Drive Pinion Shaft Assembly: Assembly

WARNING: This page is about a different variant/trim than selected.

Install the plug to drive pinion retainer.
NOTE:
- Use new O-rings.
- Apply CVTF to the O-ring.
Tightening torque:

25 N.m (2.5 kgf-m, 18.4 ft-lb)

Fig 1: Locating Drive Pinion Retainer Plug
Courtesy of SUBARU OF AMERICA, INC.
Using the ST, install the oil seal to drive pinion retainer.
NOTE:
- Apply CVTF to the oil seal press-fitting surface and lip.
- Install the oil seal in the correct direction.
ST 927720000 HOUSING BUSHING INSTALLER AND REMOVER

Fig 2: Installing Oil Seal To Drive Pinion Retainer Using Special Tool
Courtesy of SUBARU OF AMERICA, INC.

Select the drive pinion washer.

Measure the roller bearing inner race width "A" on the front side.

Fig 3: Identifying Width "A" Of Roller Bearing Inner Race
Courtesy of SUBARU OF AMERICA, INC.
Measure the roller bearing inner race width "B" on the rear side.

Fig 4: Identifying Width "B" Of Roller Bearing Inner Race
Courtesy of SUBARU OF AMERICA, INC.
Measure the spacer width "C".

Fig 5: Measuring Spacer Width "C"
Courtesy of SUBARU OF AMERICA, INC.
Using the ST, install the front roller bearing outer race to the drive pinion retainer.
ST1 28499TC010 INSTALLER

ST2 398177700 INSTALLER

Fig 6: Installing Front Roller Bearing Outer Race To Drive Pinion Retainer Using Special Tools
Courtesy of SUBARU OF AMERICA, INC.
Using the ST, install the rear roller bearing outer race to the drive pinion retainer.
ST 20099AE020 INSTALLER

Fig 7: Installing Rear Roller Bearing Outer Race To Drive Pinion Retainer Using Special Tool
Courtesy of SUBARU OF AMERICA, INC.
Place the drive pinion retainer on the surface plate, and install the inner race to the rear roller bearing outer race.
NOTE: Place the drive pinion retainer so that the mating surface of the drive pinion retainer (mating surface with the converter case) contacts the surface plate.
Measure the height "D" from the end face of the rear roller bearing inner race to the surface plate.

Fig 8: Measuring Height "D" From End Face Of Rear Roller Bearing Inner Race To Surface Plate
Courtesy of SUBARU OF AMERICA, INC.
Install the inner race to the front roller bearing outer race.
Measure the depth "E" from the end face of the front roller bearing inner race to the end face of the ST.
ST 499575400 GAUGE

Fig 9: Measuring Depth "E" From End Face Of Front Roller Bearing Inner Race To Gauge
Courtesy of SUBARU OF AMERICA, INC.

Using following formula, select one to three drive pinion washers.

T (mm) = D - (A + B + C + E - 15) - (0±0.0125)

[T (in) = D - (A + B + C + E - 0.591) - (0±0.0005)]

A: Front roller bearing width

B: Rear roller bearing width

C: Spacer width

D: Height from end face of rear roller bearing inner race to surface plate

E: Depth from end face of front roller bearing inner race to end face of ST

15 mm (0.591 in): Thickness of ST

T: Drive pinion washer thickness

0±0.0125 mm (0±0.0005 in): Clearance

Drive pinion washer
Part No.	Thickness mm (in)
38336AA750	0.150 (0.0059)
38336AA760	0.175 (0.0069)
38336AA770	0.200 (0.0079)
38336AA780	0.225 (0.0089)
38336AA790	0.250 (0.0098)
38336AA800	0.275 (0.0108)
38336AA810	0.300 (0.0118)
38336AA820	0.400 (0.0157)

Measure and record the drive pinion shim thickness to be reused.
Install the drive pinion shim that is reused for the drive pinion shaft.
Using the ST1 and ST2, press-fit the inner race to the drive pinion shaft.
ST1 899580100 INSTALLER

ST2 927130000 EXTENSION DRIVE SHAFT

Fig 10: Pressing-Fit Inner Race To Drive Pinion Shaft Using Special Tools
Courtesy of SUBARU OF AMERICA, INC.
Install the drive pinion spacer.
NOTE: Replace the O-ring with a new part after tooth contact inspection.

Fig 11: Identifying Drive Pinion Spacer
Courtesy of SUBARU OF AMERICA, INC.
Install the selected drive pinion washer.

Fig 12: Installing Selected Drive Pinion Washer
Courtesy of SUBARU OF AMERICA, INC.
Insert the drive pinion shaft into the drive pinion retainer.
CAUTION: Be careful not to damage the oil seal.
Install the inner bearing and lock nut.
NOTE: Use a new lock nut.

Fig 13: Installing Inner Bearing And Lock Nut
Courtesy of SUBARU OF AMERICA, INC.

Using the ST, tighten the lock nut to the specified torque so that the starting torque of the drive pinion shaft is within the specified range.

CAUTION: Before inspecting the starting torque, apply differential gear oil to roller of bearing and rotate the bearing several times.

