LEMON Manuals: Even more car manuals for everyone
Home >> Subaru >> 2012 >> Outback Base, Standard Trans >> Repair and Diagnosis >> Transmission >> Manual Trans >> Manual Transmission And Differential >> Drive Pinion Shaft Assembly >> Assembly

Drive Pinion Shaft Assembly: Assembly

  1. Install the sleeve and the gear and hub assembly by matching the alignment marks.
    NOTE:
    • Position the open ends of the spring 120° apart.
    • Use the new gear & hub assembly, if replacing the gear or hub.
      Fig 1: Identifying Sleeve And Hub Assembly
      G07915192Courtesy of SUBARU OF AMERICA, INC.
  2. Install the 1st driven gear, inner baulk ring, synchro cone and outer baulk ring and 1st-2nd synchronizer hub onto driven shaft.
    NOTE:
    • Take care to install the gear and hub assembly in proper direction.
    • Align the baulk ring and gear & hub assembly with the key groove.
      Fig 2: Identifying 1st Driven Gear, Inner Baulk Ring, Synchro Cone, Outer Baulk Ring, 1st-2nd Synchronizer Hub Onto Driven Shaft
      G07915193Courtesy of SUBARU OF AMERICA, INC.
  3. Install the 2nd driven gear bushing onto driven shaft using ST and a press.
    CAUTION: Do not apply a load in excess of 10 kN (1 ton, 1.1 US ton, 1.0 Imp ton).
    NOTE:
    • Attach a cloth to the end of the driven shaft to prevent damage.
    • When press fitting, align the oil holes of the shaft and bushing

    ST 18654AA000 INSTALLER

    Fig 3: Installing 2nd Driven Gear Bushing Onto Driven Shaft Using ST And Press
    G07915194Courtesy of SUBARU OF AMERICA, INC.
  4. Attach the 1st-2nd coupling sleeve and 1st-2nd shifting insert key to the driven shaft.
    NOTE:
    • Install the 1st-2nd coupling sleeve with the long flange side facing the 1st driven gear.
    • Install the 1st-2nd shifting insert keys at 120° interval positions.
      Fig 4: Attaching 1st-2nd Coupling Sleeve And 1st-2nd Shifting Insert Key To Driven Shaft
      G07915195Courtesy of SUBARU OF AMERICA, INC.
  5. Install the outer baulk ring, synchro cone, inner baulk ring and 2nd driven gear to driven shaft.
    Fig 5: Installing Outer Baulk Ring, Synchro Cone, Inner Baulk Ring And 2nd Driven Gear To Driven Shaft
    G07915196Courtesy of SUBARU OF AMERICA, INC.
    Fig 6: Identifying Outer Baulk Ring, Synchro Cone, Inner Baulk Ring And 2nd Driven Gear
    G07915197Courtesy of SUBARU OF AMERICA, INC.
  6. After installing key on driven shaft, install the 3rd-4th driven gear using an ST and a press.
    CAUTION: Do not apply a load in excess of 10 kN (1 ton, 1.1 US ton, 1.0 Imp ton).
    NOTE: Align the groove in baulk ring with the insert.

    ST 499277200 INSTALLER

    Fig 7: Aligning Groove In Baulk Ring
    G06652419Courtesy of SUBARU OF AMERICA, INC.
  7. Install a set of roller bearings onto the driven shaft using ST and a press.
    CAUTION: Do not apply a load in excess of 10 kN (1 ton, 1.1 US ton, 1.0 Imp ton).

    ST 499277200 INSTALLER

    Fig 8: Installing Set Of Roller Bearings Onto Driven Shaft Using ST And Press
    G06652420Courtesy of SUBARU OF AMERICA, INC.
  8. Install the 5th driven gear onto driven shaft using ST and a press.
    CAUTION: Do not apply a load in excess of 10 kN (1 ton, 1.1 US ton, 1.0 Imp ton).
    NOTE: Install the 5th driven gear with the groove side facing the 6th driven gear.

    ST 499277200 INSTALLER

    Fig 9: Installing 5th Driven Gear With Groove Side Facing
    G07915200Courtesy of SUBARU OF AMERICA, INC.
  9. Install the drive pinion spacer to driven shaft, then install the 6th driven gear to driven shaft using the ST and a press.
    CAUTION: Do not apply a load in excess of 10 kN (1 ton, 1.1 US ton, 1.0 Imp ton).
    NOTE: Install the 6th driven gear with the stepped side facing the 5th driven gear.

    ST 499277200 INSTALLER

    Fig 10: Installing 6th Driven Gear With Stepped Side Facing
    G07915201Courtesy of SUBARU OF AMERICA, INC.
  10. Install the ball bearing onto driven shaft using ST and a press.
    CAUTION: Do not apply a load in excess of 10 kN (1 ton, 1.1 US ton, 1.0 Imp ton).

    ST 499277200 INSTALLER

    Fig 11: Installing Ball Bearing Onto Driven Shaft Using ST And Press
    G07915202Courtesy of SUBARU OF AMERICA, INC.
  11. Tighten the lock nuts to the specified torque using ST1 and ST2.
    NOTE: Use a new lock nut.

    Tightening torque: 

    440 N.m (44.9 kgf-m, 324.5 ft-lb) 

    ST1 499987300 SOCKET WRENCH (50)

    ST2 18680AA020 HOLDER

    Fig 12: Tightening Lock Nuts To Specified Torque Using ST1 And ST2
    G06652424Courtesy of SUBARU OF AMERICA, INC.
  12. Using a spring scale, check that starting torque of the roller bearing is 0.1 to 1.5 N (0.01 to 0.15 kgf, 0.02 to 0.34 lbf).
    Fig 13: Checking Starting Torque Of Roller Bearing
    G06652425Courtesy of SUBARU OF AMERICA, INC.
  13. Crimp the locknut in 2 locations.
  14. Install the roller bearing onto drive pinion.
    NOTE: When installing the roller bearing, note its directions (front and rear) because the knock pin hole of outer race is offset.
    Fig 14: Identifying Roller Bearing And Knock Pin Hole
    G07915205Courtesy of SUBARU OF AMERICA, INC.
  15. Install the washer using ST1, ST2 and a press.
    CAUTION: Do not apply a load in excess of 10 kN (1 ton, 1.1 US ton, 1.0 Imp ton).

    ST1 499277100 BUSHING 1-2 INSTALLER

    ST2 499277200 INSTALLER

    Fig 15: Installing Washer Using ST1, ST2 And Press
    G07915206Courtesy of SUBARU OF AMERICA, INC.
  16. Install the thrust bearing and needle bearing. Install the driven shaft assembly.
    Fig 16: Installing Thrust Bearing And Needle Bearing
    G06652428Courtesy of SUBARU OF AMERICA, INC.
  17. Install the drive pinion collar, needle bearing, adjusting washer No. 2, thrust bearing, adjusting washer No. 1 and differential bevel gear sleeve in this order.
    Fig 17: Identifying Drive Pinion Collar, Needle Bearing, Adjusting Washers, Thrust Bearing, And Differential Bevel Gear Sleeve
    G07915208Courtesy of SUBARU OF AMERICA, INC.
  18. Adjust the thrust bearing preload. Refer to Drive Pinion Shaft Assembly  .
scientia non olet · About LEMON Manuals