Subaru Outback (BR): Shift Link Assembly

A: 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 and the neutral position switch. <Ref. to 6MT-37, REMOVAL, Switches and Harness.>

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

4) Remove the extension case assembly.

5) Remove the center differential and transfer driven gear as a unit.

6) Pull out the straight pin.

1. Selector lever COMPL
2. Straight pin

7) Use the ST to remove the spring pin, and remove the selector lever COMPL.

ST 398791700 SPRING PIN REMOVER 2

1. Selector lever COMPL
2. Selector arm No. 2
3. Spring pin

8) Pull out the selector arm No. 2 from neutral set spring.

1. Selector arm No. 2
2. Neutral set spring

9) Remove the shifter arm collar and neutral set spring from transfer case.

1. Shifter arm collar
2. Neutral set spring

10) Remove the shifter arm No. 2, washers and thrust bearing from transfer case.

1. Shifter arm No. 2
2. Washer
3. Thrust bearing

11) Use the ST to remove the spring pin, and remove the shifter arm and selector arm.

ST 398791700 SPRING PIN REMOVER 2

1. Shifter arm
2. Selector arm
3. Spring pin

12) Remove the oil seal from the transfer case by using a screwdriver wrapped with vinyl tape etc.

NOTE: The illustration shows the oil seal of selector lever COMPL. Perform the same procedures for removing the shifter arm No. 2.

1. Oil seal

13) Remove the needle bearing from the transfer case by using a tube with the diameter of 20 mm (0.79 in) or 21 mm (0.83 in) and the ST.

ST 18763AA000 COMPRESSOR SHAFT

14) Set ST1, ST2 and transfer case to a press.

NOTE:

• Set the ST2 under ST1.
• Set the transfer case so that the hole for shifter arm is positioned vertically.

ST1 498267300 CYLINDER HEAD TABLE
ST2 498267200 CYLINDER HEAD TABLE

15) Remove the roller bearing by using a round bar with the diameter of 22 mm (0.87 in) or 23 mm (0.91 in).

16) Flip over the transfer case, and set an iron plate between transfer case and ST.

NOTE:

• Insert the iron plate which is thicker than the exposed length of the transfer case knock pin between the ST and transfer case.
• Set the iron plate so that the transfer case knock pin does not ride on the iron plate.

17) Remove the roller bearing by using a tube with the diameter of 22 mm (0.87 in) or 23 mm (0.91 in).

1. Iron plate

18) Remove the plunger and check ball spring from transmission cover.

1. Plunger
2. Checking ball spring
3. Transmission cover
4. Seal ring
5. Seal bolt

B: INSTALLATION

1) Install the plunger and check ball spring to transmission cover.

NOTE: Use a new seal ring.

Tightening torque: 25 N*m (2.5 kgf-m, 18.4 ft-lb)

1. Plunger
2. Checking ball spring
3. Transmission cover
4. Seal ring
5. Seal bolt

2) Using the ST, install the needle bearing to the transfer case.

NOTE:

• Use a new needle bearing.
• If the press-fit depth exceeds the service limit, replace with a new needle bearing.

ST1 18763AA000 COMPRESSOR SHAFT
ST2 498277200 STOPPER SET

Press-fit depth of needle bearing: A: 8.5+-0.2 mm (0.33+-0.01 in) from the end of transfer case

B: 0.2+-0.2 mm (0.01+-0.01 in) from the end of transfer case

3) Set ST1, ST2 and transfer case to a press.

NOTE:

• Set the ST2 under ST1.
• Set the transfer case so that the hole for shifter arm is positioned vertically.

ST1 498267300 CYLINDER HEAD TABLE
ST2 498267200 CYLINDER HEAD TABLE

4) Using the ST, install the roller bearing to the transfer case.

NOTE:

• Use a new bearing.
• Gradually perform the press-fit operation while measuring the press-fit depth.
• If the press-fit depth exceeds the service limit, replace with a new bearing.

