Drive Pinion Shaft Assembly: Installation

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

Remove the front differential assembly.
Hypoid gear set match mark/No.: The number (A) on top of the drive pinion, and the number on the hypoid driven gear are set numbers for the two gears. Use a pair having the same numbers. The figure (B) below shows a number for shim adjustment. If no number is shown, the value is zero.

Fig 1: Identifying Set Number And Number For Shim Adjustment
Courtesy of SUBARU OF AMERICA, INC.
Place the drive pinion shaft assembly on transmission main case RH without shim and tighten the bearing mounting bolts.
Perform the adjustment of ST.
1. Loosen the two bolts and adjust so that the scale indicates 0.5 correctly when the plate end and the scale end are on the same level.
  ST 499917500 DRIVE PINION GAUGE ASSY
  
  Fig 2: Loosening Plate Bolt
  Courtesy of SUBARU OF AMERICA, INC.
2. Tighten the two bolts.
Position the ST by inserting the knock pin of ST into the knock hole of transmission case.
ST 499917500 DRIVE PINION GAUGE ASSY
Slide the drive pinion gauge scale with finger tip and read the value at the point where it matches with the end face of drive pinion.
ST 499917500 DRIVE PINION GAUGE ASSY

Fig 3: Adjusting Clearance To Zero Without Drive Pinion Shims
Courtesy of SUBARU OF AMERICA, INC.
The thickness of drive pinion shims shall be determined by adding the value indicated on drive pinion to the value indicated on the ST. (Add if the number on drive pinion is prefixed by +, and subtract if the number is prefixed by -.)

Select one to three drive pinion shim(s) from the following table for the value determined as described above, and take the shim(s) whose thickness is closest to the said value.

NOTE: Install the shim with it's cut in facing the shifter fork & rod side.

Drive pinion shim
Part No.	Thickness mm (in)
32295AA031	0.150 (0.0059)
32295AA041	0.175 (0.0069)
32295AA051	0.200 (0.0079)
32295AA061	0.225 (0.0089)
32295AA071	0.250 (0.0098)
32295AA081	0.275 (0.0108)
32295AA091	0.300 (0.0118)
32295AA101	0.500 (0.0197)

Install the front differential assembly. Ref. to MANUAL TRANSMISSION AND DIFFERENTIAL (6MT)>Front Differential Assembly>INSTALLATION .
Fit the transmission case knock pin to the knock pin hole of the roller bearing and install the drive pinion shaft assembly.
Install the main shaft assembly. Ref. to MANUAL TRANSMISSION AND DIFFERENTIAL (6MT)>Main Shaft Assembly>INSTALLATION .
Check each shifter fork. Ref. to MANUAL TRANSMISSION AND DIFFERENTIAL (6MT)>Shifter Fork and Rod>INSPECTION .
Install the transmission case. Ref. to MANUAL TRANSMISSION AND DIFFERENTIAL (6MT)>Transmission Case>INSTALLATION .
Install the transfer case together with the extension case assembly. Ref. to MANUAL TRANSMISSION AND DIFFERENTIAL (6MT)>Transfer Case and Extension Case Assembly>INSTALLATION .
Install the manual transmission assembly to the vehicle. Ref. to MANUAL TRANSMISSION AND DIFFERENTIAL (6MT)>Manual Transmission Assembly>INSTALLATION .