Transmission Unit Assembly: Disassembly

Removal of manual transmission filler plug
1. Remove the manual transmission filler plug and the gasket.
  
  Fig 1: Locating Manual Transmission Filler Plug
  Courtesy of SUBARU OF AMERICA, INC.
Removal of manual transmission drain plug
1. Remove the manual transmission drain plug and the gasket.
  
  Fig 2: Locating Manual Transmission Drain Plug
  Courtesy of SUBARU OF AMERICA, INC.
Removal of clutch release fork support
1. Remove the clutch release fork support from the clutch housing.
  
  Fig 3: Locating Clutch Release Fork Support
  Courtesy of SUBARU OF AMERICA, INC.
Removal of back-up light switch assembly
1. Release the 3 clamps.
  
  Fig 4: Locating Back-Up Light Switch Assembly Clamps
  Courtesy of SUBARU OF AMERICA, INC.
2. Remove the back-up light switch assembly and the gasket.
  
  Fig 5: Locating Back-Up Light Switch Assembly
  Courtesy of SUBARU OF AMERICA, INC.
Removal of neutral switch
1. Release the clamp.
  
  Fig 6: Locating Neutral Switch Clamp
  Courtesy of SUBARU OF AMERICA, INC.
2. Remove the neutral switch and the gasket.
  
  Fig 7: Locating Neutral Switch
  Courtesy of SUBARU OF AMERICA, INC.
Removal of wiring harness clamp bracket
1. Remove the bolt, and then remove the wiring harness clamp bracket.
  
  Fig 8: Locating Wiring Harness Clamp Bracket Bolt
  Courtesy of SUBARU OF AMERICA, INC.
Removal of lock ball pin
1. Remove the head straight screw plug, compression spring, and lock ball pin.
  
  Fig 9: Locating Lock Ball Pin
  Courtesy of SUBARU OF AMERICA, INC.
Removal of holder
1. Remove the holder, compression spring, and lock ball pin.
  
  Fig 10: Locating Holder, Compression Spring And Lock Ball Pin
  Courtesy of SUBARU OF AMERICA, INC.
Removal of transmission extension housing sub-assembly (MTM)
1. Remove the bolt.
  
  Fig 11: Locating Transmission Extension Housing Sub-Assembly Bolt
  Courtesy of SUBARU OF AMERICA, INC.
2. Remove the 8 bolts and the clamp.
  
  Fig 12: Locating Transmission Extension Housing Sub-Assembly Bolts And Clamp
  Courtesy of SUBARU OF AMERICA, INC.
3. Remove the transmission extension housing sub-assembly (MTM).
  CAUTION:
  - Do not damage the transmission extension housing sub-assembly (MTM).
  - Be sure to remove the transmission extension housing sub-assembly (MTM) with the shift position in neutral status.
  Fig 13: Removing Transmission Extension Housing Sub-Assembly (MTM)
  Courtesy of SUBARU OF AMERICA, INC.
Removal of extension housing rear oil seal
1. Remove the extension housing rear oil seal.
  
  Fig 14: Removing Extension Housing Rear Oil Seal
  Courtesy of SUBARU OF AMERICA, INC.
  
  CAUTION: Do not damage the transmission extension housing sub-assembly (MTM).
  
  NOTE: Remove while applying a cloth to prevent damage to the transmission extension housing sub-assembly (MTM).
Removal of extension housing dust deflector
1. Remove the extension housing dust deflector.
  
  Fig 15: Removing Extension Housing Dust Deflector
  Courtesy of SUBARU OF AMERICA, INC.
Removal of transmission extension housing oil seal
1. Remove the transmission extension housing oil seal.
  
  Fig 16: Removing Transmission Extension Housing Oil Seal
  Courtesy of SUBARU OF AMERICA, INC.
  
  CAUTION: Do not damage the transmission extension housing sub-assembly (MTM).
  
  NOTE: Remove while applying a cloth to prevent damage to the transmission extension housing sub-assembly (MTM).
Removal of extension housing oil receiver pipe No. 2
1. Remove the extension housing oil receiver pipe No. 2.
  
  Fig 17: Locating Extension Housing Oil Receiver Pipe No. 2
  Courtesy of SUBARU OF AMERICA, INC.
Removal of extension housing oil receiver pipe No. 1
1. Remove the bolt to remove the extension housing oil receiver pipe No. 1 and the stopper plate.
  
  Fig 18: Locating Extension Housing Oil Receiver Pipe No. 1
  Courtesy of SUBARU OF AMERICA, INC.
2. Remove the straight pin.
  
