Drive Pinion Shaft Assembly: Assembly

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

NOTE:

Match the alignment marks, and install the coupling sleeve to the synchronizer hub and then install the shifting insert.
Make sure that there is no large clearance at both sides of the shifting insert after assembly.

Fig 1: Identifying Shifting Insert, Synchronizer Hub, Coupling Sleeve Alignment Marks

Courtesy of SUBARU OF AMERICA, INC.

Install the 1st driven gear, 1st inner baulk ring, 1st synchro cone, 1st outer baulk ring and 1st-2nd synchronizer hub.
NOTE:
- Install the 1st-2nd synchronizer hub in proper direction.
- Align the protrusion of the outer baulk ring into the groove of the 1st-2nd synchronizer hub.
Fig 2: Installing 1st-2nd Synchronizer Hub
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Install the 2nd driven gear bushing using ST and a press.
CAUTION: Do not apply a load in excess of 10 kN (1 ton, 1.1 US ton, 1.0 Imp ton).
NOTE:
- Attach a cloth to the end of the driven shaft to prevent damage.
- When press fitting, align the oil holes of the driven shaft and 2nd driven gear bushing.
ST 18654AA000 INSTALLER

Fig 3: Pressing Driven Shaft And 2nd Driven Gear Bushing
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Install the 1st-2nd coupling sleeve.
NOTE:
- Install the 1st-2nd coupling sleeve in proper direction.
- Align the alignment marks of 1st-2nd coupling sleeve and the 1st-2nd synchronizer hub.
Fig 4: Aligning Alignment Marks Of 1st-2nd Coupling Sleeve And 1st-2nd Synchronizer Hub
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Install the 1st-2nd shifting insert.
NOTE: Press in the ball part to install.

Fig 5: Installing 1st-2nd Shifting Insert
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Install the 2nd outer baulk ring, 2nd synchro cone, 2nd inner baulk ring and 2nd driven gear.

Fig 6: Installing 2nd Outer Baulk Ring, 2nd Synchro Cone And 2nd Inner Baulk Ring
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Install the key to the driven shaft.
Using the ST and a press, install the 3rd-4th driven gear.
CAUTION: Do not apply a load in excess of 10 kN (1 ton, 1.1 US ton, 1.0 Imp ton).
NOTE:
- Match the groove on the 3rd-4th driven gear to the key.
- Install the 3rd-4th driven gear in the proper direction.
ST 499277200 INSTALLER

Fig 7: Installing 3rd-4th Driven Gear
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Using the ST and a press, install the double ball bearing.
CAUTION: Do not apply a load in excess of 10 kN (1 ton, 1.1 US ton, 1.0 Imp ton).

NOTE: Use a new double ball bearing.

ST 499277200 INSTALLER

Fig 8: Installing Double Ball Bearing
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Install the 5th driven gear using ST and press.
CAUTION: Do not apply a load in excess of 10 kN (1 ton, 1.1 US ton, 1.0 Imp ton).

NOTE: Install the 5th driven gear with the groove side facing the 6th driven gear.

ST 499277200 INSTALLER

Fig 9: Installing 5th Driven Gear Using ST
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Install the drive pinion spacer to the driven shaft.
Install the 6th driven gear using ST and press.
CAUTION: Do not apply a load in excess of 10 kN (1 ton, 1.1 US ton, 1.0 Imp ton).

NOTE: Install with the stepped side on the end surface of the 6th driven gear facing the rear ball bearing side.

ST 499277200 INSTALLER

Fig 10: Installing Stepped Side Facing Rear Ball Bearing
Courtesy of SUBARU OF AMERICA, INC.
Using the ST and a press, install the ball bearing.
CAUTION: Do not apply a load in excess of 10 kN (1 ton, 1.1 US ton, 1.0 Imp ton).

ST 499277200 INSTALLER

Fig 11: Installing Ball Bearing
Courtesy of SUBARU OF AMERICA, INC.
Install the lock nut using ST1 and ST2.
NOTE: Use a new lock nut.

Tightening torque:

440 N.m (44.9 kgf-m, 324.5 ft-lb)

ST1 499987300 SOCKET WRENCH (50)

ST2 18680AA020 HOLDER

Fig 12: Installing Lock Nut Using ST1 And ST2
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Using a spring scale, check that starting load of the ball bearing is 0.1 to 1.5 N (0.01 to 0.15 kgf, 0.02 to 0.34 lbf).

Fig 13: Checking Starting Load Of Ball Bearing
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Crimp the lock nut at two locations so that the dimension (B) becomes 39.1 mm (1.54 in) or less.
CAUTION: When crimping the lock nut, be careful not to crack it.

Fig 14: Identifying Crimp Lock Nut Dimension
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Install the roller bearing.
NOTE:
- Use a new roller bearing.
- Install with the knock pin hole of the roller bearing outer race facing the rear side.
Fig 15: Installing Knock Pin Hole Of Roller Bearing Outer Race Facing Rear Side
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Install the washer 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 499277100 BUSHING 1-2 INSTALLER

ST2 499277200 INSTALLER

Fig 16: Installing Washer Using ST1, ST2
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Install the thrust bearing and needle bearing and install the driven shaft assembly.

Fig 17: Installing Thrust Bearing And Needle Bearing
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Install the drive pinion collar, needle bearing, adjusting washer No. 2, thrust bearing, adjusting washer No. 1 and differential bevel gear sleeve in this order.

Fig 18: Identifying Drive Pinion Collar, Needle Bearing, Adjusting Washer No. 2 And Thrust Bearing
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Adjust the thrust bearing preload. <Ref. to THRUST BEARING PRELOAD , ADJUSTMENT, Drive Pinion Shaft Assembly.>