Transmission Case: Installation

WARNING: This page is about a different car, the 2001 Subaru Impreza. However, it is still accessible from the selected car via links, so may be relevant.

Wipe off grease, oil and dust on the mating surfaces of transmission cases with white gasoline, and apply liquid gasket, and then put case right side and left side together.
Liquid gasket: THREE BOND 1215 or equivalent.
Tighten 17 bolts with bracket, clip, etc. as shown in the figure.
NOTE:
- Insert bolts from the bottom and tighten nuts at the top.
- Put cases together so that drive pinion shim and input shaft holder shim are not caught up in between.
- Confirm that speedometer gear is meshed.
Tightening torque:
1. 8 mm bolts : 25 N.m (2.5 kgf-m, 18.1 ft-lb)
2. 10 mm bolts : 39 N.m (4.0 kgf-m, 28.9 ft-lb)
  
  Fig 1: Locating Bolt Locations (10 mm bolts - Stars)
Tighten ball bearing attachment bolts.
Tightening torque: 29 N.m (3.0 kgf-m, 21.7 ft-lb)

Fig 2: Tightening Ball Bearing Attachment Bolts
Backlash adjustment of hypoid gear and preload adjustment of roller bearing
NOTE: Support drive pinion assembly with ST.

ST 498427100 STOPPER

Fig 3: Supporting Drive Pinion Assembly With (ST)
Inspect and adjust backlash and tooth contact of hypoid gear. See INSPECTION .
After checking the tooth contact of hypoid gears, remove the lock plate. Then loosen retainer until the O-ring groove appears. Fit O-ring into the groove and tighten retainer into the position where retainer has been tightened in.
Tighten lock plate.

NOTE: Carry out this job on both upper and lower retainers.

Tightening torque:
1. T: 25 N.m (2.5 kgf-m, 18.1 ft-lb)
Fig 4: Tightening Lock Plate
Selecting of main shaft rear plate Using ST, measure the amount (A) of ball bearing protrusion from transmission main case surface and select the proper plate in the following table:
NOTE: Before measuring, tap the end of main shaft with a plastic hammer lightly in order to make the clearance zero between the main case surface and the moving flange of bearing.

ST 498147000 DEPTH GAUGE

Fig 5: Selecting Of Main Shaft Rear Plate Chart

Fig 6: Measuring Dimension (A) Of Ball Bearing Protrusion From Transmission Main Case Surface
Install clutch release lever and bearing. See RELEASE BEARING AND LEVER .
Install transfer case and extension case assembly. See INSTALLATION - TRANSFER CASE AND EXTENSION CASE ASSEMBLY .
Install back-up light switch and neutral position switch.
Install the manual transmission assembly into the vehicle. See INSTALLATION - TRANSMISSION TO ENGINE .