Component Disassembly & Reassembly: MAINSHAFT: Disassembly

On 4WD dual range models, separate mainshaft assembly from input shaft, and remove high-low synchronizer ring. Be careful to drop needle bearing in input shaft. Remove snap ring with expander.
Remove the following parts by hand: High-low synchronizer hub with inserts, springs and sleeve, high-low synchronizer ring, input low gear, input low gear collar, needle bearing, input low gear spacer, ball and needle bearing.
On 5-speed models, remove lock nut staking, then remove lock nut. Using a press, remove 5th gear from shaft. Remove shaft key. On 4-speed models, remove snap ring from end of mainshaft.
NOTE: Snap ring should not be reused.
On all models, use press to remove ball bearing, 4th drive gear thrust plate, 4th drive gear, synchronizer hub, 4th drive gear bushing and 3rd drive gear. See Fig 1 .

Fig 1: Pressing Gears Off of Mainshaft
Courtesy of SUBARU OF AMERICA, INC.

NOTE: Do not remove 3rd drive gear bushing unless it is defective. If replacement is necessary, cut a groove in bushing, then press from mainshaft.