Driven Gear Assembly: Assembly

WARNING: This page is about a different variant/trim than selected.

NOTE: When replacing the following parts, replace as a set.

Coupling sleeve and synchronizer hub
1st outer baulk ring, 1st synchro cone and 1st inner baulk ring
2nd outer baulk ring, 2nd synchro cone and 2nd inner baulk ring.

Apply adequate transmission gear oil to the main shaft, needle bearing and 1st driven gear inner surface.
Install the needle bearing.

Fig 1: Installing Needle Bearing
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Attach the 1st driven gear to the driven shaft.

Fig 2: Attaching 1st Driven Gear To Driven Shaft
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Install the 1st inner baulk ring.

Fig 3: Installing 1st Inner Baulk Ring
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Match the protrusion of the 1st synchro cone to the hole of the 1st driven gear, then install.

Fig 4: Installing 1st Synchro Cone To 1st Driven Gear Hole
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Install the 1st outer baulk ring.

Fig 5: Installing 1st Outer Baulk Ring
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Install the 1st-2nd synchronizer hub.
CAUTION: Apply transmission gear oil onto sliding or revolving surfaces before installation.
NOTE:
- Match the cut out of the 1st-2nd synchronizer hub with the protrusion on the outer baulk ring, then install.
- Make sure that the 1st-2nd synchronizer hub is installed in the correct direction.
Fig 6: Installing 1st-2nd Synchronizer Hub
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Using the ST, install the 1st-2nd synchronizer hub and 2nd driven gear bushing.
ST 18654AA000 INSTALLER

CAUTION: Do not apply pressure in excess of 40 kN (4.0 ton, 4.4 US ton, 3.9 Imp ton).

Fig 7: Installing 1st-2nd Synchronizer Hub And 2nd Driven Gear Bushing
Courtesy of SUBARU OF AMERICA, INC.
Make sure that the 1st driven gear can be turned smoothly by hand. If it does not turn smoothly, reassemble.
Attach the 1st-2nd coupling sleeve to the 1st-2nd synchronizer hub.
NOTE:
- Make sure that the 1st-2nd coupling sleeve is installed in the correct direction.
- Align the 1st-2nd synchronizer hub cut out section (three places) and the key grooves (three places) of shifting insert that are located inside the 1st-2nd coupling sleeve.
- Set the 1st-2nd coupling sleeve and 1st driven gear so that they contact each other.
Fig 8: Attaching 1st-2nd Coupling Sleeve To 1st-2nd Synchronizer Hub
Courtesy of SUBARU OF AMERICA, INC.

Fig 9: Identifying 1st-2nd Synchronizer Hub And 1st-2nd Coupling Sleeve
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Attach the shifting insert to the appropriate position of the 1st-2nd coupling sleeve.
NOTE:
- The location angle of each shifting insert is 120°.
- Install the shifting insert to the key grooves (three places) of shifting insert that are located inside the 1st-2nd coupling sleeve.
Fig 10: Attaching Shifting Insert To Appropriate Position Of 1st-2nd Coupling Sleeve
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Install the 2nd outer baulk ring.

Fig 11: Installing 2nd Outer Baulk Ring
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Install the 2nd synchro cone.

Fig 12: Installing 2nd Synchro Cone
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Install the 2nd inner baulk ring.

Fig 13: Installing 2nd Inner Baulk Ring
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Apply adequate transmission gear oil to the 2nd driven gear bushing, needle bearing and 2nd driven gear inner surface.
Install the needle bearing and 2nd driven gear.
NOTE: Match the protrusion of the 2nd synchro cone to the hole of the 2nd driven gear, then install.

Fig 14: Installing Needle Bearing And 2nd Driven Gear
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Attach the key.

Fig 15: Identifying Key
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Using the ST, install the 3rd-4th driven gear.
ST 18654AA000 INSTALLER
CAUTION:
- Do not apply pressure in excess of 40 kN (4.0 ton, 4.4 US ton, 3.9 Imp ton).
- Apply transmission gear oil onto sliding or revolving surfaces before installation.
NOTE:
- Make sure that the 3rd-4th driven gear is installed in the correct direction.
- Match the groove on the 3rd-4th driven gear to the key.
Fig 16: Installing 3rd-4th Driven Gear
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Make sure that the 2nd driven gear can be turned smoothly by hand. If it does not turn smoothly, reassemble.
Attach the key.

Fig 17: Identifying Key
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Using the ST, install the 5th-6th driven gear.
ST 18654AA000 INSTALLER

CAUTION: Do not apply pressure in excess of 40 kN (4.0 ton, 4.4 US ton, 3.9 Imp ton).
NOTE:
- Make sure that the 5th-6th driven gear is installed in the correct direction.
- Match the groove on the 5th-6th driven gear to the key.
Fig 18: Installing 5th-6th Driven Gear
Courtesy of SUBARU OF AMERICA, INC.
Using the ST, install the ball bearing.
ST 18654AA000 INSTALLER

CAUTION: Do not apply pressure in excess of 40 kN (4.0 ton, 4.4 US ton, 3.9 Imp ton).

NOTE: Face the sealing section of the ball bearing to the lock nut side, and install the ball bearing.

Fig 19: Installing Ball Bearing
Courtesy of SUBARU OF AMERICA, INC.
Make sure that the ball bearing turns smoothly by hand. If it does not turn smoothly, reassemble.
Install a new lock nut.

Attach ST3 to the lock nut, attach ST to the driven gear assembly, and tighten the lock nut.

ST1 18666AA000 HOLDER

ST2 18664AA000 BASE

ST3 18620AA000 ADAPTER WRENCH

ST4 18852AA000 TORQUE WRENCH

Tightening torque:

530 N.m (54.0 kgf-m, 390.9 ft-lb)

Fig 20: Attaching ST3 To Lock Nut

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NOTE: When using a torque wrench other than ST4, use the calculation below to calculate and tighten the lock nut.

T = L1/(0.1 + L1) x 570

T	N.m (kgf-m, ft-lb)	Torque wrench setting
L1	m (in)	Torque wrench length
0.1 m (3.94 in)		Length of ST
570 N.m (58.1 kgf-m, 420 ft-lb)		Tightening torque (lock nut)

Fig 21: Identifying Torque Wrench Length

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Using the ST, crimp the lock nut in 4 locations, with dimensions within A 44±0.5 mm (1.73±0.02 in).
ST 18669AA000 PUNCH DRIVEN SHAFT

NOTE: Do not damage the crimp area of the lock nut.

Fig 22: Identifying Lock Nut Dimension
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