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Drive Pinion Shaft Assembly: Installation

WARNING: This page is about a different variant/trim than selected.
  1. Remove the differential assembly.
  2. Alignment marks/numbers on hypoid gear set: Use hypoid driven gear of its match number corresponding with upper one on the drive pinion (A). The figure (B) shows a number for shim adjustment Ref. to Fig 1. If no number is shown, the value is zero.
    Fig 1: Identifying Alignment Marks/Numbers On Hypoid Gear Set
    G03832110Courtesy of SUBARU OF AMERICA, INC.
  3. Place the drive pinion shaft assembly on the transmission main case RH without shim and tighten the bearing mounting bolts.
  4. Inspection and adjustment of 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 Two Bolts
    G03832111Courtesy of SUBARU OF AMERICA, INC.
  5. Position the ST by inserting the knock pin of ST into the knock hole in the 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: Positioning ST By Inserting Knock Pin Of ST Into Knock Hole
    G03832112Courtesy 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 next table for the value determined as described above, and take the shim(s) which thickness is closest to the said value.
    PART NUMBER AND THICKNESS SPECIFICATION CHART

    Drive pinion shim
    Part Number 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 differential assembly. < Ref. to , INSTALLATION , Front Differential Assembly. >
  10. Set the transmission main shaft assembly for single-range and drive pinion assembly in position (So there is no clearance between these two when moved all the way to the front). Inspect the suitable 1st - 2nd, 3rd - 4th and 5th shifter fork so that the coupling sleeve and reverse driven gear are positioned in the center of their synchronizing mechanisms. < Ref. to , INSPECTION , Drive Pinion Shaft Assembly. >
  11. Install the transmission case. < Ref. to , INSTALLATION , Transmission Case. >
  12. Install the transfer case with extension case assembly. < Ref. to , INSTALLATION , Transfer Case and Extension Case Assembly. >
  13. Install the manual transmission assembly to vehicle. < Ref. to , MANUAL TRANSMISSION ASSEMBLY . >
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