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.

Straighten the lock nut at staked portion. 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 Holder ST1 899884100, Stopper ST2 498427100 And Socket Wrench ST3 899988608
Courtesy of SUBARU OF AMERICA, INC.
Withdraw the drive pinion from driven shaft. Remove the differential bevel gear sleeve, adjusting washer No. 1, adjusting washer No. 2, thrust bearing, needle bearing, drive pinion collar, needle bearing and thrust bearing.

Fig 2: Identifying Differential Bevel Gear Sleeve, Needle Bearing, Drive Pinion Collar And Thrust Bearing
Courtesy of SUBARU OF AMERICA, INC.
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 Remover ST498077000
Courtesy of SUBARU OF AMERICA, INC.
Straighten the lock nut at staked portion. Remove the lock nut using ST1 and ST2.
ST1 499987300 SOCKET WRENCH (50)

ST2 899884100 HOLDER

Fig 4: Removing Lock Nut Using Holder ST2 899884100 And Socket Wrench ST1 499987300
Courtesy of SUBARU OF AMERICA, INC.
Remove the 5th driven gear using ST.
ST 499857000 5TH DRIVEN GEAR REMOVER

Fig 5: Removing 5th Driven Gear Using 5th Driven Gear Remover ST499857000
Courtesy of SUBARU OF AMERICA, INC.
Remove the woodruff key.
Remove the roller bearing, 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 Installer ST1 499757002 And Remover ST2 899714110
Courtesy of SUBARU OF AMERICA, INC.
Remove the key.
Remove the 2nd driven gear, inner baulk ring, synchro cone and outer baulk ring.

Fig 7: Identifying 2nd Driven Gear, Inner Baulk Ring, Synchro Cone And Outer Baulk Ring
Courtesy of SUBARU OF AMERICA, INC.
Remove the 1st driven gear, 2nd gear bushing, gear and hub using ST1 and ST2.
NOTE: Replace the gear and hub if necessary. Do not attempt to disassemble if at all possible because they must engage at a specified point. If they should be disassembled, mark engagement point beforehand.

ST1 499757002 INSTALLER

ST2 899714110 REMOVER

Fig 8: Removing 1st Driven Gear And 2nd Gear Bushing Using Installer ST1 499757002 And Remover ST2 899714110
Courtesy of SUBARU OF AMERICA, INC.
Remove the sub gear for 1st driven gear.