Output Shaft Assembly: Assembly

Installation of transmission hub sleeve No. 1
1. Apply manual transmission oil to the sliding area of the transmission clutch hub No. 1.
  NOTE: Be sure to use the recommended product or the substitute product for manual transmission oil. (Refer to MANUAL TRANSMISSION OIL )
2. Install the transmission hub sleeve No. 1 to the transmission clutch hub No. 1, and install the 3 balls after installing the 3 synchromesh shifting keys No. 1 and the 3 synchromesh shifting key springs No. 1 as a unit.
  NOTE:
  - Install the balls while pressing the synchromesh shifting key spring No. 1.
  - After the installation, settle the synchromesh shifting key spring No. 1.
  Fig 1: Pressing Synchromesh Shifting Key Spring No. 1
  Courtesy of SUBARU OF AMERICA, INC.
Installation of transmission hub sleeve No. 3
1. Apply manual transmission oil to the sliding area of the transmission clutch hub No. 3.
  NOTE: Be sure to use the recommended product or the substitute product for manual transmission oil. (Refer to MANUAL TRANSMISSION OIL )
2. Install the transmission hub sleeve No. 3 to the transmission clutch hub No. 3, and install the 3 balls after installing the 3 synchromesh shifting keys No. 1 and the 3 synchromesh shifting key springs No. 1 as a unit.
  NOTE:
  - Install the balls while pressing the synchromesh shifting key spring No. 1.
  - After the installation, settle the synchromesh shifting key spring No. 1.
  Fig 2: Pressing Synchromesh Shifting Key Spring No. 1
  Courtesy of SUBARU OF AMERICA, INC.
Reverse gear installation
1. Apply manual transmission oil to the output shaft installation portion, the reverse gear bearing, and the inner surface and the tapered cone portion of the reverse gear.
  NOTE: Be sure to use the recommended product or the substitute product for manual transmission oil. (Refer to MANUAL TRANSMISSION OIL )
2. Install the reverse gear bearing and the reverse gear to the output shaft.
  
  Fig 3: Locating Reverse Gear Bearing
  Courtesy of SUBARU OF AMERICA, INC.
Installation of transmission clutch hub No. 3
1. Install the synchronizer ring No. 3 to the reverse gear.
2. Use the SST to install the transmission clutch hub No. 3.
  SST 499277100, 398477703, 899714110
  NOTE:
  - After installing the transmission clutch hub No. 3, check that the synchronizer ring moves in the thrust direction.
  - Press-fit the transmission clutch hub No. 3 until it contacts the output shaft.
  - Match the phases of the transmission clutch hub No. 3 and the synchronizer ring No. 3.
  Fig 4: Installing Transmission Clutch Hub No. 3
  Courtesy of SUBARU OF AMERICA, INC.

Installation of shaft snap ring (transmission clutch hub No. 3)

Select a shaft snap ring so that the thrust clearance between the transmission clutch hub No. 3 and the shaft snap ring is within the standard value.

Standard value: 0 to 0.1 mm {0 to 0.00394 in}

NOTE: Select a shaft snap ring with the maximum thickness that can be installed.

Shaft snap ring type

SHAFT SNAP RING SPECIFICATION

Item number	Thickness mm {in}	Identification mark
17005AA520	1.80 {0.07086}	A
17005AA530	1.85 {0.07283}	B
17005AA540	1.90 {0.07480}	C
17005AA550	1.95 {0.07677}	D
17005AA560	2.00 {0.07874}	E
17005AA570	2.05 {0.08070}	F

Use the SST to install a new shaft snap ring to the output shaft.
SST 499895400

Fig 5: Installing Shaft Snap Ring To Output Shaft
Courtesy of SUBARU OF AMERICA, INC.

2nd gear installation
1. Apply manual transmission oil to the output shaft installation portion, the 2nd gear needle roller bearing, and the inner surface and the tapered cone portion of the 2nd gear.
  NOTE: Be sure to use the recommended product or the substitute product for manual transmission oil. (Refer to MANUAL TRANSMISSION OIL )
2. Install the 2nd gear needle roller bearing and the 2nd gear to the output shaft.
  
