Subaru Coupes/Sedans/Wagons 1985-1996 Repair Guide

Identification

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This transaxle is used in the Legacy, Loyale, STD., and XT.

The transaxle can be identified by the 11th letter in the vehicle identification number located on the bulkhead panel of the engine compartment.

The transaxle serial number label is mounted on the upper surface of the main case.

The manual transaxle 11th letter code is as follows:



G: Gunma manufacturer-full-time 4WD 5-speed
 

REMOVAL & INSTALLATION



1990-94 Legacy

See Figures 1 through 24

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Fig. Fig. 1: Removal and installation of the intake air duct-except turbocharged vehicles



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Fig. Fig. 2: Removal and installation of the resonator chamber-turbocharged vehicles



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Fig. Fig. 3: Removal and installation of the air inlet and outlet duct-turbocharged vehicles



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Fig. Fig. 4: Removing and installing the cooling duct-turbocharged vehicles



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Fig. Fig. 5: Unplug the transaxle harness, O2 connectors and ground terminal



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Fig. Fig. 6: Disconnect the hill holder cable-except turbocharged vehicles



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Fig. Fig. 7: Removal and installation of the pitching stopper bracket-turbocharged model shown



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Fig. Fig. 8: Removal and installation of the slave cylinder-hydraulic actuated clutch system



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Fig. Fig. 9: Disconnect the clutch release lever cable-manual actuated clutch system



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Fig. Fig. 10: Using a 10mm hex to remove or install the release lever shaft plug



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Fig. Fig. 11: Using a 6mm bolt remove the release lever shaft



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Fig. Fig. 12: Install special engine support tool to hold the engine in place



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Fig. Fig. 13: Removal and installation of the upper transaxle-to-engine bolts



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Fig. Fig. 14: Disconnect the center exhaust pipe-turbocharged models



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Fig. Fig. 15: Disconnect the gear shift rod and stay from the transaxle



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Fig. Fig. 16: Removal and installation of the transverse link from the transaxle housing



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Fig. Fig. 17: Drive out the spring pin and remove the halfshafts



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Fig. Fig. 18: Remove the lower transaxle-to-engine nuts



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Fig. Fig. 19: Support the transaxle with a transaxle jack



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Fig. Fig. 20: Removal and installation of the rear transaxle crossmember



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Fig. Fig. 21: Remove the release bearing from the clutch cover



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Fig. Fig. 22: Insert the release fork into the throwout bearing



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Fig. Fig. 23: Grease points indicated



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Fig. Fig. 24: Ensure that the cutout portion of the release fork shaft contacts the spring pin

  1. Disconnect the negative battery cable.
  2.  
  3. On non-turbo vehicles, remove the intake manifold cover and air intake duct.
  4.  
  5. On turbocharged vehicles perform the following:
    1. Remove the resonator chamber.
    2.  
    3. Remove the air inlet and outlet ducts.
    4.  
    5. Remove the turbocharger cooling duct.
    6.  

  6.  
  7. Unplug the following connectors:

    O 2 sensor connector
     
    Transaxle ground cable
     

  8.  
  9. Disconnect the following cables:

    Clutch release spring (except turbo)
     
    Clutch cable (except turbo)
     
    Hill holder cable (except turbo)
     
    Speedometer cable
     

  10.  
  11. Remove the starter.
  12.  
  13. Remove the pitching stopper.
  14.  
  15. On turbocharger vehicles, perform the following:
    1. Remove the slave cylinder.
    2.  
    3. Remove the release lever shaft plug.
    4.  
    5. Screw a 6mm bolt into the bolt hole of the release fork shaft and drive the shaft out.
    6.  
    7. Raise the fork to release the throwout bearing tabs.
    8.  

