Drive Pinion Shaft Assembly: Disassembly

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

NOTE:

Attach a cloth to the end of driven shaft (on the frictional side of the thrust needle bearing) to prevent damage during disassembly or reassembly.
When replacing the coupling sleeve and synchronizer hub, replace them as a set. Because these must engage at the specified point, avoid disassembly as much as possible. If it is necessary to disassemble, mark the engaging points on the splines beforehand.

Flatten the tab of the lock nut.
Remove the lock nut using ST1, ST2 and ST3.
ST1 18680AA020 HOLDER

ST2 18667AA020 HOLDER

ST3 18662AA010 SOCKET WRENCH (27)

Fig 1: Removing Lock Nut Using ST1, ST2 And ST3
Courtesy of SUBARU OF AMERICA, INC.
Remove the lock washer, washer, differential bevel gear sleeve, adjusting washer No. 1, thrust bearing and adjusting washer No. 2.

Fig 2: Removing Differential Bevel Gear Sleeve And Lock Washer
Courtesy of SUBARU OF AMERICA, INC.
Draw out the drive pinion shaft from driven shaft.
Remove the needle bearing and drive pinion collar.

Fig 3: Removing Needle Bearing And Drive Pinion Collar
Courtesy of SUBARU OF AMERICA, INC.
Remove the needle bearing and thrust bearing.

Fig 4: Removing Needle Bearing And Thrust Bearing
Courtesy of SUBARU OF AMERICA, INC.
Remove the roller bearing and washer using ST and a press.
ST 498077000 REMOVER

Fig 5: Removing Roller Bearing And Washer Using ST
Courtesy of SUBARU OF AMERICA, INC.
Flatten the tab of the lock nut.
Remove the lock nut using ST1 and ST2.
ST1 499987300 SOCKET WRENCH (50)

ST2 18680AA020 HOLDER

Fig 6: Removing Lock Nut Using ST1 And ST2
Courtesy of SUBARU OF AMERICA, INC.
Remove the ball bearing, 6th driven gear and drive pinion spacer using the ST1, ST2 and a press.
ST1 899754112 PRESS

ST2 899714110 REMOVER

Fig 7: Removing Ball Bearing, 6th Driven Gear And Drive Pinion Spacer Using ST1, ST2
Courtesy of SUBARU OF AMERICA, INC.
Remove the 5th driven gear, double ball bearing and 3rd-4th driven gear using ST1, ST2 and a press.
ST1 899754112 PRESS

ST2 899714110 REMOVER

Fig 8: Removing 5th Driven Gear, Double Ball Bearing And 3rd-4th Driven Gear
Courtesy of SUBARU OF AMERICA, INC.
Remove the key.
Remove the 2nd driven gear, 2nd inner baulk ring, 2nd synchro cone, 2nd outer baulk ring, 1st-2nd shifting insert and 1st-2nd coupling sleeve.
CAUTION: When removing 1st-2nd coupling sleeve, be careful not to lose the 1st-2nd shifting insert.
Remove the 1st driven gear, 1st inner baulk ring, 1st synchro cone, 1st outer baulk ring, 2nd driven gear bushing and 1st-2nd synchronizer hub using ST and a press.
ST 18762AA001 COMPRESSOR SPECIAL TOOL

Fig 9: Removing 1st Driven Gear, 1st Inner Baulk Ring And 1st Synchro Cone
Courtesy of SUBARU OF AMERICA, INC.