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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 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
G11267944Courtesy of SUBARU OF AMERICA, INC.
  1. 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 1st outer baulk ring into the groove of the 1st-2nd synchronizer hub.
    Fig 2: Identifying 1St Shifting Insert, Synchronizer Hub And Coupling Sleeve
    G11267945Courtesy of SUBARU OF AMERICA, INC.
  2. 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: Installing 2Nd Driven Gear Bushing Using ST And Press
    G11267946Courtesy of SUBARU OF AMERICA, INC.
  3. 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: Identifying 1St And 2Nd Coupling Sleeve
    G11267947Courtesy of SUBARU OF AMERICA, INC.
  4. Install the 1st-2nd shifting insert.
    NOTE: Press in the ball part to install.
    Fig 5: Locating 1St-2Nd Shifting Insert
    G08582082Courtesy of SUBARU OF AMERICA, INC.
  5. Install the 2nd outer baulk ring, 2nd synchro cone, 2nd inner baulk ring and 2nd driven gear.
    Fig 6: Identifying Driven Gear, 2Nd Inner Baulk Ring And Synchro Cone
    G11267949Courtesy of SUBARU OF AMERICA, INC.
  6. Install the key to the driven shaft.
  7. 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 Using ST And Press
    G08582084Courtesy of SUBARU OF AMERICA, INC.
  8. 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 Using ST And Press
    G08582085Courtesy of SUBARU OF AMERICA, INC.
  9. 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 And Press
    G11267952Courtesy of SUBARU OF AMERICA, INC.
  10. Install the drive pinion spacer to the driven shaft.
  11. 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 6Th Driven Gear Using ST And Press
    G11267953Courtesy of SUBARU OF AMERICA, INC.
  12. 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 Using ST And Press
    G08582088Courtesy of SUBARU OF AMERICA, INC.
  13. 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
    G08582074Courtesy of SUBARU OF AMERICA, INC.
  14. Using a spring scale, check that the initial load of the ball bearings is 0.1-1.5 N (0.01-0.15 kgf, 0.02-0.34 Ibf).
    Fig 13: Checking Initial Load Of Ball Bearings Using Spring Scale
    G06652425Courtesy of SUBARU OF AMERICA, INC.
  15. 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: Checking Lock Nut Outer Dimension
    G11267957Courtesy of SUBARU OF AMERICA, INC.
  16. Install the roller bearing.
    NOTE:
    • Use a new roller bearing.
    • Install the knock pin hole of the roller bearing outer race, facing the rear side.
    Fig 15: Identifying Roller Bearing And Knock Pin Hole
    G11267958Courtesy of SUBARU OF AMERICA, INC.
  17. 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 And Press
    G11267959Courtesy of SUBARU OF AMERICA, INC.
  18. Install the thrust bearing and needle bearing and install the driven shaft assembly.
    Fig 17: Installing Thrust Bearing
    G06652428Courtesy of SUBARU OF AMERICA, INC.
  19. 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 Components
    G11267961Courtesy of SUBARU OF AMERICA, INC.
  20. Adjust the thrust bearing preload. Ref. to MANUAL TRANSMISSION AND DIFFERENTIAL (6MT)>Drive Pinion Shaft Assembly>ADJUSTMENT>THRUST BEARING PRELOAD .
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