Subaru Outback (BR): General Description of Manual Transmission

A: SPECIFICATION

1. MANUAL TRANSMISSION AND DIFFERENTIAL

2. TRANSMISSION GEAR OIL

Recommended oil: GL-5 (75W-90) or equivalent

B: COMPONENT

1. TRANSMISSION CASE

1. Transmission case ASSY
2. Gasket
3. Drain plug
4. Harness clip
5. Clamp
6. Harness bracket
7. Oil level gauge
8. Transmission radio ground cord
9. Select bracket

Tightening torque: N*m (kgf-m, ft-lb)
T1: 18 (1.8, 13.3)
T2:
44 (4.5, 32.5) (Aluminum gasket, silver)
70 (7.1, 51.6) (Copper gasket, brown)
70 (7.1, 51.6) (Metal gasket, black)

Transmission case tightening torque

2. DRIVE PINION ASSEMBLY

1. Drive pinion shaft
2. Roller bearing
3. Washer
4. Thrust bearing
5. Needle bearing
6. Driven shaft
7. Key
8. Drive pinion collar
9. Needle bearing
10. 1st driven gear
11. Inner baulk ring
12. 1st synchro cone
13. Outer baulk ring
14. 1st-2nd synchronizer hub
15. 1st-2nd shifting insert key
16. 1st-2nd coupling sleeve
17. Outer baulk ring
18. 2nd synchro cone
19. Inner baulk ring
20. 2nd driven gear
21. 2nd driven gear bushing
22. 3rd-4th driven gear
23. Drive pinion shim
24. Double taper roller bearing
25. 5th driven gear
26. Drive pinion spacer
27. 6th driven gear
28. Ball bearing
29. Lock nut
30. Adjusting washer
31. Thrust bearing
32. Differential bevel gear sleeve
33. Adjusting washer
34. Lock washer
35. Lock nut

Tightening torque: N*m (kgf-m, ft-lb)
T1: 30 (3.1, 22.1)
T2: 126 (12.8, 92.9)
T3: 440 (44.9, 324.5)

3. MAIN SHAFT FOR SINGLE-RANGE

1. Oil seal
2. Needle bearing
3. Transmission main shaft
4. Needle bearing
5. 3rd drive gear
6. Inner baulk ring
7. 3rd synchro cone
8. Outer baulk ring
9. 3rd-4th coupling sleeve
10. 3rd-4th synchronizer hub
11. 3rd-4th shifting insert key
12. 4th baulk ring
13. 4th drive gear
14. 4th needle bearing race
15. Needle bearing
16. 4th gear thrust washer
17. Double taper roller bearing
18. 5th needle bearing race
19. Needle bearing
20. Main shaft rear plate
21. 5th drive gear
22. 5th baulk ring
23. 5th-6th synchronizer hub
24. 5th-6th shifting insert key
25. 5th-6th coupling sleeve
26. 6th baulk ring
27. 6th drive gear
28. 6th needle bearing race
29. Needle bearing
30. Ball bearing
31. Lock washer
32. Lock nut
33. Reverse idler gear shaft
34. Washer
35. Needle bearing
36. Reverse idler gear No. 2
37. Reverse shifting insert key
38. Reverse coupling sleeve
39. Baulk ring
40. Reverse idler gear
41. Reverse idler gear collar
42. Needle bearing
43. Washer
44. Straight pin
45. Oil case guide
46. Reverse idler gear bushing
47. Snap ring
48. Reverse idler spring
49. Reverse idler sub gear
50. Friction plate
51. Snap ring
52. Gasket

Tightening torque: N*m (kgf-m, ft-lb)
T1: 25 (2.5, 18.4)
T2: 160 (16.3, 118.0)

4. SHIFTER FORK AND SHIFTER ROD

1. Shifter arm
2. Selector arm
3. Spring pin
4. Reverse shifter fork
5. Reverse fork rod
6. 5th-6th shifter fork
7. 5th-6th fork rod
8. 3rd-4th shifter fork
9. 3rd-4th fork rod
10. 1st-2nd shifter fork
11. 1st-2nd fork rod
12. Interlock plunger
13. Interlock plunger
14. Interlock plunger
15. Checking ball plug
16. Checking ball spring
17. Check ball
18. Gasket

Tightening torque: N*m (kgf-m, ft-lb)
T: 20 (2.0, 14.8)