  16.  
  17. Remove the transaxle oil level gauge.
  18.  
  19. Install engine support 92767000 or the equivalent.
  20.  
  21. Remove the upper transaxle-to-engine nuts.
  22.  
  23. On turbocharged vehicles, perform the following:
    1. Separate the center exhaust pipe from the turbocharger.
    2.  
    3. Raise and support the vehicle.
    4.  
    5. Remove the lower turbocharger cover.
    6.  

  24.  
  25. Raise and support the vehicle.
  26.  
  27. On non-turbo vehicles, remove the Y-pipe.
  28.  
  29. Remove the gearshift spring, stay and rod from the transaxle.
  30.  
  31. On turbocharger vehicles, remove the clutch damper from the transaxle case.
  32.  
  33. Remove the sway bar-to-crossmember clamp bolts.
  34.  
  35. Remove the halfshafts.
  36.  
  37. Remove the lower transaxle-to-engine nuts.
  38.  
  39. Support the transaxle with a jack.
  40.  
  41. Remove the rear crossmember.
  42.  
  43. Lower the support jack until the mainshaft is withdrawn from the pressure plate and remove the transaxle.
  44.  

To install:
  1. On turbocharger vehicles, perform the following:
    1. Pry the throwout bearing from the clutch cover.
    2.  
    3. Install the throwout bearing onto the transaxle.
    4.  
    5. Insert the release fork into the throwout bearing tab.
    6.  
    7. Apply Fx2200® or equivalent to the splines of the transaxle and SUNLIGHT 2® or equivalent to the shaft.
    8.  
    9. Insert the shaft into the release fork.
    10.  

  2.  

Ensure the cutout portion of the release fork shaft contacts the spring pin.

    1. Install the plug and torque it to 36 ft. lbs. (49 Nm)
    2.  


  1. Install the transaxle engaging the splines.
  2.  
  3. Install the rear cushion and crossmember. Tighten cushion bolts to 20-35 ft. lbs. (27-47 Nm); crossmember front bolts to 87-116 ft. lbs. (118-157 Nm), rear 40-61 ft. lbs. (54-83 Nm).
  4.  
  5. Install the lower transaxle-to-engine nuts and torque them to 34-40 ft. lbs. (46-54 Nm).
  6.  
  7. Lower the vehicle.
  8.  
  9. On turbocharged vehicles, push the release fork and assemble the throwout bearing into the clutch cover.
  10.  
  11. Install the upper transaxle-to-engine bolts and torque them to 34-40 ft. lbs. (46-54 Nm).
  12.  
  13. Remove the engine support.
  14.  
  15. Install the pitching stopper bracket onto the transaxle. Install the pitching stopper. Torque the body side bolt to 49 ft. lbs. (67 Nm) and bracket side bolt to 40 ft. lbs. (54 Nm).
  16.  
  17. On turbocharged vehicles, install the slave cylinder.
  18.  
  19. Install the halfshafts.
  20.  
  21. Install the sway bar clamps and torque the bolts to 21 ft. lbs. (28 Nm).
  22.  
  23. Connect the shift control rod and stay to the transaxle and install the spring.
  24.  
  25. On turbocharged vehicles, install the clutch damper and torque the bolts to 23 ft. lbs. (32 Nm).
  26.  
  27. Install the driveshaft.
  28.  
  29. Install the exhaust system with new gaskets and nuts.
  30.  
  31. Install the transaxle oil level gauge.
  32.  
  33. Disconnect the following cables:

    Clutch release spring (except turbo)
     
    Clutch cable (except turbo)
     
    Hill holder cable (except turbo)
     
    Speedometer cable
     

  34.  
  35. Disconnect the following connectors:

    O 2 sensor connector
     
    Transaxle ground cable
     

  36.  
  37. Install the starter.
  38.  
  39. If equipped, install the turbocharger cooling duct.
  40.  
  41. Install the air intake system.
  42.  
  43. On non-turbo engines, install the intake manifold cover.
  44.  
  45. Connect the negative battery cable.
  46.  
  47. Fill the transaxle to the proper level with the recommended oil.
  48.  
  49. Road test the vehicle.
  50.  

