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Drive Pinion Shaft Assembly: Assembly

WARNING: This page is about a different car, the 2012 Subaru Forester. However, it is still accessible from the selected car via links, so may be relevant.
  1. Install the sleeve and the gear & hub assembly by matching the alignment marks.
    NOTE:
    • Make sure that there is no large clearance at both sides of ball detent after assembly.
      Fig 1: Ball Detent, 1st-2nd Synchronizer Hub And Reverse Driven Gear
      G07666055Courtesy of SUBARU OF AMERICA, INC.
    • Use the new gear & hub assembly, if replacing the gear or hub.
      Fig 2: 1st Gear Side, 2nd Gear Side, Flush Surface And Stepped Surface
      G07666056Courtesy of SUBARU OF AMERICA, INC.
  2. Install the washer, snap ring (outer) and sub gear onto the 1st driven gear.
  3. Install the 1st driven gear, inner baulk ring, synchro cone, outer baulk ring, and gear & hub assembly onto driven shaft.
    Fig 3: 1st Driven Gear, Synchro Cone, Inner And Outer Baulk Ring, And Gear & Hub Assy
    G00522840Courtesy of SUBARU OF AMERICA, INC.
    NOTE:
    • Take care to install the gear and hub assembly in proper direction.
    • Align the baulk ring and gear & hub assembly with the key groove.
  4. Install the 2nd driven gear bushing onto driven shaft using ST1, ST2 and a press.
    CAUTION: Do not apply a load in excess of 10 kN (1 ton, 1.1 US ton, 1.0 Imp ton).
    NOTE:
    • Attach a cloth to the end of the driven shaft to prevent damage.
    • When press fitting, align the oil holes of the shaft and bushing

    ST1 499277200 INSTALLER

    ST2 499587000 INSTALLER

    Fig 4: Installing 2nd Driven Gear Bushing Onto Driven Shaft Using ST1 And ST2
    G07666058Courtesy of SUBARU OF AMERICA, INC.
  5. Install the 2nd driven gear, inner baulk ring, synchro cone and outer baulk ring, and insert them onto driven shaft.
    Fig 5: 2nd Driven Gear, Synchro Cone, Inner And Outer Baulk Ring
    G07666059Courtesy of SUBARU OF AMERICA, INC.
  6. After installing key onto the driven shaft, install the 3rd-4th driven gear using ST1, ST2 and a press.
    CAUTION: Do not apply a load in excess of 10 kN (1 ton, 1.1 US ton, 1.0 Imp ton).
    NOTE: Align the groove in baulk ring with the insert.

    ST1 499277200 INSTALLER

    ST2 499587000 INSTALLER

    Fig 6: Installing 3rd-4th Driven Gear Using ST
    G00522841Courtesy of SUBARU OF AMERICA, INC.
  7. Install a set of roller bearings onto the driven shaft using ST1, ST2 and a press.
    CAUTION: Do not apply a load in excess of 10 kN (1 ton, 1.1 US ton, 1.0 Imp ton).

    ST1 499277200 INSTALLER

    ST2 499587000 INSTALLER

    Fig 7: Installing Roller Bearings Onto Driven Shaft Using ST
    G00522842Courtesy of SUBARU OF AMERICA, INC.
  8. Position the woodruff key in groove of the rear of driven shaft. Install the 5th driven gear to the driven shaft using ST1, ST2 and a press.
    CAUTION: Do not apply a load in excess of 10 kN (1 ton, 1.1 US ton, 1.0 Imp ton).

    ST1 499277200 INSTALLER

    ST2 499587000 INSTALLER

    Fig 8: Installing 5th Driven Gear Onto Driven Shaft Using ST
    G00522843Courtesy of SUBARU OF AMERICA, INC.
  9. Install the lock washer. Tighten the lock nuts to the specified torque using ST1 and ST2.
    NOTE:
    • Use new lock nuts and lock washers.
    • Make sure the lock washer is installed in the proper direction.

    Tightening torque: 

    260 N.m (26.5 kgf-m, 191.8 ft-lb) 

    ST1 499987300 SOCKET WRENCH (50)

    ST2 899884100 HOLDER

    Fig 9: Tightening Lock Nuts
    G00522844Courtesy of SUBARU OF AMERICA, INC.
  10. Using a spring scale, check that starting torque of the roller bearing is 0.1 to 1.5 N (0.01 to 0.15 kgf, 0.02 to 0.34 lbf).
    Fig 10: Checking Starting Torque Of Roller Bearing Using Spring Scale
    G07666064Courtesy of SUBARU OF AMERICA, INC.
  11. Crimp the lock nut at two locations so that the dimension (B) becomes 41.1 mm (1.62 in) or less.
    CAUTION: When crimping the lock nut, be careful not to crack it. 
    Fig 11: Identifying Lock Nut Crimping Locations
    G00522845Courtesy of SUBARU OF AMERICA, INC.
  12. Install the roller bearing onto the drive pinion shaft.
    NOTE: When installing the roller bearing, note its directions (front and rear) because the knock pin hole of outer race is offset.
    Fig 12: Roller Bearing And Knock Pin Hole
    G07666065Courtesy of SUBARU OF AMERICA, INC.
  13. Install the washer using ST1, ST2 and a press.
    CAUTION: Do not apply a load in excess of 10 kN (1 ton, 1.1 US ton, 1.0 Imp ton).

    ST1 499277100 BUSHING 1-2 INSTALLER

    ST2 499277200 INSTALLER

    Fig 13: Installing Washer Using ST1 And ST2
    G07666066Courtesy of SUBARU OF AMERICA, INC.
  14. Install the thrust bearing and needle bearing. Install the driven shaft assembly.
    Fig 14: Installing Driven Shaft Assembly
    G07666067Courtesy of SUBARU OF AMERICA, INC.
  15. Install the drive pinion collar, needle bearing, adjusting washer No. 2, thrust bearing, adjusting washer No. 1 and differential bevel gear sleeve in this order.
    Fig 15: Drive Pinion Shaft Assembly Components
    G07666068Courtesy of SUBARU OF AMERICA, INC.
  16. Adjust the thrust bearing preload. < Ref. to THRUST BEARING PRELOAD , ADJUSTMENT, Drive Pinion Shaft Assembly. >
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