Output Shaft Assembly: Disassembly

Thrust clearance check

Check the thrust clearances of the 1st gear, 2nd gear, and reverse gear.

Fig 1: Checking Thrust Clearances Of 1st Gear, 2nd Gear And Reverse Gear

Courtesy of SUBARU OF AMERICA, INC.

Standard value

STANDARD VALUE

Gear	Standard value mm {in}	Limit mm {in}
1st gear	0.15 to 0.40 {0.00590 to 0.0157}	0.40 {0.0157}
2nd gear	0.10 to 0.45 {0.000394 to 0.0177}	0.45 {0.0177}
Reverse gear	0.10 to 0.45 {0.000394 to 0.0177}	0.45 {0.0177}

NOTE: If the value exceeds the limit, replace the corresponding gear, transmission clutch hub, needle roller bearing, and output shaft with new ones.

Radial clearance check

Check the radial clearances of the 1st gear, 2nd gear, and reverse gear.

Fig 2: Checking Radial Clearances Of 1st Gear, 2nd Gear And Reverse Gear

Courtesy of SUBARU OF AMERICA, INC.

Standard value

STANDARD VALUE

Gear	Standard value mm {in}	Limit mm {in}
1st gear	0.015 to 0.066 {0.000590 to 0.00260}	0.066 {0.00260}
2nd gear	0.015 to 0.066 {0.000590 to 0.00260}	0.066 {0.00260}
Reverse gear	0.015 to 0.066 {0.000590 to 0.00260}	0.066 {0.00260}

NOTE: If the value exceeds the limit, replace the corresponding gear, needle roller bearing, and output shaft with new ones.

Removal of reverse gear
1. Use the SST to remove the shaft snap ring.
  SST 499895400
  
  Fig 3: Removing Shaft Snap Ring
  Courtesy of SUBARU OF AMERICA, INC.
2. Use the SST to remove the transmission clutch hub No. 3, transmission hub sleeve No. 3, reverse gear, synchronizer ring No. 3, and reverse gear bearing from the output shaft.
  SST 899714110, 899864100
  
  CAUTION: Verify the direction of the parts.
  
  Fig 4: Removing Transmission Clutch Hub No. 3
  Courtesy of SUBARU OF AMERICA, INC.
Removal of transmission hub sleeve No. 3
1. Remove the transmission hub sleeve No. 3, then remove the 3 synchromesh shifting keys No. 1, 3 synchromesh shifting key springs No. 1, and 3 balls from the transmission clutch hub No. 3.
  CAUTION:
  - Keep the synchromesh shifting keys No. 1, synchromesh shifting key springs No. 1, and balls from flying out using a cloth.
  - Be careful not to deform the synchromesh shifting key springs No. 1.
  NOTE: Perform the work without displacing the positions of the transmission clutch hub No. 3 and synchromesh shifting keys No. 1.
  
  Fig 5: Keeping Synchromesh Components From Flying Out
  Courtesy of SUBARU OF AMERICA, INC.
Removal of 6th gear
1. Remove the shaft snap ring.
  CAUTION: Keep the shaft snap ring from flying out with a cloth, etc.
  
  Fig 6: Removing Shaft Snap Ring
  Courtesy of SUBARU OF AMERICA, INC.
2. Use the SST to remove the 6th gear.
  SST 09950-00020
  
  Fig 7: Removing 6th Gear Using SST
  Courtesy of SUBARU OF AMERICA, INC.
Removal of 1st gear
1. Use the SST to remove the output shaft bearing RR, 1st gear, 1st bearing inner race, 1st gear needle roller bearing, and 1st shift restrict ball.
  SST 18722AA000
  
  CAUTION: Verify the direction of the parts.
  
  Fig 8: Removing 1st Gear
  Courtesy of SUBARU OF AMERICA, INC.
Removal of 2nd gear
1. Use the SST to remove the 2nd gear, transmission clutch hub No. 1, transmission hub sleeve No. 1, and 2nd gear needle roller bearing from the output shaft.
  SST 18722AA000
  
  CAUTION: Verify the direction of the parts.
  
  Fig 9: Removing 2nd Gear
  Courtesy of SUBARU OF AMERICA, INC.
Removal of synchronizer ring set No. 1
1. Remove the 2 synchronizer ring No. 1 sets.
Removal of transmission hub sleeve No. 1
1. Remove the transmission hub sleeve No. 1, then remove the 3 synchromesh shifting keys No. 1, 3 synchromesh shifting key springs No. 1, and 3 balls from the transmission clutch hub No. 1.
  CAUTION:
  - Keep the synchromesh shifting keys No. 1, synchromesh shifting key springs No. 1, and balls from flying out using a cloth.
  - Be careful not to deform the synchromesh shifting key springs No. 1.
  NOTE: Perform the work without displacing the positions of the transmission clutch hub No. 1 and synchromesh shifting keys No. 1.
  
  Fig 10: Keeping Synchromesh Components From Flying Out
  Courtesy of SUBARU OF AMERICA, INC.