Subaru Outback manuals

Subaru Outback: Main Shaft Assembly for Single-Range

A: REMOVAL

1) Remove the manual transmission assembly from the vehicle. <Ref. to 6MT-25, REMOVAL, Manual Transmission Assembly.>

2) Remove the transfer case together with the extension case assembly. <Ref. to 6MT-40, REMOVAL, Transfer Case and Extension Case Assembly.>

3) Remove the transmission case. <Ref. to 6MT- 57, REMOVAL, Transmission Case.>

4) Remove the drive pinion shaft assembly. <Ref. to 6MT-67, REMOVAL, Drive Pinion Shaft Assembly.>

5) Remove the main shaft assembly for single-range.

B: INSTALLATION

1) Install the needle bearing and oil seal to the front of the transmission single-range main shaft assembly.

NOTE:

2) Rotate the reverse idler sub gear by two teeth from free status to make it engage with the reverse gear of the main shaft and install the main shaft assembly.

  1. When the reverse idler sub gear is at free status, put alignment marks on reverse idler sub gear and reverse idler gear.
  2. Rotate the reverse idler sub gear in the arrow direction by two teeth from the alignment mark and secure it with a wire.

Subaru Outback. Manual Transmission and Differential

  1. After installing the main shaft assembly, check that the reverse idler gear and reverse idler sub gear are misaligned by two teeth and remove the wire.

CAUTION:

Make sure to remove the wire.

3) Align the transmission case knock pin into the knock pin hole of the needle bearing outer race.

NOTE:

Subaru Outback. Manual Transmission and Differential

Subaru Outback. Manual Transmission and Differential

4) Install the drive pinion shaft assembly. <Ref. to 6MT-67, INSTALLATION, Drive Pinion Shaft Assembly.>

5) Install the transmission case. <Ref. to 6MT-58, INSTALLATION, Transmission Case.>

6) Install the transfer case together with the extension case assembly. <Ref. to 6MT-40, INSTALLATION, Transfer Case and Extension Case Assembly.>

7) Install the manual transmission assembly to the vehicle. <Ref. to 6MT-29, INSTALLATION, Manual Transmission Assembly.>

C: DISASSEMBLY

NOTE:

1) Put vinyl tape around main shaft spline to protect the oil seal from damage. Then pull out the oil seal and needle bearing by hand.

2) Flatten the tab of the lock nut.

3) Remove the lock nut from transmission main shaft assembly for single-range.

ST1 498937000 TRANSMISSION HOLDER
ST2 499987003 SOCKET WRENCH (35)

Subaru Outback. Manual Transmission and Differential

4) Remove the 6th drive gear and ball bearing using the ST1, ST2 and a press.

ST1 899864100 REMOVER
ST2 18722AA000 REMOVER

Subaru Outback. Manual Transmission and Differential

5) Remove the needle bearing, 6th baulk ring and 5th-6th coupling sleeve.

6) Remove the 5th drive gear, 6th needle bearing race, 5th baulk ring, 5th-6th synchronizer hub and needle bearing using the ST1, ST2 and a press.

ST1 899864100 REMOVER
ST2 18722AA000 REMOVER

Subaru Outback. Manual Transmission and Differential

7) Shift the 3rd-4th coupling sleeve into 3rd, then remove the 4th drive gear, taper roller bearing and 5th needle bearing race using the ST1, ST2 and a press.

ST1 899864100 REMOVER
ST2 899714110 REMOVER

Subaru Outback. Manual Transmission and Differential

8) Remove the 4th gear thrust washer, 4th baulk ring, needle bearing and 3rd-4th coupling sleeve.

9) Remove the 3rd drive gear, 4th needle bearing race, 3rd-4th synchronizer hub, inner baulk ring, 3rd synchro cone, outer baulk ring and needle bearing using the ST1, ST2 and a press.

ST1 899864100 REMOVER
ST2 899714110 REMOVER

Subaru Outback. Manual Transmission and Differential

D: ASSEMBLY

1) When the sleeve & hub assemblies have been disassembled, reassemble by aligning the alignment marks.

NOTE: Position the open ends of the spring 120º apart.

Subaru Outback. Manual Transmission and Differential

  1. 3rd-4th hub ASSY
  2. 3rd gear side

2) Install the needle bearing, 3rd drive gear, outer baulk ring, 3rd synchro cone, inner baulk ring and 3rd-4th synchronizer hub on the transmission main shaft.

NOTE: Align the groove in baulk ring with the shifting insert.

Subaru Outback. Manual Transmission and Differential

  1. 3rd needle bearing
  2. 3rd drive gear
  3. Inner baulk ring
  4. 3rd synchro cone
  5. Outer baulk ring
  6. 3rd-4th synchronizer hub

3) Install the 4th needle bearing race onto transmission main shaft using ST1, ST2, ST3 and a press.

CAUTION: Do not apply a load in excess of 10 kN (1 ton, 1.1 US ton, 1.0 Imp ton).

ST1 899714110 REMOVER
ST2 499877000 RACE 4-5 INSTALLER
ST3 398177700 INSTALLER

Subaru Outback. Manual Transmission and Differential

  1. 4th needle bearing race

4) Install the 3rd-4th coupling sleeve, 4th baulk ring, needle bearing, 4th drive gear and 4th gear thrust washer to the transmission main shaft.

NOTE:

 

Subaru Outback. Manual Transmission and Differential

  1. Groove
  2. Face this surface to the 4th gear side.

Subaru Outback. Manual Transmission and Differential

  1. 3rd-4th coupling sleeve
  2. 4th baulk ring
  3. 4th drive gear
  4. Needle bearing
  5. 4th gear thrust washer

5) Install the double taper roller bearing into the rear section of transmission main shaft using ST1, ST2 and a press.