  Fig 19: Identifying Straight Pin
  Courtesy of SUBARU OF AMERICA, INC.
Removal of shift shaft
1. Slide and remove the shift shaft and the shift inner lock block No. 1.
  
  Fig 20: Removing Shift Shaft
  Courtesy of SUBARU OF AMERICA, INC.
Removal of shift inner lock block No. 1.
1. Remove the shift inner lock block No. 1 from the shift shaft.
  
  Fig 21: Removing Shift Inner Lock Block No. 1
  Courtesy of SUBARU OF AMERICA, INC.
Removal of shift inner lever FR
1. Remove bolt, then remove the shift inner lever FR from the shift shaft.
  CAUTION: Verify the direction of the parts.
  
  Fig 22: Locating Shift Inner Lever FR Bolt
  Courtesy of SUBARU OF AMERICA, INC.
Removal of head straight screw plug
1. Remove the 3 head straight screw plugs.
  
  Fig 23: Locating Head Straight Screw Plugs
  Courtesy of SUBARU OF AMERICA, INC.
2. Remove the 2 compression springs and the 2 balls.
  
  Fig 24: Locating Compression Springs And Balls
  Courtesy of SUBARU OF AMERICA, INC.
Removal of shift arm
1. Remove the E-ring.
  CAUTION: Hold the E-ring with a cloth to prevent it from flying out.
  
  Fig 25: Removing Shift Arm E-Ring
  Courtesy of SUBARU OF AMERICA, INC.
2. Remove the shift arm.
Removal of gear shift fork shaft No. 3
1. Remove the gear shift fork shaft No. 3.
  CAUTION:
  - Do not drop the ball of the 5th shift head.
  - The ball of the transmission case may fall in the transmission case. If the ball falls, pick the ball up when removing the transmission case.
2. Remove the ball of the 5th shift head.
  
  Fig 27: Removing Ball Of 5th Shift Head
  Courtesy of SUBARU OF AMERICA, INC.
3. Remove the ball.
  
  Fig 28: Locating Ball
  Courtesy of SUBARU OF AMERICA, INC.
Removal of 5th shift head
1. Remove the shaft snap ring.
  CAUTION: Hold the shaft snap ring with a cloth to prevent it from flying out.
  
  Fig 29: Removing 5th Shift Head Snap Ring
  Courtesy of SUBARU OF AMERICA, INC.
2. Remove the washer.
  
  Fig 30: Locating Washer
  Courtesy of SUBARU OF AMERICA, INC.
3. Remove the 5th shift head, then remove the ball and the compression spring.
  CAUTION: Do not slide the 5th shift head to prevent the ball and the compression spring from falling.
  
  Fig 31: Removing 5th Shift Head
  Courtesy of SUBARU OF AMERICA, INC.
Check of counter shaft 6th gear thrust clearance
1. Use the SST to check the thrust clearance.
  SST 09350-20015 (09350-06120), 498255400
  
  Standard value: 0.10 to 0.40 mm {0.00394 to 0.0157 in}
  
  Limit: 0.40 mm {0.0157 in}
  
  NOTE: If the value exceeds the limit, replace the counter shaft 6th gear, transmission clutch hub No. 4, 6th gear thrust washer, needle roller bearing, and counter shaft with new ones.
  
  Fig 32: Checking Counter Shaft 6th Gear Thrust Clearance
  Courtesy of SUBARU OF AMERICA, INC.
Check of counter shaft 6th gear radial clearance
1. Check the radial clearance.
  Standard value: 0.015 to 0.068 mm {0.000590 to 0.00268 in}
  
  Limit: 0.068 mm {0.00268 in}
  
  NOTE: If the value exceeds the limit, replace the counter shaft 6th gear, needle roller bearing, and counter shaft with new ones.
  
  Fig 33: Checking Counter Shaft 6th Gear Radial Clearance
  Courtesy of SUBARU OF AMERICA, INC.
Removal of transmission clutch hub No. 4
1. Remove the shaft snap ring.
  CAUTION: Hold the shaft snap ring with a cloth to prevent it from flying out.
  
  Fig 34: Removing Transmission Clutch Hub No. 4 Snap Ring
  Courtesy of SUBARU OF AMERICA, INC.
2. Use the SST to remove the transmission clutch hub No. 4 together with the transmission hub sleeve No. 4, gear shift fork No. 4, and gear shift fork shaft No. 2 as a unit.
  
  Fig 35: Removing Transmission Clutch Hub No. 4
  Courtesy of SUBARU OF AMERICA, INC.
  
