M/T - 5MT Installation Precaution/Procedure
NUMBER: 03-66-12DATE: 04/03/12
APPLICABILITY:
2000~09MY Legacy/Outback, 5MT
2009MY and later Forester, 5MT
2005MY and later Impreza, 5MT
SUBJECT:
5MT Transfer Bearing Lubrication Precaution/Procedure When Installing a New Transmission Assembly
NOTE:
THIS SERVICE BULLETIN IS APPLICABLE TO NEW TRANSMISSION ASSEMBLIES UP TO TRANSMISSION # 654880.
INTRODUCTION
The purpose of this bulletin is to inform you of a new procedure that must be completed prior to the installation of a new 5MT assembly. This procedure will insure that adequate lubrication is applied to the transfer driven gear roller bearings prior to vehicle operation. Failure to perform this procedure can result in damage to the transfer driven gear roller bearings upon initial operation.
SERVICE INFORMATION/PROCEDURE
New 5MT transmission assemblies are shipped with differential side caps and an output shaft cap installed. Do not remove these caps during the lubrication procedure. It's a good idea to keep the caps installed during the installation of the transmission to prevent any leakage/seepage.
A transmission jack capable of tilting the transmission 30 degrees in both directions may be used or an engine hoist.
1. Transfer the gear shift joint from the old assembly to the new assembly (refer to the applicable service manual).
2. Make sure the differential side caps and output shaft cap are properly seated.
3. Support the transmission using an engine hoist or transmission jack.
Caution:
Make sure the transmission is properly secured.
4. Critical Step: With the transmission level on an engine hoist or transmission jack, fill the transmission with GL-5 (75w-90) gear oil to the full mark on the dipstick gauge.
5. Tilt the tailshaft of the transmission in a downward direction at an angle of 30 degrees. Maintain this angle for no less than 5 minutes. This will permit the gear oil to flow to the transfer case.
6. Quickly shift the position of the tailshaft of the transmission to a 30 degree angle upward from the horizontal position. Note: Do not stop at the horizontal position. Maintain the transmission in a tailshaft up position for not less than 5 seconds.
7. Return the transmission to a horizontal position.
Note:
Special Tool (ST) 18631AA000 will be needed for the following steps.
8. Position the ST on the input shaft.
9. For the rotation of the input shaft, the transmission needs to be placed in 4th gear. A screwdriver may be used to assist with moving the shift linkage.
^ To find 4th gear, place the transmission in neutral by moving the shift linkage forward then back then forward stopping at the mid position. If the input shaft is rotated and the output shaft doesn't move, the transmission is in neutral.
^ Rotate the shift linkage to the right and then rearward. The transmission should now be in 4th gear.
10. Rotate the input shaft using ST a minimal of 10 revolutions while confirming that the output shaft is rotating at the same time.
11. Install the transmission in vehicle.
12. Upon completion, check and adjust the transmission gear oil to the full level as indicated on the dipstick gauge before driving.
WARRANTY/CLAIM INFORMATION
Note:
The following claim information may only be used when installing a new transmission assembly. Labor operation A323-100 includes the time for performing the procedure listed in this bulletin.
Disclaimer