Drive Pinion Shaft Assembly: Assembly

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Install the plug to drive pinion retainer.
NOTE:
- Use new O-rings.
- Apply CVTF to the O-rings.
Tightening torque:

22 N.m (2.2 kgf-m, 16.2 ft-lb)

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Using the ST, install the oil seal to drive pinion retainer.
NOTE:
- Apply CVTF to the press-fitting surface of oil seal and apply differential gear oil to the lip portion.
- Install the oil seal in the correct direction.
Preparation tool:

ST: HOUSING BUSHING INSTALLER AND REMOVER (927720000)

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Select the drive pinion washer.

Measure the roller bearing inner race width "A" on the front side.

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Measure the roller bearing inner race width "B" on the rear side.

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Measure the spacer width "C".

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Using the ST1 and ST2, install the front roller bearing outer race to the drive pinion retainer.

Preparation tool:

ST1: PRESS SNAP RING (28499TC010)

ST2: INSTALLER (398177700)

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Using the ST, install the rear roller bearing outer race to the drive pinion retainer.

Preparation tool:

ST: INSTALLER (20099AE020)

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Place the drive pinion retainer on the surface plate, and install the inner race to the rear roller bearing outer race.
NOTE: Place the drive pinion retainer so that the mating surface of the drive pinion retainer (mating surface with the converter case) contacts the surface plate.

Measure the height "D" from the end face of the rear roller bearing inner race to the surface plate.

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Install the inner race to the front roller bearing outer race.

Measure the depth "E" from the end face of the front roller bearing inner race to the end face of the ST.

Preparation tool:

ST: GAUGE (499575400)

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Using following formula, select one to three drive pinion washers.

T mm = D - (A + B + C + E - 15) - (0±0.0125)

[T in = D - (A + B + C + E - 0.591) - (0±0.0005)]

A: Front roller bearing width

B: Rear roller bearing width

C: Spacer width

D: Height from end face of rear roller bearing inner race to surface plate

E: Depth from end face of front roller bearing inner race to end face of ST

15 mm (0.591 in): Thickness of ST

T: Drive pinion washer thickness

0±0.0125 mm (0±0.0005 in): Clearance

Drive pinion washer
Part No.	Thickness mm (in)
38336AA750	0.150 (0.0059)
38336AA760	0.175 (0.0069)
38336AA770	0.200 (0.0079)
38336AA780	0.225 (0.0089)
38336AA790	0.250 (0.0098)
38336AA800	0.275 (0.0108)
38336AA810	0.300 (0.0118)
38336AA820	0.400 (0.0157)

Measure and record the drive pinion shim thickness to be reused. When reuse is not possible, select the drive pinion shim.

Using a precise round bar, measure the height "G" from the mating surface of transmission case of the converter case to the upper end of the round bar. Also, measure and record the diameter "M" of the round bar.

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Using the following formula, calculate the height "A1" from the mating surface of transmission case of the converter case to the bottom end of the differential side retainer hole.
A1 mm = G - M

[A1 in = G - M]

G: Height from the mating surface of transmission case of the converter case to the upper end of the round bar

M: Diameter of the round bar

Measure the hole inner diameter "R" of differential side retainer of the converter case.

NOTE: Perform the measurement at the contact surface of the bearing outer race.

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Using the following formula, calculate the hole radius "A2" of the differential side retainer.
A2 mm = R/2

[A2 in = R/2]

R: Hole inner diameter of differential side retainer of the converter case

Using the following formula, calculate the differential center distance "A" from the mating surface of transmission case of the converter case.

A mm = A1 + A2

[A in = A1 + A2]

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Measure the depth "B1" from the ST to the mating surface of drive pinion retainer. Then, using the following formula, calculate the height "B" from the mating surface of transmission case of the converter case to the mating surface of drive pinion retainer.

Preparation tool:

ST: GAUGE (499575400)

B mm = B1 - 15

[B in = B1 - 0.591]

B1: Depth from ST to the drive pinion retainer mating surface

15 mm (0.591 in): Thickness of ST

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Using following formula, select one to three drive pinion shims.

T mm = (A - B + E - 15) - 90.8 + (0±0.0125)

[T in = (A - B + E - 0.591) - 3.575 + (0±0.0005)]

A: Differential center distance from the mating surface of transmission case of the converter case

B: Height from the mating surface of transmission case of the converter case to the mating surface of the drive pinion retainer

E: Depth from the end face of the front roller bearing inner race to the end face of the ST, measured in (9) in "3. Select the drive pinion washer"

15 mm (0.591 in): Thickness of ST

T: Drive pinion shim thickness

90.8 mm (3.575 in): Ideal distance from the differential center to the drive pinion end surface

0±0.0125 mm (0±0.0005 in): Clearance

Drive pinion shim
Part No.	Thickness mm (in)
31451AA320	0.150 (0.0059)
31451AA330	0.175 (0.0069)
31451AA340	0.200 (0.0079)
31451AA350	0.225 (0.0089)
31451AA360	0.250 (0.0098)
31451AA370	0.275 (0.0108)

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Install the drive pinion shim that is reused for the drive pinion shaft.
Using the ST1 and ST2, press-fit the inner race to the drive pinion shaft.
Preparation tool:

ST1: INSTALLER (899580100)

ST2: EXTENSION DRIVE SHAFT (927130000)

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Install the drive pinion spacer.
NOTE: Replace the O-ring with a new part after tooth contact inspection.

