Main Shaft Assembly for Single-Range: Disassembly

NOTE:

When replacing the coupling sleeve and synchronizer hub, replace them as a set.
Do not disassemble the coupling sleeve & synchronizer hub; the engaging point is pre-determined. If it is necessary to disassemble, mark the engaging points on the splines beforehand.

Put vinyl tape around the main shaft spline and pull out the oil seal and needle bearing by hand to prevent the oil seal from being damaged.
Flatten the tab of the lock nut.
Remove the lock nut from transmission main shaft assembly for single-range.
ST1 498937000 TRANSMISSION HOLDER

ST2 499987003 SOCKET WRENCH (35)

Fig 1: Removing Lock Nut From Transmission Main Shaft Assembly Using Special Tools
Courtesy of SUBARU OF AMERICA, INC.
Remove the 6th drive gear and ball bearing using the ST1, ST2 and a press.
ST1 899864100 REMOVER

ST2 18722AA010 REMOVER

Fig 2: Removing 6th Drive Gear And Ball Bearing Using Special Tools
Courtesy of SUBARU OF AMERICA, INC.
Remove the needle bearing, 6th baulk ring, shifting insert and 5th-6th coupling sleeve.
CAUTION: When removing 5th-6th coupling sleeve, be careful not to lose the shifting insert.
Remove the 5th drive gear, 6th needle bearing race, 5th baulk ring, 5th-6th synchronizer hub and needle bearing using the ST1, ST2 and a press.
ST1 899864100 REMOVER

ST2 18722AA010 REMOVER

Fig 3: Removing 5th Drive Gear, 6th Needle Bearing Race, 5th Baulk Ring, 5th-6th Synchronizer Hub And Needle Bearing Using Special Tools
Courtesy of SUBARU OF AMERICA, INC.
Shift the 3rd-4th coupling sleeve to the 3rd side.
Remove the 4th drive gear, double taper roller bearing and 5th needle bearing race using the ST1, ST2 and a press.
ST1 899864100 REMOVER

ST2 899714110 REMOVER

Fig 4: Removing 4th Drive Gear, Double Taper Roller Bearing And 5th Needle Bearing Race Using Special Tools
Courtesy of SUBARU OF AMERICA, INC.
Remove the 4th gear thrust washer, 4th baulk ring, needle bearing, shifting insert and 3rd-4th coupling sleeve.
CAUTION: When removing 3rd-4th coupling sleeve, be careful not to lose the shifting insert.
Remove the 3rd drive gear, 4th needle bearing race, 3rd-4th synchronizer hub, inner baulk ring, 3rd synchro cone, outer baulk ring and needle bearing using the ST1, ST2 and a press.
ST1 899864100 REMOVER

ST2 899714110 REMOVER

Fig 5: Removing 3rd Drive Gear, 4th Needle Bearing Race, 3rd-4th Synchronizer Hub, 3rd Synchro Cone, Inner Or Outer Baulk Ring And Needle Bearing Using Special Tools
Courtesy of SUBARU OF AMERICA, INC.