Subaru ff-1/1300/1400/1600/1800/Brat 1970-1984 Repair Guide

Transaxle

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REMOVAL & INSTALLATION



Except Turbo Engines

The transaxle can be removed separately from the vehicle.

  1. Raise and secure the hood.
  2.  
  3. If equipped, remove the spare wheel from engine compartment.
  4.  
  5. Disconnect the negative (-) battery cable.
  6.  
  7. Remove the spare wheel supporter clamps and the supporter from the vehicle.
  8.  
  9. If equipped with a carburetor, remove the air duct.
  10.  
  11. Disconnect the diaphragm vacuum hose (2WD) and/or the air breather hose (4WD).
  12.  
  13. From the transaxle, disconnect and remove the speedometer cable.
  14.  
  15. Disconnect the speedometer cable clip.
  16.  
  17. Disengage the electrical wiring connectors from the back-up lamp switch.
  18.  
  19. Disconnect the O 2 sensor (exhaust pipe), the transaxle-to-chassis ground strap and starter.
  20.  
  21. Remove the starter and move it aside.
  22.  
  23. If equipped with a turbocharger, perform the following procedures:
  24.  
    1. Remove the accelerator cable cover from the transaxle.
    2.  
    3. Remove the turbo covers from the turbocharger and the center exhaust pipe.
    4.  
    5. Disconnect the exhaust pipe-to-turbocharger bolts.
    6.  
    7. Raise and support the front of the vehicle with jackstands.
    8.  
    9. Disconnect the center exhaust pipe-to-rear pipe nuts/bolts.
    10.  
    11. Remove the center exhaust pipe-to-vehicle hanger bolt.
    12.  
    13. Disconnect the exhaust pipe from the transaxle.
    14.  
    15. Remove the center exhaust pipe and lower the vehicle to the floor.
    16.  

  25. Remove the timing hole from the flywheel housing.
  26.  
  27. Working through the timing plug hole, remove the torque converter-to-drive plate bolts.
  28.  

Be careful that the bolts do not fall into the converter housing.

  1. Disconnect and plug the oil cooler hoses from the transaxle; be careful not to damage the O-ring.
  2.  
  3. From the right-side, remove the engine/transaxle assembly-to-chassis support (pitching stopper rod) nut/bolt and loosen the lower nuts.
  4.  
  5. Remove the exhaust pipe-to-cylinder head nuts, the exhaust pipe-to-rear pipe nuts/bolts, the exhaust pipe-to-hanger bracket and the front exhaust pipe from the vehicle.
  6.  
  7. If equipped with 4WD, disconnect the driveshaft from the rear of the transaxle and plug the opening to prevent oil from draining from the opening.
  8.  
  9. Disconnect the linkage rod from the shift lever.
  10.  
  11. Loosen the stabilizer-to-transverse link nuts and bolts, on the lower side of the plate.
  12.  
  13. Remove the transverse link by performing the following procedures:
  14.  
    1. Remove the hand brake cable bracket from the transverse link.
    2.  
    3. Remove the transverse link-to-crossmember nut/bolt and the link from the vehicle.
    4.  

  15. Using a hammer and the pin punch, drive the spring pin (discard it) from the axle shaft/drive shaft assembly.
  16.  
  17. Push the tire outward to separate the axle shaft from the driveshaft; perform this procedures on each side.
  18.  
  19. Remove the engine-to-transaxle nuts.
  20.  
  21. Position a transmission jack under the transaxle and secure the jack to the transaxle. Remove the rear rubber cushion mounting nuts.
  22.  
  23. Remove the rear crossmember-to-chassis bolts and the crossmember from the vehicle.
  24.  
  25. Moving the floor jack rearward and downward, remove the transaxle from the vehicle.
  26.  

To install:

  1. Align the chamfered holes of the axle shaft with the driveshaft (install a new spring pin) and reverse the removal procedures.
  2.  
  3. Tighten the crossmember-to-chassis bolts to 27-49 ft. lbs. (36-66 Nm), the rubber cushion-to-crossmember bolts to 20-35 ft. lbs. (27-47 Nm).
  4.  
  5. Tighten the lower engine-to-transaxle bolts to 34-40 ft. lbs. (46-54 Nm) and the transverse link-to-front crossmember nuts/bolts (use new self-locking nuts) to 43-51 ft. lbs. (58-69 Nm).
  6.  
  7. Tighten the transverse link-to-stabilizer bolts to 14-22 ft. lbs. (18-29 Nm) and the pitching stopper rod-to-engine/transaxle assembly nut/bolt to 34-40 ft. lbs. (46-54 Nm)
  8.  