CAUTION: Do not apply a load in excess of 10 kN (1 ton, 1.1 US ton, 1.0 Imp ton).

NOTE: Install the double taper roller bearing with snap ring side facing the 5th drive gear side.

ST1 899714110 REMOVER
ST2 499877000 RACE 4-5 INSTALLER

Subaru Outback. Manual Transmission and Differential

6) Install the 5th needle bearing race into the rear section of transmission main shaft using ST1, ST2 and a press.

CAUTION: Do not apply a load in excess of 10 kN (1 ton, 1.1 US ton, 1.0 Imp ton).

ST1 899714110 REMOVER
ST2 499877000 RACE 4-5 INSTALLER

Subaru Outback. Manual Transmission and Differential

  1. 5th needle bearing race

7) Install the needle bearing, 5th drive gear, 5th baulk ring, and 5th-6th synchronizer hub on the transmission main shaft.

NOTE:

Subaru Outback. Manual Transmission and Differential

  1. 5th-6th synchronizer hub
  2. 5th baulk ring
  3. 5th drive gear

Subaru Outback. Manual Transmission and Differential

  1. 5th-6th synchronizer hub
  2. 5th baulk ring
  3. 5th drive gear
  4. 5th needle bearing (cage: black)

8) Install the 6th needle bearing race onto transmission main shaft using ST1, ST2 and a press.

CAUTION: Do not apply a load in excess of 10 kN (1 ton, 1.1 US ton, 1.0 Imp ton).

ST1 899714110 REMOVER
ST2 499877000 RACE 4-5 INSTALLER

Subaru Outback. Manual Transmission and Differential

  1. 6th needle bearing race

9) Install the 5th-6th coupling sleeve, 6th baulk ring, 6th drive gear and needle bearing on the transmission main shaft.

NOTE: Install the 5th-6th coupling sleeve with the short flange side facing the 5th drive gear.

Subaru Outback. Manual Transmission and Differential

  1. 6th baulk ring
  2. 5th-6th coupling sleeve
  3. 5th-6th shifting insert key
  4. Face this side to 5th gear (short flange side)

Subaru Outback. Manual Transmission and Differential

  1. 5th-6th coupling sleeve
  2. 6th baulk ring
  3. 6th drive gear
  4. 5th needle bearing (cage: black)
  5. 6th needle bearing (cage: silver)

10) Install the ball bearing onto transmission main shaft using ST2 and a press.

CAUTION: Do not apply a load in excess of 10 kN (1 ton, 1.1 US ton, 1.0 Imp ton).

NOTE: Install the ball bearing with the side which does not have lock nut mounting dent facing 6th drive gear.

ST1 899714110 REMOVER
ST2 899754112 PRESS

Subaru Outback. Manual Transmission and Differential

  1. Ball bearing

11) Tighten the lock nuts to the specified torque using ST1 and ST2.

NOTE: Lock nuts and lock washers must be replaced with new parts.

Tightening torque: 160 N*m (16.3 kgf-m, 118.0 ft-lb)

ST1 499987003 SOCKET WRENCH (35)
ST2 498937000 TRANSMISSION HOLDER

Subaru Outback. Manual Transmission and Differential

12) Crimp lock nuts in two locations after tightening.

E: INSPECTION

Disassembled parts should be washed with cleaning solvent first, then inspected carefully.

1) Bearing

Replace the bearings in the following cases.

2) Bushing (each gear)

Replace the bushing in following cases.

3) Gear

Replace gears in the following cases.

4) Baulk ring

Replace the baulk ring in the following cases.

Clearance (A): 0.5 mm (0.020 in) or more

Subaru Outback. Manual Transmission and Differential

Subaru Outback. Manual Transmission and Differential

5) Shifting insert key

Replace the insert key if deformed, excessively worn or defective in any way.

Subaru Outback. Manual Transmission and Differential

6) Coupling sleeve and synchronizer hub

7) Oil seal

Replace the oil seal if the lip is deformed, hardened, worn or defective in any way.

8) Gearshift mechanism

Repair or replace the gearshift mechanism if excessively worn, bent or defective in any way.

F: ADJUSTMENT

Selection of main shaft rear plate: Measure the protrusion amount (A) of ball bearing from transmission main case surface, and select a suitable 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 moving flange of bearing.

ST 498147001 DEPTH GAUGE

Subaru Outback. Manual Transmission and Differential

READ NEXT:

 Drive Pinion Shaft Assembly

A: REMOVAL 1) Remove the manual transmission assembly from the vehicle. <Ref. to 6MT-25, REMOVAL, Manual Transmission Assembly.> 2) Remove the transfer case together with the extension case ass

 Front Differential Assembly

A: REMOVAL 1) Remove the manual transmission assembly from the vehicle. <Ref. to 6MT-25, REMOVAL, Manual Transmission Assembly.> 2) Remove the transfer case together with the extension case ass

 Reverse Idler Gear

REMOVAL 1) Remove the manual transmission assembly from the vehicle. <Ref. to 6MT-25, REMOVAL, Manual Transmission Assembly.> 2) Remove the back-up light switch neutral position switch. <Ref

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 Ignition switch

WARNING ● Never turn the ignition switch to “LOCK” while the vehicle is being driven or towed because that will lock the steering wheel, preventing steering control. And when the engine is turned off, it takes a much greater effort than usual to steer. ● Before leaving the ve

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