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Release Bearing and Lever: Installation

WARNING: This page is about a different car, the 2004 Subaru Outback, 2004 Subaru Legacy, and 2004 Subaru Baja. However, it is still accessible from the selected car via links, so may be relevant.
  1. NON-TURBO MODEL 
    1. Before assembly, lubricate the following points with a coat of grease.
      • Contact surface of lever and pivot
      • Contact surface of lever and bearing
      • Transmission main shaft spline (Use grease containing molybdenum disulphide.)
      • Contact surface of lever and operating cylinder
    2. While pushing the fork to pivot and twisting it to both sides, fit the retainer spring onto the constricted portion of pivot.

      Apply grease (SUNLIGHT 2: P/N 003602010) to the contact point of release lever and operating cylinder.

    3. Confirm that the retainer spring is securely fitted by observing it through the release lever hole.
      Fig 1: Installing Retainer Spring
      G00919679Courtesy of SUBARU OF AMERICA, INC.
    4. Install the release bearing and fasten it with two clips.
    5. Install the release lever dust cover.
      Fig 2: Installing Release Lever Dust Cover
      G00919680Courtesy of SUBARU OF AMERICA, INC.
    6. Verify that the bearing moves smoothly with operating release fork.
    7. Install the transmission assembly. Refer to INSTALLATION , Manual Transmission Assembly.
  2. TURBO MODEL 
    1. Install the release bearing on transmission.
    2. Insert the release fork into release bearing tab.
      Fig 3: Installing Release Fork Into Release Bearing Tab
      G00919681Courtesy of SUBARU OF AMERICA, INC.
    3. Apply grease to the specified points:
      • Spline FX2200 (Part No. 000040901)
      • Shaft SUNLIGHT 2 (Part No. 003602010)
        Fig 4: Applying Grease To Shaft SUNLIGHT 2 & Spline FX2200
        G00919682Courtesy of SUBARU OF AMERICA, INC.
    4. Insert the fork shaft into release fork.
      NOTE: Make sure the cutout portion of fork shaft contacts spring pin.
      Fig 5: Installing Fork Shaft Into Release Fork
      G00919683Courtesy of SUBARU OF AMERICA, INC.
    5. Tighten the plug.
      1. Tightening torque: 44 N.m (4.5 kgf-m, 32.5 ft-lb) 
        Fig 6: Tightening Plug
        G00919684Courtesy of SUBARU OF AMERICA, INC.
    6. Install the transmission assembly.

      Refer to INSTALLATION , Manual Transmission Assembly.

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