1995-96 Legacy and 1993-96 Impreza
  1. Disconnect the negative battery cable.
  2.  
  3. Remove the air intake duct.
  4.  
  5. Unplug or disconnect the following cables and connectors:

    Front oxygen sensor connector
     
    Neutral position switch connector
     
    Back-up light switch connector
     
    Clutch cable
     
    Clutch release spring
     

  6.  
  7. Remove the starter.
  8.  
  9. Remove the pitching stopper.
  10.  
  11. Remove the drive belt cover.
  12.  
  13. Install engine support assembly 927670000 or equivalent.
  14.  
  15. Remove the bolt securing the right upper side of the transaxle to the engine.
  16.  
  17. Raise and support the vehicle safely.
  18.  
  19. Remove the front Y-pipe.
  20.  
  21. Disconnect the rear oxygen sensor connector.
  22.  
  23. Remove the center exhaust pipe and the heat shield cover.
  24.  
  25. Remove the hanger bracket from the right side of the transaxle.
  26.  
  27. Remove the driveshaft.
  28.  
  29. Remove the spring and disconnect the shifter stay and rod from the transaxle.
  30.  
  31. Remove the bolts securing the sway bar clamps to the crossmember.
  32.  
  33. Disconnect the ball joints from the steering knuckle.
  34.  
  35. Separate the halfshafts from the transaxle.
  36.  
  37. Remove the 2 nuts securing the lower side of the transaxle to the engine.
  38.  
  39. Support the transaxle with a jack.
  40.  
  41. Remove the rear transaxle crossmember.
  42.  
  43. Remove the transaxle from the vehicle.
  44.  

To install:
  1. Install the transaxle assembly and secure to the engine block.
  2.  
  3. Install and torque the crossmember to the following specifications:
  4.  

Legacy:


T1-40-62 ft. lbs. (54-84 Nm)
 
T2-87-115 ft. lbs. (117-157 Nm)
 

Impreza:


T1-20 ft. lbs. (26 Nm)
 
T2-35 ft. lbs. (47 Nm)
 
T3-61 ft. lbs. (83 Nm)
 

  1. Remove the transmission jack.
  2.  
  3. Install the nuts securing the lower portion of the engine to the transaxle and torque them to 40 ft. lbs. (54 Nm).
  4.  
  5. Install the bolt securing the right upper side of the transaxle to the engine and torque it to 40 ft. lbs. (54 Nm).
  6.  
  7. Remove the engine support.
  8.  
  9. Install the drive belt cover.
  10.  
  11. Install the pitching stopper and torque the bolts to the following specifications:

    T1-40 ft. lbs. (54 Nm)
     
    T2-49 ft. lbs. (67 Nm)
     

  12.  
  13. Insert the halfshafts into the transaxle and install new roll pins.
  14.  
  15. Connect the ball joint to the steering knuckle and torque the bolt to 22 ft. lbs. (29 Nm).
  16.  
  17. Connect the sway bar to the crossmember and torque the clamp bolts to 21 ft. lbs. (28 Nm).
  18.  
  19. Connect the shift control rod and stay to the transaxle and install the spring.
  20.  
  21. Install the driveshaft.
  22.  
  23. Install the heat shield cover, if removed.
  24.  
  25. Install the Y-pipe with new gaskets and nuts.
  26.  
  27. Install the hanger bracket on the right side of the transaxle, if removed.
  28.  
  29. Connect the rear oxygen sensor connector.
  30.  
  31. Install the transaxle connectors bracket.
  32.  
  33. Install the drive belt cover.
  34.  
  35. Install the pitching stopper.
  36.  
  37. Install the starter.
  38.  
  39. Connect the following cables and connectors:

    Front oxygen sensor connector
     
    Neutral position switch connector
     
    Back-up light switch connector
     
    Clutch cable
     
    Clutch release spring
     

  40.  
  41. Install the air intake duct and connector the airflow sensor connector.
  42.  
  43. Connect the negative battery cable.
  44.  

