Main Shaft Assembly for Single-Range: Assembly

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.

When the sleeve & hub assemblies have been disassembled, reassemble by aligning the alignment marks.
NOTE: Position the open ends of the spring 120° apart.

Fig 1: Identifying 3rd-4th Hub Assy And 3rd Gear Side
Courtesy of SUBARU OF AMERICA, INC.
Install the 3rd drive gear, outer baulk ring, synchro cone, inner baulk ring, sleeve & hub assembly for the 3rd needle bearing, on the transmission main shaft.
NOTE: Align the groove in baulk ring with the shifting insert.

Fig 2: Identifying 3rd Needle Bearing, 3rd Drive Gear, Inner Baulk Ring, Synchro Cone And Outer Baulk Ring
Courtesy of SUBARU OF AMERICA, INC.
Install the 4th needle bearing race onto transmission main shaft using ST1, ST2 and press.
CAUTION: Do not apply a load in excess of 10 kN (1 ton, 1.1 US ton, 1.0 Imp ton).

ST1 899714110 REMOVER

ST2 499877000 RACE 4-5 INSTALLER

Fig 3: Identifying 4th Needle Bearing Race
Courtesy of SUBARU OF AMERICA, INC.
Install the baulk ring, needle bearing, 4th drive gear and 4th gear thrust washer to the transmission main shaft.
NOTE:
- Align the baulk ring and sleeve & hub assembly with the key groove.
- Make sure the thrust washer is facing the correct direction.
  
  Fig 4: Identifying Groove And Face Surface To 4th Gear Side
  Courtesy of SUBARU OF AMERICA, INC.
Press-fit the ball bearing into the rear section of transmission main shaft using ST1, ST2 and a press.
CAUTION: Do not apply a load in excess of 10 kN (1 ton, 1.1 US ton, 1.0 Imp ton).

ST1 899714110 REMOVER

ST2 499877000 RACE 4-5 INSTALLER

Fig 5: Pressing To Fit Ball Bearing Into Rear Section Of Transmission Main Shaft Using ST1, ST2 And Press
Courtesy of SUBARU OF AMERICA, INC.
Using the ST1 and ST2, install the 5th gear thrust washer and 5th needle bearing race onto the rear section of transmission main shaft.
CAUTION: Do not apply a load in excess of 10 kN (1 ton, 1.1 US ton, 1.0 Imp ton).

NOTE: Make sure the thrust washer is facing the correct direction.

ST1 899714110 REMOVER

ST2 499877000 RACE 4-5 INSTALLER

Fig 6: Identifying Face Surface To 5th Gear Side
Courtesy of SUBARU OF AMERICA, INC.
Install rest of the parts to the rear section of the transmission main shaft.
CAUTION:
- Install the baulk lever so that the concave side faces toward the 5th hub.
  
  Fig 7: Identifying Baulk Lever And 5th Hub
  Courtesy of SUBARU OF AMERICA, INC.
- Align the protruded section of baulk ring between the baulk levers.
  
  Fig 8: Aligning Protruded Section Of Baulk Ring Between The Baulk Levers
  Courtesy of SUBARU OF AMERICA, INC.
  
  Fig 9: Identifying Needle Bearing, 5th Drive Gear, Baulk Ring, Lock Washer, Lock Nut And Baulk Lever
  Courtesy of SUBARU OF AMERICA, INC.
Tighten the lock nuts to the specified torque using ST1 and ST2.
NOTE:
- Use new lock nuts and lock washers.
- Make sure the lock washer is installed in the proper direction.
Tightening torque:

120 N.m (12.2 kgf-m, 88.5 ft-lb)

ST1 499987003 SOCKET WRENCH (35)

ST2 498937000 TRANSMISSION HOLDER
Crimp lock nuts in two locations after tightening.