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Home >> Subaru >> 2003 >> Forester XS, Automatic >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 1 (Manual Transmission And Differential) >> Manual Transmission Assembly >> Installation

Manual Transmission Assembly: Installation

WARNING: This page is about a different variant/trim than selected.
  1. Replace the differential side retainer oil seal with a new one. Refer to REPLACEMENT , Differential Side Retainer Oil Seal.
  2. Install the rear cushion rubber to transmission assembly.
    1. Tightening torque:  35 N.m (3.57 kgf-m, 25.8 ft-lb)
  3. Install the transmission onto engine.
    1. Gradually raise the transmission with transmission jack.
    2. Engage them at splines.
    NOTE: Be careful not to strike the 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)
    5. Fig 1: Installing Transmission Rear Crossmember
    G02093608Courtesy of SUBARU OF AMERICA, INC.
  5. Take off the transmission jack.
  6. Tighten the nuts and bolts which hold lower side of transmission to engine.
    1. Tightening torque:  50 N.m (5.1 kgf-m, 36.9 ft-lb)
    7. Fig 2: Tightening Nuts & Bolts Holding Lower Side Of Transmission To Engine
    G02093609Courtesy of SUBARU OF AMERICA, INC.
  7. Connect the engine and transmission.
    1. Install the starter. Refer to INSTALLATION , Starter.
    2. Tighten the bolt which holds upper side of transmission to engine.
      1. Tightening torque:  50 N.m (5.1 kgf-m, 36.9 ft-lb)
    8. Fig 3: Tightening Bolt Holding Upper Side Of Transmission To Engine
    G02093610Courtesy of SUBARU OF AMERICA, INC.
  8. Remove the ST.
    9. Fig 4: Removing ST
    G02093611Courtesy of SUBARU OF AMERICA, INC.
  9. 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)
    10. Fig 5: Installing Pitching Stopper
    G02093612Courtesy of SUBARU OF AMERICA, INC.
  10. Lift-up the vehicle.
  11. Install the front drive shaft into transmission. Refer to INSTALLATION , Front Drive Shaft.
  12. 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)
    13. Fig 6: Installing Ball Joints Of Lower Arm Into Knuckle Arm Of Housing
    G02093613Courtesy of SUBARU OF AMERICA, INC.
  13. Install the stabilizer link from transverse link.
    1. Tightening torque:  45 N.m (4.6 kgf-m, 33.2 ft-lb)
    14. Fig 7: Installing Stabilizer Link From Transverse Link
    G02093614Courtesy of SUBARU OF AMERICA, INC.
  14. Install the gear shift rod and stay.
    1. Install the gear shift rod onto transmission.
      1. Tightening torque:  18 N.m (1.8 kgf-m, 13.0 ft-lb)
      Fig 8: Installing Gear Shift Rod Onto Transmission
      G02093615Courtesy of SUBARU OF AMERICA, INC.
    2. Install the stay onto transmission.
      1. Tightening torque:  18 N.m (1.8 kgf-m, 13.0 ft-lb)
  15. Install the propeller shaft.
  16. Install the heat shield cover.
  17. Install the hanger bracket on right side of transmission.
    18. Fig 9: Installing Hanger Bracket On Right Side Of Transmission
    G02093616Courtesy of SUBARU OF AMERICA, INC.
  18. Install the rear exhaust pipe and muffler.
  19. Install the front exhaust pipe and center exhaust pipe.

    Refer to INSTALLATION , Front Exhaust Pipe and INSTALLATION , Center Exhaust Pipe.

  20. Install the under cover.
  21. Install the operating cylinder.
    1. Tightening torque:  37 N.m (3.8 kgf-m, 27.5 ft-lb)
    22. Fig 10: Installing Operating Cylinder
    G02093617Courtesy of SUBARU OF AMERICA, INC.
  22. Connect the following connectors:
    1. Transmission ground cable
      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
  23. Install the air cleaner case stay.
  24. Fill gear oil into the gauge hole.

    Refer to REPLACEMENT , Transmission Gear Oil.

    1. Tightening torque:  16 N.m (1.6 kgf-m, 11.6 ft-lb)
  25. Install the air intake chamber and duct.
  26. Connect the battery ground cable to battery.
  27. Take off the vehicle from lift.
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