ST 899864100 REMOVER

Press-fit depth of roller bearing: A: 5.1+-0.2 mm (0.20+-0.01 in) from the finished surface of transfer case

5) Flip over the transfer case, and set an iron plate between transfer case and ST.

NOTE:

• Insert the iron plate which is thicker than the exposed length of the transfer case knock pin between the ST and transfer case.
• Set the parts while taking care that the transfer case knock pin and the roller bearing do not ride over the iron plate.

6) Using the ST, install the roller bearing to the transfer case.

NOTE:

• Use a new bearing.
• Gradually perform the press-fit operation while measuring the press-fit depth.
• If the press-fit depth exceeds the service limit, replace with a new bearing.

ST 899864100 REMOVER

Press-fit depth of roller bearing: A: 0+-0.2 mm (0+-0.01 in) from the end of transfer case

7) Using the ST, install the oil seal to the transfer case.

NOTE:

• Use a new oil seal.
• The illustration shows the oil seal of selector lever COMPL. Perform the same procedures for installing the shifter arm No. 2.
• Apply transmission gear oil to the oil seal lips.

ST 18657AA000 INSTALLER

Press-fit depth of oil seal: 1+-0.2 mm (0.04+-0.01 in) from the end of transfer case

8) Insert the shifter arm into the selector arm, and fix with a spring pin.

NOTE: Use new spring pin.

ST 398791700 SPRING PIN REMOVER 2

1. Shifter arm
2. Selector arm
3. Spring pin

9) Install the shifter arm No. 2, washers and thrust bearing to transfer case.

1. Shifter arm No. 2
2. Washer
3. Thrust bearing

10) Install the shifter arm collar and neutral set spring to transfer case.

NOTE: Use a new gasket.

Tightening torque: 6.4 N*m (0.7 kgf-m, 4.7 ft-lb)

11) Install the selector arm No. 2 to neutral set spring.

1. Selector arm No. 2
2. Neutral set spring

12) Insert the selector lever COMPL into the selector arm No. 2, and fix with a spring pin.

NOTE: Use new spring pin.

ST 398791700 SPRING PIN REMOVER 2

1. Selector lever COMPL
2. Selector arm No. 2
3. Spring pin

13) Insert a new straight pin.

1. Selector lever COMPL
2. Straight pin

14) Apply liquid gasket seamlessly to the mating surface of transmission cover.

Liquid gasket: THREE BOND 1215 (Part No. 004403007) or equivalent

15) Install the transmission cover to transfer case.

Tightening torque: 25 N*m (2.5 kgf-m, 18.4 ft-lb)

1. Transmission cover

16) Install the center differential and transfer driven gear as a unit.

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

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

19) Install the back-up light switch and the neutral position switch. <Ref. to 6MT-37, INSTALLATION, Switches and Harness.>

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

Transmission Case

A: REMOVAL

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

2) Remove the clutch release lever. <Ref. to CL- 15, REMOVAL, Release Bearing and Lever.>

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

4) Remove the bearing mounting bolt.

5) Remove the main shaft rear plate.

1. Main shaft rear plate

6) Separate the transmission case into the right and left cases by loosening the coupling bolts and nuts.

7) Remove the drive pinion shaft assembly from the left side of the transmission case.

NOTE: Use a hammer handle, etc. to remove if too tight.

1. Main shaft ASSY for single-range
2. Drive pinion shaft ASSY

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

9) Remove the front differential assembly.

10) Remove the differential side retainers and bearing outer races on the right and left sides.

<Ref. to 6MT-77, REMOVAL, Front Differential Assembly.>

NOTE: Do not confuse the right and left roller bearing outer races.

11) Remove the reverse idler gear. <Ref. to 6MT- 90, REMOVAL, Shifter Fork and Rod.>

12) Remove the shifter fork and rod. <Ref. to 6MT- 90, REMOVAL, Shifter Fork and Rod.>

B: INSTALLATION

1) Wipe off grease, oil and dust on the mating surfaces of transmission cases with cleaning solvent.