  SST 09950-30012 (09951-03010, 09953-03010, 09956-03010)
  
  CAUTION: Verify the direction of the parts.
Removal of gear shift fork No. 4
1. Remove the bolt, then remove the gear shift fork No. 4 from the gear shift fork shaft No. 2.
  
  Fig 36: Locating Gear Shift Fork No. 4 Bolt
  Courtesy of SUBARU OF AMERICA, INC.
Removal of transmission hub sleeve No. 4
1. Remove the hole snap ring.
  
  Fig 37: Removing Transmission Hub Sleeve No. 4 Snap Ring
  Courtesy of SUBARU OF AMERICA, INC.
2. Remove the transmission hub sleeve No. 4, then remove the 3 synchromesh shifting keys No. 1, 3 synchromesh shifting key springs No. 1, and 3 balls from the transmission clutch hub No. 4.
  CAUTION:
  - Keep the synchromesh shifting keys No. 1, synchromesh shifting key springs No. 1, and balls from flying out using a cloth.
  - Be careful not to deform the synchromesh shifting key springs No. 1.
  - Verify the direction of the parts.
  NOTE: Perform the work without displacing the positions of the transmission clutch hub No. 4 and synchromesh shifting keys No. 1.
  
  Fig 38: Keeping Transmission Hub Sleeve No. 4 Components From Flying Out
  Courtesy of SUBARU OF AMERICA, INC.
Removal of synchronizer ring No. 2
1. Remove the synchronizer ring No. 2.
  
  Fig 39: Removing Synchronizer Ring No. 2
  Courtesy of SUBARU OF AMERICA, INC.
Removal of counter shaft 6th gear
1. Remove the counter shaft 6th gear.
  
  Fig 40: Removing Counter Shaft 6th Gear
  Courtesy of SUBARU OF AMERICA, INC.
Removal of needle roller bearing
1. Remove the needle roller bearing.
  
  Fig 41: Removing Needle Roller Bearing
  Courtesy of SUBARU OF AMERICA, INC.
Removal of 6th gear thrust washer
1. Remove the 6th gear thrust washer.
  CAUTION: Verify the direction of the parts.
  
  Fig 42: Removing 6th Gear Thrust Washer
  Courtesy of SUBARU OF AMERICA, INC.
2. Remove the straight pin.
  
  Fig 43: Locating Straight Pin
  Courtesy of SUBARU OF AMERICA, INC.
Removal of gear shift head No. 2
1. Remove the slotted spring pin.
2. Remove the gear shift head No. 2 from the gear shift fork shaft No. 2.
  CAUTION:
  - Hold the slotted spring pin with a cloth to prevent it from flying out.
  - Do not drop the slotted spring pin from the fork shaft hole into the inside.
  - Verify the direction of the parts.
  Fig 44: Removing Gear Shift Head No. 2
  Courtesy of SUBARU OF AMERICA, INC.
Removal of gear shift head No. 1.
1. Remove the slotted spring pin.
2. Remove the gear shift head No. 1 from the gear shift fork shaft No. 1.
  
  Fig 45: Removing Gear Shift Head No. 1
  Courtesy of SUBARU OF AMERICA, INC.
Removal of gear shift head No. 3
1. Remove the slotted spring pin.
2. Remove the gear shift head No. 3 from the gear shift fork shaft No. 3.
  
  Fig 46: Removing Gear Shift Head No. 3
  Courtesy of SUBARU OF AMERICA, INC.
Removal of bearing retainer RR
1. Remove 4 TORX bolts to remove the bearing retainer RR.
  
  Fig 47: Locating Bearing Retainer RR Bolts
  Courtesy of SUBARU OF AMERICA, INC.
2. Remove the shift arm pivot.
  
  Fig 48: Locating Shift Arm Pivot
  Courtesy of SUBARU OF AMERICA, INC.
Removal of transmission case
1. Use the SST to remove the shaft snap ring.
  SST 499895400
  
  Fig 49: Removing Shaft Snap Ring
  Courtesy of SUBARU OF AMERICA, INC.
2. Remove the reverse idler gear shaft fixing bolt and the gasket. (Transmission case side)
  
  Fig 50: Locating Reverse Idler Gear Shaft Fixing Bolt
  Courtesy of SUBARU OF AMERICA, INC.
3. Remove the 9 bolts and the clump.
  
  Fig 51: Locating Transmission Case Bolts
  Courtesy of SUBARU OF AMERICA, INC.
4. Remove the transmission case.
  CAUTION: Do not damage the transmission case.
  
