Drive Pinion Shaft Assembly: Disassembly

WARNING: This page is about a different variant/trim than selected.

NOTE: Attach a cloth to the end of driven shaft (on the frictional side of thrust needle bearing) to prevent damage during disassembly or reassembly.

Unlock the caulking of lock nut. Remove the lock nut using ST1, ST2 and ST3.
ST1 899884100 HOLDER

ST2 498427100 STOPPER

ST3 899988608 SOCKET WRENCH (27)

Fig 1: Removing Lock Nut Using ST1, ST2 And ST3
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Draw out the drive pinion from driven shaft.
Remove the differential bevel gear sleeve, adjusting washer No. 1, adjusting washer No. 2, thrust bearing, needle bearing and drive pinion collar.

Fig 2: Identifying Differential Bevel Gear Sleeve, Adjusting Washer No. 1, Adjusting Washer No. 2, Thrust Bearing, Needle Bearing And Drive Pinion Collar
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Remove the roller bearing and washer using ST and press.
NOTE: Do not reuse the roller bearing.

ST 498077000 REMOVER

Fig 3: Removing Roller Bearing And Washer Using ST And Press
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Unlock the caulking of lock nut. Remove the lock nut using ST1 and ST2.
ST1 499987300 SOCKET WRENCH (50)

ST2 899884100 HOLDER

Fig 4: Removing Lock Nut Using ST1 And ST2
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Remove the 5th driven gear using ST.
ST 499857000 5TH DRIVEN GEAR REMOVER

Fig 5: Removing 5th Driven Gear Using ST
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Remove the woodruff key.
Remove the roller bearing and 3rd-4th driven gear using ST1 and ST2.
ST1 499757002 INSTALLER

ST2 899714110 REMOVER

Fig 6: Removing Roller Bearing And 3rd-4th Driven Gear Using ST1 And ST2
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Remove the key.
Remove the 2nd driven gear, inner baulk ring, synchro cone and outer baulk ring.

Fig 7: Removing 2nd Driven Gear, Inner Baulk Ring, Synchro Cone And Outer Baulk Ring
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Remove the 1st driven gear, 2nd gear bushing, gear and hub using ST1 and ST2. (Non-turbo model).

Fig 8: Removing 1st Driven Gear, 2nd Gear Bushing, Gear And Hub Using ST1 And ST2 (Non-Turbo Model)
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Remove the 1st driven gear, inner baulk ring, synchro cone, outer baulk ring, 2nd gear bushing, gear and hub using ST1 and ST2. (Turbo model)

Fig 9: Identifying 1st Driven Gear, Inner Baulk Ring, Synchro Cone, Outer Baulk Ring, 2nd Gear Bushing

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NOTE: Replace the gear and hub if necessary. Do not disassemble because they must engage at a specified point. If they have to be disassembled, mark the engaging point on the spline beforehand.

ST1 499757002 INSTALLER

ST2 899714110 REMOVER

Fig 10: Identifying ST1 499757002 Installer And ST2 899714110 Remover

Courtesy of SUBARU OF AMERICA, INC.