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Manual Transmission Assembly: Removal

  1. Set the vehicle on a lift.
  2. Remove the front wheels.
  3. Open the front hood completely.
  4. Remove the collector cover. (turbo model)
  5. Remove the air intake duct. Refer to AIR INTAKE DUCT . Refer to AIR INTAKE DUCT .
  6. Remove the 10 clips and detach the grille bracket.
    Fig 1: Locating Grille Bracket Clips
    G07915027Courtesy of SUBARU OF AMERICA, INC.
  7. Disconnect the ground cable from battery.
  8. Remove the air intake boot assembly. (non-turbo model) Refer to AIR INTAKE BOOT .
  9. Remove the intercooler and the intercooler stay. (turbo model) Refer to INTERCOOLER .
  10. Disconnect the engine harness connector.
    • Non-turbo model
      Fig 2: Identifying Engine Harness Connector (Non-Turbo Model)
      G06652255Courtesy of SUBARU OF AMERICA, INC.
    • Turbo model
      Fig 3: Identifying Engine Harness Connector (Turbo Model)
      G06652256Courtesy of SUBARU OF AMERICA, INC.
  11. Disconnect the connector back-up light switch & neutral position switch.
    • Non-turbo model
      Fig 4: Identifying Back-Up Light Switch And Neutral Position Switch Connectors (Non-Turbo Model)
      G07915030Courtesy of SUBARU OF AMERICA, INC.
    • Turbo model
      Fig 5: Identifying Back-Up Light Switch And Neutral Position Switch Connectors (Turbo Model)
      G07915031Courtesy of SUBARU OF AMERICA, INC.
  12. Disconnect the transmission radio ground terminal.
    • Non-turbo model
      Fig 6: Identifying Transmission Radio Ground Terminal (Non-Turbo Model)
      G06652259Courtesy of SUBARU OF AMERICA, INC.
    • Turbo model
      Fig 7: Identifying Transmission Radio Ground Terminal (Turbo Model)
      G06652260Courtesy of SUBARU OF AMERICA, INC.
  13. Remove the throttle body. (non-turbo model) Refer to THROTTLE BODY .
  14. Remove the starter. Refer to STARTER .
  15. Remove the operating cylinder from the transmission, and suspend on a wire.
    Fig 8: Locating Operating Cylinder Mounting Bolts
    G06652261Courtesy of SUBARU OF AMERICA, INC.
  16. Lift up the vehicle.
  17. Remove the front under cover. Refer to FRONT UNDER COVER .
  18. Drain transmission gear oil completely. Refer to REPLACEMENT  .
  19. Remove the front, center and rear exhaust pipes. (non-turbo model) Refer to FRONT EXHAUST PIPE . Refer to CENTER EXHAUST PIPE . Refer to REAR EXHAUST PIPE .
  20. Remove the center and rear exhaust pipes. (turbo model) Refer to CENTER EXHAUST PIPE . Refer to REAR EXHAUST PIPE .
    CAUTION: When removing the exhaust pipes, make sure that each exhaust pipe does not drop off.
  21. Remove the heat shield cover.
    Fig 9: Identifying Heat Shield Cover
    G05661238Courtesy of SUBARU OF AMERICA, INC.
  22. Remove the steering shaft universal joint. Refer to UNIVERSAL JOINT .
  23. Remove the propeller shaft. Refer to PROPELLER SHAFT .
  24. Remove the MT gear shift cable and MT gear select cable from MT gear shift lever. Refer to MT GEAR SHIFT LEVER .
    CAUTION:
    • Do not bend MT gear shift cable and MT gear select cable at a sharp angle.
    • Disconnect the MT gear shift cable and MT gear select cable at the MT gear shift lever side.
    • Always use new MT gear select cable if the cable is removed from selector lever COMPL of transmission side.
  25. Disconnect the stabilizer link from the front arm. Refer to FRONT STABILIZER .
  26. Remove the bolt securing the ball joint of the front arm to the housing, then separate the front arms and the housing. Refer to FRONT BALL JOINT .
  27. Separate the front drive shafts on both sides from the transmission. Refer to FRONT DRIVE SHAFT .
  28. Lower the vehicle.
  29. Remove the engine hanger rear, and install the engine hanger rear for turbo model. (non-turbo model)

    Tightening torque: 

    16 N.m (1.6 kgf-m, 11.8 ft-lb) 

    Part No. 10004AA180 Engine hanger rear

    Fig 10: Identifying Engine Hanger Rear
    G06652263Courtesy of SUBARU OF AMERICA, INC.
  30. Remove the nuts connecting the engine mounting and the transmission main mounting bracket.
    Fig 11: Locating Engine Mounting And Transmission Main Mounting Bracket Nuts
    G06652264Courtesy of SUBARU OF AMERICA, INC.
  31. Set the ST on the vehicle.
    CAUTION:
    • Set the chain so that it does not contact the sensors.
    • Set the arms of ST (ENGINE HANGER) at the locations shown in the figure.

