Main Shaft Assembly: Assembly

WARNING: This page is about a different car, the 2004 Subaru Impreza. However, it is still accessible from the selected car via links, so may be relevant.

Assemble each sleeve and hub assembly.
NOTE: Position the open ends of spring 120° apart.

Fig 1: [Assembling Each Sleeve & Hub Assembly]
Courtesy of SUBARU OF AMERICA, INC.
Install the 3rd drive gear, outer baulk ring, synchro cone, inner baulk ring, sleeve and hub assembly for 3rd needle bearing on transmission main shaft.
NOTE: Align the groove in baulk ring with shifting insert.

Fig 2: Installing 3rd Drive Gear, Outer Baulk Ring, Synchro Cone, Inner Baulk Ring, Sleeve & Hub Assembly
Courtesy of SUBARU OF AMERICA, INC.
Install the 4th needle bearing race onto transmission main shaft using ST1, ST2 and a press.
NOTE: Do not apply pressure in excess of 10 kN (1 ton, 1.1 US ton, 1.0 lmp ton).

ST1 899714110 REMOVER

ST2 499877000 RACE 4-5 INSTALLER

Fig 3: Installing 4th Needle Bearing Race Onto Transmission Main Shaft
Courtesy of SUBARU OF AMERICA, INC.
Install the baulk ring, needle bearing, 4th drive gear and 4th gear thrust washer to transmission main shaft.
NOTE: Align the baulk ring and gear & hub assembly with key groove.

Fig 4: Aligning Baulk Ring & Gear & Hub Assembly With Key Groove
Courtesy of SUBARU OF AMERICA, INC.
Drive the ball bearing onto the rear section of transmission main shaft using ST1, ST2 and a press.
NOTE: Do not apply pressure in excess of 10 kN (1 ton, 1.1 US ton, 1.0 lmp ton).

ST1 899714110 REMOVER

ST2 499877000 RACE 4-5 INSTALLER

Fig 5: Installing Ball Bearing Onto Rear Section Of Transmission Main Shaft
Courtesy of SUBARU OF AMERICA, INC.
Using the ST1 and ST2, install the 5th gear thrust washer and 5th needle bearing race onto the rear section of transmission main shaft.
NOTE:
- Do not apply pressure in excess of 10 kN (1 ton, 1.1 US ton, 1.0 lmp ton).
- Face the thrust washer in correct direction.
ST1 899714110 REMOVER

ST2 499877000 RACE 4-5 INSTALLER

Fig 6: Identifying 5th Gear Thrust Washer Installation Face To 5th Gear Side
Courtesy of SUBARU OF AMERICA, INC.
Install the bearing onto synchro cone.
Install the baulk ring and synchro cone onto 5th-Rev sleeve and hub assembly using ST and a press.
NOTE:
- Do not apply pressure in excess of 10 kN (1 ton, 1.1 US ton, 1.0 lmp ton).
- Use a new ball bearing.
- After press fitting, make sure the synchro cone rotates freely.
ST 499757002 INSTALLER

Fig 7: Installing Baulk Ring & Synchro Cone Onto 5th-Rev Sleeve & Hub Assembly
Courtesy of SUBARU OF AMERICA, INC.
Install the synchro cone stopper and snap ring to 5th-Rev sleeve and hub assembly.

Fig 8: Installing Synchro Cone Stopper & Snap Ring To 5th-Rev Sleeve & Hub Assembly
Courtesy of SUBARU OF AMERICA, INC.
Install the rest parts to the rear section of transmission main shaft.
NOTE: Align the groove in baulk ring with shifting insert.

Fig 9: Installing Rest Parts To Rear Section Of Transmission Main Shaft
Courtesy of SUBARU OF AMERICA, INC.
Tighten the lock nuts to the specified torque using ST1 and ST2.
NOTE: Secure the lock nuts in two places after tightening.

ST1 499987003 SOCKET WRENCH

ST2 498937000 TRANSMISSION HOLDER

Tightening torque:

120 N.m (12.2 kgf-m, 88.5 ft-lb)