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Drive Pinion Shaft: Installation

  1. Remove the front differential assembly.
  2. Hypoid gear set match mark/No.: The number (A) on top of the drive pinion, and the number on the hypoid driven gear are set numbers for the two gears. Use a pair having the same numbers.

    The figure (B) below shows a number for shim adjustment. If no number is shown, the value is zero.

    G14611803Courtesy of SUBARU OF AMERICA, INC.
  3. Place the drive pinion shaft assembly on transmission main case RH without shim and tighten the bearing mounting bolts.
  4. Perform the adjustment of ST.
    1. Loosen the two bolts and adjust so that the scale indicates 0.5 correctly when the plate end and the scale end are on the same level.

      Preparation tool: 

      ST: DRIVE PINION GAUGE ASSY (499917500)

      G14611804Courtesy of SUBARU OF AMERICA, INC.
    2. Tighten the two bolts.
  5. Position the ST (DRIVE PINION GAUGE ASSY) by inserting the knock pin of ST into the knock hole of transmission case.
  6. Slide the scale of ST with finger tip and read the value at the point where it matches with the end face of drive pinion.

    Preparation tool: 

    ST: DRIVE PINION GAUGE ASSY (499917500)

    G14611805Courtesy of SUBARU OF AMERICA, INC.
  7. The thickness of drive pinion shims shall be determined by adding the value indicated on drive pinion to the value indicated on the ST (DRIVE PINION GAUGE ASSY). (Add if the number on drive pinion is prefixed by +, and subtract if the number is prefixed by -.)
  8. Select one to three drive pinion shim(s) from the following table for the value determined as described above, and take the shim(s) whose thickness is closest to the said value.
    NOTE:

    Install the shim with it's cut in facing the shifter fork & rod side. 

    Drive pinion shim
    Part No. Thickness mm (in)
    32295AA031 0.150 (0.0059)
    32295AA041 0.175 (0.0069)
    32295AA051 0.200 (0.0079)
    32295AA061 0.225 (0.0089)
    32295AA071 0.250 (0.0098)
    32295AA081 0.275 (0.0108)
    32295AA091 0.300 (0.0118)
    32295AA101 0.500 (0.0197)
  9. Install the front differential assembly. Ref. to MANUAL TRANSMISSION AND DIFFERENTIAL (TY75)>FRONT DIFFERENTIAL>INSTALLATION 
  10. Fit the transmission case knock pin to the knock pin hole of the roller bearing and install the drive pinion shaft assembly.
  11. Install the main shaft assembly. Ref. to MANUAL TRANSMISSION AND DIFFERENTIAL (TY75)>MAIN SHAFT>INSTALLATION 
  12. Check each shifter fork. Ref. to MANUAL TRANSMISSION AND DIFFERENTIAL (TY75)>SHIFTER FORK AND ROD>INSPECTION 
  13. Install the transmission case. Ref. to MANUAL TRANSMISSION AND DIFFERENTIAL (TY75)>TRANSMISSION CASE>INSTALLATION 
  14. Install the transfer case together with the extension case assembly. Ref. to MANUAL TRANSMISSION AND DIFFERENTIAL (TY75)>TRANSFER CASE AND EXTENSION CASE>INSTALLATION 
  15. Install the manual transmission assembly to the vehicle. Ref. to MANUAL TRANSMISSION AND DIFFERENTIAL (TY75)>TRANSMISSION ASSEMBLY>INSTALLATION 
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