Subaru Outback manuals

Subaru Outback: General Description

A: SPECIFICATION

1. MANUAL TRANSMISSION AND DIFFERENTIAL

Subaru Outback. Manual Transmission and Differential

2. TRANSMISSION GEAR OIL

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

B: COMPONENT

1. TRANSMISSION CASE

Subaru Outback. Manual Transmission and Differential

  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

Subaru Outback. Manual Transmission and Differential

2. DRIVE PINION ASSEMBLY

Subaru Outback. Manual Transmission and Differential

  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

Subaru Outback. Manual Transmission and Differential

  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

Subaru Outback. Manual Transmission and Differential

  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

Subaru Outback. Manual Transmission and Differential

  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

Subaru Outback. Manual Transmission and Differential

  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

Subaru Outback. Manual Transmission and 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

Subaru Outback. Manual Transmission and Differential

  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

D: PREPARATION TOOL

1. SPECIAL TOOL

Subaru Outback. Manual Transmission and Differential

Subaru Outback. Manual Transmission and Differential

Subaru Outback. Manual Transmission and Differential

Subaru Outback. Manual Transmission and Differential

Subaru Outback. Manual Transmission and Differential

Subaru Outback. Manual Transmission and Differential

Subaru Outback. Manual Transmission and Differential

Subaru Outback. Manual Transmission and Differential

Subaru Outback. Manual Transmission and Differential

Subaru Outback. Manual Transmission and Differential

2. GENERAL TOOL

Subaru Outback. Manual Transmission and Differential

READ NEXT:

 Transmission Gear Oil

A: INSPECTION 1) Park the vehicle on a level surface. 2) Turn the ignition switch to OFF, and wait until the engine cools. 3) Remove the collector cover. (turbo model) 4) Remove the oil level gau

 Transmission Mounting System

A: REMOVAL 1. CROSSMEMBER AND CUSHION RUBBER 1) Disconnect the ground cable from battery. 2) Lift up the vehicle. 3) Remove the front under cover. <Ref. to EI-35, REMOVAL, Front Under Cover.>

 Oil Seal

A: INSPECTION Check for transmission gear oil leaks at oil seal area. If there is an oil leak, replace the oil seal with new one and check the propeller shaft. B: REPLACEMENT 1) Remove the collector

SEE MORE:

 Brake fluid level warning

This light illuminates when the brake fluid level has dropped to near the “MIN” level of the brake fluid reservoir with the ignition switch in the “ON” position and with the parking brake released. If the brake system warning light should illuminate while driving (with the parking bra

 Power seat (if equipped)

WARNING To prevent the passenger from sliding under the seatbelt in the event of a collision, always put the seatback in the upright position while the vehicle is in motion. Also, do not place objects such as cushions between the passenger and the seatback. If you do so, the risk of sliding

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