Drive Pinion Shaft Assembly: Inspection

Disassembled parts should be washed with unleaded gasoline first and then inspected carefully.

1. Bearings

   Replace the bearing in following cases:

   • When the bearing balls, outer races and inner races are broken or rusty.
   • When the bearing is worn.
   • When the bearings fail to turn smoothly or emit noise in rotation after gear oil lubrication.
   • The ball bearing on the rear side of the drive pinion shaft should be checked for smooth rotation before the drive pinion assembly is disassembled. In this case, because a preload is working on the bearing, its rotation feels like it is slightly dragging unlike other bearings.
     Fig 1: Identifying Ball Bearing And Drive Pinion Shaft

     Courtesy of SUBARU OF AMERICA, INC.
   • When bearings have other defects:
2. Bushing (each gear)

   Replace the bushings in following cases:

   • When the sliding surface is damaged or abnormally worn.
   • When the inner wall is abnormally worn.
3. Gears
   • Replace gears with new ones if their tooth surfaces are broken, damaged or excessively worn.
   • Correct or replace if the cone that contacts the baulk ring is rough or damaged.
   • Correct or replace if the inner surface or end face is damaged.
4. Baulk ring

   Replace the ring in following cases:

   • When the inner surface and end face are damaged.
   • When the ring inner surface is abnormally or partially worn.
   • If the gap between the end faces of ring and the gear splined part is excessively small, check the clearance (A) while pressing the ring against the cone.

     Clearance (A): 

     0.5 - 1.0 mm (0.020 - 0.040 in) 

     Fig 2: Identifying Gap Between End Faces Of Ring And Gear Splined

     Courtesy of SUBARU OF AMERICA, INC.
   • When the contact surface of synchronizer ring insert is scratched or abnormally worn.
5. Shifting insert key

   Replace the insert key if deformed, excessively worn, or defective in any way.

   Fig 3: Identifying Key And Gear

   Courtesy of SUBARU OF AMERICA, INC.
6. Oil seal

   Replace the oil seal if the lip is deformed, hardened, worn or defective in any way.

7. O-ring

Replace the O-ring if the sealing face is deformed, hardened, damaged, worn, or defective in any way.