Main Shaft Assembly for Single-Range: Assembly

Match the alignment marks, and install the coupling sleeve to the synchronizer hub and then install the shifting insert.
NOTE: Make sure that there is no large clearance at both sides of the shifting insert after assembly.

Fig 1: Identifying Shifting Insert, Synchronizer Hub And Coupling Sleeve
Courtesy of SUBARU OF AMERICA, INC.
Install the needle bearing, 3rd drive gear, outer baulk ring, 3rd synchro cone, inner baulk ring and 3rd-4th synchronizer hub on the transmission main shaft.
NOTE:
- Install the 3rd-4th synchronizer hub in the correct direction.
- Align the protrusion of the outer baulk ring into the groove of the 3rd-4th synchronizer hub.
  
  Fig 2: Identifying 3rd Drive Gear, Needle Bearing, 3rd Synchro Cone, 3rd-4th Synchronizer Hub, Inner And Outer Baulk Ring
  Courtesy of SUBARU OF AMERICA, INC.
Install the 4th needle bearing race onto transmission main shaft using ST1, ST2, ST3 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 899714110 REMOVER

ST2 499877000 RACE 4-5 INSTALLER

ST3 398177700 INSTALLER

Fig 3: Installing 4th Needle Bearing Race Onto Transmission Main Shaft Using Special Tools
Courtesy of SUBARU OF AMERICA, INC.
Install the 3rd-4th coupling sleeve to the 3rd-4th synchronizer hub.
NOTE:
- Install the 3rd-4th coupling sleeve in the correct direction.
- Align the alignment marks of 3rd-4th coupling sleeve and the 3rd-4th synchronizer hub.
  
  Fig 4: Identifying 3rd-4th Coupling Sleeve
  Courtesy of SUBARU OF AMERICA, INC.
Install the shifting insert.
NOTE: Press in the ball part to install.

Fig 5: Installing Shifting Insert
Courtesy of SUBARU OF AMERICA, INC.
Install the 4th baulk ring, needle bearing, 4th drive gear and 4th gear thrust washer to the transmission main shaft.
NOTE:
- Align the protrusion of the 4th baulk ring into the groove of the 3rd-4th synchronizer hub.
- Install the 4th gear thrust washer with the groove side facing the 4th drive gear.
  
  Fig 6: Identifying 4th Drive Gear Surface And Groove
  Courtesy of SUBARU OF AMERICA, INC.
  
  Fig 7: Identifying 3rd-4th Coupling Sleeve, 4th Baulk Ring, 4th Drive Gear, Needle Bearing And 4th Gear Thrust Washer
  Courtesy of SUBARU OF AMERICA, INC.
Install the double taper roller bearing into the rear section of transmission main shaft 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).
NOTE:
- Use a new double taper roller bearing.
- Install the double taper roller bearing with snap ring side facing the 5th drive gear side.
ST1 899714110 REMOVER

ST2 499877000 RACE 4-5 INSTALLER

Fig 8: Installing Double Taper Roller Bearing Using Special Tools
Courtesy of SUBARU OF AMERICA, INC.
Make sure that the double taper roller bearing turns smoothly.
Install the 5th needle bearing race onto the transmission main shaft 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 899714110 REMOVER

ST2 499877000 RACE 4-5 INSTALLER

Fig 9: Installing 5th Needle Bearing Race Onto Transmission Main Shaft Using Special Tools
Courtesy of SUBARU OF AMERICA, INC.
Install the needle bearing, 5th drive gear, 5th baulk ring, and 5th-6th synchronizer hub on the transmission main shaft.
NOTE:
- Align the protrusion part of the 5th baulk ring with the groove of the 5th-6th synchronizer hub.
- Install the 5th-6th synchronizer hub in the correct direction.
  
  Fig 10: Identifying 5th-6th Synchronizer Hub, 5th Baulk Ring, Drive Gear And Needle Bearing
  Courtesy of SUBARU OF AMERICA, INC.
Install the 6th needle bearing race onto the transmission main shaft 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 899714110 REMOVER

ST2 499877000 RACE 4-5 INSTALLER

Fig 11: Installing 6th Needle Bearing Race Onto Transmission Main Shaft Using Special Tools
Courtesy of SUBARU OF AMERICA, INC.
Install the 5th-6th coupling sleeve to the 5th-6th synchronizer hub.
NOTE:
- Install the 5th-6th coupling sleeve in the correct direction.
- Align the alignment marks of 5th-6th coupling sleeve and the 5th-6th synchronizer hub.
  
  Fig 12: Identifying 5th-6th Coupling Sleeve
  Courtesy of SUBARU OF AMERICA, INC.
Install the shifting insert.
NOTE: Press in the ball part to install.

Fig 13: Installing Shifting Insert
Courtesy of SUBARU OF AMERICA, INC.
Install the 6th baulk ring, 6th drive gear and needle bearing to the transmission main shaft.

Fig 14: Identifying 5th-6th Coupling Sleeve, 6th Baulk Ring, Drive Gear And Needle Bearing
Courtesy of SUBARU OF AMERICA, INC.
Install the ball bearing onto transmission main shaft using 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).

NOTE: Install the ball bearing with the side which does not have lock nut mounting dent facing 6th drive gear.

ST1 899714110 REMOVER

ST2 899754112 PRESS

Fig 15: Installing Ball Bearing Onto Transmission Main Shaft Using Special Tools
Courtesy of SUBARU OF AMERICA, INC.
Install the lock washer.
NOTE:
- Use a new lock washer.
- Install the lock washer in the correct direction.
  
  Fig 16: Identifying Lock Washer Installation Position
  Courtesy of SUBARU OF AMERICA, INC.
Tighten the lock nuts to the specified torque using ST1 and ST2.
NOTE: Use a new lock nut.

Tightening torque:

160 N.m (16.3 kgf-m, 118.0 ft-lb)

ST1 498937000 TRANSMISSION HOLDER

ST2 499987003 SOCKET WRENCH (35)

Fig 17: Tightening Lock Nuts To Specified Torque Using Special Tools
Courtesy of SUBARU OF AMERICA, INC.
Crimp the lock nut at two locations so that the dimension (B) becomes 23.3 mm (0.92 in) or less.
CAUTION: When crimping the lock nut, be careful not to crack it.

Fig 18: Identifying Lock Nut Crimping Dimension
Courtesy of SUBARU OF AMERICA, INC.