Safety Warning

DIY auto repair can cause serious injury, fire, or vehicle damage. These guides are for informational purposes only. Always follow OEM torque specs, wear PPE, and consult a certified mechanic if you are unsure. You are solely responsible for your safety.

2005 Subaru Outback RFACTORY OEM SERVICE PROCEDURE

Starting/Charging Systems (H4SO): Generator: Disassembly

Remove the four through-bolts.

Fig 1: Removing Four Through-Bolts
Courtesy of SUBARU OF AMERICA, INC.
Heat portion (A) of rear cover to 50° (122°) with a heater drier.

Fig 2: Heating Portion Of Rear Cover To 50°
Courtesy of SUBARU OF AMERICA, INC.
Then insert the tip of a flat tip screwdriver into the gap between stator core and front cover. Pry them apart to disassemble.

Fig 3: Inserting Tip Of A Flat Tip Screwdriver Into Gap Between Stator Core And Front Cover
Courtesy of SUBARU OF AMERICA, INC.
Hold the rotor with a vise and remove pulley nut.

Fig 4: Removing Pulley Nut
Courtesy of SUBARU OF AMERICA, INC.

Factory Service Tools

Use the Manual With the Right Hardware

Pair factory procedures with proven DIY tools so the instructions are easier to execute.

Disclosure: Verified tool recommendations may earn an affiliate commission at no cost to you.

Shop Manual-Ready Tools Compare Repair Quote Quote Shield Pro

When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

• You smell fuel, burning insulation, or see smoke.
• Brakes feel soft, pull hard to one side, or make grinding noises.
• The engine overheats, stalls repeatedly, or misfires under load.
• You are missing required tools, torque specs, or safe lifting equipment.
• You are not confident in the next step or safety outcome.