Component Disassembly & Reassembly: MAINSHAFT: Reassembly

If removed, install new 3rd gear bushing using press and installer and retainer. Assemble synchro assemblies ensuring that hub spring ends are 120 degrees apart. Note also that the shorter inserts are installed in 3rd-4th synchro and longer inserts in the 1st-2nd synchro. See Fig 1 .

Fig 1: Exploded View of Synchro Hub Assembly
Courtesy of SUBARU OF AMERICA, INC.
Install 3rd drive gear and synchro assembly on mainshaft ensuring that narrower tooth width of synchro spline is on 3rd gear side. Press synchro assembly on mainshaft, if necessary.
Press 4th drive gear bushing onto mainshaft. Install 4th drive gear and thrust plate. Press bearing onto shaft. On 4-speed models, install 1 of 12 available snap rings on shaft to obtain 0-.002" (0-.05 mm) end play. On 5-speed models, install shaft key and press 5th drive gear onto shaft. Install lock nut, tighten and restake.
On 4WD single range models, install washer, drive pinion collar, transfer needle bearing race and transfer drive gear to drive pinion with press and installer. Tighten lock washer and nut. Do not stake at this time.
On 4WD dual range models, install 3 high-low synchronizer inserts, sleeve and 2 springs on synchronizer hub. Install springs so that relative positions of cut ends are 120 degrees apart.
Install needle bearing, ball, input low gear spacer, needle bearing, input low gear collar, input low gear, high-low synchronizer ring and hub assembly previously assembled.