NOTE:

Tighten the lock nut while directly aligning ST2 and torque wrench.
If the starting torque is not within the specified range, select the drive pinion washer, and repeat the step until the starting torque is within the specified range.
When a thicker drive pinion washer is selected, the starting torque decreases. When a thinner drive pinion washer is selected, the starting torque increases.

Starting torque:

5.1 - 17.1 N (0.5 - 1.7 kgf, 1.1 - 3.8 lbf)

ST1 499787500 ADAPTER

ST2 499787700 WRENCH

ST3 498937110 HOLDER

Using the following formula, calculate the tightening torque for a torque wrench.

T2 = L2/(L1 + L2) x T1

T1: 170 - 250 N.m (17.3 - 25.5 kgf-m, 125.4 - 184.4 ft-lb) [Specified tightening torque range]

T2: Tightening torque

L1: ST1 length 0.072 m (2.83 in)

L2: Torque wrench length

Example:

Torque wrench length m (in)	Tightening torque N.m (kgf-m, ft-lb)
0.4 (15.75)	144 - 211 (14.7 - 21.5, 106.2 - 155.6)
0.45 (17.72)	147 - 215 (15.0 - 21.9, 108.4 - 158.6)
0.5 (19.69)	149 - 218 (15.2 - 22.2, 109.9 - 160.8)
0.55 (21.65)	150 - 221 (15.3 - 22.5, 110.6 - 163.0)

Fig 14: Removing Drive Pinion Shaft Assembly Lock Nut Using Special Tools

Courtesy of SUBARU OF AMERICA, INC.

Fig 15: Calculating Lock Nut Tightening Torque Using Torque Wrench

Courtesy of SUBARU OF AMERICA, INC.

Install the drive pinion retainer to the converter case, and check the backlash and tooth contact. Refer to ADJUSTMENT and ADJUSTMENT .
Remove the drive pinion retainer from converter case. Refer to REMOVAL .
Remove the drive pinion spacer from the drive pinion shaft. Refer to DISASSEMBLY .
Install the O-ring to the drive pinion shaft.
NOTE:
- Use new O-rings.
- Apply CVTF to the O-ring.
  
  Fig 16: Locating Drive Pinion Shaft Assembly O-Ring
  Courtesy of SUBARU OF AMERICA, INC.
Install the drive pinion spacer to the drive pinion shaft.

Fig 17: Identifying Drive Pinion Spacer
Courtesy of SUBARU OF AMERICA, INC.
Install the drive pinion washer.

Fig 18: Installing Selected Drive Pinion Washer
Courtesy of SUBARU OF AMERICA, INC.
Insert the drive pinion shaft into the drive pinion retainer.
CAUTION: Be careful not to damage the oil seal.

Fig 19: Identifying Drive Pinion Shaft
Courtesy of SUBARU OF AMERICA, INC.
Install the inner bearing and lock nut.

Fig 20: Installing Inner Bearing And Lock Nut
Courtesy of SUBARU OF AMERICA, INC.

Using the ST, tighten the lock nut to the specified torque so that the starting torque of the drive pinion shaft is within the specified range.

CAUTION: Before inspecting the starting torque, apply differential gear oil to roller of bearing and rotate the bearing several times.

NOTE:

Tighten the lock nut while directly aligning ST2 and torque wrench.
If the starting torque is not within the specified range, select the drive pinion washer, and repeat the step until the starting torque is within the specified range.
When a thicker drive pinion washer is selected, the starting torque decreases. When a thinner drive pinion washer is selected, the starting torque increases.

Starting torque:

5.1 - 17.1 N (0.5 - 1.7 kgf, 1.1 - 3.8 lbf)

ST1 499787500 ADAPTER

ST2 499787700 WRENCH

ST3 498937110 HOLDER

Using the following formula, calculate the tightening torque for a torque wrench.

T2 = L2/(L1 + L2) x T1

T1: 170 - 250 N.m (17.3 - 25.5 kgf-m, 125.4 - 184.4 ft-lb) [Specified tightening torque range]

T2: Tightening torque

L1: ST1 length 0.072 m (2.83 in)

L2: Torque wrench length

Example:

Torque wrench length m (in)	Tightening torque N.m (kgf-m, ft-lb)
0.4 (15.75)	144 - 211 (14.7 - 21.5, 106.2 - 155.6)
0.45 (17.72)	147 - 215 (15.0 - 21.9, 108.4 - 158.6)
0.5 (19.69)	149 - 218 (15.2 - 22.2, 109.9 - 160.8)
0.55 (21.65)	150 - 221 (15.3 - 22.5, 110.6 - 163.0)

Fig 21: Removing Drive Pinion Shaft Assembly Lock Nut Using Special Tools

Courtesy of SUBARU OF AMERICA, INC.

Fig 22: Calculating Lock Nut Tightening Torque Using Torque Wrench

Courtesy of SUBARU OF AMERICA, INC.

Crimp the lock nut in 2 locations.
Using the ST, install the plug.
ST1 499755602 PRESS SNAP RING

ST2 398177700 INSTALLER

Fig 23: Installing Drive Pinion Shaft Assembly Plug Using Special Tools
Courtesy of SUBARU OF AMERICA, INC.