Drive Pinion Shaft Assembly: Disassembly

WARNING: This page is about a different car, the 2013 Subaru Forester. However, it is still accessible from the selected car via links, so may be relevant.

NOTE: Attach a cloth to the end of driven shaft (on the frictional side of the thrust needle bearing) to prevent damage during disassembly or reassembly.

Flatten the tab of the lock nut. Remove the lock nut with ST1, ST2 and ST3.
ST1 899884100 HOLDER

ST2 498427100 STOPPER

ST3 899988608 SOCKET WRENCH (27)

Fig 1: Removing Lock Nut Using ST1, ST2 And ST3
Courtesy of SUBARU OF AMERICA, INC.
Draw out the drive pinion shaft from driven shaft. Remove the differential bevel gear sleeve, adjusting washer No. 1, adjusting washer No. 2, thrust bearing, needle bearing and drive pinion collar.

Fig 2: Identifying Drive Pinion Shaft, Driven Shaft And Related Components
Courtesy of SUBARU OF AMERICA, INC.
Remove the roller bearing and washer using ST and a press.
NOTE: Do not reuse the roller bearing.

ST 498077000 REMOVER

Fig 3: Removing Roller Bearing And Washer Using Remover
Courtesy of SUBARU OF AMERICA, INC.
Flatten the tab of the lock nut. Remove the lock nut using ST1 and ST2.
ST1 499987300 SOCKET WRENCH (50)

ST2 899884100 HOLDER

Fig 4: Removing Lock Nut Using ST1 And ST2
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
Courtesy of SUBARU OF AMERICA, INC.
Remove the woodruff key.
Remove the roller bearing and 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 And Remover
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, inner baulk ring, synchro cone, outer baulk ring, 2nd gear bushing and gear & hub assembly using ST1 and ST2.

Fig 8: Identifying 1st Driven Gear, Inner Baulk Ring, Synchro Cone, Outer Baulk Ring, 2nd Gear Bushing And Gear & Hub Assembly
Courtesy of SUBARU OF AMERICA, INC.

NOTE: If necessary, use a new gear and hub assembly as a set, when replacing the gear or hub. Because these must engage at the specified point, avoid disassembly as much as possible. If it must be disassembled, mark the engaging point on the spline beforehand.

ST1 499757002 INSTALLER

ST2 899714110 REMOVER

Fig 9: Removing 1st Driven Sub Gear, Washer And Snap Ring
Courtesy of SUBARU OF AMERICA, INC.
Remove the sub gear, washer and snap ring (outer) of the 1st driven gear.