- Drain the transmission gear oil and remove the 10 8mm bolts holding the bellhousing to the transaxle.
- Remove the release bearing and the seal from the old bellhousing and press or drive out the oil slinger sleeve
located behind the input shaft seal. It comes out towards the clutch side of the housing. (Not required for
bellhousing with built-in slinger.)
- Install the new input shaft seal into the SmallCar bellhousing using an appropriate tool.
- For 1998 and earlier Subaru engines, install the provided insert into the threaded hole in the bellhousing
for the lower starter bolt. The original stud or a bolt can be used in this position. For bellhousing shipped
after 4/15/2011 Skip to step 16
- On the input shaft sticking out of the transmission, locate and expand the circlip near the sleeve on the inner
end of the shaft and slide the sleeve toward you enough to allow the input shaft to be unscrewed from the
transmission. It is helpful to locate the point on the ring gear carrier housing with an oiling hole which
allows some additional clearance for the sleeve.
- For non-Syncro transmissions prior to about 1986, step 6 should allow you to successfully remove the input
shaft and proceed to step 14. For Syncro transmissions and later 4 speeds, steps 8 through 13 are necessary.
- Wipe out excess grease and remove the hub plug from one of the output flanges using a pointed tool. It is
usually necessary to damage the plug to remove it.
- Remove the retaining ring holding the CV flange to the transmission and pull off the drive flange. A small
screwdriver is helpful in removing the ring and the flange can be tapped with a hammer to aid in removal.
- Remove the two Phillips screws holding the flanged plastic retainer.
- Mark the aluminum differential retainer nut and the housing in an adjacent spot so the nut can be reinstalled
in the same position.
- With an appropriate tool, unscrew the retainer nut. Click to purchase retainer tool
- With the differential assembly out of the way, the input shaft sleeve can be reached easily.
- Unscrew the stud from the mainshaft and thread in the stud provided. Position the provided circlip to replace
- Place the spacer sleeve provided onto the mainshaft inside the transmission housing, then reinstall the input
shaft by turning it clockwise until snug. Unscrew the input shaft 1/2 to 1 1/2 turn then slide the sleeve back
over the inner shaft. Reinstall the snap ring.
- If you needed steps 8 through 13, reinstall the differential and the threaded retainer nut to its original
position, reattach the plastic retainer, the cv flange, retaining ring and plug.
- Install the oil drain plug into the new bellhousing.
- If the pressure plate to be used is not an OEM or a SmallCar part, a trial assembly of the bellhousing to
the engine with the pressure plate and release assembly installed is a good idea to check for clearance
between the release assembly and the pressure plate.
- Also check that the release bearing contact diameter is correct on your pressure plate. The maximum diameter
for the pressure plate fingers where the release bearing rides is 2 1/8" or 55mm.
- Collapse the bearing portion of the hydraulic release bearing and place the nose into a container of brake
fluid. Release the bearing and the slave cylinder will fill with brake fluid.
- Install the release bearing assembly onto the bellhousing using the 6mm bolts and washers provided. A little
Locktite® will ensure that the bolts will not loosen. Torque to 10 lb/ft. Replace the plastic plug on the
hydraulic end to keep debris out of the assembly.
- Clean the transmission sealing surface and apply a thin coat of RTV or similar sealant.
- Install the bellhousing onto the transaxle using the supplied bolts and washers in the four lower holes and six
of the original bolts in the upper holes. Torque these to 16-18 lb/ft.
- The recommended amount of gear oil can now be added to the transaxle.
- Make sure an alignment tool (a VW sized) is used to align the clutch disc when the pressure plate is installed
onto the flywheel.
- The release bearing assembly will create a small amount of resistance when mating the engine and transmission
but the two parts should go together smoothly and completely.
- Be sure to install and align with the two dowells located on the engine's mounting surface. These dowells should
be smooth and without burrs or other damage.
- The engine can now be bolted to the transmission using the stock Subaru 10mm bolts. Torque these bolts to 30 lb/ft.
- Install the engine and transmission into the Vanagon.
- Attach the supplied hydraulic fitting onto the Van's clutch line. This is best done prior to installing the
fitting onto the release assembly.
- Insert the snap ring into the supplied hydraulic fitting, remove the protective cap from the release assembly
and install the fitting onto the snout of the assembly.
- If the hydraulic line needs to be removed or re-tightened after installing onto the bellhousing, be sure to
stabilize the fitting with a wrench on both sides of this hydraulic connection.
- Install the clutch master cylinder spacer. Clutch master cylinder spacer instructions
- The hydraulic system should be bled using the bleeder screw located on the hydraulic fitting.