Drive Pinion Shaft (4WD): Reassembly

Press roller bearing and washer onto drive pinion. Position hole in outer race so it engages locating pin.
Install thrust bearing and needle bearing. Install driven gear assembly, drive pinion collar, needle bearing, adjuster washer No. 2, thrust bearing, adjuster washer No. 1, and differential bevel gear sleeve.
Select adjuster washer No. 2 so dimension "H" is zero as estimated visually. See Fig 1. Install washer, lock washer, and lock nut. Tighten lock nut to 81-93 ft. lbs. (110-126 N.m).

Measure starting torque. If starting torque is not 3-7 INCH lbs. (.3-.8 N.m), select and install new adjuster washer No. 1. Recheck starting torque. See ADJUSTER WASHER NO. 1 .

Fig 1: Selecting Adjuster Washer

Courtesy of SUBARU OF AMERICA, INC.

ADJUSTER WASHER NO. 1

Part No.	Thickness In. (mm)
803025051	.1545 (3.925)
803025052	.1555 (3.950)
803025053	.1565 (3.975)
803025054	.1575 (4.000)
803025055	.1585 (4.025)
803025056	.1594 (4.050)
803025057	.1604 (4.075)

If starting torque is not within specification with new adjuster washer No. 1 installed, select another adjuster washer No. 2. See ADJUSTER WASHER NO. 2 . Recheck starting torque. When starting torque is correct, stake lock nut in 4 places.

ADJUSTER WASHER NO. 2

Part No.	Thickness In. (mm)
803025059	.1516 (3.850)
803025054	.1575 (4.000)
803025058	.1634 (4.150)