Drive Pinion Shaft Assembly: Assembly

WARNING: This page is about a different car, the 2021 Subaru Impreza. However, it is still accessible from the selected car via links, so may be relevant.

Install the sleeve and the gear and hub assembly by matching the alignment marks.

NOTE:

Make sure that there is no large clearance at both sides of the 1st-2nd shifting insert after assembly.

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Use the new gear & hub assembly, if replacing the gear or hub.

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Install the 1st driven gear, inner baulk ring, synchro cone, outer baulk ring, and gear & hub assembly.
CAUTION: Make sure the gear & hub assembly is facing the correct direction.

NOTE: Align the baulk ring and gear & hub assembly with the key groove.

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Install the 2nd driven gear bushing 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:
- Attach a cloth to the end of the driven shaft to prevent damage.
- When press fitting, align the oil holes of the shaft and bushing.
Preparation tool:

ST1: INSTALLER (499277200)

ST2: INSTALLER (499587000)

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Attach and insert the 2nd driven gear, inner baulk ring, synchro cone and outer baulk ring.
NOTE: Align the groove of the baulk ring with the 1st-2nd shifting insert.

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After installing the key onto the driven shaft, install the 3rd-4th driven gear 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).

Preparation tool:

ST1: INSTALLER (499277200)

ST2: INSTALLER (499587000)

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Install a new double taper roller bearing using the 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).

Preparation tool:

ST1: INSTALLER (499277200)

ST2: INSTALLER (499587000)

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Position the woodruff key in groove of the rear of driven shaft. Install the 5th driven gear 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).
- Face the groove for identification of the 5th driven gear toward the nut.
Preparation tool:

ST1: INSTALLER (499277200)

ST2: INSTALLER (499587000)

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Install a new lock washer.
CAUTION: Make sure the lock washer is facing the correct direction.
Tighten a new lock nuts using ST1 and ST2.
Tightening torque:

260 N.m (26.5 kgf-m, 191.8 ft-lb)

Preparation tool:

ST1: SOCKET WRENCH (50) (499987300)

ST2: HOLDER (899884100)

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Using a spring scale, check that the starting torque of the double taper roller bearing is 0.1 - 1.5 N (0.01 - 0.15 kgf, 0.02 - 0.34 lbf).

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Crimp the lock nut at two locations so that the dimension (B) becomes 41.1 mm (1.62 in) or less.
CAUTION: When crimping the lock nut, be careful not to crack it.

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Install a new roller bearing.
NOTE: Install with the knock pin hole of the roller bearing outer race facing the rear side.

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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).

Preparation tool:

ST1: BUSHING 1-2 INSTALLER (499277100)

ST2: INSTALLER (499277200)

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Install the thrust bearing and needle bearing and install the driven shaft assembly.

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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.

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Adjust the thrust bearing preload. Ref. to MANUAL TRANSMISSION AND DIFFERENTIAL (5MT)>DRIVE PINION SHAFT ASSEMBLY>ADJUSTMENT>THRUST BEARING PRELOAD .