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Home >> Subaru >> 2005 >> Baja Base, Standard >> Repair and Diagnosis >> Transmission >> Manual Trans >> Manual Transmission And Differential >> Main Shaft Assembly >> Assembly

Main Shaft Assembly: Assembly

  1. Assemble each sleeve and hub assembly.
    NOTE: Position the open ends of spring 120° apart.
    Fig 1: Assembling Each Sleeve And Hub Assembly
    G03751067Courtesy of SUBARU OF AMERICA, INC.
  2. 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: Assembling Main Shaft Assembly
    G03751068Courtesy of SUBARU OF AMERICA, INC.
  3. 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 Imp ton).

    ST1 899714110 REMOVER

    ST2 499877000 RACE 4-5 INSTALLER

    Fig 3: Installing 4Th Needle Bearing Race Onto Transmission Main Shaft using Remover ST1-899714110 And Installer ST2-499877000 RACE 4-5
    G03751069Courtesy of SUBARU OF AMERICA, INC.
  4. 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 And Gear Hub Assembly
    G03751070Courtesy of SUBARU OF AMERICA, INC.
  5. 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 Imp ton).

    ST1 899714110 REMOVER

    ST2 499877000 RACE 4-5 INSTALLER

    Fig 5: Installing Ball Bearing Onto Rear Section Of Transmission Main Shaft Using Remover ST1-899714110 and Installer ST2-499877000 RACE 4-5
    G03751071Courtesy of SUBARU OF AMERICA, INC.
  6. 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 Imp ton).
    • Face the thrust washer in correct direction.

    ST1 899714110 REMOVER

    ST2 499877000 RACE 4-5 INSTALLER

    Fig 6: Identifying Thrust Washer
    G03751072Courtesy of SUBARU OF AMERICA, INC.
  7. Install the bearing onto synchro cone.
  8. 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 Imp ton).
    • Use a new ball bearing.
    • After press fitting, make sure the synchro cone rotates freely.

    ST 499757002 INSTALLER

    Fig 7: Installing Baulk Ring And Synchro Cone Onto 5Th-Rev Sleeve Using Installer ST499757002
    G03751073Courtesy of SUBARU OF AMERICA, INC.
  9. Install the synchro cone stopper and snap ring to 5th-Rev sleeve and hub assembly.
    Fig 8: Installing Synchro Cone Stopper And Snap Ring
    G03751074Courtesy of SUBARU OF AMERICA, INC.
  10. 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
    G03751075Courtesy of SUBARU OF AMERICA, INC.
  11. 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) 

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