Drive Pinion Shaft Assembly: Assembly

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

Install the sleeve and hub assembly by matching alignment marks.
NOTE: Use a new gear and hub assembly, if gear or hub have been replaced.

Fig 1: Identifying Sleeve And Hub Assembly
Courtesy of SUBARU OF AMERICA, INC.
Install the washer, snap ring and sub gear to 1st driven gear.
Install the 1st driven gear, 1st baulk ring, gear and hub assembly onto driven shaft.
NOTE:
- Take care to install the gear and hub assembly in proper direction.
- Align the baulk ring and gear & hub assembly with key groove.
Install the 2nd driven gear bushing onto driven shaft using ST1, ST2 and 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 bush.
ST1 499277200 INSTALLER

ST2 499587000 INSTALLER

Fig 2: Installing 2nd Driven Gear Bushing Using Installer ST1 499277200 And Installer ST2 499587000
Courtesy of SUBARU OF AMERICA, INC.
Install the 2nd driven gear, inner baulk ring, synchro cone, outer baulk ring and insert onto driven shaft.

Fig 3: Identifying 2nd Driven Gear, Inner Baulk Ring, Synchro Cone And Outer Baulk Ring
Courtesy of SUBARU OF AMERICA, INC.
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 4: Installing 3rd-4th Driven Gear Using Installer ST499277200
Courtesy of SUBARU OF AMERICA, INC.
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 5: Installing Roller Bearings Onto Driven Shaft Using Installer ST499277200
Courtesy of SUBARU OF AMERICA, INC.
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 6: Installing 5th Driven Gear Onto Driven Shaft Using Installer ST499277200
Courtesy of SUBARU OF AMERICA, INC.
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 7: Installing Lock Nut Using Socket Wrench ST499987300
Courtesy of SUBARU OF AMERICA, INC.
NOTE:
- Stake the lock nut at two points.
- Using the 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 lb).
Fig 8: Checking Starting Torque Of Roller Bearing
Courtesy of SUBARU OF AMERICA, INC.
Install the roller bearing onto drive pinion.
NOTE: When installing the roller bearing, note its directions (front and rear) because the knock pin hole in outer race is offset.

Fig 9: Identifying Roller Bearing And Knock Pin Hole
Courtesy of SUBARU OF AMERICA, INC.
Install the washer using ST1, ST2 and press.
ST1 499277100 BUSH 1-2 INSTALLER

ST2 499277200 INSTALLER

Fig 10: Installing Washer Using Bush 1-2 Installer ST1 499277100 And Installer ST2 499277200
Courtesy of SUBARU OF AMERICA, INC.
Install the thrust bearing and needle bearing. Install the driven shaft assembly.

Fig 11: Installing Driven Shaft Assembly
Courtesy of SUBARU OF AMERICA, INC.
Install the drive pinion collar, needle bearing, adjusting washer No. 2, thrust bearing, adjusting washer No. 1 and differential bevel gear sleeve in that order.
NOTE: Be careful because the spacer must be installed in proper direction.

Fig 12: Identifying Drive Pinion Collar, Needle Bearing, Thrust Bearing And Differential Bevel Gear Sleeve
Courtesy of SUBARU OF AMERICA, INC.
Adjust the thrust bearing preload. < Ref. to ADJUSTMENT , Drive Pinion Shaft Assembly. >