    ST1 99099AJ000 ENGINE HANGER

    ST2 99099AJ010 CHAIN BALANCER

    Fig 12: Identifying Engine Hanger (ST1 99099AJ000)
    G06652265Courtesy of SUBARU OF AMERICA, INC.
    Fig 13: Identifying Chain Balancer (ST2 99099AJ010)
    G06652265Courtesy of SUBARU OF AMERICA, INC.
  32. Remove the stopper rod.
    Fig 14: Identifying Stopper Rod
    G00525678Courtesy of SUBARU OF AMERICA, INC.
  33. Lift the engine slightly and remove the engine mounting bolts.
  34. Remove the engine mounting nut and bolt to remove the engine mounting.
    Fig 15: Locating Engine Mounting Nut And Bolts
    G06652268Courtesy of SUBARU OF AMERICA, INC.
  35. Temporarily attach ST by using two bolts.

    ST 41099AJ000 SPECIAL TOOL H4

    Fig 16: Locating Special Tool Attaching Bolts
    G07915041Courtesy of SUBARU OF AMERICA, INC.
  36. Lift up the engine unit high enough to install the bolt and nut to vehicle.
    CAUTION:
    • Do not lift up higher than enough level to install the ST to avoid damage to the hoses and pipes inside the engine room.
    • Do not tighten the bolts and nuts excessively, or the engine mounting bracket may be deformed.
    NOTE: If it is difficult to pull out the stud bolt from transmission mounting bracket, slightly shake the engine unit while lifting up.
  37. Tighten the mounting bolts on the engine side.

    Tightening torque: 

    25 N.m (2.6 kgf-m, 18.4 ft-lb) 

    Fig 17: Locating Special Tool Attaching Bolts
    G07915042Courtesy of SUBARU OF AMERICA, INC.
  38. Remove the ST (ENGINE HANGER).
  39. Remove the transmission main mounting bracket.
    NOTE: First, remove the transmission mounting bracket on the right side of vehicle, and then tilt the engine unit to remove the left transmission mounting bracket.
    Fig 18: Locating Transmission Main Mounting Bracket Bolts
    G06652270Courtesy of SUBARU OF AMERICA, INC.
  40. Remove the two mounting bolts on the upper side of the transmission.
    Fig 19: Locating Transmission Upper Side Mounting Bolts
    G05335715Courtesy of SUBARU OF AMERICA, INC.
  41. Set the ST (ENGINE HANGER) again to loosen the chain sling.
  42. Lift up the vehicle.
  43. Place the transmission jack under the transmission.
    CAUTION: Always support the transmission case with a transmission jack.
    Fig 20: Supporting Transmission Case With Transmission Jack
    G05002965Courtesy of SUBARU OF AMERICA, INC.
  44. Remove the bolts and nuts which hold lower side of transmission to engine.
    Fig 21: Locating Transmission Lower Side Holding Bolts And Nuts
    G05002964Courtesy of SUBARU OF AMERICA, INC.
  45. Remove the front crossmember and rear crossmember from the vehicle.
    Fig 22: Locating Front Crossmember And Rear Crossmember Mounting Bolts And Nuts
    G06652274Courtesy of SUBARU OF AMERICA, INC.
  46. Lower the transmission rear end (dust cover rear end).
    CAUTION: When lowering the transmission rear end, be careful not to let the converter case and steering mechanical parts contact each other.
    NOTE: Lower the transmission rear end by approx. 80 mm (3.1 in) (reference).
  47. Rotate the handle of ST (ENGINE HANGER) to apply tension to the chain sling.
  48. Remove the transmission assembly.
    NOTE:
    • Move the transmission jack towards the rear until the main shaft is withdrawn from the clutch disc.
    • Remove it while moving the transmission jack up and down so that the engine and transmission remain directly aligned.
  49. Remove the transmission cushion rubber.
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