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Home >> Subaru >> 1988 >> XT DL >> Repair and Diagnosis >> Transmission >> Manual Trans >> Overhaul - 4 & 5-Speed >> Transaxle Disassembly >> All Except Dual Range Models

All Except Dual Range Models

  1. Mount transaxle in work stand. Disconnect release bearing holder return springs. On 4WD single range models, remove transfer case cover and gasket. Drive out shift fork retaining pin. Remove transfer shift rail, then remove shift fork, ball and spring.
  2. Remove extension housing retaining bolts, extension housing and gasket. Lock transaxle in gear and install gear holder (498787000). Remove staking from pinion shaft lock nut and then remove lock nut. Shift gear to 1st position. Remove lock washer and transfer drive gear from pinion shaft.
  3. Remove transfer case mounting bolts. Using a plastic hammer, tap transfer case off and remove gasket and shim. When removing shifter fork rail, be careful ball does not pop out of transmission case.
  4. On all models, remove clutch release fork and release bearing holder. Remove transmission rear case, main case rear gasket, main shaft rear plate and back-up light clip. Remove drive pinion attaching bolts.
  5. Clean spline portion of the axle drive shafts on right and left sides and wrap with vinyl tape. Separate transmission main case into right and left halves. Remove clutch cable bracket, back-up light cord clip, radio ground and oxygen sensor harness clip.
  6. Remove drive pinion as shown in Fig 1 . Remove transmission main shaft. Remove differential. On 5-speed models, remove spring pin and 5th shifter fork. DO NOT  mix right and left roller bearing outer races.
  7. On all models, remove plugs, gaskets, springs and balls from case. Unscrew shifter fork set screws, and remove 3rd-4th and 1st-2nd shifter forks as well as shifter rails. Remove shifter set screw, reverse shifter rail arm and reverse shifter rail.
  8. Remove oil seal holder lock plates, axle shaft oil seal holders and "O" rings. Remove snap ring and speedometer driven gear. Remove knock pins, reverse idler gear shaft, reverse idler gear and shifter lever.
    Fig 1: Prying Pinion Shaft Out of Case
    G95B55823Courtesy of SUBARU OF AMERICA, INC.
  9. On 5-speed, use a punch to drive out 5th gear shift fork lock pin and remove fork. On all models, remove 3 shift rail plugs, springs and balls. Unscrew shift fork set screws and remove shift forks and fork rails.
    NOTE: When pulling out a rail, keep other rails in neutral position. To remove 3rd-4th rail, rotate it 90°. Take care not to drop shifter rail plungers.
  10. On 4-speed, remove reverse shift fork set screw and remove reverse shift rail arm and reverse shift rail. Remove transaxle case bolts and remove output shaft oil seal holder lock plates. Using remover (399780111), remove drive axle shaft oil seal holder and "O" ring.
  11. Remove speedometer driven gear snap ring and gear. Lightly tap speedometer shaft out of case. Oil seal should come out with shaft. Remove reverse idler gear shaft retaining pins. Remove reverse idler gear shaft, idler gear and shift lever.
  12. On 5-speed, remove reverse idler gear shaft retaining pins. Remove reverse idler gear shaft, idler gear and shift lever. Remove reverse shift rail outer snap ring, then remove shift rail arm and shift rail. Remove reverse shift ball, spring and plunger.
  13. Remove output shaft oil seal holder. Using remover (399780111), remove drive axle shaft oil seal holder and "O" ring. Remove speedometer driven gear snap ring and gear. Lightly tap speedometer shaft out of case. Oil seal should come out with shaft.
NOTE: When removing reverse shift rail arm, ensure ball does not pop out of case.
Fig 2: Removing Mainshaft & Differential Assembly From Transaxle Case
G95C55824Courtesy of SUBARU OF AMERICA, INC.
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