2WD & 4WD Selective Model

Mount transaxle on stand. Remove 2 clutch sleeve clips. Remove release bearing holder (non-turbo vehicles) or release bearing (turbo vehicles). DO NOT deform clutch sleeve clips during removal. Remove dust cover. Remove retainer spring from release lever by pushing lever arm outside case. Remove release lever.
On 4WD models, remove spring pin connecting transfer shift shaft and transfer shift lever on right side of transfer case. Remove transfer cover. Remove pin from transfer shift fork. See Fig 1. Rotate transfer shift rod 180 degrees and remove.
Loosen reverse check sleeve bolts so assembly can move outward away from case approximately .08-.12" (2.0-3.0 mm). See Fig 2. Remove shift fork. Remove ball and spring from case.

Fig 1: Transfer Case & Shifter Assembly (4WD Except Full Time)
Courtesy of SUBARU OF AMERICA, INC.

Fig 2: Exploded View Of Shifting Components
Courtesy of SUBARU OF AMERICA, INC.

CAUTION: DO NOT allow ball and spring to drop when removing shift rod and fork.
On 4WD models, remove extension housing, transfer gear and shifter assembly. Remove transfer shift shaft from right side of transfer case. Remove case plug, gasket, reverse detent spring and ball. Remove shift fork bolt. Remove transfer case and shifter assembly from transmission case. On 2WD models, remove rear case and shifter assembly from transmission case.
On all models, remove bearing mounting bolts, located behind drive pinion shaft. Remove mainshaft rear plate. Wrap tape around drive axle splines. With nuts of case retaining bolts facing upward, remove transaxle case bolts and separate cases. Remove drive pinion shaft. Remove mainshaft assembly from case.
Remove differential assembly from case. Mark side bearing race location. Remove pin from 5th shift fork and remove fork. Remove 3 check ball springs and plugs from transaxle case. Drive pins toward inside of case on 1st-2nd and 3rd-4th shift forks. Remove 3rd-4th shift rod and fork. Remove 1st-2nd rod and fork.
CAUTION: Set all shift rods in Neutral position while removing shift rods and forks.
Remove pin from reverse idler gear shaft. Remove reverse idler gear and washer. See Fig 3. Remove outer snap ring and reverse fork rod arm from reverse fork rod. Remove ball, spring and interlock plunger from rod. Remove reverse fork rod.
CAUTION: DO NOT allow ball to fall from reverse fork rod arm during removal.
Remove differential side retainer from transaxle case. Remove outer snap ring and speedometer driven gear. Remove speedometer shaft and washer.

Fig 3: Exploded View Of Mainshaft Assemblies

Courtesy of SUBARU OF AMERICA, INC.