And Lock Ball Pin
  Courtesy of SUBARU OF AMERICA, INC.
Installation of wiring harness clamp bracket
1. Install the wiring harness clamp bracket with a new bolt.
  Standard value: T=7.0N.m {71kgf.cm} {5.2ft.lbf}
  
  Fig 65: Locating Wiring Harness Clamp Bracket
  Courtesy of SUBARU OF AMERICA, INC.
Installation of neutral switch
1. Install the neutral switch and a new gasket.
  Standard value: T=32.3N.m {329.4kgf.cm} {23.8ft.lbf}
  
  CAUTION: When tightening by combining a torque wrench and union nut wrench to extend the whole length, the actual torque will be excessive if tightened until the reading of the torque wrench reaches the specified tightening torque. (Refer to WORKING PRECAUTIONS AND NOTES )
  
  Fig 66: Locating Neutral Switch
  Courtesy of SUBARU OF AMERICA, INC.
2. Engage the clamp to connect the neutral switch wire.
  
  Fig 67: Locating Neutral Switch Wire Clamp
  Courtesy of SUBARU OF AMERICA, INC.
Installation of back-up light switch assembly
1. Install the back-up light switch assembly and a new gasket.
  Standard value: T=32.3N.m {329.4kgf.cm} {23.8ft.lbf}
  
  CAUTION: When tightening by combining a torque wrench and union nut wrench to extend the whole length, the actual torque will be excessive if tightened until the reading of the torque wrench reaches the specified tightening torque. (Refer to WORKING PRECAUTIONS AND NOTES )
  
  Fig 68: Locating Back-Up Light Switch Assembly
  Courtesy of SUBARU OF AMERICA, INC.
2. Engage all of the 3 clamps from the rear side with a slack of the harness positioned only at the forward end, and connect the back-up light switch assembly wire and the neutral switch wire.
  
  Fig 69: Locating Back-Up Light Switch Assembly Clamps
  Courtesy of SUBARU OF AMERICA, INC.
Installation of clutch release fork support
1. Install the clutch release fork support to the clutch housing.
  Standard value: T=16N.m {163kgf.cm} {11.8ft.lbf}
  
  Fig 70: Locating Clutch Release Fork Support
  Courtesy of SUBARU OF AMERICA, INC.
Installation of manual transmission drain plug
1. Install the manual transmission drain plug to the transmission case via a new gasket.
  Standard value: T=37N.m {377kgf.cm} {27.3ft.lbf}
  
  Fig 71: Locating Manual Transmission Drain Plug
  Courtesy of SUBARU OF AMERICA, INC.
Installation of manual transmission filler plug
1. Install the manual transmission filler plug to the transmission case via a new gasket.
  Standard value: T=37N.m {377kgf.cm} {27.3ft.lbf}
  
  Fig 72: Locating Manual Transmission Filler Plug
  Courtesy of SUBARU OF AMERICA, INC.