Subaru Crosstrek manuals

Subaru Crosstrek Service Manual: Installation

MANUAL TRANSMISSION AND DIFFERENTIAL(5MT) > Manual Transmission Assembly

INSTALLATION

1. Replace the differential side retainer oil seal. Differential Side Retainer Oil Seal > REPLACEMENT">

NOTE:

Be sure to replace the oil seal after removing the front drive shaft.

When a new oil seal has been installed, replacement is not required.

ST 18675AA000DIFFERENTIAL SIDE OIL SEAL INSTALLER

2. Strike and bend the transmission hanger of transmission rear with a rubber hammer etc. so that it gets in contact with the transmission case.

CAUTION:

Do not apply excessive load or impact to the transmission case.

3. Install the transmission cushion rubber to the transmission, and tighten the bolt (A).

4. Install the transmission cushion rubber to the center crossmember, and temporarily tighten the nut (B).

Tightening torque:

Bolt (A)

35 N·m (3.6 kgf-m, 25.8 ft-lb)

5. Install the transmission assembly onto the engine.

(1) Lift up the transmission gradually using a transmission jack.

(2) Engage at the spline section.

NOTE:

Be careful not to hit the main shaft against the clutch cover.

6. While raising the transmission jack, loosen the turnbuckle of the ST, and set the engine unit to the original position.

7. Install the front crossmember and rear crossmember.

8. Tighten the transmission cushion rubber mounting nut.

Tightening torque:

T1: 70 N·m (7.1 kgf-m, 51.6 ft-lb)

T2: 140 N·m (14.3 kgf-m, 103.3 ft-lb)

T3: 35 N·m (3.6 kgf-m, 25.8 ft-lb)

9. Take out the transmission jack.

10. Tighten the bolts and nuts which hold the lower side of transmission to the engine.

Tightening torque:

50 N·m (5.1 kgf-m, 36.9 ft-lb)

11. Lower the vehicle.

12. Install the starter. Starter > INSTALLATION">

13. Tighten the bolts which hold the upper side of the transmission to the engine.

Tightening torque:

50 N·m (5.1 kgf-m, 36.9 ft-lb)

14. Remove the ST.

15. Install the ground cable.

Tightening torque:

19 N·m (1.9 kgf-m, 14.0 ft-lb)

16. Install the pitching stopper.

Tightening torque:

T1: 50 N·m (5.1 kgf-m, 36.9 ft-lb)

T2: 58 N·m (5.9 kgf-m, 42.8 ft-lb)

17. Lift up the vehicle.

18. Set the ST to differential side retainer.

ST 28399SA010OIL SEAL PROTECTOR

19. Replace the circlip of the drive shaft with a new part.

20. Install the front drive shaft and remove ST.

ST 28399SA010OIL SEAL PROTECTOR

21. Insert the front arm ball joint and tighten the mounting bolt.

Tightening torque:

50 N·m (5.1 kgf-m, 36.9 ft-lb)

(A)

Front arm

(B)

Ball joint

22. Install the stabilizer link.

Tightening torque:

60 N·m (6.1 kgf-m, 44.3 ft-lb)

23. Attach the gear shift rod and stay.

(1) Install the gear shift rod.

NOTE:

Use a new self-locking nut.

Tightening torque:

12 N·m (1.2 kgf-m, 8.9 ft-lb)

(A)

Gear shift rod

(2) Install the stay.

NOTE:

Use a new self-locking nut.

Tightening torque:

18 N·m (1.8 kgf-m, 13.3 ft-lb)

(A)

Stay

(B)

Shift bracket

24. Install the propeller shaft. Propeller Shaft > INSTALLATION">

25. Install the hanger bracket.

Tightening torque:

23 N·m (2.3 kgf-m, 17.0 ft-lb)

26. Install the center exhaust cover.

Tightening torque:

18 N·m (1.8 kgf-m, 13.3 ft-lb)

27. Install the center exhaust pipe. Center Exhaust Pipe > INSTALLATION">

28. Install the front under cover. Front Under Cover > INSTALLATION">

29. Lower the vehicle.

30. Install the operating cylinder.

Tightening torque:

37 N·m (3.8 kgf-m, 27.3 ft-lb)

31. Install the transmission radio ground cord terminal.

Tightening torque:

13 N·m (1.3 kgf-m, 9.6 ft-lb)

32. Install the engine hanger rear.

Tightening torque:

21 N·m (2.1 kgf-m, 15.5 ft-lb)

33. Install the air breather hose.

34. Connect the engine harness connector, then attach the harness bracket.

Tightening torque:

7.5 N·m (0.8 kgf-m, 5.5 ft-lb)

(A)

Engine harness connectors

(B)

Engine hanger rear

(C)

Harness bracket

(D)

Air breather hose

35. Connect the following connectors and secure the clip.

(A)

Neutral position switch connector (brown)

(B)

Back-up light switch connector (gray)

(C)

Clip

36. Pour in transmission gear oil and check the oil level. Transmission Gear Oil">

37. Install the air intake boot. Air Intake Boot > INSTALLATION">

38. Install the front tires.

39. Connect the battery ground terminal.

Manual transmission assembly
...

Removal
MANUAL TRANSMISSION AND DIFFERENTIAL(5MT) > Manual Transmission AssemblyREMOVAL1. Disconnect the ground cable from battery.2. Remove the clip (A) from the air intake boot.3. Loosen the clamp (B) co ...

Other materials:

Inspection
VEHICLE DYNAMICS CONTROL (VDC) (DIAGNOSTICS) > Warning Light Illumination PatternINSPECTION(1)Ignition switch(6)Light OFF(11)2 seconds or more(2)OFF(7)Light ON(12)Brake warning light (EBD warning light)(3)ON(8)2 seconds(13)Parking brake(4)Engine start(9)VDC OFF indicator light(14)Released(5)ABS w ...

Installation
EXTERIOR/INTERIOR TRIM > Rear BumperINSTALLATIONInstall each part in the reverse order of removal.CAUTION:Before installing the bumper face, match the claws on the bracket - rear bumper with the engaging position of flange section on the bumper face side. If the engaging position is not correct, ...

Removal
MANUAL TRANSMISSION AND DIFFERENTIAL(5MT) > Front Differential AssemblyREMOVAL1. Remove the manual transmission assembly from the vehicle. Manual Transmission Assembly > REMOVAL">2. Remove the transfer case together with the extension case assembly. Transfer Case and Extension Case A ...

© 2016-2020 Copyright www.sucross.com