Main Shaft Assembly for Single-Range: Assembly: Notes

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

NOTE:

Match the alignment marks, and install the coupling sleeve 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 And Coupling Sleeve Alignment Marks

Courtesy of SUBARU OF AMERICA, INC.

Install the needle bearing, 3rd drive gear, 3rd outer baulk ring, 3rd synchro cone, 3rd inner baulk ring and 3rd-4th synchronizer hub.
NOTE:
- Install the 3rd-4th synchronizer hub in the correct direction.
- Align the protrusion of the outer baulk ring into the groove of the 3rd-4th synchronizer hub.
Fig 2: Installing 3rd-4th Synchronizer Hub
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Install the 4th needle bearing race using ST1, ST2, ST3 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

ST3 398177700 INSTALLER

Fig 3: Installing 4th Needle Bearing Race Using ST1, ST2 And ST3
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Install the 3rd-4th coupling sleeve.
NOTE:
- Install the 3rd-4th coupling sleeve in the correct direction.
- Align the alignment marks of 3rd-4th coupling sleeve and the 3rd-4th synchronizer hub.
Fig 4: Installing 3rd-4th Coupling Sleeve
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Install the 3rd-4th shifting insert.
NOTE: Press in the ball part to install.

Fig 5: Installing 3rd-4th Shifting Insert
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Install the 4th baulk ring, needle bearing, 4th drive gear and 4th gear adjusting washer.
NOTE:
- Align the protrusion of the 4th baulk ring into the groove of the 3rd-4th synchronizer hub.
- Install the 4th gear adjusting washer with the groove side facing the 4th drive gear.
Fig 6: Aligning Protrusion Of 4th Baulk Ring Into Groove Of 3rd-4th Synchronizer Hub
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Fig 7: Installing 4th Gear Adjusting Washer With Groove Side Facing 4th Drive Gear
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Install the double taper roller bearing 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).
NOTE:
- Use a new double taper roller bearing.
- Install the double taper roller bearing with snap ring side facing the 5th drive gear side.
ST1 899714110 REMOVER

ST2 499877000 RACE 4-5 INSTALLER

Fig 8: Installing Double Taper Roller Bearing Using ST1, ST2
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Make sure that the double taper roller bearing turns smoothly.
Install the 5th needle bearing race 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 9: Installing 5th Needle Bearing Race Using ST1, ST2
Courtesy of SUBARU OF AMERICA, INC.
Install the needle bearing, 5th drive gear, 5th baulk ring, and 5th-6th synchronizer hub.
NOTE:
- Align the protrusion part of the 5th baulk ring with the groove of the 5th-6th synchronizer hub.
- Install the 5th-6th synchronizer hub in the correct direction.
Fig 10: Installing 5th-6th Synchronizer Hub
Courtesy of SUBARU OF AMERICA, INC.
Install the 6th needle bearing race 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 11: Installing 6th Needle Bearing Race Using ST1, ST2
Courtesy of SUBARU OF AMERICA, INC.
Install the 5th-6th coupling sleeve.
NOTE:
- Install the 5th-6th coupling sleeve in the correct direction.
- Align the alignment marks of 5th-6th coupling sleeve and the 5th-6th synchronizer hub.
Fig 12: Installing 5th-6th Coupling Sleeve
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Install the 5th-6th shifting insert.
NOTE: Press in the ball part to install.

Fig 13: Installing 5th-6th Shifting Insert
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Install the 6th baulk ring, 6th drive gear and needle bearing.

Fig 14: Installing 6th Baulk Ring, 6th Drive Gear And Needle Bearing
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Install the ball bearing using 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).

NOTE: Install the ball bearing with the side which does not have lock nut mounting dent facing 6th drive gear.

ST1 899714110 REMOVER

ST2 899754112 PRESS

Fig 15: Installing Ball Bearing Using ST2
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Install the lock washer.
NOTE:
- Use a new lock washer.
- Install the lock washer in the correct direction.
Fig 16: Installing Lock Washer
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Install the lock nut using ST1 and ST2.
NOTE: Use a new lock nut.

Tightening torque:

160 N.m (16.3 kgf-m, 118.0 ft-lb)

ST1 498937000 TRANSMISSION HOLDER

ST2 499987003 SOCKET WRENCH (35)

Fig 17: Installing Lock Nut Using ST1 And ST2
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Crimp the lock nut at two locations so that the dimension (B) becomes 23.3 mm (0.92 in) or less.
CAUTION: When crimping the lock nut, be careful not to crack it.

Fig 18: Identifying Crimp Lock Nut Dimension
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