Main Shaft Assembly for Single-range: Assembly

WARNING: This page is about a different car, the 2006 Subaru Outback and 2006 Subaru Legacy. However, it is still accessible from the selected car via links, so may be relevant.

When the sleeve & hub assemblies have been disassembled, reassemble by aligning the alignment marks.
NOTE: Position the open ends of the spring 120° apart.

Fig 1: Identifying 3rd-4th Hub Assy And 5th-Rev Hub Assy
Install the 3rd drive gear, outer bulk ring, synchro cone, inner bulk ring, sleeve and hub assembly for the 3rd needle bearing, on the transmission main shaft.

Fig 2: Identifying 3rd Drive Gear, Outer Bulk Ring, Synchro Cone, Sleeve And Hub Assembly

NOTE: Align the groove in bulk ring with the shifting insert.
Install the 4th needle bearing race onto transmission main shaft using ST1, ST2 and 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
Install the bulk ring, needle bearing, 4th drive gear and 4th gear thrust washer to the transmission main shaft.
NOTE: Align the bulk ring and gear & hub assembly with the key groove.

Fig 4: Identifying 4Th Gear Thrust Washer
Press-fit the ball bearing into 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 Race 4-5 Installer ST2 499877000
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 the correct direction.
ST1 899714110 REMOVER

ST2 499877000 RACE 4-5 INSTALLER

Fig 6: Identifying 5th Gear Thrust Washer
Install the bearing onto the synchro cone.
Install the bulk ring and synchro cone onto the 5th-Rev sleeve & hub assembly using the 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 smoothly.
ST 499757002 INSTALLER

Fig 7: Installing Bulk Ring And Synchro Cone Using Installer ST 499757002
Install the synchro cone stopper and snap ring to the 5th-Rev sleeve & hub assembly.

Fig 8: Identifying Synchro Cone Stopper And Snap Ring
Install rest of the parts to the rear section of the transmission main shaft.
NOTE: Align the groove in bulk ring with the shifting insert.

Fig 9: Identifying Needle Bearing, 5th Drive Gear, Bulk Ring, Lock Washer And Lock Nut
Tighten the lock nuts to the specified torque using ST1 and ST2.
NOTE: Crimp lock nuts in two locations after tightening.

ST1 499987003 SOCKET WRENCH

ST2 498937000 TRANSMISSION HOLDER

Tightening torque:

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