  Fig 52: Removing Transmission Case
  Courtesy of SUBARU OF AMERICA, INC.
Removal of oil receiver pipe
1. Remove the oil receiver pipe.
  
  Fig 53: Removing Oil Receiver Pipe
  Courtesy of SUBARU OF AMERICA, INC.
Removal of bearing retainer FR
1. Remove the 7 bolts, then remove the bearing retainer FR.
  
  Fig 54: Locating Bearing Retainer FR Bolts
  Courtesy of SUBARU OF AMERICA, INC.
Removal of transmission front bearing retainer oil seal
1. Remove the transmission front bearing retainer oil seal.
  
  Fig 55: Removing Transmission Front Bearing Retainer Oil Seal
  Courtesy of SUBARU OF AMERICA, INC.
  
  CAUTION: Do not damage the bearing retainer FR.
  
  NOTE: Remove while applying a cloth to prevent damage to the bearing retainer FR.
Removal of counter shaft
1. Use the SST to remove the 2 shaft snap rings.
  SST 499895400
  
  NOTE: Remove the shaft snap rings on the input shaft side and the counter shaft side.
  
  Fig 56: Removing Shaft Snap Rings
  Courtesy of SUBARU OF AMERICA, INC.
2. Remove the bolt and the gasket to free the reverse idler gear and the reverse idler gear shaft. (Clutch housing side)
  
  Fig 57: Locating Reverse Idler Gear Bolt
  Courtesy of SUBARU OF AMERICA, INC.
3. Remove 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 by hitting them from the clutch housing side with the handle of a hammer.
  
  Fig 58: Removing Counter Shaft, Reverse Idler Gear, Reverse Idler Gear Shaft
  Courtesy of SUBARU OF AMERICA, INC.
Removal of gear shift fork shaft No. 2
1. Remove the shaft snap ring.
  CAUTION: Hold the shaft snap ring with a cloth to prevent it from flying out.
  
  Fig 59: Removing Gear Shift Fork Shaft No. 2 Snap Ring
  Courtesy of SUBARU OF AMERICA, INC.
2. Remove the bolt, then remove the gear shift fork shaft No. 2.
  
  Fig 60: Locating Gear Shift Fork Shaft No. 2 Bolt
  Courtesy of SUBARU OF AMERICA, INC.
Removal of gear shift fork shaft No. 1
1. Remove the shaft snap ring.
  CAUTION: Hold the shaft snap ring with a cloth to prevent it from flying out.
  
  Fig 61: Removing Gear Shift Fork Shaft No. 1 Snap Ring
  Courtesy of SUBARU OF AMERICA, INC.
2. Remove the gear shift fork shaft No. 1 and the gear shift fork No. 1 as a unit.
  
  Fig 62: Removing Gear Shift Fork Shaft No. 1
  Courtesy of SUBARU OF AMERICA, INC.
3. Remove the shaft snap ring.
  CAUTION: Hold the shaft snap ring with a cloth to prevent it from flying out.
  
  Fig 63: Removing Shaft Snap Ring
  Courtesy of SUBARU OF AMERICA, INC.
4. Remove the bolt, then remove the gear shift fork shaft No. 1.
  
  Fig 64: Locating Gear Shift Fork Shaft No. 1 Bolt
  Courtesy of SUBARU OF AMERICA, INC.
Removal of gear shift fork shaft No. 3
1. Remove the bolt, then remove the gear shift fork shaft No. 3.
  
  Fig 65: Locating Gear Shift Fork Shaft No. 3 Bolt
  Courtesy of SUBARU OF AMERICA, INC.
Removal of input shaft
1. Remove the input shaft from the output shaft.
  
  Fig 66: Identifying Input And Output Shafts
  Courtesy of SUBARU OF AMERICA, INC.
Check of reverse idler gear radial clearance
1. Secure the reverse idler gear shaft with a vise and check the radial clearance.
  Standard value: 0.040 to 0.082 mm {0.00157 to 0.00323 in}
  
  Limit: 0.082 mm {0.00323 in}
  
  NOTE: If the value exceeds the limit, replace the reverse idler gear and the reverse idler gear shaft with new ones.
  
  Fig 67: Checking Reverse Idler Gear Radial Clearance
  Courtesy of SUBARU OF AMERICA, INC.
Removal of reverse idler gear shaft
1. Remove the reverse idler gear shaft from the reverse idler gear.
  
  Fig 68: Identifying Reverse Idler Gear Shaft
  Courtesy of SUBARU OF AMERICA, INC.