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Main Shaft Assembly: Assembly

WARNING: This page is about a different variant/trim than selected.
NOTE: When replacing the following parts, replace as a set.
  1. Apply adequate transmission gear oil to the main shaft, needle bearing and 3rd drive gear inner surface.
  2. Install the needle bearing and 3rd drive gear to the main shaft.
    Fig 1: Installing Needle Bearing And 3rd Drive Gear To Main Shaft
    G10269088Courtesy of SUBARU OF AMERICA, INC.
  3. Install the 3rd inner baulk ring, 3rd synchro cone and 3rd outer baulk ring.
    Fig 2: Installing 3rd Inner Baulk Ring, 3rd Synchro Cone And 3rd Outer Baulk Ring
    G10269089Courtesy of SUBARU OF AMERICA, INC.
    NOTE: Install the 3rd synchro cone by aligning the protrusion of the 3rd synchro cone with the hole on the 3rd drive gear.
    Fig 3: Installing 3rd Synchro Cone
    G05336142Courtesy of SUBARU OF AMERICA, INC.
  4. Install the 3rd-4th synchronizer hub and 4th needle bearing race.
    CAUTION: Apply transmission gear oil onto sliding or revolving surfaces before installation.
    1. Being careful of the install direction of the 3rd-4th synchronizer hub, set to the main shaft.
      Fig 4: Installing 3rd-4th Synchronizer Hub And 4th Needle Bearing Race
      G10269091Courtesy of SUBARU OF AMERICA, INC.
    2. With the main shaft oil hole and 4th needle bearing race oil hole out of alignment, attach to the main shaft.
      Fig 5: Identifying Main Shaft Oil Hole And 4th Needle Bearing Race Oil Hole
      G10269092Courtesy of SUBARU OF AMERICA, INC.
    3. Using the ST, push in to the 3rd-4th synchronizer hub and 4th needle bearing race all at once.

      ST1 18651AA000 INSTALLER

      ST2 398177700 INSTALLER

      CAUTION: Do not apply pressure in excess of 40 kN (4.0 ton, 4.4 US ton, 3.9 Imp ton).
      NOTE: When pushing into the 3rd-4th synchronizer hub and 4th needle bearing race, move the 3rd outer baulk ring to match the protrusion of the 3rd outer baulk ring and the cut out of the 3rd-4th synchronizer hub.
      Fig 6: Pushing 3rd-4th Synchronizer Hub And 4th Needle Bearing Race
      G10269093Courtesy of SUBARU OF AMERICA, INC.
  5. Make sure that the 3rd drive gear can be turned smoothly by hand. If it does not turn smoothly, reassemble.
  6. Attach the 3rd-4th shifting insert at the appropriate position of the 3rd-4th coupling sleeve.
    NOTE:
    • The location angle of each shifting insert is 120°.
    • Refer to the following figure to install the shifting insert.
    Fig 7: Attaching 3rd-4th Shifting Insert Of 3rd-4th Coupling Sleeve
    G10269094Courtesy of SUBARU OF AMERICA, INC.
  7. Attach the 3rd-4th coupling sleeve to the 3rd-4th synchronizer hub.
    CAUTION: Apply transmission gear oil onto sliding or revolving surfaces before installation.
    NOTE:
    • There is an identification groove on the 3rd-4th coupling sleeve.
    • Place the groove towards the 3rd drive gear, and attach the 3rd-4th coupling sleeve.
    Fig 8: Placing Groove Towards 3rd Drive Gear
    G10269095Courtesy of SUBARU OF AMERICA, INC.
  8. Install the 4th baulk ring.
    Fig 9: Installing 4th Baulk Ring
    G05003392Courtesy of SUBARU OF AMERICA, INC.
  9. Apply adequate transmission gear oil to the main shaft, needle bearing and 4th drive gear inner surface.
  10. Install the needle bearing and 4th drive gear.
    Fig 10: Installing Needle Bearing And 4th Drive Gear
    G10269097Courtesy of SUBARU OF AMERICA, INC.
  11. Install the 5th drive gear bushing.
    1. With the main shaft oil hole and 5th drive gear bushing oil hole out of alignment, attach to the main shaft.
      Fig 11: Installing 5th Drive Gear Bushing
      G10269098Courtesy of SUBARU OF AMERICA, INC.
    2. Using the ST, push into the 5th drive gear bushing.

      ST1 18651AA000 INSTALLER

      ST2 398177700 INSTALLER

      CAUTION: Do not apply pressure in excess of 40 kN (4.0 ton, 4.4 US ton, 3.9 Imp ton).
      Fig 12: Pushing 5th Drive Gear Bushing
      G05003395Courtesy of SUBARU OF AMERICA, INC.
  12. Make sure that the 4th drive gear can be turned smoothly by hand. If it does not turn smoothly, reassemble.
  13. Apply adequate transmission gear oil to the main shaft, needle bearing and 5th drive gear inner surface.
  14. Install the needle bearing and 5th drive gear.
    Fig 13: Installing Needle Bearing And 5th Drive Gear
    G10269100Courtesy of SUBARU OF AMERICA, INC.
  15. Install the 5th baulk ring.
    Fig 14: Installing 5th Baulk Ring
    G05003397Courtesy of SUBARU OF AMERICA, INC.
  16. Install the 5th-6th synchronizer hub.
    CAUTION: Apply transmission gear oil onto sliding or revolving surfaces before installation.
    1. Being careful of the install direction of the 5th-6th synchronizer hub, set to the main shaft.
      Fig 15: Installing 5th-6th Synchronizer Hub
      G10269103Courtesy of SUBARU OF AMERICA, INC.
    2. Using the ST, push into the 5th-6th synchronizer hub.