Turbo Engines
  1. Open the front hood and support it securely. Remove the spare tire.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Remove the spare tire mounting bracket.
  6.  
  7. Remove the thermosensor.
  8.  
  9. Disconnect vacuum hoses from the air intake shutter, transaxle breather, and vacuum control diaphragm.
  10.  
  11. Disconnect the accelerator cable and link and move them out of the way.
  12.  
  13. Disconnect the speedometer cable at the transaxle and move it out of the way.
  14.  
  15. Disengage wiring harnesses at the transfer solenoid connector.
  16.  
  17. Disengage transaxle kickdown solenoid connector.
  18.  
  19. Disengage the body ground and O 2 sensor connector.
  20.  
  21. Disengage the starter connector.
  22.  
  23. Remove the upper cover from the turbocharger.
  24.  
  25. Remove the center exhaust pipe by:
  26.  
    1. Detaching it at the turbocharger body.
    2.  
    3. Removing the rear cover.
    4.  
    5. Removing the bolt supporting the pipe at the transaxle and disconnecting it from the rear exhaust pipe.
    6.  
    7. Removing the hanger bolt from the bottom of the transaxle.
    8.  
    9. Disengage the pipe from the attaching studs and remove it.
    10.  

  27. Loosen (do not remove) the attaching bolts and remove the front exhaust pipe cover.
  28.  
  29. Remove the turbocharger as follows:
  30.  
    1. Remove the intake duct.
    2.  
    3. Remove the air flow meter boot.
    4.  
    5. Disconnect the inlet oil pipe.
    6.  
    7. Unfasten the mounting bolts and remove the turbocharger together with the outlet oil hose.
    8.  
    9. Lower cover and gasket. (You may want to refer to the Turbocharger Removal and Installation procedure in for more detail).
    10.  

  31. Raise the car and support it with jackstands.
  32.  
  33. Remove the bolts attaching the tighten converter to the drive plate.
  34.  
  35. Remove the bolts joining the engine and transaxle to one another.
  36.  
  37. Remove the bolts joining the starter to the transaxle. The starter-to-battery cable may be left connected.
  38.  
  39. Disconnect both oil cooler lines at the transaxle.
  40.  
  41. Loosen the retaining bolt on the transaxle side of the pitching stopper about 0.39 in. (10mm) and tighten the nut on the opposite side a corresponding amount. This will tilt the engine backward to aid in transaxle removal. Do not loosen/tighten the nuts more than the specified amount!
  42.  
  43. Drain the torque converter.
  44.  
  45. Remove the oil supply pipe, being careful not to damage the O-ring.
  46.  
  47. Mark the position of the transaxle shift rod nut. Remove the nut for the transaxle shift rod and disconnect the rod. Set the selector lever on the transaxle to Park position if it is not already there.
  48.  
  49. Remove the stabilizer by removing the two bolts and nut.
  50.  
  51. Remove the right and left side hand brake clamps.
  52.  
  53. Remove the inner transverse link by removing the nut and bolt on both sides that fastens it to the front suspension crossmember. Lower the link and remove it.
  54.  
  55. Separate the right and left side axle shafts from the transaxle driveshaft.
  56.  
  57. On each side, remove the spring pin, and then separate the axle shaft from the driveshaft by pushing the rear of either front wheel outward.
  58.  
  59. Remove the lower engine-to-transaxle nuts. Do not loosen upper nuts yet.
  60.  
  61. Remove the rear transaxle mount nuts.
  62.  
  63. Disconnect the driveshaft, and cap off the opening to retain transaxle fluid.
  64.  
  65. Support the transaxle securely with a jack.
  66.  
  67. Remove the rear crossmember.
  68.  
  69. Remove the upper transaxle-to-engine mounting nuts.
  70.  
  71. Move the jack rearward until the front of the transaxle is no longer in contact with the front crossmember.
  72.  
  73. Lower the transaxle and pull it out.
  74.  

To install:

  1. Use new spring pins in the axle shafts.
  2.  
  3. When installing the rear crossmember, make sure it's positioned properly on the rubber bushings. There are guides on the crossmember and bushings. Tighten the 8mm nuts to 7-13 ft. lbs. (9-17 Nm), and the 12mm nuts to 65-87 ft. lbs. (88-117 Nm).
  4.  
  5. Additional torque figures are:

    Lower transaxle-to-engine nuts: 34-40 ft. lbs. (46-54 Nm)
     
    Driveshaft bolts/nuts: 13-18 ft. lbs. (17-24 Nm)
     
    Rear mount nuts: 14-25 ft. lbs. (18-33 Nm)
     
    Transverse link bolts (use new self-locking nuts): 13-16 ft. lbs. (17-21 Nm)
     
    Stabilizer (make sure slits on bushings face inward) 13-16 ft. lbs. (17-21 Nm)
     
    Linkage rod nut: 5.8-8.7 ft. lbs. (7-11 Nm)
     
    Pitching stopper (adjusted to 2mm clearance): 6.5-9.4 ft. lbs. (8-12 Nm)
     
    Starter-to-transaxle and engine: 34-40 ft. lbs. (46-54 Nm)
     
    Torque converter to drive plate: 17-20 ft. lbs. (23-27 Nm)
     

  6.  

Make sure the transaxle fluid level is correct with the engine idling.

 
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