5. TRANSFER CASE AND EXTENSION

1. Shifter arm
2. Interlock plate
3. Gasket
4. Transfer case
5. Transmission cover
6. Gasket
7. Gasket
8. Neutral position switch
9. Back-up light switch
10. Roller bearing
11. Transfer driven gear
12. Roller bearing
13. Adjusting washer
14. Ball bearing
15. Center differential
16. Adjusting washer
17. Transfer drive gear
18. Ball bearing
19. Snap ring
20. Extension case
21. Bushing
22. Oil seal
23. Dust cover
24. Dust cover (OUTBACK model)
25. Shift bracket
26. Oil guide
27. Outer race
28. Outer race
29. Gasket
30. Precoat bolt
31. Needle bearing
32. Snap ring

Tightening torque: N*m (kgf-m, ft-lb)
T1: x15 (1.5, 11.1)
T2: 18 (1.8, 13.3)
T3: T3:
T4: 24.5 (2.5, 18.1)
T5: 25 (2.5, 18.4)
T6: 26 (2.7, 19.2)
T6: 26 (2.7, 19.2)
T8: 40 (4.1, 29.5)

6. SHIFT LINK ASSEMBLY

1. Selector lever COMPL
2. Selector arm No. 2
3. Shifter arm collar
4. Neutral set spring
5. Spring pin
6. Selector arm
7. Shifter arm
8. Shift lever COMPL
9. Shifter arm No. 2
10. Washer
11. Thrust bearing
12. Oil seal
13. Straight pin
14. Transfer case
15. Gasket
16. Checking ball spring
17. Plunger
18. Seal bolt
19. Interlock plate
20. Transmission cover
21. Seal ring
22. Gasket
23. Neutral position switch
24. Needle bearing
25. Roller bearing

Tightening torque: N*m (kgf-m, ft-lb)
T1: 6.4 (0.7, 4.7)
T2: 20 (2.0, 14.8)
T3: 25 (2.5, 18.4)
T4: 32.3 (3.3, 23.8)

7. FRONT DIFFERENTIAL

1. Drive pinion shaft
2. Hypoid driven gear
3. Pinion shaft
4. Straight pin
5. Washer
6. Differential bevel gear
7. Differential bevel pinion
8. Roller bearing
9. Differential case
10. Oil seal
11. Differential side retainer
12. O-ring
13. Retainer lock plate

Tightening torque: N*m (kgf-m, ft-lb)
T1: 25 (2.5, 18.4)
T2: 62 (6.3, 45.7)

8. TRANSMISSION MOUNTING

1. Spacer
2. Lower cushion rubber
3. Front plate
4. Transmission cushion rubber
5. Rear crossmember (turbo model)
6. Upper cushion rubber
7. Center crossmember (turbo model)
8. Front crossmember
9. Rear cushion rubber
10. Rear plate
11. Transmission main mounting bracket (RH)
12. Transmission main mounting bracket (LH)
13. Rear crossmember (non-turbo model)
14. Center crossmember (non-turbo model)
15.  

Tightening torque: N*m (kgf-m, ft-lb)
T1: 35 (3.6, 25.8)
T2: 45 (4.6, 33.2)
T3: 70 (7.1, 51.6)
T4: 75 (7.6, 55.3)
T5: 140 (14.3, 103.3)

C: CAUTION

• Wear appropriate work clothing, including a cap, protective goggles and protective shoes when performing any work.
• Remove contamination including dirt and corrosion before removal, installation or disassembly.
• Keep the disassembled parts in order and protect them from dust and dirt.
• Before removal, installation or disassembly, be sure to clarify the failure. Avoid unnecessary removal, installation, disassembly and replacement.
• When disassembling the case and other light alloy parts, use a plastic hammer to force it apart. Do not pry apart with screwdrivers or other tools.
• Vehicle components are extremely hot after driving.

  Be wary of receiving burns from heated parts.

• Use SUBARU genuine gear oil, grease or equivalent.

  Do not mix gear oil, grease, etc. of different grades or manufacturers.

• Be sure to tighten fasteners including bolts and nuts to the specified torque.
• Place shop jacks or rigid racks at the specified points.
• Apply gear oil onto sliding or revolving surfaces before installation.
• Replace deformed or damaged snap rings with new parts.
• Before installing O-rings or oil seals, apply sufficient amount of gear oil to avoid damage and deformation.
• Be careful not to incorrectly install or fail to install O-rings, snap rings and other such parts.
• Before securing a part on a vise, place cushioning material such as wood blocks, aluminum plate, or cloth between the part and the vise.
• Avoid damaging the mating surface of the case.
• Before applying liquid gasket, completely remove the old liquid gasket.

D: PREPARATION TOOL

1. SPECIAL TOOL

2. GENERAL TOOL

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