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Install the selected drive pinion washer.

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Insert the drive pinion shaft into the drive pinion retainer.
CAUTION: Be careful not to damage the oil seal.
Install the inner bearing and lock nut.
NOTE:
- Use a new lock nut.
- Apply differential gear oil to the threaded portion of the drive pinion shaft.
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Using the ST1, ST2 and ST3, tighten the lock nut to the specified torque so that the starting torque of the drive pinion shaft is within the specified range.

CAUTION: Before inspecting the starting torque, apply differential gear oil to roller of bearing and rotate the bearing several times.

NOTE:

Tighten the lock nut while directly aligning ST2 and torque wrench.
If the starting torque is not within the specified range, select the drive pinion washer, and repeat the step until the starting torque is within the specified range.
When a thicker drive pinion washer is selected, the starting torque decreases. When a thinner drive pinion washer is selected, the starting torque increases.

Starting torque:

5.1 - 17.1 N (0.5 - 1.7 kgf, 1.1 - 3.8 lbf)

Preparation tool:

ST1: ADAPTER (499787500)

ST2: WRENCH (499787700)

ST3: HOLDER (498937110)

Using the following formula, calculate the tightening torque for a torque wrench.

T2 = L2/(L1 + L2) x T1

T1: 170 - 250 N.m (17.3 - 25.5 kgf-m, 125.4 - 184.4 ft-lb) [Specified tightening torque range]

T2: Tightening torque

L1: ST1 length 0.072 m (2.83 in)

L2: Torque wrench length

Example:

Torque wrench length m (in)	Tightening torque N.m (kgf-m, ft-lb)
0.4 (15.75)	144 - 211 (14.7 - 21.5, 106.2 - 155.6)
0.45 (17.72)	147 - 215 (15.0 - 21.9, 108.4 - 158.6)
0.5 (19.69)	149 - 218 (15.2 - 22.2, 109.9 - 160.8)
0.55 (21.65)	150 - 221 (15.3 - 22.5, 110.6 - 163.0)

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Install the drive pinion retainer to the converter case, and check the backlash and tooth contact. Refer to CONTINUOUSLY VARIABLE TRANSMISSION (TR580 IMPREZA)>DRIVE PINION SHAFT ASSEMBLY>ADJUSTMENT . Refer to CONTINUOUSLY VARIABLE TRANSMISSION (TR580 IMPREZA)>FRONT DIFFERENTIAL ASSEMBLY>ADJUSTMENT .
Remove the drive pinion retainer from converter case. Refer to CONTINUOUSLY VARIABLE TRANSMISSION (TR580 IMPREZA)>DRIVE PINION SHAFT ASSEMBLY>REMOVAL .
Remove the drive pinion spacer from the drive pinion shaft. Refer to CONTINUOUSLY VARIABLE TRANSMISSION (TR580 IMPREZA)>DRIVE PINION SHAFT ASSEMBLY>DISASSEMBLY .
Install the O-ring to the drive pinion shaft.
NOTE:
- Use new O-rings.
- Apply the differential gear oil to O-ring.
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Install the drive pinion spacer to the drive pinion shaft.

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Install the drive pinion washer.

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Insert the drive pinion shaft into the drive pinion retainer.
CAUTION: Be careful not to damage the oil seal.

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Install the inner bearing and lock nut.
NOTE: Apply differential gear oil to the threaded portion of the drive pinion shaft.

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Using the ST1, ST2 and ST3, tighten the lock nut to the specified torque so that the starting torque of the drive pinion shaft is within the specified range.

CAUTION: Before inspecting the starting torque, apply differential gear oil to roller of bearing and rotate the bearing several times.

NOTE:

Tighten the lock nut while directly aligning ST2 and torque wrench.
If the starting torque is not within the specified range, select the drive pinion washer, and repeat the step until the starting torque is within the specified range.
When a thicker drive pinion washer is selected, the starting torque decreases. When a thinner drive pinion washer is selected, the starting torque increases.

Starting torque:

5.1 - 17.1 N (0.5 - 1.7 kgf, 1.1 - 3.8 lbf)

Preparation tool:

ST1: ADAPTER (499787500)

ST2: WRENCH (499787700)

ST3: HOLDER (498937110)

Using the following formula, calculate the tightening torque for a torque wrench.

T2 = L2/(L1 + L2) x T1

T1: 170 - 250 N.m (17.3 - 25.5 kgf-m, 125.4 - 184.4 ft-lb) [Specified tightening torque range]

T2: Tightening torque

L1: ST1 length 0.072 m (2.83 in)

L2: Torque wrench length

Example:

Torque wrench length m (in)	Tightening torque N.m (kgf-m, ft-lb)
0.4 (15.75)	144 - 211 (14.7 - 21.5, 106.2 - 155.6)
0.45 (17.72)	147 - 215 (15.0 - 21.9, 108.4 - 158.6)
0.5 (19.69)	149 - 218 (15.2 - 22.2, 109.9 - 160.8)
0.55 (21.65)	150 - 221 (15.3 - 22.5, 110.6 - 163.0)

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Crimp the lock nut in 2 locations.
Install the plug using ST1 and ST2.
Preparation tool:

ST1: PRESS SNAP RING (499755602)

ST2: INSTALLER (398177700)

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