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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
  1. Apply adequate transmission gear oil to the main shaft, 1st needle bearing and 1st driven gear inner surface.
  2. Install the needle bearing.
    Fig 1: Identifying Needle Bearing
    G05003425Courtesy of SUBARU OF AMERICA, INC.
  3. Attach the 1st driven gear to the driven shaft.
    Fig 2: Identifying 1st Driven Gear To Driven Shaft
    G06346052Courtesy of SUBARU OF AMERICA, INC.
  4. Install the 1st inner baulk ring.
    Fig 3: Installing 1st Inner Baulk Ring
    G06346053Courtesy of SUBARU OF AMERICA, INC.
  5. Match the protrusion of the 1st synchro cone to the hole of the 1st driven gear, then install.
    Fig 4: Matching Protrusion Of 1st Synchro Cone To 1st Driven Gear Hole
    G05336185Courtesy of SUBARU OF AMERICA, INC.
  6. Install the 1st outer baulk ring.
    Fig 5: Identifying 1st Outer Baulk Ring
    G05003429Courtesy of SUBARU OF AMERICA, INC.
  7. 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
    G10294199Courtesy of SUBARU OF AMERICA, INC.
  8. 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
    G10294200Courtesy of SUBARU OF AMERICA, INC.
  9. Make sure that the 1st driven gear can be turned smoothly by hand. If it does not turn smoothly, reassemble.
  10. 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: Setting 1st-2nd Coupling Sleeve And 1st Driven Gear
    G10294201Courtesy of SUBARU OF AMERICA, INC.
    Fig 9: Identifying 1st-2nd Coupling Sleeve And 1st-2nd Synchronizer Hub
    G10294202Courtesy of SUBARU OF AMERICA, INC.
  11. 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
    G10294203Courtesy of SUBARU OF AMERICA, INC.
  12. Install the 2nd outer baulk ring.
    Fig 11: Installing 2nd Outer Baulk Ring
    G06346061Courtesy of SUBARU OF AMERICA, INC.
  13. Install the 2nd synchro cone.
    Fig 12: Installing 2nd Synchro Cone
    G05336192Courtesy of SUBARU OF AMERICA, INC.
  14. Install the 2nd inner baulk ring.
    Fig 13: Installing 2nd Inner Baulk Ring
    G05003436Courtesy of SUBARU OF AMERICA, INC.
  15. Apply adequate transmission gear oil to the 2nd driven gear bushing, needle bearing and 2nd driven gear inner surface.
  16. 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: Matching Protrusion Of 2nd Synchro Cone To 2nd Driven Gear Hole
    G10294207Courtesy of SUBARU OF AMERICA, INC.
  17. Attach the key.
    Fig 15: Identifying Key
    G05003438Courtesy of SUBARU OF AMERICA, INC.
  18. 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: Matching Groove On 3rd-4th Driven Gear To Key
    G10294209Courtesy of SUBARU OF AMERICA, INC.
  19. Make sure that the 2nd driven gear can be turned smoothly by hand. If it does not turn smoothly, reassemble.
  20. Attach the key.
    Fig 17: Identifying Key
    G05003440Courtesy of SUBARU OF AMERICA, INC.
  21. 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: Matching Groove On 5th-6th Driven Gear To Key
    G10294211Courtesy of SUBARU OF AMERICA, INC.
  22. 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
    G10294212Courtesy of SUBARU OF AMERICA, INC.
  23. Make sure that the ball bearing turns smoothly by hand. If it does not turn smoothly, reassemble.
  24. Install a new lock nut.
  25. 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: Tightening Lock Nut
    G05003443Courtesy of SUBARU OF AMERICA, INC.
    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
    G10294214Courtesy of SUBARU OF AMERICA, INC.
  26. 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: Tapping Lock Nut
    G05003445Courtesy of SUBARU OF AMERICA, INC.
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