LEMON Manuals: Even more car manuals for everyone
Home >> Subaru >> 2004 >> Outback L.L. Bean Edition >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 17 (Manual Transmission And Differential) >> Manual Transmission Assembly >> Removal

Manual Transmission Assembly: Removal

WARNING: This page is about a different variant/trim than selected.
  1. Open the front hood fully, and support with stay or the air intake chamber.
  2. Disconnect ground cable from battery.
  3. Remove the air intake duct and cleaner case or the air intake chamber. (Non-TURBO model)

    U5 model 

    Refer to REMOVAL , Air Intake Chamber.

    Refer to REMOVAL , Air Intake Duct.

    Except U5 model 

    Refer to REMOVAL , Air Intake Duct.

    Refer to REMOVAL , Air Cleaner Case.

  4. Remove the air cleaner case stay. (Non-TURBO model)
    Fig 1: Removing Air Cleaner Case Stay
    G00916356Courtesy of SUBARU OF AMERICA, INC.
  5. Remove the intercooler. (Turbo model) Refer to REMOVAL , Intercooler.
  6. Disconnect the following connectors:
    1. Neutral position switch connector
    2. Back-up light switch connector
    3. Vehicle speed sensor
    Fig 2: Disconnecting Vehicle Speed Sensor
    G00916357Courtesy of SUBARU OF AMERICA, INC.
  7. Remove the starter. Refer to REMOVAL , Starter.
  8. Remove the operating cylinder from transmission.
    • NON-TURBO MODEL
      Fig 3: Removing Operating Cylinder From Transmission (Non-Turbo Model)
      G00916358Courtesy of SUBARU OF AMERICA, INC.
    • TURBO MODEL
      Fig 4: Removing Operating Cylinder From Transmission (Turbo Model)
      G00916359Courtesy of SUBARU OF AMERICA, INC.
  9. Remove the pitching stopper.
    Fig 5: Removing Pitching Stopper
    G00916360Courtesy of SUBARU OF AMERICA, INC.
  10. Set the ST.

    ST 41099AA000 ENGINE SUPPORT ASSY

    Fig 6: Setting ST
    G00916361Courtesy of SUBARU OF AMERICA, INC.
  11. Separate the clutch release fork from release bearing. (Turbo model)
    1. Remove the clutch operating cylinder from transmission.
    2. Remove the plug using 10 mm hexagon wrench.
      Fig 7: Removing Plug Using 10 MM Hexagon Wrench
      G00916362Courtesy of SUBARU OF AMERICA, INC.
    3. Screw the 6 mm dia. bolt into release fork shaft, and then remove it.
      Fig 8: Screwing Bolt Into Release Fork Shaft
      G00916363Courtesy of SUBARU OF AMERICA, INC.
    4. Raise the release fork and unfasten the release bearing tabs to free release fork.
    NOTE: Step (4) is required to prevent interference with engine when removing the engine from transmission.
  12. Remove the bolt which holds the right upper side of transmission to engine.
    Fig 9: Removing Bolt Which Holds Right Upper Side Of Transmission To Engine
    G00916364Courtesy of SUBARU OF AMERICA, INC.
  13. Remove the front and center exhaust pipes. (Non-TURBO model). Refer to REMOVAL , Front Exhaust Pipe.
  14. Remove the center exhaust pipe. (Turbo model). Refer to REMOVAL , Center Exhaust Pipe.
  15. Remove the rear exhaust pipe and muffler.
    CAUTION: When removing the exhaust pipes, be careful each exhaust pipe does not drop out. 
  16. Remove the heat shield cover. (If equipped)
  17. Remove the hanger bracket from right side of transmission.
    Fig 10: Removing Hanger Bracket From Right Side Of Transmission
    G00916365Courtesy of SUBARU OF AMERICA, INC.
  18. Remove the propeller shaft. .
  19. Remove the gear shift rod and stay from transmission.
    1. Disconnect the stay from transmission.
    2. Disconnect the rod from transmission.
      Fig 11: Disconnecting Rod From Transmission
      G00916366Courtesy of SUBARU OF AMERICA, INC.
  20. Disconnect the stabilizer link from transverse link.
    Fig 12: Disconnecting Stabilizer Link From Transverse Link
    G00916367Courtesy of SUBARU OF AMERICA, INC.
  21. Remove the bolt securing ball joint of transverse link to housing.
  22. Remove the spring pins and separate the front drive shafts from each side of transmission (Non-TURBO model).
    NOTE: Discard the removing spring pin. Replace with a new one.
    Fig 13: Removing Spring Pins & Separate Front Drive Shafts
    G00916368Courtesy of SUBARU OF AMERICA, INC.
  23. Pull out the front drive shaft from transmission (TURBO model).
    1. Face the "MT" mark on ST toward transmission side.

      ST 28399SA000 DRIVE SHAFT REMOVER

      Fig 14: Identifying ST 28399SA000 Drive Shaft Remover
      G00916369Courtesy of SUBARU OF AMERICA, INC.
    2. Insert the ST into between transmission and front drive shaft.
      NOTE: Contact the protrusion part of ST to transmission case.

      ST 28399SA000 DRIVE SHAFT REMOVER

      Fig 15: Inserting ST Into Between Transmission & Front Drive Shaft
      G00916370Courtesy of SUBARU OF AMERICA, INC.
    3. While holding the joint portion (AAR) of front drive shaft with your hand, push the housing outside to remove from transmission.
  24. Remove the nuts which hold the lower side of transmission to engine.
    Fig 16: Removing Nuts Which Hold Lower Side Of Transmission To Engine
    G00916371Courtesy of SUBARU OF AMERICA, INC.
  25. Place the transmission jack under transmission.
    CAUTION: Always support the transmission case with a transmission jack. 
    Fig 17: Placing Transmission Jack Under Transmission
    G00916372Courtesy of SUBARU OF AMERICA, INC.
  26. Remove the transmission rear crossmember from vehicle.
    Fig 18: Removing Transmission Rear Crossmember From Vehicle
    G00916373Courtesy of SUBARU OF AMERICA, INC.
  27. Remove the transmission.
    NOTE: Move the transmission jack toward rear until main shaft is withdrawn from clutch cover.
  28. Separate the transmission assembly and rear cushion rubber.
  29. Remove the clutch release bearing from engine side. (Turbo model) Refer to REMOVAL , Release Bearing and Lever.
scientia non olet · About LEMON Manuals