Subaru Forester 1998-05

Transmission Removal & Installation

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  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. On automatic transmission vehicles, drain the automatic transmission fluid and the front differential.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Air intake and chamber, then the chamber stays
     
    Intercooler on turbo models
     
    Air cleaner case stay
     
    Front and rear Oxygen (O2S) sensor connectors, if equipped
     
    Transmission harness connector, if equipped with an automatic transmission
     
    Transmission ground terminal
     
    Neutral position switch connector, if equipped with a manual transmission
     
    Backup light switch connector, if equipped with a manual transmission
     
    2 Vehicle Speed (VSS) sensor connectors
     
    Starter
     
    Clutch slave cylinder and hold it aside with wire, on non-turbo engines with a manual transmission
     
    Pitching stopper
     

  6.  
  7. On automatic transmission vehicles, remove the timing hole inspection plug. Matchmark the torque converter-to-driveplate and remove the 4 bolts which hold torque converter to driveplate.
  8.  
  9. Remove or disconnect the following:

    Automatic transmission fluid dipstick and tube
     

  10.  
  11. Install engine support assembly ST 41099AA020. (Also available as part no. 927670000).

    Clutch operating cylinder from the transmission by removing the plug using a 10mm wrench, on turbo models with a manual transmission
     


    Click image to see an enlarged view

    Fig. Remove the plug using a 10mm wrench-DOHC engines



    Click image to see an enlarged view

    Fig. Screw the 6mm bolt into the release fork and remove it - DOHC engines

    Screw the 6mm bolt into the release fork and remove it
     
    Raise the release fork and unfasten the release bearing tabs to free the fork.
     

  12.  
  13. Remove or disconnect the following:

    Bolt securing the right upper side of the transmission to the engine
     
    Engine undercover
     
    Front Y-pipe
     

  14.  
  15. Disconnect connector from rear O2S sensor
  16.  
  17. Remove or disconnect the following:

    Center exhaust pipe from rear pipe and hanger bolt
     
    Rear exhaust pipe and if equipped the heat shield cover
     
    Hanger bracket from the right side of the transmission
     
    Transmission cooler lines
     
    Rear driveshaft, matchmark for reassembly
     
    Center bearing bracket
     

  18.  


NOTE
Plug the opening at the rear of the extension housing to prevent oil from flowing out.



Shifter stay and rod from the transmission, on manual transmission
 
Gear shift cable from the transmission select lever, on automatic transmission
 
Sway bar from the transverse link
 
Parking brake cable bracket from the transverse link and bolt holding the transverse link to the crossmember on each side, lower the transverse link
 
Lower ball joint from knuckle
 
Spring pin and separate the halfshaft from the transmission on each side
 


NOTE
Use a small punch to remove the spring pin. Discard old spring pin and always install a new pin.

  1. Disconnect the halfshaft from transmission on each side. Be sure to remove the axle shaft from the transmission by pushing the rear of the tire outward.
  2.  
  3. Remove the engine-to-transmission mounting nuts
  4.  
  5. Support the transmission with a jack.
  6.  


NOTE
Do not place jack under the transmission oil pan, otherwise the oil pan may be damaged.

  1. Remove or disconnect the following:

    Rear transmission crossmember
     
    Transmission
     

  2.  

To install:

  1. If equipped with a manual transmission, perform the following:
    1. Remove the release bearing from the clutch cover using a flat bladed tool.
    2.  
    3. Install the release bearing onto the transmission.
    4.  
    5. Install the release fork into the release bearing tab.
    6.  
    7. Apply a small amount of grease to the splines of the mainshaft.
    8.  
    9. Insert the release fork shaft into the release fork. Make sure the cutout portion of the release fork shaft contacts the spring pin.
    10.  


      Click image to see an enlarged view

      Fig. Release fork and related components-DOHC engines

    11. Install the plug and tighten to 32 ft. lbs. (44 Nm).
    12.  

  2.  
  3. Install or connect the following:

    Special tool 498277200 to torque converter clutch case
     
    Transmission to the engine
     
    Transmission crossmember. Torque the front (outer) nuts/bolts to 51 ft. lbs. (69 Nm) and the rear (inner) nuts to 103 ft. lbs. (140 Nm), on manual transmissions
     
    Transmission crossmember. Torque the inner nuts/bolts to 26 ft. lbs. (35 Nm) and the outer nuts to 51 ft. lbs. (69 Nm), on automatic transmissions
     

  4.  
  5. Remove the transmission jack.
  6.  
  7. Install or connect the following:

    Transmission-to-engine mounting nuts. Torque the nuts/bolts to 37 ft. lbs. (50 Nm).
     
    Torque converter-to-driveplate bolts on automatic transmission vehicles. Torque the bolts to 18 ft. lbs. (25 Nm).
     

  8.  
  9. Remove special tool 927670000.
  10.  
  11. Install or connect the following:

    Pitching stopper
     
    Halfshaft to transmission and spring pin into place
     

  12.  


