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Manual Transaxle & Differential: Removal & Installation Subaru Outback BS

Manual Trans 28 illustrations ~1990 words

REPLACEMENT

  1. Lift up the vehicle.
  2. Remove the front under cover. Refer to «REMOVAL»(ref-646002-S00701002792014072500000) .
  3. Using the TORX® bit T70, remove the drain plug, and drain the transmission gear oil completely.
  4. Tighten the drain plug using TORX® bit T70. NOTE: Use a new gasket. Tightening torque: 44 N.m (4.5 kgf-m, 32.5 ft-lb) (Aluminum gasket silver) 70 N.m (7.1 kgf-m, 51.6 ft-lb) (Copper gasket, brown) 70 N.m (7.1 kgf-m, 51.6 ft-lb) (Metal gasket, black)
  5. Remove the center exhaust pipe. Refer to «REMOVAL»(ref-646019-S19251222692014072500000) .
  6. Separate the front drive shaft from the transmission. Refer to «REMOVAL»(ref-645998-S03685232552014072500000) .
  7. Remove the differential side retainer oil seal. NOTE: Use the ST 398527700 PULLER ASSY to remove the oil seal. If removing the oil seal with a flat tip screwdriver, be careful not to scratch the differential side retainer.
  8. Using the ST, install the differential side retainer oil seal by lightly tapping with a plastic hammer. NOTE: Apply transmission gear oil to the oil seal lips, and install the oil seal while being careful not to deform the lip. Check the identification marks (L, R) during installation not to mix up the oil seal RH and LH. Use a new oil seal. ST 18675AA000 DIFFERENTIAL SIDE OIL SEAL INSTALLER
  9. Install the front drive shaft. Refer to «INSTALLATION»(ref-645998-S27218978612014072500000) .
  10. Install the center exhaust pipe. Refer to «INSTALLATION»(ref-646019-S38975430962014072500000) .
  11. Install the front under cover. Refer to «INSTALLATION»(ref-646002-S01834874552014072500000) .
  12. Lower the vehicle.
  13. Add the transmission gear oil through the oil level gauge hole. Refer to «TRANSMISSION GEAR OIL»(ref-645990-S32949908802014072500000) .

Scheme 99

Scheme 99: BACK-UP LIGHT AND NEUTRAL POSITION SWITCH
Scheme 99: BACK-UP LIGHT AND NEUTRAL POSITION SWITCH

Scheme 100

Scheme 100
Scheme 100
  1. Disconnect the ground cable from battery.
  2. Remove the air intake boot assembly. Refer to «REMOVAL»(ref-645985-S19408889572014072500000) .
  3. Disconnect the connector back-up light switch & neutral position switch.
  4. Lift up the vehicle.
  5. Remove the back-up light switch & neutral position switch with the harness.

Scheme 101

Scheme 101: BACK-UP LIGHT SWITCH & NEUTRAL POSITION SWITCH
Scheme 101: BACK-UP LIGHT SWITCH & NEUTRAL POSITION SWITCH
  1. Install the back-up light switch & neutral position switch with the harness. NOTE: Use a new gasket. Tightening torque: 32.3 N.m (3.3 kgf-m, 23.8 ft-lb)
  2. Lower the vehicle.
  3. Connect the connectors of back-up light switch & neutral position switch.
  4. Install the air intake boot assembly. Refer to «INSTALLATION»(ref-645985-S25796957322014072500000) .
  5. Connect the battery ground terminal.

INSTALLATION

  1. Install the transfer drive gear. Tightening torque: 26 N.m (2.7 kgf-m, 19.2 ft-lb)
  2. Install the transfer driven gear. Refer to «INSTALLATION»(ref-645990-S20692629432014072500000) .
  3. Select a thrust washer. Refer to «INSTALLATION»(ref-645990-S12292030082014072500000) .
  4. Install the extension case assembly. Refer to «INSTALLATION»(ref-645990-S12292030082014072500000) .
  5. Install the transfer case and the extension case assembly. Refer to «INSTALLATION»(ref-645990-S12292030082014072500000) .
  6. Install the back-up light switch and the neutral position switch. Refer to «INSTALLATION»(ref-645990-S16936247582014072500000) .
  7. Install the manual transmission assembly to the vehicle. Refer to «INSTALLATION»(ref-645990-S24838663312014072500000) .