Loyale, STD. and XT
  1. Disconnect the negative battery cable. Remove the air cleaner assembly.
  2.  
  3. Remove the clutch cable and the hill holder cable. Remove the speedometer cable.
  4.  
  5. Remove the oxygen sensor electrical connector and the neutral switch connector.
  6.  
  7. Unplug the electrical connections at the back-up light and differential lock indicator switch assembly. Disconnect the differential lock vacuum hose.
  8.  
  9. Disconnect the starter electrical connections. Remove the starter retaining bolts. Remove the starter from the transaxle case.
  10.  
  11. Remove the air intake boot. Disconnect the pitching stopper rod from its mounting bracket. Remove the right side engine to transaxle mounting bolt.
  12.  
  13. Install engine support bracket 927160000 and engine support tool 927150000 or their equivalents. Remove the buffer rod from the engine and body side bracket.
  14.  

Before attaching the special engine support tools, connect the adjuster to the buffer rod assembly on the right side of the engine.

  1. Raise and support the vehicle safely.
  2.  
  3. Disconnect the exhaust pipes at the exhaust manifold flange. Remove the exhaust system up to the rear exhaust pipe assembly.
  4.  
  5. Matchmark and remove the driveshaft.
  6.  
  7. Remove the spring and disconnect the shifter stay and rod from the transaxle.
  8.  
  9. Loosen the upper bolt and nut from the plate that secures the transverse link to the stabilizer. Remove the lower bolt and separate the link from the stabilizer.
  10.  
  11. Remove the right brake cable bracket from the transverse link. Remove the bolt retaining the link to the crossmember on each side.
  12.  
  13. Lower the transverse link. Using tool 398791700 or equivalent, remove the spring pin and separate the axle shaft from the driveshaft on each side of the assembly by pushing the rear of the tire outward.
  14.  
  15. Remove the engine to transaxle mounting bolts. Position the proper transaxle jack under the transaxle assembly.
  16.  
  17. Remove the rear cushion rubber mounting bolts. Remove the rear crossmember assembly.
  18.  
  19. Turn the engine support tool adjuster counterclockwise in order to slightly raise the engine.
  20.  
  21. Move the transaxle jack toward the rear of the vehicle until the mainshaft is withdrawn from the clutch cover.
  22.  
  23. Carefully remove the transaxle assembly from the vehicle.
  24.  

To install:
  1. Carefully raise the transaxle until the mainshaft is aligned with the clutch side. Install the engine to the transaxle and temporarily tight the mounting bolts.
  2.  
  3. Install the rear crossmember rubber cushion and tighten nuts to 20-35 ft. lbs. (27-47 Nm). Install the rear crossmember and tighten front bolts to 65-87 ft. lbs. (88-118 Nm); rear bolts to 27-49 ft. lbs. (37-67 Nm).
  4.  
  5. Tighten the engine to transaxle nuts to 34-40 ft. lbs. (46-54 Nm). Remove the transaxle jack.
  6.  
  7. Install the halfshaft into the differential and spring pin into place. Install the transverse link and stabilizer temporarily to the front crossmember. Install the brake cable bracket. Lower the vehicle and tighten transverse link bolt to 43-51 ft. lbs. (59-69 Nm); stabilizer bolts to 14-22 ft. lbs. (20-29 Nm).
  8.  
  9. Connect the shift control rod and stay to the transaxle and install the spring.
  10.  
  11. Install the driveshaft (4WD vehicles). Install the starter, pitching stopper, timing hole plug, air intake boot and speedometer cable. Reconnect all electrical and vacuum connectors.
  12.  
  13. Connect the clutch cable and hill holder. Install the front exhaust pipe.
  14.  
  15. Connect the negative battery cable, check the transaxle fluid level and test drive the vehicle.
  16.  

 
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