2) Install the shifter fork and rod. <Ref. to 6MT-91, INSTALLATION, Shifter Fork and Rod.>

3) Select the drive pinion shim. <Ref. to 6MT-67, INSTALLATION, Drive Pinion Shaft Assembly.>

4) Install the differential side retainer, from which the bearing outer race and O-ring have already been removed, to the transmission case LH side.

5) Install the front differential assembly.

6) Install the main shaft assembly for single-range.

Install the transmission case knock pin into the knock pin hole of needle bearing.

7) Install the drive pinion shaft assembly.

Install the transmission case knock pin into the roller bearing knock pin hole.

8) Apply liquid gasket, then join the right side and left side of the case together.

Liquid gasket: THREE BOND 1215 (Part No. 004403007) or equivalent

9) With brackets and clips as shown in the figure, tighten the seventeen bolts.

NOTE: Match the cases together so that the drive pinion shims are not caught between the cases.

Tightening torque:
8 mm bolt
25 N*m (2.5 kgf-m, 18.4 ft-lb)
10 mm bolt
40 N*m (4.1 kgf-m, 29.5 ft-lb)

10) Tighten the taper roller bearing mounting bolts.

Tightening torque: 30 N*m (3.1 kgf-m, 22.1 ft-lb)

11) Perform backlash adjustment of the hypoid gear and preload measurement of the roller bearing.

NOTE: Attach the ST on drive pinion assembly.

ST 18667AA020 HOLDER

12) Place the transmission with the left side of case facing downward, and put ST1 on bearing race.

13) Screw the retainer assembly from the bottom into left case using ST2. Fit the ST3 on transmission main shaft. Shift the gear into 4th or 5th, and turn the shaft several times. Screw in the retainer while rotating the ST3 until a slight resistance is felt on ST2.

This is the contact point of the hypoid gear and the drive pinion shaft. Repeat the above sequence several times to ensure the contact point.

ST1 399780104 WEIGHT
ST2 18630AA010 WRENCH COMPL RETAINER
ST3 499927100 HANDLE

14) Remove the weight, and screw in the retainer without the O-ring on the upper side, and stop at the point where a slight resistance is felt.

NOTE: In this condition, the backlash between hypoid gear and drive pinion shaft is zero.

ST 18630AA010 WRENCH COMPL RETAINER

15) Loosen the retainer on the lower side by 3 notches, and turn the retainer on the upper side by the same amount in order to apply backlash.

16) Rotate the retainer of the upper side additionally by 1 notch in order to apply preload on taper roller bearing.

17) Temporarily attach both the upper and lower lock plates, and put marks both the retainer and lock plate for later readjustment.

NOTE: If it is hard to install the lock plates, reverse the sides and install them.

18) Turn the transmission main shaft several times while tapping around the retainer lightly with plastic hammer.

19) Inspect and adjust backlash and tooth contact of the hypoid gear. <Ref. to 6MT-81, INSPECTION, Front Differential Assembly.>

20) After checking the tooth contact of the hypoid gears, remove the lock plate. Then loosen the retainer until the O-ring groove appears. Fit the O-ring into the groove and tighten the retainer into the position before it was loosened.

Install the lock plate.

NOTE:

• When loosening the retainer, record the number of the turns made.
• Perform this operation for both upper and lower retainers.
• Use new O-rings.

Tightening torque: T: 25 N*m (2.5 kgf-m, 18.4 ft-lb)

21) Select a main shaft rear plate. <Ref. to 6MT-66, ADJUSTMENT, Main Shaft Assembly for Single- Range.>

22) Install the clutch release lever and bearing.

<Ref. to CL-16, INSTALLATION, Release Bearing and Lever.>

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

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

C: INSPECTION

Check the transmission case for cracks, damage, or oil leaks.

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