Scheme 102

Scheme 102: DISASSEMBLY
Scheme 102: DISASSEMBLY

Scheme 103

Scheme 103
Scheme 103
  1. Remove the snap ring.
  2. Remove the ball bearing. NOTE: Do not reuse the ball bearing. ST 899864110 REMOVER
  3. Remove the snap ring from transfer drive gear, and remove the needle bearing.

Scheme 104

Scheme 104: ASSEMBLY
Scheme 104: ASSEMBLY
  1. Install the needle bearing and snap ring to the transfer drive gear.
  2. Set the ST to the bearing inner race, then install the transfer drive gear to the bearing. CAUTION: Do not apply a load in excess of 10 kN (1 ton, 1.1 US ton, 1.0 Imp ton). NOTE: Use a new ball bearing. ST 398177700 INSTALLER
  3. Install the snap ring on the transfer drive shaft.
  4. Inspect the clearance between the snap ring and the ball bearing. Refer to «INSPECTION»(ref-645990-S03743488782014072500000) .

Scheme 105

Scheme 105: INSPECTION
Scheme 105: INSPECTION
  1. Bearing Replace the bearings in the following cases. In case of broken or rusty bearings In case of wear or damage When the bearings fail to turn smoothly or emit noise in rotation after gear oil lubrication.
  2. Drive gear If the drive gear tooth surface and shaft are excessively broken or damaged, replace the drive gear.
  3. Measure the clearance between snap ring and inner race of ball bearing with a thickness gauge. Clearance: 0.01 - 0.15 mm (0.0004 - 0.0059 in) If the measurement is not within specification, select a suitable snap ring and replace it. Snap ring (outer-30) Part No. Thickness mm (in) 805030041 1.53 (0.0602) 805030042 1.65 (0.0650) 805030043 1.77 (0.0697)

Scheme 106

Scheme 106
Scheme 106
  1. Remove the manual transmission assembly from the vehicle. Refer to «REMOVAL»(ref-645990-S08806509112014072500000) .
  2. Remove the back-up light switch and the neutral position switch. Refer to «REMOVAL»(ref-645990-S23757368862014072500000) .
  3. Remove the transfer case together with the extension case assembly. Refer to «REMOVAL»(ref-645990-S23238927522014072500000) .
  4. Remove the extension case assembly.
  5. Remove the transfer driven gear and center differential as a unit.
  6. Remove the bearing outer race from the extension case and transfer case.

Scheme 107

Scheme 107: INSTALLATION
Scheme 107: INSTALLATION
  1. Install the bearing outer race to transfer case.
  2. Install the transfer driven gear and center differential as a unit.
  3. Select a thrust washer. Refer to «INSTALLATION»(ref-645990-S12292030082014072500000) .
  4. Install the selected thrust washer and bearing outer race to the extension case.
  5. Install the transfer case and the extension case assembly. Refer to «INSTALLATION»(ref-645990-S12292030082014072500000) .
  6. Install the back-up light switch and the neutral position switch. Refer to «INSTALLATION»(ref-645990-S16936247582014072500000) .
  7. Install the manual transmission assembly to the vehicle. Refer to «INSTALLATION»(ref-645990-S24838663312014072500000) .

Scheme 108

Scheme 108: DISASSEMBLY
Scheme 108: DISASSEMBLY

Scheme 109

Scheme 109
Scheme 109
  1. Using the ST, remove the roller bearing (extension case side). ST 498077000 REMOVER
  2. Using ST1 and ST2, remove the roller bearing (transfer case side). ST1 498077000 REMOVER ST2 899864100 REMOVER

Scheme 110

Scheme 110: ASSEMBLY
Scheme 110: ASSEMBLY

Scheme 111

Scheme 111
Scheme 111
  1. Using ST, install the roller bearing (transfer case side). CAUTION: Do not apply a load in excess of 10 kN (1 ton, 1.1 US ton, 1.0 Imp ton). ST 927640000 INSTALLER
  2. Using the ST, install the roller bearing (extension case side). CAUTION: Do not apply a load in excess of 10 kN (1 ton, 1.1 US ton, 1.0 Imp ton). ST1 498175500 INSTALLER ST2 899864100 REMOVER