  Fig 6: Locating 2nd Gear Needle Roller Bearing
  Courtesy of SUBARU OF AMERICA, INC.
Installation of transmission clutch hub No. 1
1. Align the synchronizer ring set No. 1 (for 2nd gear) to the position shown in the figure and install it.
  CAUTION:
  - Align the middle ring claw with the gear groove.
  - Align the inner ring claw with the outer ring claw groove.
  Fig 7: Locating Transmission Clutch Hub No. 1
  Courtesy of SUBARU OF AMERICA, INC.
2. Use the SST to install the transmission clutch hub No. 1.
  SST 499277100, 899714110, 398477703, 499277000
  NOTE:
  - After installing the transmission clutch hub No. 1, check that the synchronizer ring set No. 1 (for 2nd gear) moves in the thrust direction.
  - Press-fit the transmission clutch hub No. 1 until it contacts the output shaft.
  Fig 8: Installing Transmission Clutch Hub No. 1
  Courtesy of SUBARU OF AMERICA, INC.
3. Align the synchronizer ring set No. 1 (for 1st gear) to the position shown in the figure and install it.
  CAUTION:
  - Align the protruded section of the outer ring with the hub groove.
  - Align the inner ring claw with the outer ring claw groove.
  Fig 9: Locating Outer Ring Claw Groove
  Courtesy of SUBARU OF AMERICA, INC.
1st gear installation
1. Apply manual transmission oil to the output shaft installation portion, the needle roller bearing inner race, and the inner surface and the tapered cone portion of the 1st gear.
  NOTE: Be sure to use the recommended product or the substitute product for manual transmission oil. (Refer to MANUAL TRANSMISSION OIL )
2. Install the 1st shift restrict ball, 1st gear, 1st gear needle roller bearing, and 1st gear bearing inner race to the output shaft.
  CAUTION: Align the middle ring claw with the gear groove.
  
  Fig 10: Installing 1st Shift Restrict Ball
  Courtesy of SUBARU OF AMERICA, INC.
Installation of output shaft bearing RR
1. Use the SST to install the output shaft bearing RR.
  SST 499277100, 899714110, 398477703, 499277000
  
  NOTE: Press-fit the output shaft bearing RR until it contacts the 1st gear bearing inner race.
  
  Fig 11: Installing Output Shaft Bearing RR
  Courtesy of SUBARU OF AMERICA, INC.
6th gear installation
1. Use the SST to install the 6th gear.
  SST 499277100, 899714110, 398477703, 499277000
  
  NOTE: Press-fit the 6th gear until it contacts the output shaft bearing RR.
  
  Fig 12: Installing 6th Gear Using SST
  Courtesy of SUBARU OF AMERICA, INC.

Installation of shaft snap ring (6th gear)

Select a shaft snap ring so that the thrust clearance between the 6th gear and the shaft snap ring is within the standard value.

Standard value: 0.1 to 0.11 mm {0.00394 to 0.00433 in}

NOTE: Select a shaft snap ring with the maximum thickness that can be installed.

Shaft snap ring type

SHAFT SNAP RING SPECIFICATION

Item number	Thickness mm {in}	Identification mark
17005AA350	2.67 {0.10511}	A
17005AA360	2.73 {0.10748}	B
17005AA370	2.79 {0.10984}	C
17005AA380	2.85 {0.11220}	D
17005AA390	2.91 {0.11456}	E
17005AA400	2.97 {0.11692}	F
17005AA410	3.03 {0.11929}	G
17005AA420	3.09 {0.12165}	H
17005AA430	3.15 {0.12401}	J
17005AA440	3.21 {0.12638}	K
17005AA450	3.27 {0.12874}	L

Install a new shaft snap ring to the output shaft.

Fig 13: Installing Shaft Snap Ring To Output Shaft
Courtesy of SUBARU OF AMERICA, INC.