Drive Pinion Shaft Assembly: Inspection

Disassembled parts should be washed with cleaning solvent first, 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 bearing on the rear side of the drive pinion shaft should be checked for smooth rotation before the drive pinion shaft 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 Drive Pinion Shaft And Ball Bearing

     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 gears 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, synchro cone

   Replace the baulk ring and synchro cone in the following cases.

   • When the inner surface or end face is damaged.
   • When the ring inner surface is abnormally or partially worn down.
   • When the contact surface of the baulk ring insert section is damaged or abnormally worn.
   • 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.
   • Apply gear oil to the cone of the gear and while press-fitting the baulk ring, check there is no rotation in the circumferential direction.
5. Coupling sleeve and synchronizer hub
   • Check the slipping condition of the coupling sleeve.
   • Check the splines on the coupling sleeve and synchronizer hub for wear.
6. Shifting insert key

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

7. Ball detent

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

8. Oil seal

   Replace the oil seal if the lip is deformed, hardened, worn or defective in any way.

9. O-ring

   Replace the O-ring if the sealing face is deformed, hardened, damaged, worn or defective in any way.