REMOVAL

  1. Remove the manual transmission assembly from the vehicle. Refer to «REMOVAL»(ref-645990-S08806509112014072500000) .
  2. Remove the back-up light switch and the neutral position switch. Refer to «REMOVAL»(ref-645990-S23757368862014072500000) .
  3. Remove the transfer case together with the extension case assembly. Refer to «REMOVAL»(ref-645990-S23238927522014072500000) .
  4. Remove the extension case assembly. Refer to «REMOVAL»(ref-645990-S23238927522014072500000) .
  5. Remove the center differential and transfer driven gear as a unit. Refer to «REMOVAL»(ref-645990-S17834920522014072500000) .
  1. Install the center differential and transfer driven gear into the transfer case as a unit. Refer to «INSTALLATION»(ref-645990-S20692629432014072500000) .
  2. Select a thrust washer. Refer to «INSTALLATION»(ref-645990-S12292030082014072500000) .
  3. Install the transfer driven gear. Refer to «INSTALLATION»(ref-645990-S20692629432014072500000) .
  4. Install the extension case assembly. Refer to «INSTALLATION»(ref-645990-S12292030082014072500000) .
  5. Install the transfer case together with the extension case assembly. Refer to «INSTALLATION»(ref-645990-S12292030082014072500000) .
  6. Install the back-up light switch and the neutral position switch. Refer to «INSTALLATION»(ref-645990-S16936247582014072500000) .
  7. Install the manual transmission assembly to the vehicle. Refer to «INSTALLATION»(ref-645990-S24838663312014072500000) .
  1. Remove the manual transmission assembly from the vehicle. Refer to «REMOVAL»(ref-645990-S08806509112014072500000) .
  2. Remove the transfer case together with the extension case assembly. Refer to «REMOVAL»(ref-645990-S23238927522014072500000) .
  3. Remove the drive pinion shaft assembly. Refer to «REMOVAL»(ref-645990-S30839780312014072500000) .
  4. Remove the main shaft assembly for single-range.

Scheme 112

Scheme 112: INSTALLATION
Scheme 112: INSTALLATION

Scheme 113

Scheme 113
Scheme 113

Scheme 114

Scheme 114
Scheme 114
  1. Install the needle bearing and oil seal to the front of the transmission single-range main shaft assembly. NOTE: Wrap the clutch splined section with vinyl tape to prevent damage to the oil seal. Apply NICHIMOLY N-130 or the equivalent to the sealing lip of the oil seal. Use a new oil seal.
  2. Rotate the reverse idler gear by two teeth from free status in the direction of the arrow to make it engage with the main shaft reverse gear and install the main shaft assembly. When the reverse idler sub gear is at free status, put alignment marks on reverse idler sub gear and reverse idler gear. Rotate the alignment mark on the reverse idler sub gear side in the arrow direction by two teeth, and secure it with a wire.
  3. Fit the transmission case knock pin to the knock pin hole of the needle bearing outer race and install the main shaft assembly. NOTE: Align the end face of the seal with surface (A) when installing the oil seal. Face the cutout portion of the snap ring for the double taper roller bearing to the drive pinion shaft assembly.
  4. After installing the main shaft, check that the reverse idler gear and reverse idler sub gear are misaligned by two teeth and remove the wire.
  5. Install the drive pinion shaft assembly. Refer to «INSTALLATION»(ref-645990-S13236806022014072500000) .
  6. Check each shift fork. Refer to «INSPECTION»(ref-645990-S18121991872014072500000) .
  7. Select a main shaft rear plate. Refer to «MAIN SHAFT ASSEMBLY FOR SINGLE-RANGE»(ref-645990-S26315173732014072500000) .
  8. Install the transmission case. Refer to «INSTALLATION»(ref-645990-S26418187792014072500000) .
  9. Install the transfer case together with the extension case assembly. Refer to «INSTALLATION»(ref-645990-S12292030082014072500000) .
  10. Install the manual transmission assembly to the vehicle. Refer to «INSTALLATION»(ref-645990-S24838663312014072500000) .
  1. Remove the manual transmission assembly from the vehicle. Refer to «REMOVAL»(ref-645990-S08806509112014072500000) .
  2. Remove the transfer case together with the extension case assembly. Refer to «REMOVAL»(ref-645990-S23238927522014072500000) .
  3. Remove the transmission case. Refer to «REMOVAL»(ref-645990-S18989512262014072500000) .
  4. Remove the drive pinion shaft assembly. Refer to «REMOVAL»(ref-645990-S30839780312014072500000) .
  5. Remove the main shaft assembly for single-range. Refer to «REMOVAL»(ref-645990-S35195793452014072500000) .
  6. Remove the front differential assembly. NOTE: Do not confuse the right and left roller bearing outer races. Be careful not to damage the oil seal of retainer.
  7. Remove the differential side retainers using ST. ST 18630AA010 WRENCH COMPL RETAINER
  8. Remove the bearing outer race from the transmission case. ST 398527700 PULLER ASSY
  1. Install the differential side retainers using ST. ST 18630AA010 WRENCH COMPL RETAINER
  2. Install the bearing outer race to the transmission case.
  3. Install the front differential assembly. CAUTION: Make sure the oil seal lip is not folded.
  4. Install the main shaft assembly for single-range. Refer to «INSTALLATION»(ref-645990-S21072091912014072500000) .
  5. Install the drive pinion shaft assembly. Refer to «INSTALLATION»(ref-645990-S13236806022014072500000) .
  6. Install the transmission case. Refer to «INSTALLATION»(ref-645990-S26418187792014072500000) .
  7. Install the transfer case together with the extension case assembly. Refer to «INSTALLATION»(ref-645990-S12292030082014072500000) .
  8. Install the manual transmission assembly to the vehicle. Refer to «INSTALLATION»(ref-645990-S24838663312014072500000) .

