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Manual Transmission Assembly: Installation

WARNING: This page is about a different car, the 2003 Subaru Impreza. However, it is still accessible from the selected car via links, so may be relevant.
  1. Install the rear cushion rubber to the transmission assembly.
    1. Tightening torque:  35 N.m (3.6 kgf-m, 26.3 ft-lb)
  2. Install the clutch release lever and bearing onto the transmission (Turbo model). See TURBO MODEL , INSTALLATION, Release Bearing and Lever.
  3. Install the transmission onto the engine.
    1. Gradually raise the transmission with transmission jack.
    2. Engage them at splines.
    CAUTION: Be careful not to strike main shaft against clutch cover.
  4. Install the transmission rear crossmember.

    Tightening torque: 

    1. T1:  70 N.m (7.1 kgf-m, 51 ft-lb)
    2. T2:  140 N.m (14.3 kgf-m, 103 ft-lb)
    Fig 1: Installing Transmission Rear Crossmember
    G01999414Courtesy of SUBARU OF AMERICA, INC.
  5. Take off the transmission jack.
  6. Tighten the nuts which hold lower side of transmission to the engine.
    1. Tightening torque:  50 N.m (5.1 kgf-m, 36.9 ft-lb)
    Fig 2: Tightening Nuts Holding Lower Side Of Transmission To Engine
    G01999415Courtesy of SUBARU OF AMERICA, INC.
  7. Connect the engine and transmission.
    1. Install the starter. See INSTALLATION , Starter.
    2. Tighten the bolt which holds right upper side of transmission to the engine.
    1. Tightening torque:  50 N.m (5.1 kgf-m, 36.9 ft-lb)
    Fig 3: Tightening Bolt Holding Right Upper Side Of Transmission To Engine
    G01999416Courtesy of SUBARU OF AMERICA, INC.
  8. Remove ST.
    Fig 4: Removing ST
    G01999417Courtesy of SUBARU OF AMERICA, INC.
  9. Push the clutch release lever to fit bearing into clutch cover.
    Fig 5: Pushing Clutch Release Lever To Fit Bearing Into Clutch Cover
    G01999418Courtesy of SUBARU OF AMERICA, INC.
  10. Install the plug.
    1. Tightening torque:  44 N.m (4.5 kgf-m, 32.5 ft-lb)
    Fig 6: Installing Plug
    G01999419Courtesy of SUBARU OF AMERICA, INC.
  11. Install the pitching stopper.

    Tightening torque: 

    1. T1:  50 N.m (5.1 kgf-m, 37 ft-lb)
    2. T2:  58 N.m (5.9 kgf-m, 43 ft-lb)
    Fig 7: Installing Pitching Stopper
    G01999420Courtesy of SUBARU OF AMERICA, INC.
  12. Lift-up the vehicle.
  13. Install the front drive shaft into the transmission.
  14. Drive the spring pin into the chamfered hole of drive shaft.
    CAUTION: Always use a new spring pin.
    Fig 8: Driving Spring Pin Into Chamfered Hole Of Drive Shaft
    G01999421Courtesy of SUBARU OF AMERICA, INC.
  15. Install the ball joints of lower arm into knuckle arm of housing, and tighten the installing bolts.
    1. Tightening torque:  49 N.m (5.0 kgf-m, 36 ft-lb)
    Fig 9: Installing Ball Joints Of Lower Arm Into Knuckle Arm Of Housing
    G01999422Courtesy of SUBARU OF AMERICA, INC.
  16. Install the stabilizer link from the transverse link.
    • Tightening torque:  30 N.m (3.1 kgf-m, 22.1 ft-lb)
      • Fig 10: Installing Stabilizer Link From Transverse Link (Except Sedan Turbo Model)
      G01999424Courtesy of SUBARU OF AMERICA, INC.
    • Tightening torque:  45 N.m (4.6 kgf-m, 33.2 ft-lb)
    Fig 11: Installing Stabilizer Link From Transverse Link (Sedan Turbo Model)
    G01999425Courtesy of SUBARU OF AMERICA, INC.
  17. Install the gear shift rod and stay.
    1. Connect the rod to the joint.
      1. Tightening torque:  18 N.m (1.8 kgf-m, 13.0 ft-lb)
      Fig 12: Installing Gear Shift Rod & Stay
      G00391315Courtesy of SUBARU OF AMERICA, INC.
    2. Connect the stay to the transmission bracket.
      1. Tightening torque:  18 N.m (1.8 kgf-m, 13.0 ft-lb)
      Fig 13: Connecting Stay To Transmission Bracket
      G01999426Courtesy of SUBARU OF AMERICA, INC.
  18. Install the propeller shaft. See INSTALLATION , Propeller Shaft.
  19. Install the heat shield cover (If equipped).
  20. Install the rear exhaust pipe and muffler.
  21. Install the hanger bracket on the right side of transmission.
    Fig 14: Installing Hanger Bracket On Right Side Of Transmission
    G01999427Courtesy of SUBARU OF AMERICA, INC.
  22. Install the front exhaust pipe and center exhaust pipe (Non-turbo model). See INSTALLATION , Front Exhaust Pipe.
  23. Install the center exhaust pipe (Turbo model). See INSTALLATION , Center Exhaust Pipe.
  24. Install the under cover.
  25. Install the operating cylinder.
    1. Tightening torque:  37 N.m (3.8 kgf-m, 27.5 ft-lb)
    Fig 15: Installing Operating Cylinder (Non-Turbo Model)
    G01999428Courtesy of SUBARU OF AMERICA, INC.
    Fig 16: Installing Operating Cylinder (Turbo Model)
    G01999429Courtesy of SUBARU OF AMERICA, INC.
  26. Connect the following connectors.
    1. Transmission ground terminal
      1. Tightening torque:  13 N.m (1.3 kgf-m, 9.4 ft-lb)
    2. Vehicle speed sensor connector
    3. Neutral position switch connector
    4. Back-up light switch connector
  27. Install the air cleaner case stay.
    1. Tightening torque:  16 N.m (1.6 kgf-m, 11.6 ft-lb)
  28. Install the air intake duct and cleaner case (Non-turbo model).

    See INSTALLATION , Air Cleaner Case and INSTALLATION , Air Intake Duct.

  29. Install the intercooler (Turbo model). See INSTALLATION , Inter-cooler.
  30. Connect the battery ground terminal.
  31. Take off the vehicle from lift arms.
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