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Drive Pinion Shaft Assembly: Installation

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. Remove the front differential assembly.
  2. Hypoid gear set match mark/No.: The number (A) on top of the drive pinion, and the number on the hypoid driven gear are set numbers for the two gears. Use a pair having the same numbers.

    The illustration (B) below shows a number for shim adjustment. If no number is shown, the value is zero.

    Fig 1: Number On Top Of Drive Pinion And Hypoid Driven Gear
    G07666043Courtesy of SUBARU OF AMERICA, INC.
  3. Place the drive pinion shaft assembly on transmission main case RH without shim and tighten the bearing mounting bolts.
  4. Check and adjust the ST.
    NOTE:
    • Loosen the two bolts and adjust so that the scale indicates 0.5 correctly when the plate end and the scale end are on the same level.
    • Tighten the two bolts.

    ST 499917500 DRIVE PINION GAUGE ASSY

    Fig 2: Tightening Bolts With Drive Pinion Gauge
    G07666044Courtesy of SUBARU OF AMERICA, INC.
  5. Position the ST by inserting the knock pin of ST into the knock hole of transmission case.

    ST 499917500 DRIVE PINION GAUGE ASSY

  6. Slide the drive pinion gauge scale with finger tip and read the value at the point where it matches with the end face of drive pinion.

    ST 499917500 DRIVE PINION GAUGE ASSY

    Fig 3: Sliding Drive Pinion Gauge Scale
    G07666045Courtesy of SUBARU OF AMERICA, INC.
  7. The thickness of shim shall be determined by adding the value indicated on drive pinion to the value indicated on the ST. (Add if the number on drive pinion is prefixed by +, and subtract if the number is prefixed by -.)

    ST 499917500 DRIVE PINION GAUGE ASSY

  8. Select one to three shims in the following table for the value determined as described above, and take the shim (s) which thickness is closest to the said value.
    PARTS THICKNESS SPECIFICATION CHART

    Drive pinion shim
    Part No. Thickness mm (in)
    32295AA031 0.150 (0.0059)
    32295AA041 0.175 (0.0069)
    32295AA051 0.200 (0.0079)
    32295AA061 0.225 (0.0089)
    32295AA071 0.250 (0.0098)
    32295AA081 0.275 (0.0108)
    32295AA091 0.300 (0.0118)
    32295AA101 0.500 (0.0197)
  9. Install the front differential assembly. < Ref. to INSTALLATION , Front Differential Assembly. >
  10. Set the transmission main shaft assembly for single-range and drive pinion shaft assembly in position. Inspect a suitable 1st-2nd, 3rd-4th and 5th shifter fork so that the coupling sleeve and reverse driven gear are positioned in the center of the synchronizing mechanism. < Ref. to INSPECTION , Shifter Fork and Rod. >
  11. Install the transmission case. < Ref. to INSTALLATION , Transmission Case. >
  12. Install the transfer case together with the extension case assembly. < Ref. to INSTALLATION , Transfer Case and Extension Case Assembly. >
  13. Install the manual transmission assembly to the vehicle. < Ref. to INSTALLATION , Manual Transmission Assembly. >
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