Main Shaft Assembly: Assembly

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

Fig 1: Identifying 3rd-4th Hub Assy And 5th-Rev Hub Assy
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: Identifying 3rd Drive Gear, Outer/Inner Baulk Ring, Synchro Cone And Needle Bearing
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 Imp ton).

ST1 899714110 REMOVER

ST2 499877000 RACE 4-5 INSTALLER

Fig 3: Installing 4th Needle Bearing Race Using Race 4-5 Installer ST2 499877000
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: Identifying 4th Gear Thrust Washer
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 Imp ton).

ST1 899714110 REMOVER

ST2 499877000 RACE 4-5 INSTALLER

Fig 5: Installing Ball Bearing Using Remover ST1 899714110 And Race 4-5 Installer ST2 499877000
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 Imp ton).
- Face the thrust washer in correct direction.
ST1 899714110 REMOVER

ST2 499877000 RACE 4-5 INSTALLER

Fig 6: Identifying 5th Gear Thrust Washer
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 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 Using Installer ST499757002
Courtesy of SUBARU OF AMERICA, INC.
Install the synchro cone stopper and snap ring to 5th-Rev sleeve and hub assembly.

Fig 8: Identifying Synchro Cone Stopper And Snap Ring
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: Identifying Needle Bearing, 5h Drive Gear, Baulk Ring, 5th-Rev Sleeve And Hub Assy
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)