      ST1 18651AA000 INSTALLER

      ST2 398177700 INSTALLER

      CAUTION: Do not apply pressure in excess of 40 kN (4.0 ton, 4.4 US ton, 3.9 Imp ton).
      NOTE: When pushing into the 5th-6th synchronizer hub, move the 5th outer baulk ring to match the protrusion of the 5th outer baulk ring and the cut out of the 5th-6th drive gear bushing.
      Fig 16: Pushing 5th-6th Synchronizer Hub
      G10269104Courtesy of SUBARU OF AMERICA, INC.
  17. Make sure that the 5th drive gear can be turned smoothly by hand. If it does not turn smoothly, reassemble.
  18. Attach the 5th-6th shifting insert at the appropriate position of the 5th-6th coupling sleeve.
    NOTE:
    • The location angle of each shifting insert is 120°.
    • Refer to the following figure to install the shifting insert key.
    Fig 17: Attaching 5th-6th Shifting Insert At Appropriate Position Of 5th-6th Coupling Sleeve
    G10269105Courtesy of SUBARU OF AMERICA, INC.
  19. Attach the 5th-6th coupling sleeve to the 5th-6th synchronizer hub.
    CAUTION: Apply transmission gear oil onto sliding or revolving surfaces before installation.
    NOTE:
    • There are two identification grooves on the 5th-6th sleeve.
    • Place the grooves towards the 5th drive gear, and attach the 5th-6th coupling sleeve.
    Fig 18: Attaching 5th-6th Coupling Sleeve To 5th-6th Synchronizer Hub
    G10269106Courtesy of SUBARU OF AMERICA, INC.
  20. Install the 6th baulk ring.
    Fig 19: Installing 6th Baulk Ring
    G05003402Courtesy of SUBARU OF AMERICA, INC.
  21. Apply adequate transmission gear oil to the main shaft, 6th needle bearing and 6th drive gear inner surface.
  22. Install the 6th drive gear.
    Fig 20: Installing 6th Drive Gear
    G05003403Courtesy of SUBARU OF AMERICA, INC.
  23. Install the 6th needle bearing.
    Fig 21: Installing 6th Needle Bearing
    G05003404Courtesy of SUBARU OF AMERICA, INC.
  24. With 6th drive gear bushing oil hole and the main shaft oil hole out of alignment, attach to the main shaft.
    Fig 22: Identifying 6th Drive Gear Bushing Oil Hole And Main Shaft Oil Hole
    G10269109Courtesy of SUBARU OF AMERICA, INC.
  25. Using the ST, install the 6th drive gear bushing.

    ST1 18651AA000 INSTALLER

    ST2 398177700 INSTALLER

    CAUTION: Do not apply pressure in excess of 40 kN (4.0 ton, 4.4 US ton, 3.9 Imp ton).
    Fig 23: Installing 6th Drive Gear Bushing
    G05003406Courtesy of SUBARU OF AMERICA, INC.
  26. Make sure that the 6th drive gear can be turned smoothly by hand. If it does not turn smoothly, reassemble.
  27. Using the ST, install the double taper roller bearing inner race (front side).

    ST1 18651AA000 INSTALLER

    ST2 398177700 INSTALLER

    CAUTION: Do not apply pressure in excess of 40 kN (4.0 ton, 4.4 US ton, 3.9 Imp ton).
    NOTE: Use a new double taper roller bearing.
    Fig 24: Installing Double Taper Roller Bearing Inner Race (Front Side)
    G05003407Courtesy of SUBARU OF AMERICA, INC.
  28. Using the ST, install the outer race and inner race (rear side) of the double taper roller bearing.

    ST1 18651AA000 INSTALLER

    ST2 398177700 INSTALLER

    CAUTION: Do not apply pressure in excess of 40 kN (4.0 ton, 4.4 US ton, 3.9 Imp ton).
    NOTE:
    • Confirm that the outer race and inner race are installed in the proper direction.
    • Push in until there is no backlash on the double taper roller bearing outer race and the bearing turns smoothly by hand.
    Fig 25: Installing Outer Race And Inner Race (Rear Side) Of Double Taper Roller Bearing
    G10269112Courtesy of SUBARU OF AMERICA, INC.
  29. Make sure that the double taper roller bearing turns smoothly by hand. If it does not turn smoothly, replace the double taper roller bearing as a set, and reassemble.
  30. Attach a new lock washer and a new lock nut.
    CAUTION: Apply transmission gear oil to the lock washer and lock nut before installation.
  31. Set the main shaft assembly to the ST, and tighten the lock nut.

    ST1 18665AA000 HOLDER

    ST2 18664AA000 BASE

    NOTE: Make sure the lock washer is installed in the proper direction.

    Tightening torque: 

    392 N.m (40.0 kgf-m, 289.1 ft-lb) 

    Fig 26: Attaching Lock Washer And Lock Nut
    G10269113Courtesy of SUBARU OF AMERICA, INC.
  32. Using the ST, crimp the lock nut in 4 locations, with dimensions within A 27±0.3 mm (1.06±0.01 in).

    ST 18668AA000 PUNCH

    NOTE: Do not damage the crimp area of the lock nut.
    Fig 27: Tapping Lock Nut Using ST
    G05003410Courtesy of SUBARU OF AMERICA, INC.
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