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Home >> Subaru >> 2005 >> Outback R VDC Limited >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 26 (Manual Transmission And Differential (5MT)) >> Drive Pinion Shaft Assembly >> Assembly

Drive Pinion Shaft Assembly: Assembly

WARNING: This page is about a different variant/trim than selected.
  1. Install the sleeve and hub assembly by matching alignment marks.
    NOTE: Use the new gear and hub assembly, when replacing the gear or hub.
    Fig 1: Installing Sleeve And Hub Assembly
    G03832123Courtesy of SUBARU OF AMERICA, INC.
  2. Install the washer to 1st driven gear.
  3. Install the 1st driven gear, 1st baulk ring, gear and hub assembly onto driven shaft. (Non-turbo model).
    Fig 2: Installing 1st Driven Gear, 1st Baulk Ring, Gear And Hub Assembly Onto Driven Shaft - Non-Turbo Model
    G03832124Courtesy of SUBARU OF AMERICA, INC.
  4. Install the 1st driven gear, inner baulk ring, synchro cone, outer baulk ring, gear and hub assembly onto driven shaft. (Turbo model)
    Fig 3: Installing 1st Driven Gear, Inner Baulk Ring, Synchro Cone, Outer Baulk Ring, Gear And Hub Assembly - Turbo model
    G03832125Courtesy of SUBARU OF AMERICA, INC.
    NOTE:
    • Take care to install the gear and hub assembly in proper direction.
    • Align the baulk ring and gear and hub assembly with key groove.
  5. Install the 2nd driven gear bushing onto driven shaft using ST1, ST2 and a press.
    NOTE:
    • Do not apply pressure in excess of 10 kN (1 ton, 1.1 US ton, 1.0 Imp ton).
    • Attach a cloth to the end of driven shaft to prevent damage.
    • When press-fitting, align the oil holes of shaft and bushing.

    ST1 499277200 INSTALLER

    ST2 499587000 INSTALLER

    Fig 4: Installing 2nd Driven Gear Bushing Onto Driven Shaft Using ST1, ST2 And A Press
    G03832126Courtesy of SUBARU OF AMERICA, INC.
  6. Install the 2nd driven gear, inner baulk ring, synchro cone and outer baulk ring, and insert onto driven shaft.
    Fig 5: Identifying 2nd Driven Gear, Inner Baulk Ring, Synchro Cone And Outer Baulk Ring
    G03832127Courtesy of SUBARU OF AMERICA, INC.
  7. After installing the key on driven shaft, install the 3rd-4th driven gear using ST and press.
    NOTE:
    • Do not apply pressure in excess of 10 kN (1 ton, 1.1 US ton, 1.0 Imp ton).
    • Align the groove in baulk ring with insert.

    ST 499277200 INSTALLER

    Fig 6: Installing 3rd-4th Driven Gear Using ST And Press
    G03832128Courtesy of SUBARU OF AMERICA, INC.
  8. Install a set of roller bearings onto the driven shaft using ST and press.
    NOTE: Do not apply pressure in excess of 10 kN (1 ton, 1.1 US ton, 1.0 Imp ton).

    ST 499277200 INSTALLER

    Fig 7: Installing A Set Of Roller Bearings Onto Driven Shaft Using ST And Press
    G03832129Courtesy of SUBARU OF AMERICA, INC.
  9. Position the woodruff key in groove on the rear of driven shaft. Install the 5th driven gear onto driven shaft using ST and press.
    NOTE: Do not apply pressure in excess of 10 kN (1 ton, 1.1 US ton, 1.0 Imp ton).

    ST 499277200 INSTALLER

    Fig 8: Installing 5th Driven Gear Onto Driven Shaft Using ST And Press
    G03832130Courtesy of SUBARU OF AMERICA, INC.
  10. Install the lock washer. Install the lock nut and tighten to the specified torque using ST.

    ST 499987300 SOCKET WRENCH (50)

    Tightening torque: 

    260 N.m (26.5 kgf-m, 191.7 ft-lb) 

    Fig 9: Installing Lock Nut
    G03832131Courtesy of SUBARU OF AMERICA, INC.
    NOTE:
    • Stake the caulking of lock nut at two points.
    • Using a spring balancer, check that starting torque of roller bearing is 0.1 to 1.5 N (0.01 to 0.15 kgf, 0.02 to 0.33 lbf).
    Fig 10: Checking Starting Torque Of Roller Bearing Using A Spring Balancer
    G03832132Courtesy of SUBARU OF AMERICA, INC.
  11. Install the roller bearing onto drive pinion.
    NOTE: When installing roller bearing, note its directions (front and rear) because the knock pin hole in outer race is offset.
    Fig 11: Installing Roller Bearing Onto Drive Pinion
    G03832133Courtesy of SUBARU OF AMERICA, INC.
  12. Install the washer using ST1, ST2 and a press.
    NOTE: Do not apply pressure 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 12: Installing Washer Using ST1, ST2 And A Press
    G03832134Courtesy of SUBARU OF AMERICA, INC.
  13. Install the thrust bearing and needle bearing. Install the driven shaft assembly.
    Fig 13: Installing Thrust Bearing And Needle Bearing
    G03832135Courtesy of SUBARU OF AMERICA, INC.
  14. 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.
    NOTE: Be careful because the spacer must be installed in proper direction.
    Fig 14: Installing Drive Pinion Collar, Needle Bearing, Adjusting Washer No. 2 And Thrust Bearing
    G03832136Courtesy of SUBARU OF AMERICA, INC.
  15. Adjust the thrust bearing preload. < Ref. to , THRUST BEARING PRELOAD , ADJUSTMENT, Drive Pinion Shaft Assembly. >
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