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Main Shaft Assembly for Single-Range: Assembly

WARNING: This page is about a different variant/trim than selected.
  1. Assemble each sleeve and hub assembly.
    NOTE: Position open ends of spring 120° apart.
    Fig 1: Assembling Sleeve & Hub Assembly
    G02876437Courtesy of SUBARU OF AMERICA, INC.
  2. Install 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 groove in baulk ring with shifting insert.
    Fig 2: Installing 3rd Drive Gear
    G02876438Courtesy of SUBARU OF AMERICA, INC.
  3. Install 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 Imp ton).
    1. ST1 899714110 REMOVER
    2. ST2 499877000 RACE 4-5 INSTALLER
    Fig 3: Installing 4th Needle Bearing Race
    G02876439Courtesy of SUBARU OF AMERICA, INC.
  4. Install baulk ring, needle bearing, 4th drive gear and 4th gear thrust washer to transmission main shaft.
    NOTE: Align baulk ring and gear & hub assembly with key groove.
    Fig 4: Aligning Baulk Ring & Gear Hub Assembly With Key Groove
    G02876440Courtesy of SUBARU OF AMERICA, INC.
  5. Drive 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 Imp ton).
    1. ST1 899714110 REMOVER
    2. ST2 499877000 RACE 4-5 INSTALLER
    Fig 5: Driving Ball Bearing Onto Rear Section
    G02876441Courtesy of SUBARU OF AMERICA, INC.
  6. Using 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 Imp ton).
    • Face thrust washer in the correct direction.
    1. ST1 899714110 REMOVER
    2. ST2 499877000 RACE 4-5 INSTALLER
    Fig 6: Installing 5th Gear Thrust Washer & Needle Bearing Race
    G02876442Courtesy of SUBARU OF AMERICA, INC.
  7. Install bearing onto synchro cone.
  8. Install 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 Imp ton).
    • Use new ball bearing.
    • After press fitting, make sure synchro cone rotates freely.
    1. ST 499757002 INSTALLER
    Fig 7: Installing Baulk Ring & Synchro Cone
    G02876443Courtesy of SUBARU OF AMERICA, INC.
  9. Install synchro cone stopper and snap ring to 5th-Rev sleeve and hub assembly.
    Fig 8: Installing Synchro Cone Stopper & Snap Ring
    G02876444Courtesy of SUBARU OF AMERICA, INC.
  10. Install the rest parts to the rear section of transmission main shaft.
    NOTE: Align groove in baulk ring with shifting insert.
    Fig 9: Identifying Rest Parts To Rear Section Of Transmission Main Shaft
    G02876445Courtesy of SUBARU OF AMERICA, INC.
  11. Tighten lock nuts to the specified torque using ST1 and ST2.
NOTE: Secure lock nuts in two places after tightening.
  1. ST1 499987003 SOCKET WRENCH
  2. ST2 498937000 TRANSMISSION HOLDER
  1. Tightening torque:  120 N.m (12.2 kgf-m, 88.2 ft-lb)
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