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Home >> Subaru >> 2004 >> Forester XS, Standard >> Repair and Diagnosis >> Transmission >> Manual Trans >> Manual Transmission And Differential >> Main Shaft Assembly (Single-Range) >> Disassembly

Main Shaft Assembly (Single-Range): Disassembly

  1. Put vinyl tape around the main shaft splines to protect oil seal from damage. Then pull out the oil seal and needle bearing by hand.
  2. Remove the lock nut from transmission main shaft assembly.
    NOTE: Remove the caulking before Identifying lock nut.

    ST1 498937000 TRANSMISSION HOLDER

    ST2 499987003 SOCKET WRENCH (35)

    Fig 1: Disassembling Transmission Main Shaft Assembly
    G00937318Courtesy of SUBARU OF AMERICA, INC.
  3. Remove the 5th-Rev sleeve and hub assembly, 5th bulk ring, 5th drive gear and needle bearing.
    Fig 2: Identifying 5th-Rev Sleeve And Hub Assembly
    G00937319Courtesy of SUBARU OF AMERICA, INC.
  4. Remove the snap ring and synchro cone stopper from 5th-Rev sleeve and hub assembly.
    Fig 3: Identifying Snap Ring And Synchro Cone Stopper
    G00937320Courtesy of SUBARU OF AMERICA, INC.
  5. Using the ST1, ST2 and a press, remove the ball bearing, synchro cone and baulk ring (Rev).
    NOTE: Replace the sleeve and hub with new ones. Do not attempt to disassemble because they must engage at a specified point. If they should be disassembled, mark engagement point on splines before-hand.

    ST1 499757002 INSTALLER

    ST2 498077400 SYNCHRO CONE REMOVER

    Fig 4: Identifying Ball Bearing, Synchro Cone
    G00937321Courtesy of SUBARU OF AMERICA, INC.
  6. Using the ST1 and ST2, remove rest of the parts.
    NOTE: Replace the sleeve and hub with new ones. Do not attempt to disassemble because they must engage at a specified point. If they should be disassembled, mark engagement point on splines before-hand.

    ST1 899864100 REMOVER

    ST2 899714110 REMOVER

    Fig 5: Identifying ST1 And ST2
    G00937322Courtesy of SUBARU OF AMERICA, INC.