    Click image to see an enlarged view

    Fig. Exploded view of the manual transmission mounting



    Click image to see an enlarged view

    Fig. Exploded view of the automatic transmission mounting



NOTE
Always use new spring pin. Be sure to align the axle shaft and shaft from the transmission at chamfered holes and install shaft splines correctly.



Lower ball joint to knuckle
 
Sway bar to the crossmember. Torque the clamp bolts to 18 ft. lbs. (25 Nm).
 
Shift control rod, shifter stay to the transmission and the spring, on manual transmission vehicles
 
Gear shift cable to the select lever, on automatic transmission vehicles
 
Fluid cooler lines
 
Driveshaft. Tighten the bolts to 23 ft. lbs. (31 Nm).
 
Center bearing bracket. Torque the bolt to 38 ft. lbs. (52 Nm).
 
Heat shield cover, if removed
 
Center exhaust pipe from rear pipe and hanger bolt
 
Rear exhaust pipe and heat shield cover
 
Hanger bracket from the right side of the transmission
 
Y-pipe with new gaskets and nuts
 
Rear O2S sensor connector
 
Clutch slave cylinder on manual transmission vehicles. Torque the mounting bolts to 27 ft. lbs. (37 Nm).
 
Automatic transmission fluid dipstick tube
 
Transmission connector bracket
 
Starter. Torque the mounting bolts to 37 ft. lbs. (50 Nm).
 
Front and rear O2S sensor connectors
 
Transmission harness connector, on automatic transmission vehicles
 
Transmission ground terminal
 
Neutral position switch connector, on manual transmission vehicles
 
Backup light switch connector, on manual transmission vehicles
 
2 VSS connectors
 
Air intake and chamber, and the camber stays
 
Intercooler, on turbo models
 
Negative battery cable
 

  1. On automatic transmission vehicles, fill the automatic transmission fluid with Dexron®II or III or equivalent.
  2.  
  3. On manual transmission vehicles, check and fill the transmission with 75W-90 gear oil.
  4.  
  5. Road test the vehicle.
  6.  



Click image to see an enlarged view

Fig. Manual transmission crossmember and related components-1998-2003



Click image to see an enlarged view

Fig. Manual transmission crossmember and related components-2004-2006

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Open the hood to the full open position.
  4.  
  5. Disconnect the negative battery cable.
  6.  
  7. Drain the transmission gear oil.
  8.  
  9. On non turbocharged engine, remove the air intake duct and cleaner case.
  10.  
  11. On turbocharged engine, remove the intercooler assembly.
  12.  
  13. Disconnect the neutral position switch connector and the back up light switch connector. Disconnect the VSS sensor electrical connector.
  14.  
  15. On 1998-2003 vehicles, disconnect the ground cable.
  16.  
  17. Remove the starter. Remove the clutch operating cylinder from the transmission, and suspend it with wire.
  18.  
  19. Remove the pitching stopper. Position engine support tool ST41099AA010, or equivalent to hold the engine assembly in place.
  20.  
  21. Remove the bolts which holds the upper side of the transmission to the engine.
  22.  
  23. On non turbocharged engine, remove the front and center exhaust pipes.
  24.  
  25. On turbocharged engine, remove the center exhaust pipe.
  26.  
  27. Remove the rear exhaust pipe and muffler. If equipped, remove the heat shield cover.
  28.  
  29. Remove the hanger bracket from the right side of the transmission.
  30.  
  31. Remove the driveshaft.
  32.  
  33. Remove the gear shift rod and the stay from the transmission.
  34.  
  35. Separate the stabilizer link from the transverse link. Remove the bolt securing the ball joint of the transverse link to housing. Separate the transverse link and the housing.
  36.  
  37. On 1998-2003 vehicles, remove the spring pins and separate the front halfshafts from each side of the transmission. Remove the halfshafts.
  38.  
  39. On 2004-2005 vehicles, using tool ST28399SA000, remove the halfshaft from the transmission side. Hold the transmission side joint (AARi) of the front halfshaft by hand and extract the housing from the transmission by pressing it outside so as not to stretch the boot on the AARi side.
    NOTE
    Face letters -MT- on the handle of the tool to the transmission side. Use an angle so that the protrusion of the tool touches the transmission case during the operation.

  40.  
  41. Remove the nuts that hold the lower side of the transmission to the engine.
  42.  
  43. Position a transmission jack under the transmission assembly.
  44.  
  45. Remove the transmission rear crossmember retaining bolts. Remove the rear crossmember from the vehicle.
  46.  
  47. Carefully remove the transmission from the vehicle.
    NOTE
    Move the transmission jack rearward until the main shaft is withdrawn from the clutch cover.

  48.  
  49. Separate the transmission assembly and rear cushion rubber.
  50.  

To install:

  1. Installation is the reverse of the removal procedure.
  2.  
  3. Tighten the engine to transmission retaining bolts to 36.9 ft. lbs.
  4.  
  5. Be sure to fill the transmission with the proper grade and type transmission fluid.
  6.  
  7. Start the engine and check for leaks, correct as required.
  8.  
  9. Road test the vehicle.
  10.  

 
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