Drive Pinion Shaft Assembly: Inspection

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

1. Bearing

   Replace the bearings in the following cases.

   • When the bearing balls, outer races and inner races are broken or rusty.
   • When the bearing is worn.
   • When the bearings fail to turn smoothly or emit noise in rotation 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 other bearings.
     Fig 1: Identifying Ball Bearing And Drive Pinion Shaft

     Courtesy of SUBARU OF AMERICA, INC.
   • When bearing has other defects.
2. Bushing (each gear)

   Replace the bushing in following cases.

   • When the sliding surface is damaged or abnormally worn.
   • When the inner wall is abnormally worn.
3. Gear

   Replace the bearings in the following cases.

   • Replace the gear with new part if its tooth surfaces are broken, damaged or excessively worn.
   • Correct or 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 rings in the following cases.

   • When the inner surface or 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, check the clearance (A) while pressing the ring against the cone.

     Clearance (A): 

     0.5 mm (0.020 in) or more 

     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 section is scratched or abnormally worn.
5. Shifting insert key

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

   Fig 3: Shifting Insert Key

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

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