Scheme 115

Scheme 115: DIFFERENTIAL CASE ASSY
Scheme 115: DIFFERENTIAL CASE ASSY

Scheme 116

Scheme 116
Scheme 116

Scheme 117

Scheme 117
Scheme 117

Scheme 118

Scheme 118
Scheme 118
  1. Loosen the twelve bolts and remove hypoid driven gear.
  2. Drive out the straight pin from differential assembly toward hypoid driven gear side. ST 899904100 STRAIGHT PIN REMOVER
  3. Pull out the pinion shaft, and remove the differential bevel pinion, differential bevel gear and washer.
  4. Using the ST, remove the roller bearing. ST 899524100 PULLER SET

Scheme 119

Scheme 119: SIDE RETAINER
Scheme 119: SIDE RETAINER

Scheme 120

Scheme 120
Scheme 120
  1. Remove the O-ring.
  2. Remove the oil seal. NOTE: Remove it by using flat tip screwdriver. Do not reuse the oil seal. Replace the oil seal with a new part.

Scheme 121

Scheme 121: DIFFERENTIAL CASE ASSY
Scheme 121: DIFFERENTIAL CASE ASSY

Scheme 122

Scheme 122
Scheme 122

Scheme 123

Scheme 123
Scheme 123

Scheme 124

Scheme 124
Scheme 124

Scheme 125

Scheme 125
Scheme 125
  1. Install the differential bevel gear and differential bevel pinion together with washer, and insert the pinion shaft. NOTE: Face the chamfered side of washer toward bevel gear.
  2. Measure the backlash between the differential bevel gear and differential bevel pinion. Adjust the backlash if not within specified limit. Refer to «BEVEL PINION GEAR BACKLASH»(ref-645990-S23635613112014072500000) . NOTE: Be sure the pinion gear teeth contacts adjacent gear teeth during measurement. Standard backlash 0.13 - 0.18 mm (0.0051 - 0.0071 in) ST1 498247001 MAGNET BASE ST2 498247100 DIAL GAUGE
  3. Align the pinion shaft and differential case with each hole, and drive the straight pin into the holes from the hypoid driven gear side using the ST. NOTE: Use a new straight pin. ST 899904100 STRAIGHT PIN REMOVER
  4. Install the roller bearing to differential case. CAUTION: Do not apply a load in excess of 10 kN (1 ton, 1.1 US ton, 1.0 Imp ton). NOTE: Be careful because the roller bearing outer races are used as a set. ST1 499277100 BUSHING 1-2 INSTALLER ST2 398497701 ADAPTER
  5. Install the hypoid driven gear to the differential case using twelve bolts. Tightening torque: T: 62 N.m (6.3 kgf-m, 45.7 ft-lb)

Scheme 126

Scheme 126: SIDE RETAINER
Scheme 126: SIDE RETAINER
  1. Install the oil seal. CAUTION: Apply transmission gear oil to the oil seal lips, and install the oil seal while being careful not to deform the lip. When press-fitting the oil seal to the side retainer, tap with a plastic hammer etc. to press in. Never use a press. Check the identification marks (L, R), attach the oil seal RH and LH. NOTE: Use a new oil seal. ST 18675AA000 DIFFERENTIAL SIDE OIL SEAL INSTALLER
  2. Install the O-ring. NOTE: Use new O-rings. Do not stretch or damage the O-ring.

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