Main Shaft Assembly for Single-Range: Assembly

1. When the sleeve & hub assemblies have been disassembled, reassemble with aligning each engaging point.
   NOTE: Position open ends of spring 120° apart.
   Fig 1: Identifying Hub Assemblies

   Courtesy of SUBARU OF AMERICA, INC.
2. Install the 3rd drive gear, outer baulk ring, synchro cone, inner baulk ring, sleeve & hub assembly for 3rd needle bearing, on the transmission main shaft.
   Fig 2: Installing 3rd Drive Gear, Outer Baulk Ring, Synchro Cone, Inner Baulk Ring

   Courtesy of SUBARU OF AMERICA, INC.
   NOTE: Align the groove in baulk ring with shifting insert.
3. Install the 4th needle bearing race onto transmission main 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).

   ST1 899714110 REMOVER

   ST2 499877000 RACE 4-5 INSTALLER

   Fig 3: Installing 4th Needle Bearing Race Onto Transmission Main Shaft Using ST1, ST2 And A Press

   Courtesy of SUBARU OF AMERICA, INC.
4. Install the baulk ring, needle bearing, 4th drive gear and 4th gear thrust washer to transmission main shaft.
   NOTE: Align the baulk ring and gear & hub assembly with key groove.
   Fig 4: Identifying Grooves Of Gear

   Courtesy of SUBARU OF AMERICA, INC.
5. Press the ball bearing into the rear section of transmission main 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).

   ST1 899714110 REMOVER

   ST2 499877000 RACE 4-5 INSTALLER

   Fig 5: Pressing Ball Bearing Into Rear Section Of Transmission Main Shaft Using ST1, ST2 And A Press

   Courtesy of SUBARU OF AMERICA, INC.
6. Using the ST1 and ST2, install the 5th gear thrust washer and 5th needle bearing race onto the rear section of transmission main shaft.
   NOTE:

   • Do not apply pressure in excess of 10 kN (1 ton, 1.1 US ton, 1.0 Imp ton).
   • Face the thrust washer in the correct direction.

   ST1 899714110 REMOVER

   ST2 499877000 RACE 4-5 INSTALLER

   Fig 6: Identifying Face thrust Washer

   Courtesy of SUBARU OF AMERICA, INC.
7. Install the bearing onto synchro cone.
8. Install the baulk ring and synchro cone onto 5th-Rev sleeve & hub assembly using ST and a press.
   NOTE:

   • Do not apply pressure in excess of 10 kN (1 ton, 1.1 US ton, 1.0 Imp ton).
   • Use new ball bearing.
   • Make sure the synchro cone rotates smoothly after press-fitting.

   ST 499757002 INSTALLER

   Fig 7: Installing Baulk Ring And Synchro Cone Onto 5th-Rev Sleeve & Hub Assembly Using ST And A Press

   Courtesy of SUBARU OF AMERICA, INC.
9. Install the synchro cone stopper and snap ring to 5th-Rev sleeve & hub assembly.
   Fig 8: Installing Synchro Cone Stopper And Snap Ring To 5th-Rev Sleeve & Hub Assembly

   Courtesy of SUBARU OF AMERICA, INC.
10. Install the rest of parts to the rear section of transmission main shaft.
    NOTE: Align the groove in baulk ring with shifting insert.
    Fig 9: Identifying Needle Bearing, Baulk Ring And Lock Washer

    Courtesy of SUBARU OF AMERICA, INC.
11. Tighten the lock nuts to the specified torque using ST1 and ST2.

ST1 499987003 SOCKET WRENCH

ST2 498937000 TRANSMISSION HOLDER

Tightening torque: 

120 N.m (12.2 kgf-m, 88.5 ft-lb)