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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.
G13261598Courtesy 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.
    G13261599Courtesy 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
    G13261600Courtesy 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.
    G13261601Courtesy of SUBARU OF AMERICA, INC.
  4. Install the 1st-2nd shifting insert.
    NOTE: Press in the ball part to install.
    G08582082Courtesy of SUBARU OF AMERICA, INC.
  5. Install the 2nd outer baulk ring, 2nd synchro cone, 2nd inner baulk ring and 2nd driven gear.
    G13261603Courtesy 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
    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
    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
    G13261606Courtesy 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
    G13261607Courtesy 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
    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
    G08582074Courtesy of SUBARU OF AMERICA, INC.
  14. Using a spring scale, check that the initial load of the ball bearings is 0.1 to 1.5 N (0.01 to 0.15 kgf, 0.02 to 0.34 lbf).
    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.
    G13261611Courtesy of SUBARU OF AMERICA, INC.
  16. Install the roller bearing.
    NOTE:
    • Use a new roller bearing.
    • Install with the knock pin hole of the roller bearing outer race facing the rear side.
    G13261612Courtesy 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
    G13261613Courtesy of SUBARU OF AMERICA, INC.
  18. Install the thrust bearing and needle bearing and install the driven shaft assembly.
    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.
    G13261615Courtesy of SUBARU OF AMERICA, INC.
  20. Adjust the thrust bearing preload. Refer to MANUAL TRANSMISSION AND DIFFERENTIAL (6MT) (TY75)>DRIVE PINION SHAFT ASSEMBLY>ADJUSTMENT>THRUST BEARING PRELOAD .
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