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Manual Transmission Assembly: Installation

WARNING: This page is about a different variant/trim than selected.
  1. Replace the differential side oil seal with a new one. Refer to DIFFERENTIAL SIDE RETAINER OIL SEAL  .
    NOTE: It is not necessary to replace the oil seal if a new one installed.
  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 clutch release lever and bearing onto transmission. (Turbo model) Refer to INSTALLATION , Release Bearing and Lever.
  4. 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.
  5. 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
    G00916374Courtesy of SUBARU OF AMERICA, INC.
  6. Take off the transmission jack.
  7. Tighten the nuts which hold the lower side of transmission to engine.
    1. Tightening torque: 50 N.m (5.1 kgf-m, 36.9 ft-lb) 
    Fig 2: Tightening Nuts Which Hold Lower Side Of Transmission To Engine
    G00916375Courtesy of SUBARU OF AMERICA, INC.
  8. Connect the engine and transmission.
    1. Install the starter.

      Refer to INSTALLATION , Starter.

    2. Tighten the bolt which holds right upper side of transmission to engine.
      1. Tightening torque: 50 N.m (5.1 kgf-m, 36.9 ft-lb) 
      Fig 3: Tightening Bolt Which Holds Right Upper Side Of Transmission To Engine
      G00916376Courtesy of SUBARU OF AMERICA, INC.
  9. Remove the ST.
    Fig 4: Removing ST
    G00916377Courtesy of SUBARU OF AMERICA, INC.
  10. 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 5: Installing Pitching Stopper
    G00916378Courtesy of SUBARU OF AMERICA, INC.
  11. Lift-up the vehicle.
  12. Install the front drive shaft into transmission.
  13. Drive the spring pin into chamfered hole of drive shaft. (Non-TURBO model)
    NOTE: Always use a new spring pin.
    Fig 6: Installing Front Drive Shaft Into Transmission
    G00916379Courtesy of SUBARU OF AMERICA, INC.
  14. Replace the circlip with a new one, and insert the front drive shaft to transmission. (TURBO model) .

    ST 28399SA010 FRONT DRIVE SHAFT OIL SEAL PROTECTOR

  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 7: Installing Ball Joints Of Lower Arm Into Knuckle Arm Of Housing
    G00916380Courtesy of SUBARU OF AMERICA, INC.
  16. Install the stabilizer link from transverse link.
    1. Tightening torque: 30 N.m (3.1 kgf-m, 22.1 ft-lb) 
    Fig 8: Installing Stabilizer Link From Transverse Link
    G00916381Courtesy of SUBARU OF AMERICA, INC.
  17. Install the gear shift rod and stay.
    1. Install the gear shift rod onto transmission.
      Fig 9: Installing Gear Shift Rod Onto Transmission
      G00916382Courtesy of SUBARU OF AMERICA, INC.
    2. Install the stay onto transmission.
  18. Install the propeller shaft. .
  19. Install the heat shield cover. (If equipped)
  20. Install the hanger bracket on right side of transmission.
    Fig 10: Installing Hanger Bracket On Right Side Of Transmission
    G00916383Courtesy of SUBARU OF AMERICA, INC.
  21. Install the rear exhaust pipe and muffler.
  22. Install the front exhaust pipe and center exhaust pipe. (Non-TURBO model)

    Except U5 model 

    Refer to INSTALLATION , Front Exhaust Pipe.

    U5 model 

    Refer to INSTALLATION , Front Exhaust Pipe.

  23. Install the center exhaust pipe. (TURBO model) Refer to INSTALLATION , Front Exhaust Pipe.
  24. Install the under cover.
  25. Push the clutch release lever to fit the bearing into clutch cover. (TURBO model)
    Fig 11: Pushing Clutch Release Lever To Fit Bearing Into Clutch Cover
    G00916384Courtesy of SUBARU OF AMERICA, INC.
  26. Install the operating cylinder.
    1. Tightening torque: 37 N.m (3.8 kgf-m, 27.5 ft-lb) 
    • Non-TURBO MODEL
      Fig 12: Installing Operating Cylinder
      G00916385Courtesy of SUBARU OF AMERICA, INC.
    • TURBO MODEL
      Fig 13: Installing Operating Cylinder Turbo Model
      G00916386Courtesy of SUBARU OF AMERICA, INC.
  27. 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
  28. Install the air cleaner case stay. (Non-TURBO model)
    1. Tightening torque: 16 N.m (1.6 kgf-m, 11.6 ft-lb) 
  29. Install the air cleaner case or the air intake chamber and duct. (Non-TURBO model)
  30. Install the intercooler. (TURBO model)
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