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Main 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
G11267907Courtesy of SUBARU OF AMERICA, INC.
  1. Install the 3rd 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 3rd outer baulk ring into the groove of the 3rd-4th synchronizer hub. MT02478
    Fig 2: Identifying 3rd And 4th Synchronizer Hub Components
    G11267909Courtesy of SUBARU OF AMERICA, INC.
  2. 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, St3 And Press
    G11267910Courtesy of SUBARU OF AMERICA, INC.
  3. 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 And 4Th Coupling Sleeve
    G11267911Courtesy of SUBARU OF AMERICA, INC.
  4. Install the 3rd-4th shifting insert.
    NOTE: Press in the ball part to install.
    Fig 5: Locating 3Rd-4Th Shifting Insert
    G08582047Courtesy of SUBARU OF AMERICA, INC.
  5. Install the 4th baulk ring, 4th needle bearing, 4th drive gear and 4th gear thrust washer.
    NOTE:
    • Align the protrusion of the 4th baulk ring into the groove of the 3rd-4th synchronizer hub.
    • Install the 4th gear thrust washer with the groove side facing the 4th drive gear.
    Fig 6: Identifying Groove And Face Surface To 4Th Gear Side
    G11267913Courtesy of SUBARU OF AMERICA, INC.
    Fig 7: Identifying 3rd And 4th Synchronizer Hub Components
    G11267914Courtesy of SUBARU OF AMERICA, INC.
  6. 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 And Press
    G08582050Courtesy of SUBARU OF AMERICA, INC.
  7. Make sure that the double taper roller bearing turns smoothly.
  8. 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 And Press
    G11267916Courtesy of SUBARU OF AMERICA, INC.
  9. Install the 5th 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: Identifying 5Th Needle Bearing, 5Th Drive Gear, 5Th Baulk Ring And 5Th-6Th Synchronizer Hub
    G11267917Courtesy of SUBARU OF AMERICA, INC.
  10. 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 And Press
    G11267918Courtesy of SUBARU OF AMERICA, INC.
  11. 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: Identifying 5Th - 6Th Coupling Sleeve
    G11267919Courtesy of SUBARU OF AMERICA, INC.
  12. Install the 5th-6th shifting insert.
    NOTE: Press in the ball part to install.
    Fig 13: Locating 5Th-6Th Shifting Insert
    G08582055Courtesy of SUBARU OF AMERICA, INC.
  13. Install the 6th baulk ring, 6th drive gear and 6th needle bearing.
    Fig 14: Identifying 6Th Baulk Ring, 6Th Drive Gear And 6Th Needle Bearing
    G11267921Courtesy of SUBARU OF AMERICA, INC.
  14. 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 And Press
    G08582057Courtesy of SUBARU OF AMERICA, INC.
  15. Install the lock washer.
    NOTE:
    • Use a new lock washer.
    • Install the lock washer in the correct direction.
    Fig 16: Locating Lock Nut
    G11267923Courtesy of SUBARU OF AMERICA, INC.
  16. 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
    G08582038Courtesy of SUBARU OF AMERICA, INC.
  17. 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: Checking Lock Nut Outer Dimension
G11267925Courtesy of SUBARU OF AMERICA, INC.
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