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Drive Pinion Shaft Assembly: Disassembly

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.
NOTE: Attach a cloth to the end of driven shaft (on the frictional side of the thrust needle bearing) to prevent damage during disassembly or reassembly.
  1. Flatten the tab of the lock nut. Remove the lock nut using ST1, ST2 and ST3.

    Preparation tool: 

    ST1: HOLDER (899884100)

    ST2: STOPPER (498427100)

    ST3: SOCKET WRENCH (27) (899988608)

    G10323044Courtesy of SUBARU OF AMERICA, INC.
  2. Remove the lock washer, washer, differential bevel gear sleeve, adjusting washers No. 1, No. 2 and thrust bearing.
  3. Pull out the drive pinion shaft, and remove the needle bearing and drive pinion collar from driven shaft.
  4. Remove the needle bearing and thrust bearing from drive pinion shaft.
    G13937436Courtesy of SUBARU OF AMERICA, INC.
  5. Remove the roller bearing and washer using ST and a press.

    Preparation tool: 

    ST: REMOVER (498077000)

    G10323046Courtesy of SUBARU OF AMERICA, INC.
  6. Flatten the tab of the lock nut. Remove the lock nut and lock washer using ST1 and ST2.

    Preparation tool: 

    ST1: SOCKET WRENCH (50) (499987300)

    ST2: HOLDER (899884100)

    G10323047Courtesy of SUBARU OF AMERICA, INC.
  7. Remove the 5th driven gear using ST.

    Preparation tool: 

    ST: 5TH DRIVEN GEAR REMOVER (499857000)

    G10323048Courtesy of SUBARU OF AMERICA, INC.
  8. Remove the woodruff key.
  9. Remove the double taper roller bearing and 3rd-4th driven gear using ST1 and ST2.

    Preparation tool: 

    ST1: INSTALLER (499757002)

    ST2: REMOVER (899714110)

    G10323049Courtesy of SUBARU OF AMERICA, INC.
  10. Remove the key.
  11. Remove the 2nd driven gear, inner baulk ring, synchro cone and outer baulk ring.
    G13937441Courtesy of SUBARU OF AMERICA, INC.
  12. Remove the 1st driven gear, inner baulk ring, synchro cone, outer baulk ring, 2nd driven gear bushing, and gear & hub assembly using ST1 and ST2.
    G13937442Courtesy of SUBARU OF AMERICA, INC.
    CAUTION:
    • If gears or hubs are necessary to replace, replace with a new gear & hub assembly as a set.
    • Since the gear & hub assembly must engage at the specified position, avoid disassembly as much as possible.
    • If it is necessary to disassemble, mark the engaging points on the splines beforehand.

    Preparation tool: 

    ST1: INSTALLER (499757002)

    ST2: REMOVER (899714110)

    G10323052Courtesy of SUBARU OF AMERICA, INC.
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