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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.
G13937744Courtesy 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.
    G13937745Courtesy 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).

    Preparation tool:  ST1: REMOVER (899714110)

    ST2: RACE 4-5 INSTALLER (499877000)

    ST3: INSTALLER (398177700)

    G13937746Courtesy 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.
    G13937747Courtesy of SUBARU OF AMERICA, INC.
  4. Install the 3rd-4th shifting insert.
    NOTE: Press in the ball part to install.
    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.
    G13937749Courtesy of SUBARU OF AMERICA, INC.
    G13937750Courtesy of SUBARU OF AMERICA, INC.
  6. 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).
    • Install the double taper roller bearing with its snap ring side facing the 5th drive gear side.

    Preparation tool:  ST1: REMOVER (899714110)

    ST2: RACE 4-5 INSTALLER (499877000)

    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 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: REMOVER (899714110)

    ST2: RACE 4-5 INSTALLER (499877000)

    G13937752Courtesy 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.
    G13937753Courtesy of SUBARU OF AMERICA, INC.
  10. Install the 6th needle bearing race 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: REMOVER (899714110)

    ST2: RACE 4-5 INSTALLER (499877000)

    G13937754Courtesy 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.
    G13937755Courtesy of SUBARU OF AMERICA, INC.
  12. Install the 5th-6th shifting insert.
    NOTE: Press in the ball part to install.
    G08582055Courtesy of SUBARU OF AMERICA, INC.
  13. Install the 6th baulk ring, 6th drive gear and 6th needle bearing.
    G13937757Courtesy of SUBARU OF AMERICA, INC.
  14. Install the ball 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: Install the ball bearing with the side which does not have lock nut mounting dent facing 6th drive gear.

    Preparation tool:  ST1: REMOVER (899714110)

    ST2: PRESS (899754112)

    G08582057Courtesy of SUBARU OF AMERICA, INC.
  15. Install a new lock washer.
    CAUTION: Make sure the lock washer is facing the correct direction.
    G13937759Courtesy of SUBARU OF AMERICA, INC.
  16. Install a new lock nuts using ST1 and ST2.

    Tightening torque:  160 N.m (16.3 kgf-m, 118.0 ft-lb)

    Preparation tool:  ST1: TRANSMISSION HOLDER (498937000)

    ST2: SOCKET WRENCH (35) (499987003)

    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.
    G13937761Courtesy of SUBARU OF AMERICA, INC.
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