Drive Pinion Shaft Assembly: Inspection

Disassembled parts should be washed clean first and then inspected carefully.

1. Bearings

   Replace the bearings in the following cases:

   • Bearings whose balls, outer races and inner races are broken or rusty.
   • Worn bearings
   • Bearings that fail to turn smoothly or make abnormal noise when turned 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 the other bearings.
     Fig 1: Identifying Drive Pinion Shaft And Ball Bearing

     Courtesy of SUBARU OF AMERICA, INC.
   • Bearings having other defects
2. Bushing (each gear)

   Replace the bushing in the following cases:

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

   Replace the ring in the following cases:

   • When the inner surface and end face are damaged.
   • When the ring inner surface is abnormally or partially worn down.
   • If the gap between the end faces of the ring and the gear splined part is excessively small when the ring is pressed 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 Part

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

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

   Fig 3: Identifying Shifting Insert Key

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

   Replace the oil seal if the lip is deformed, hardened, damaged, 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.